JP2017189939A - Mold and method of manufacturing mold - Google Patents
Mold and method of manufacturing mold Download PDFInfo
- Publication number
- JP2017189939A JP2017189939A JP2016081281A JP2016081281A JP2017189939A JP 2017189939 A JP2017189939 A JP 2017189939A JP 2016081281 A JP2016081281 A JP 2016081281A JP 2016081281 A JP2016081281 A JP 2016081281A JP 2017189939 A JP2017189939 A JP 2017189939A
- Authority
- JP
- Japan
- Prior art keywords
- mold
- release film
- substrate
- molding
- less
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 15
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 39
- 239000010439 graphite Substances 0.000 claims abstract description 25
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 25
- 239000000758 substrate Substances 0.000 claims abstract description 23
- 238000000465 moulding Methods 0.000 claims description 57
- 239000000463 material Substances 0.000 claims description 29
- 229920005989 resin Polymers 0.000 claims description 16
- 239000011347 resin Substances 0.000 claims description 16
- 239000000853 adhesive Substances 0.000 claims description 13
- 230000001070 adhesive effect Effects 0.000 claims description 13
- 229910052799 carbon Inorganic materials 0.000 claims description 11
- 238000007493 shaping process Methods 0.000 claims description 9
- 239000002131 composite material Substances 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 4
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 3
- 229910052731 fluorine Inorganic materials 0.000 claims description 3
- 239000011737 fluorine Substances 0.000 claims description 3
- 230000000630 rising effect Effects 0.000 claims description 2
- 238000010422 painting Methods 0.000 claims 1
- 239000004918 carbon fiber reinforced polymer Substances 0.000 abstract description 32
- 238000000034 method Methods 0.000 description 23
- 238000012360 testing method Methods 0.000 description 17
- 239000010410 layer Substances 0.000 description 10
- 239000011148 porous material Substances 0.000 description 10
- 239000002994 raw material Substances 0.000 description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 5
- 239000004810 polytetrafluoroethylene Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- -1 polytetrafluoroethylene Polymers 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 230000001186 cumulative effect Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 230000003014 reinforcing effect Effects 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 239000002033 PVDF binder Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000006837 decompression Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 238000001746 injection moulding Methods 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920002493 poly(chlorotrifluoroethylene) Polymers 0.000 description 2
- 239000005023 polychlorotrifluoroethylene (PCTFE) polymer Substances 0.000 description 2
- 229920002620 polyvinyl fluoride Polymers 0.000 description 2
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- UKCBKQLNTLMFAA-UHFFFAOYSA-N F.[F] Chemical compound F.[F] UKCBKQLNTLMFAA-UHFFFAOYSA-N 0.000 description 1
- 229910001374 Invar Inorganic materials 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 229920000840 ethylene tetrafluoroethylene copolymer Polymers 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000007770 graphite material Substances 0.000 description 1
- 229920006015 heat resistant resin Polymers 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 239000003039 volatile agent Substances 0.000 description 1
Abstract
Description
本発明は、複合材料の成形に用いられる成形型に関する。特に、熱硬化性樹脂または熱可塑性樹脂を炭素繊維に含浸させたプリプレグなどの中間素材を原料として、炭素繊維強化プラスチックを成形するために用いる成形型に関する。 The present invention relates to a mold used for molding a composite material. In particular, the present invention relates to a molding die used for molding a carbon fiber reinforced plastic using an intermediate material such as a prepreg obtained by impregnating carbon fiber with a thermosetting resin or a thermoplastic resin.
炭素繊維強化プラスチックの製造方法として、例えばプレス法、樹脂注入成形法、オートクレーブ成形法などが知られている。プレス法は、プリプレグなどを積層した板に、プレス機で圧力と熱とをかけて成形する方法である。樹脂注入成形法は、強化繊維を立体的な形状にしたプリフォームを金型に封入し、溶融している熱硬化性樹脂や熱可塑性樹脂を低圧下で注入して加熱硬化する方法である。オートクレーブ成形法は、成形型にプリプレグを積層して気密性の高いバッグに収容し、オートクレーブ内で加圧しながら内包された空気や揮発物を真空除去し、さらに熱をかけて樹脂を硬化させる方法である。オートクレーブ成形法は、強度に優れた炭素繊維強化プラスチックを製造することができ、また製品の品質が優れて安定しているために、航空宇宙産業などを中心に広く普及している。 As a method for producing a carbon fiber reinforced plastic, for example, a press method, a resin injection molding method, an autoclave molding method and the like are known. The pressing method is a method in which pressure and heat are applied to a plate laminated with prepreg and the like with a press machine. The resin injection molding method is a method in which a preform having reinforcing fibers in a three-dimensional shape is sealed in a mold, and a molten thermosetting resin or thermoplastic resin is injected under a low pressure to be cured by heating. Autoclave molding method is a method of stacking prepreg on a mold and storing it in a highly air-tight bag, removing the air and volatiles contained in the autoclave while applying pressure in the autoclave, and further applying heat to cure the resin. It is. The autoclave molding method is widely used mainly in the aerospace industry because it can produce carbon fiber reinforced plastics with excellent strength and the quality of the product is excellent and stable.
熱硬化性樹脂であるエポキシ樹脂が用いられているプリプレグをオートクレーブ成形法で成形する場合、成形型に樹脂が付着して硬化することを防ぐために、種々の離型剤を塗布する必要があった。たとえば離型剤として有機溶媒を塗布する場合には、工程中に塗布と乾燥のための作業工程と作業場所を確保する必要があり、作業効率の向上を阻む一因となっていた。特許文献１には、離型剤を塗布せずに離型性を向上させる技術が開示されている。特許文献１の成形型は、黒鉛基材と、この基材の上に形成されたフッ素樹脂を含む接合層と、接合層の上面に形成されたフッ素樹脂の表面層とを備えている。 When molding a prepreg using an epoxy resin, which is a thermosetting resin, by autoclave molding, it was necessary to apply various release agents to prevent the resin from adhering to the mold and curing. . For example, when an organic solvent is applied as a release agent, it is necessary to secure a work process and a work place for application and drying during the process, which is one factor that hinders improvement in work efficiency. Patent Document 1 discloses a technique for improving the releasability without applying a release agent. The mold of Patent Document 1 includes a graphite base material, a joining layer containing a fluororesin formed on the base material, and a fluororesin surface layer formed on the top surface of the joining layer.
また、特許文献２および特許文献３には、熱膨張率を成形材料にほぼ等しくした炭素繊維強化プラスチック成形用の成形型が開示されている。 Patent Documents 2 and 3 disclose a mold for molding a carbon fiber reinforced plastic having a thermal expansion coefficient substantially equal to that of a molding material.
特許文献１は、ウレタンフォームを効率よく成形するために、ウレタンとの離型性を向上させた型を開示している。また、特許文献２および３は、製品の寸法精度を向上させるために、熱膨張率を最適化した成形型を開示している。しかしながら、炭素繊維強化プラスチックの離型性を向上させた成形型はこれまで知られていない。 Patent document 1 is disclosing the type | mold which improved the mold release property with urethane in order to shape | mold a urethane foam efficiently. Patent Documents 2 and 3 disclose a mold having an optimized coefficient of thermal expansion in order to improve the dimensional accuracy of the product. However, a mold that improves the releasability of the carbon fiber reinforced plastic has not been known so far.
本願は、このような現状に鑑みてなされたものであって、特に炭素繊維強化プラスチック（以下、ＣＦＲＰとも言う）の離型性が良く、従来よりもＣＦＲＰの製造工程の簡略化と迅速化が可能であり、しかも耐久性に優れた成形型の提供を、解決すべき課題としてなされたものである。 The present application has been made in view of such a situation, and in particular, the releasability of carbon fiber reinforced plastic (hereinafter also referred to as CFRP) is good, and the production process of CFRP can be simplified and expedited more than before. Providing a mold that is possible and excellent in durability has been made as a problem to be solved.
上記課題を解決するための、本発明に係る成形型は、特に複合材料を成形するための成形型であって、開気孔率１８％以下の多孔質等方性黒鉛からなる基材と、基材の表面に形成されたフッ素系樹脂からなる離型膜とを、備えている。成形型の基材は、熱伝導率が１３Ｗ／ｍＫよりも大きく２００Ｗ／ｍＫ未満であり、且つ離型膜の膜厚が５０μｍ以上５００μｍ以下であることを特徴とする。 In order to solve the above problems, a mold according to the present invention is a mold particularly for molding a composite material, and is composed of a base material made of porous isotropic graphite having an open porosity of 18% or less, a base And a release film made of a fluorine-based resin formed on the surface of the material. The base material of the mold is characterized in that the thermal conductivity is greater than 13 W / mK and less than 200 W / mK, and the thickness of the release film is 50 μm or more and 500 μm or less.
本発明の成形型は、基材が、炭素系接着剤により複数の部材を接合してなることが好ましい。 In the molding die of the present invention, the substrate is preferably formed by joining a plurality of members with a carbon-based adhesive.
本発明はまた、複合材料を成形するための成形型の製造方法を開示する。本発明の成形型の製造方法は、複合材料成形用の型の製造方法であって、開気孔率１８％以下の多孔質等方性黒鉛からなる複数の部材を炭素系接着剤によって接着して基材を構成する工程と、基材を２〜５ｋｇｆ／ｃｍ２の圧着力で加圧した状態で１３〜１００℃／ｈｒの昇温速度で室温から９０〜２２０℃まで昇温し、９０〜２５０℃で１〜２０時間維持し、放冷する工程と、基材の表面に離型膜を形成する工程とを備えることを特徴とする。 The present invention also discloses a method for producing a mold for molding a composite material. The method for producing a mold according to the present invention is a method for producing a mold for molding a composite material, in which a plurality of members made of porous isotropic graphite having an open porosity of 18% or less are bonded with a carbon-based adhesive. The step of constituting the substrate, and the substrate was heated from room temperature to 90 to 220 ° C. at a temperature increase rate of 13 to 100 ° C./hr in a state where the substrate was pressurized with a pressure of 2 to 5 kgf / cm 2 , 90 to It is characterized by comprising a step of maintaining at 250 ° C. for 1 to 20 hours and allowing to cool, and a step of forming a release film on the surface of the substrate.
本発明に係る成形型によれば、成形型の基材の熱伝導率を１３Ｗ／ｍＫよりも大きく２００Ｗ／ｍＫ未満とすることで、成形時の加熱工程および冷却工程を極めて迅速におこなうことができる。 According to the mold according to the present invention, the heating process and the cooling process at the time of molding can be performed very rapidly by setting the thermal conductivity of the base material of the mold to be greater than 13 W / mK and less than 200 W / mK. it can.
離型膜の膜厚を５０μｍ以上５００μｍ以下とすることで、基材である開気孔率１８％以下の多孔質等方性黒鉛の表面の空隙を封止して気密性を確保し、オートクレーブによるＣＦＲＰの製造時に必要な真空度を保証することができる。 By setting the film thickness of the release film to 50 μm or more and 500 μm or less, the void on the surface of the porous isotropic graphite having an open porosity of 18% or less as a base material is sealed to ensure airtightness, and by autoclave The degree of vacuum required when manufacturing CFRP can be ensured.
離型膜の膜厚を５０μｍ以上５００μｍ以下とすることで、離型膜の耐久性を確保し、ＣＦＲＰを脱型するときの工程を長期間に亘って簡略化することができる。 By setting the film thickness of the release film to 50 μm or more and 500 μm or less, it is possible to ensure the durability of the release film and simplify the process for removing the CFRP over a long period of time.
複数の部材を炭素系接着剤で接着して構成することで、大型であったり凹凸やコンターのある複雑な三次元形状であったとしても、表面の精度の高い本発明の成形型が容易に形成される。 By forming multiple members by bonding with a carbon-based adhesive, the mold of the present invention with high surface accuracy can be easily obtained even if it is large or has a complicated three-dimensional shape with irregularities and contours. It is formed.
本発明にかかる製造方法で製造された成形型は、接着面の発泡が未然に防止されて、長期信頼性が担保される。従来の金属を溶接した成形型と比較すると、接着部分に歪みが残らず、より容易に製造することができる。また必要な部分のみに補強部材を接着して、全体として軽量な成形型を得ることができる。 The molding die manufactured by the manufacturing method according to the present invention prevents the adhesive surface from foaming and ensures long-term reliability. Compared with a conventional mold in which a metal is welded, there is no distortion in the bonded portion, and it can be manufactured more easily. In addition, a reinforcing member can be bonded only to a necessary portion to obtain a lightweight mold as a whole.
本発明の成形型と成形型の製造方法の好適な実施形態を列記する。
（１）基材として、切り出し方向による特性差が認められない等方性黒鉛が使用される。本発明で用いる等方性黒鉛は、熱膨張率がインバーと同等の０．５×１０−６Ｋから２×１０−６Ｋであることが好ましい。熱膨張率が小さいことで、成形型の変形に由来するＣＦＲＰの成形品の歪みを小さくすることができる。
（２）基材として、密度が１．７５ｇ／ｃｍ３よりも高く、平均気孔半径が０．３〜１．９μｍであり、且つ開気孔率が１１〜１８％である多孔質等方性黒鉛が好適に用いられる。検討の結果、開気孔率が１９％以上であると、たとえ離型膜が厚くても減圧を伴う成形工程で、リークして気密性が維持できない可能性があり、また表面粗度が悪化することが明らかとなった。そのため、切り出し方向による特性差が認められず、また平均気孔半径が小さく、開気孔率が１８％以下の多孔質等方性黒鉛が、本発明の実施形態における最も好適な基材である。なお、開気孔率は、以下の式で定義される。
開気孔率（％）＝かさ密度（Ｍｇ／ｍ３）×累積細孔容積（ｍ３／Ｍｇ）×１００
・・・（式１）
ここで、累積細孔容積は、細孔半径０．００７４μｍ〜６８．７μｍの細孔の体積の累積値であって、水銀ポロシメトリー法により測定される。
（３）基材の接着には、フェノール系樹脂に黒鉛粉、コークス粉、ピッチ粉を混合した炭素系接着剤を用いることが好ましい。
（４）離型膜を形成する組成物としては、テトラフルオロエチレン−パーフルオロアルキルビニルエーテル共重合体（以下、ＰＦＡとも言う）、ポリテトラフルオロエチレン（ＰＴＦＥ）、ポリテトラフルオロエチレンオリゴマー（ＰＴＦＥ−ｏｌｉｇｏｍｅｒ）、テトラフルオロエチレン１−ヘキサフルオロプロピレン共重合体（ＦＥＰ）、テトラフルオロエチレン−エチレン共重合体（Ｅ／ＴＦＥ）、ポリクロロトリフルオロエチレン（ＰＣＴＦＥ）、ポリビニリデンフルオライド（ＰＶＤＦ）、ポリビニルフルオライド（ＰＶＦ）等のフッ素系樹脂を用いることができる。
（５）離型膜として、フッ素系樹脂の焼き付け塗装を行う場合、その膜厚は５０μｍ以上５００μｍ以下であることが好ましい。基材の上に膜厚の厚い樹脂層を形成する方法は、一般に、焼き付け塗装を繰り返して複数の層を積層する工程を含む。このため、５００μｍを超える膜厚の離型膜を形成した場合、複数回の焼き付け工程の熱が加わった下層では、樹脂の特性が変化している可能性があり好ましくない。また、膜厚の薄いフッ素系樹脂の層には電気的なピンホールが発生することがあり、その径は１００μｍ程度である。等方性黒鉛の上の離型膜にピンホールがあると、必要な気密性が確保されず、複合材料のオートクレーブ成形に適さない可能性が高い。予備検討の結果、ＣＦＲＰのオートクレーブ成形工程に必要な気密性を確保するには、フッ素系樹脂の膜厚が５０μｍ以上必要であることが確認された。
（６）離型膜は、基材上に複数の膜を焼付塗装によって厚さ２００μｍ±３０μｍの厚さで堆積することが特に好ましい。この膜厚で形成された離型膜は、最下層の樹脂の層に劣化等の特性変化がなく、しかも複合材料全般のオートクレーブ成形に必要な気密性が確保できる。
Preferred embodiments of the mold and the method for producing the mold of the present invention will be listed.
(1) Isotropic graphite in which no difference in characteristics depending on the cutting direction is observed is used as the base material. The isotropic graphite used in the present invention preferably has a thermal expansion coefficient of 0.5 × 10 −6 K to 2 × 10 −6 K, which is equivalent to Invar. Since the coefficient of thermal expansion is small, the distortion of the molded product of CFRP derived from the deformation of the mold can be reduced.
(2) Porous isotropic graphite having a density higher than 1.75 g / cm 3 as the substrate, an average pore radius of 0.3 to 1.9 μm, and an open porosity of 11 to 18%. Are preferably used. As a result of investigation, if the open porosity is 19% or more, even if the release film is thick, there is a possibility that leaking may not be maintained in the molding process involving decompression, and the surface roughness is deteriorated. It became clear. Therefore, porous isotropic graphite having no difference in characteristics depending on the cutting direction, a small average pore radius, and an open porosity of 18% or less is the most preferred substrate in the embodiment of the present invention. The open porosity is defined by the following formula.
Open porosity (%) = bulk density (Mg / m 3 ) × cumulative pore volume (m 3 / Mg) × 100
... (Formula 1)
Here, the cumulative pore volume is a cumulative value of pore volumes having a pore radius of 0.0074 μm to 68.7 μm, and is measured by a mercury porosimetry method.
(3) For adhesion of the base material, it is preferable to use a carbon-based adhesive obtained by mixing a graphite resin, graphite powder, coke powder, and pitch powder.
(4) As a composition for forming a release film, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (hereinafter also referred to as PFA), polytetrafluoroethylene (PTFE), polytetrafluoroethylene oligomer (PTFE-oligomer). ), Tetrafluoroethylene 1-hexafluoropropylene copolymer (FEP), tetrafluoroethylene-ethylene copolymer (E / TFE), polychlorotrifluoroethylene (PCTFE), polyvinylidene fluoride (PVDF), polyvinyl fluoride Fluorine-based resins such as ride (PVF) can be used.
(5) When baking coating of fluororesin is performed as the release film, the film thickness is preferably 50 μm or more and 500 μm or less. A method of forming a thick resin layer on a substrate generally includes a step of laminating a plurality of layers by repeating baking coating. For this reason, when a release film having a film thickness exceeding 500 μm is formed, there is a possibility that the characteristics of the resin may change in the lower layer where heat is applied in a plurality of baking processes, which is not preferable. Moreover, an electrical pinhole may occur in the thin fluororesin layer, and the diameter thereof is about 100 μm. If there is a pinhole in the release film on the isotropic graphite, the required airtightness is not ensured, and there is a high possibility that it is not suitable for autoclave molding of a composite material. As a result of the preliminary study, it was confirmed that the film thickness of the fluororesin was required to be 50 μm or more in order to ensure the airtightness necessary for the CFRP autoclave molding process.
(6) It is particularly preferable that the release film is formed by depositing a plurality of films on the substrate by baking coating to a thickness of 200 μm ± 30 μm. The release film formed with this film thickness does not change characteristics such as deterioration in the lowermost resin layer, and can secure the airtightness necessary for autoclave molding of all composite materials.
以下に、本発明を、プリプレグを原料としてＣＦＲＰをオートクレーブ成形法によって成形するための成形型に適用した実施例について、詳細に説明する。しかしながら、本発明はこれらの実施例によって限定されるものではない。 Below, the Example which applied this invention to the shaping | molding die for shape | molding CFRP by the autoclave shaping | molding method from prepreg as a raw material is demonstrated in detail. However, the present invention is not limited to these examples.
（実施例１）
図１に、本実施例の成形型１の製造方法のフローチャートを示す。本実施例では、軽量ソリッドカーボン（等方性多孔質黒鉛）製のプレート（平板）に機械加工を施し、その上に離型材を３３０℃以上で焼付塗装して離型膜を形成して、離型膜付き治工具として完成させる。また、随意的に成形品の上側に搭載するカウルプレートを用いる場合は、カウルプレートについても材料に対向する面に対して同様の離型膜を形成することができる。完成した成形型１は、離型材がソリッドカーボンの気孔内に浸透しており、離型材の基材に対するアンカー効果が得られている。
Example 1
In FIG. 1, the flowchart of the manufacturing method of the shaping | molding die 1 of a present Example is shown. In this example, a plate (flat plate) made of lightweight solid carbon (isotropic porous graphite) is machined, and a release material is baked and coated thereon at 330 ° C. or more to form a release film. Completed as a tool with a release film. In addition, when a cowl plate that is optionally mounted on the upper side of the molded product is used, a similar release film can be formed on the surface of the cowl plate facing the material. In the completed mold 1, the release material penetrates into the pores of the solid carbon, and the anchor effect of the release material on the base material is obtained.
このような離型膜付きの成形型１とカウルプレート４１との間にＣＦＲＰの原料であるプリプレグ４０を積層してオートクレーブ成形を行うことで、ＣＦＲＰを成形することができる。図２に、本実施例の成形型１を使用し、プリプレグ４０を原料としたＣＦＲＰのオートクレーブ成形を模した試験を行った試験形態の縦断面図を示す。本実施例の成形型１は、ソリッドカーボンからなる基材１０に、ＰＦＡからなる離型膜１１が形成されている。成形型１の上に、プリプレグ４０を複数枚積層し、その上に離型膜を形成したカウルプレート４１を搭載し、さらに離型フィルム４２とブリーザー４３を重ねている。さらに、成形型１とその上に積層した全ての物品を気密性のあるバッグフィルム４４で被覆している。バッグフィルム４４端部と成形型１との間には、シールテープ４５が配置される。成形型１の上面で、プリプレグ４０とカウルプレート４１と離型フィルム４２とブリーザー４３とはバッグフィルム４４とシールテープ（エポシール）４５とによって封止される。図２に記載したプリプレグ４０、カウルプレート４１、離型フィルム４２、ブリーザー４３、バッグフィルム４４、およびシールテープ４５は、その配置をより明確に示すために、厚さ方向の寸法を実際よりも拡大して強調表示している。 CFRP can be molded by laminating a prepreg 40, which is a raw material of CFRP, between the mold 1 having such a release film and the cowl plate 41 and performing autoclave molding. FIG. 2 shows a longitudinal cross-sectional view of a test configuration in which a test simulating CFRP autoclave molding using prepreg 40 as a raw material was performed using molding die 1 of this example. In the mold 1 of this embodiment, a release film 11 made of PFA is formed on a base material 10 made of solid carbon. A plurality of prepregs 40 are stacked on the mold 1, a cowl plate 41 on which a release film is formed is mounted thereon, and a release film 42 and a breather 43 are stacked. Further, the mold 1 and all the articles laminated thereon are covered with an airtight bag film 44. A seal tape 45 is disposed between the end of the bag film 44 and the mold 1. On the upper surface of the mold 1, the prepreg 40, the cowl plate 41, the release film 42, and the breather 43 are sealed with a bag film 44 and a seal tape (epoch seal) 45. The prepreg 40, the cowl plate 41, the release film 42, the breather 43, the bag film 44, and the seal tape 45 shown in FIG. 2 are enlarged in size in the thickness direction to show the arrangement more clearly. And highlighted.
成形型１の基材１０の板厚を変更したときの気密性について評価を行った。１０ｍｍと５ｍｍの二種類の基材１０について、図２に示した使用状態で成形型１の気密性を試験した結果を図３に示す。試験した成形型１は、密度１．８８ｇ／ｃｍ３の等方性多孔質黒鉛からなる基材１０に膜厚５０μｍ〜１００μｍのテトラフルオロエチレン−パーフルオロアルキルビニルエーテル共重合体（ＰＦＡ）からなる離型膜１１を形成している。また比較例として、同じ大きさのアルミニウム製の成形型を用いた。これらの成形型１の上にプリプレグ４０を積層し、図２に示した使用状態に封止した。さらに、バッグフィルム４４を貫通する真空ホースを配置して真空ポンプによって−０．０９６ＭＰａまで真空引きした後１０分間の真空度の変化を真空計によって３０秒ごとに測定した。 The airtightness when the thickness of the substrate 10 of the mold 1 was changed was evaluated. FIG. 3 shows the results of testing the airtightness of the mold 1 for the two types of base materials 10 of 10 mm and 5 mm in the usage state shown in FIG. The tested mold 1 has a base material 10 made of isotropic porous graphite having a density of 1.88 g / cm 3 and a release plate made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) having a film thickness of 50 μm to 100 μm. A mold film 11 is formed. As a comparative example, an aluminum mold having the same size was used. A prepreg 40 was laminated on these molds 1 and sealed in the use state shown in FIG. Furthermore, a vacuum hose penetrating the bag film 44 was arranged, and after evacuating to -0.096 MPa with a vacuum pump, the change in the degree of vacuum for 10 minutes was measured every 30 seconds with a vacuum gauge.
図３に示すように、等方性多孔質黒鉛からなる基材１０を用いた成形型は、１０ｍｍの板厚のものも５ｍｍの板厚のものも、比較例のアルミニウム製の成形型と同等の真空度の変化を示しており、比較例と同等の気密性を有していた。この実験により、ＰＦＡの離型膜は、５０μｍ〜１００μｍの厚さで形成することで、オートクレーブ成形に必要な、十分な気密性を示すことが確認された。 As shown in FIG. 3, the mold using the base material 10 made of isotropic porous graphite is equivalent to the aluminum mold of the comparative example, both having a thickness of 10 mm and a thickness of 5 mm. The change in the degree of vacuum was shown, and it had the same airtightness as the comparative example. From this experiment, it was confirmed that the PFA release film was formed with a thickness of 50 μm to 100 μm, thereby exhibiting sufficient airtightness necessary for autoclave molding.
（実施例２）
本実施例の成形型の基材２０は、横断面形状がほぼ台形の角柱状に削り出し加工された多孔質等方性黒鉛で構成されている。本実施例で用いた基材２０は、密度１．８８ｇ／ｃｍ３，開気孔率１１％，熱膨張率４．９×１０−６／Ｋ、熱伝導率１４０Ｗ／ｍＫの多孔質等方性黒鉛である。また基材２０の平均気孔半径は１．７μｍである。
(Example 2)
The base material 20 of the molding die of this example is made of porous isotropic graphite that has been machined into a prismatic shape having a substantially trapezoidal cross section. The substrate 20 used in this example has a density of 1.88 g / cm 3 , an open porosity of 11%, a thermal expansion coefficient of 4.9 × 10 −6 / K, and a thermal isotropic conductivity of 140 W / mK. Graphite. The average pore radius of the substrate 20 is 1.7 μm.
基材２０の上面および側面に、ＰＦＡが離型膜２１として焼付け塗装されている。多孔質等方性黒鉛をオートクレーブ成形法に用いる場合、ＰＦＡを成膜することは、表面の開気孔を塞いでリークを防止すると同時に、離型性を向上させる効果がある。本実施例では、基材２にＰＦＡを２００μｍ±３０μｍの厚さで積層している。 PFA is baked and applied as a release film 21 on the upper surface and side surfaces of the substrate 20. When porous isotropic graphite is used in the autoclave molding method, forming PFA has the effect of blocking the open pores on the surface to prevent leakage and at the same time improving the releasability. In this embodiment, PFA is laminated on the base material 2 with a thickness of 200 μm ± 30 μm.
図４は、本実施例の成形型２を用いて、複数のプリプレグ４０と離型フィルム４２とブリーザー４３を重ね、さらに、バッグフィルム４４で被覆してシールテープ４５によって端部を封止してオートクレーブ成形を行った試験形態を模式的に示す斜視図である。図５は、図４のＸ−Ｘ断面図である。なお、離型膜２１は基材２０の底面以外の全面に被覆されている。 In FIG. 4, a plurality of prepregs 40, a release film 42, and a breather 43 are stacked using the molding die 2 of the present embodiment, and further covered with a bag film 44 and sealed with a sealing tape 45. It is a perspective view which shows typically the test form which performed autoclave shaping | molding. FIG. 5 is a cross-sectional view taken along the line XX of FIG. The release film 21 is covered on the entire surface other than the bottom surface of the substrate 20.
成形型２を用いて、ＣＦＲＰのオートクレーブ成形を模した成形と脱型の試験を４０回繰り返して、成形型２の種々の特性を評価する耐久性試験を実施した。本実施例では、カウルプレートを用いずに、複数配置したシート状のプリプレグ４０の最上面とブリーザー４３との間に離型フィルム４２を配置している。すなわち、複数のプリプレグ４０を覆うように離型フィルム４２が配置され、さらにその上にブリーザー４３が配置される。最外層として、バッグフィルム４４が、プリプレグ４０と離型フィルム４２とブリーザー４３とを被覆しており、バッグフィルム４４の端部が成形型２に対してシールテープ４５を用いて接着されて封止がされている。本実施例では、真空引き用のアダプタ１４を成形型２の上面に配置しており、このアダプタ１４にバックフィルム４４を貫通させた真空ホース１５を接続して、図示されない真空ポンプで減圧を行いつつ真空計１６で真空度を監視している。なお、図４および図５に記載したプリプレグ４０、離型フィルム４２、ブリーザー４３、バッグフィルム４４、およびシールテープ４５は、その配置をより明確に示すために、厚さ方向の寸法を実際よりも拡大し、強調して表示している。 Using the mold 2, a durability test for evaluating various characteristics of the mold 2 was performed by repeating the molding and demolding tests imitating the autoclave molding of CFRP 40 times. In this embodiment, a release film 42 is disposed between the uppermost surface of the plurality of sheet-like prepregs 40 and the breather 43 without using a cowl plate. That is, the release film 42 is disposed so as to cover the plurality of prepregs 40, and the breather 43 is further disposed thereon. As the outermost layer, a bag film 44 covers the prepreg 40, the release film 42, and the breather 43, and the end of the bag film 44 is adhered and sealed to the mold 2 using a seal tape 45. Has been. In this embodiment, an evacuating adapter 14 is arranged on the upper surface of the mold 2, a vacuum hose 15 having a back film 44 penetrated is connected to the adapter 14, and decompression is performed by a vacuum pump (not shown). While the vacuum gauge 16 monitors the degree of vacuum. Note that the prepreg 40, the release film 42, the breather 43, the bag film 44, and the seal tape 45 described in FIGS. 4 and 5 have dimensions in the thickness direction that are larger than the actual dimensions in order to show the arrangement more clearly. Enlarged and highlighted.
図４，５に示した試験形態で成形型２を用いて封止したプリプレグ４０を、１８０℃、０．５ＭＰａの加熱加圧条件下で、１．５時間オートクレーブ焼成した。そして冷却後、完成したＣＦＲＰを脱型し、成形型２の特性を評価した。 The prepreg 40 sealed with the mold 2 in the test form shown in FIGS. 4 and 5 was fired in an autoclave for 1.5 hours at 180 ° C. under a heating and pressing condition of 0.5 MPa. After cooling, the completed CFRP was removed from the mold, and the characteristics of the mold 2 were evaluated.
図６（Ａ）に、本実施例の耐久性試験の回数と離型膜の膜厚（μｍ）の変化との関係を示す。膜厚は、成形型２のプリプレグ４０が配置される面上のそれぞれ異なるＡ，Ｂ，Ｃの３箇所で、ＥｌｅｋｔｒｏＰｈｙｓｉｋ社製ＭｉｎｉＴｅｓｔ７３により測定している。図６（Ｂ）に、耐久性試験の回数と離型膜の表面の水滴面積（ｍｍ２）の変化との関係を示す。水滴面積とは表面の撥水性を示す指標であって、１回につき１００ｍｌの水をスポイトに貯留し、スポイト１回押しを３回行って滴下した水の水滴面積を、デジタルマイクロスコープ（ＤＩＮＯ ＡＭ ４１３ＺＴ）を用いて倍率５０倍で観察したときの水滴面積の平均値である。水滴面積も又、成形型２の上面上の特にプリプレグ４０が配置される面のそれぞれ異なるＡ，Ｂ，Ｃの３箇所で、測定を行ってそれぞれの平均値を示している。いずれの特性値も、耐久性試験の回数に対してほとんど変化が認められず、複数回脱型を繰り返した後も良好な特性を示している。以上の試験結果から、実施例２の成形型２は、非常に耐久性に優れていることが確認された。 FIG. 6A shows the relationship between the number of durability tests of this example and the change in the film thickness (μm) of the release film. The film thickness is measured by MiniTest 73 manufactured by ElektroPhysik at three different locations A, B, and C on the surface on which the prepreg 40 of the mold 2 is disposed. FIG. 6B shows the relationship between the number of durability tests and the change in the water droplet area (mm 2 ) on the surface of the release film. The water drop area is an index indicating the water repellency of the surface, and 100 ml of water is stored in a dropper at one time, and the drop area of the water dropped by pressing once with the dropper three times is used as a digital microscope (DINO AM). 413ZT) is an average value of the water droplet area when observed at a magnification of 50 times. The water drop area is also measured at three different points A, B, and C on the upper surface of the mold 2, particularly on the surface where the prepreg 40 is disposed, and the average value is shown. All the characteristic values show almost no change with respect to the number of durability tests, and show good characteristics even after repeated demolding. From the above test results, it was confirmed that the mold 2 of Example 2 was extremely excellent in durability.
図１０は、本実施例の成形型２の他の使用状態を模式的に示す斜視図である。図１１に図１０に対応する成形型２の使用状態の縦断面図を示す。この使用状態では、成形型２は金属製の基台２２上に配置されている。成形型２の上にシート状のプリプレグ４０が配置され、その上に離型フィルム４２が配置されている。さらにその上にブリーザー４３が配置されている。最外層として、バッグフィルム４４が、プリプレグ４０と離型フィルム４２とブリーザー４３に加えて成形型２全体を被覆しており、バッグフィルム４４の端部は、基台２２の上面に到達しており、バッグフィルム４４は基台２２に対して、シールテープ４５を用いて接着され封止を行っている。真空引き用のアダプタ１４が基台２２の上面に配置されており、このアダプタ１４にバックフィルム４４を貫通させた真空ホースを１５を接続して、図示されない真空ポンプで減圧を行いつつ真空計１６で真空度を監視してオートクレーブ成形が行われる。 FIG. 10 is a perspective view schematically showing another usage state of the mold 2 of the present embodiment. FIG. 11 shows a longitudinal sectional view of the molding die 2 in use corresponding to FIG. In this use state, the mold 2 is arranged on a metal base 22. A sheet-like prepreg 40 is disposed on the mold 2, and a release film 42 is disposed thereon. Furthermore, the breather 43 is arrange | positioned on it. As the outermost layer, the bag film 44 covers the entire mold 2 in addition to the prepreg 40, the release film 42 and the breather 43, and the end of the bag film 44 reaches the upper surface of the base 22. The bag film 44 is adhered and sealed to the base 22 using a seal tape 45. An evacuating adapter 14 is disposed on the upper surface of the base 22, and a vacuum hose 15 having a back film 44 penetrated through the adapter 14 is connected to the vacuum gauge 16 while decompressing with a vacuum pump (not shown). The autoclave molding is performed by monitoring the degree of vacuum.
基台２２を配置して成形型２を用いる場合、封止はバッグフィルム４４と基台２２との間で行われるので、成形型２の気密性は問題とされず、成形型２には離型性のみが必要となる。この使用形態では、基台２２を設けることで、全体の重量や体積は増すことになるが、運搬や一時保管等が容易となることがある。 When the base 22 is disposed and the mold 2 is used, since the sealing is performed between the bag film 44 and the base 22, the airtightness of the mold 2 is not a problem, and the mold 2 is separated from the mold 2. Only type is required. In this form of use, the provision of the base 22 increases the overall weight and volume, but may facilitate transportation and temporary storage.
（実施例３）
図７（Ａ）は、本実施例の成形型３をオートクレーブ成形によるＣＦＲＰの製造試験に適用した形態を模式的に示した上面斜視図である。図７（Ｂ）は、成形型３の裏面から見た斜視図である。また、図８（Ａ）に、本実施例の成形型３にＣＦＲＰの原料を配置したときの部分縦断面図を示し、図８（Ｂ）に、本実施例の成形型３からＣＦＲＰを脱型するときの治具の動作を模式的に示す。本実施例の成形型３０は、略矩形形状の上面部材３１と、上面部材３１の四辺に接着された平板状の二組の側面部材３２，３３とを備えており、全体として下面が開放された直方体形状となっている。上面部材３１には、脱型を容易にするための脱型部材３６を収容するための凹部３５が２箇所に配置されている。図７（Ｂ）に示すように、上面部材３１の凹部３５が設けられている箇所の裏面には、同一の素材の補強部材３７が接着により取り付けられている。本実施例でもまた、カウルプレートを用いずに、複数配置したプリプレグ４０の最上面とブリーザー４３との間に離型フィルム４２を配置した形態を示す。プリプレグ４０、離型フィルム４２、ブリーザー４３、バッグフィルム４４、およびシールテープ４５は、実施例２と同一の順序で積層されている。なお、他の実施例と同様に、図７（Ａ）および図８に記載したプリプレグ４０、離型フィルム４２、ブリーザー４３、バッグフィルム４４、およびシールテープ４５は、その配置をより明確に示すために、厚さ方向の寸法を実際よりも拡大し、強調して表示している。
(Example 3)
FIG. 7A is a top perspective view schematically showing a form in which the molding die 3 of the present embodiment is applied to a CFRP production test by autoclave molding. FIG. 7B is a perspective view seen from the back surface of the mold 3. FIG. 8A shows a partial longitudinal sectional view when the CFRP raw material is arranged in the molding die 3 of this embodiment, and FIG. 8B shows the CFRP removed from the molding die 3 of this embodiment. The operation | movement of the jig | tool at the time of shaping | molding is shown typically. The molding die 30 of the present embodiment includes a substantially rectangular upper surface member 31 and two flat plate-shaped side members 32 and 33 bonded to four sides of the upper surface member 31, and the lower surface is opened as a whole. It has a rectangular parallelepiped shape. The upper surface member 31 is provided with two concave portions 35 for accommodating a demolding member 36 for facilitating demolding. As shown in FIG. 7B, a reinforcing member 37 made of the same material is attached to the back surface of the upper surface member 31 where the recess 35 is provided by adhesion. Also in this embodiment, a form in which a release film 42 is disposed between the uppermost surface of a plurality of prepregs 40 and the breather 43 without using a cowl plate is shown. The prepreg 40, the release film 42, the breather 43, the bag film 44, and the seal tape 45 are laminated in the same order as in the second embodiment. As in the other embodiments, the prepreg 40, the release film 42, the breather 43, the bag film 44, and the seal tape 45 shown in FIGS. 7A and 8 are shown more clearly. In addition, the dimension in the thickness direction is enlarged and displayed with emphasis.
本発明における成形型３の製造方法を、図９に示す。成形型３は、以下のように製造される。成形型３の上面部材３１と側面部材３２，３３を構成する、密度１．８８ｇ／ｃｍ３，開気孔率１１％、熱膨張率４．９×１０−６／Ｋ、熱伝導率１４０Ｗ／ｍＫの多孔質等方性黒鉛の平板を準備する（ステップＳ１）。それぞれの平板の接合面となる箇所に、炭素系接着剤を塗布して、接着する（ステップＳ２）。接着剤としては、フェノール系樹脂に黒鉛粉、コークス粉、ピッチ粉を混合した炭素系接着剤を使用する。接着後の成形型３を、２〜５ｋｇｆ／ｃｍ２の圧着力で加圧した状態で、１３〜１００℃／ｈｒの昇温速度で９０℃〜２５０℃まで昇温する（ステップＳ３）。成形型３を、加圧した状態で９０〜２５０℃で１〜２０時間維持する（ステップＳ４）。室温で放冷し（ステップＳ５）、治工具形状にＮＣ加工等で加工し（ステップＳ６）、サンディング等で表面仕上げを行い（ステップＳ７）、実施例１と同一の構成の離型膜を焼付け塗装する（ステップＳ８）。成形型３の上面部材３１と、側面部材３２，３３と、凹部３５の表面にもまた、ＰＦＡが離型膜として厚さ２００μｍ±３０μｍの層となるように焼付け塗装されている。 The manufacturing method of the shaping | molding die 3 in this invention is shown in FIG. The mold 3 is manufactured as follows. The upper surface member 31 and the side members 32 and 33 of the molding die 3 have a density of 1.88 g / cm 3 , an open porosity of 11%, a thermal expansion coefficient of 4.9 × 10 −6 / K, and a thermal conductivity of 140 W / mK. A flat plate of porous isotropic graphite is prepared (step S1). A carbon-based adhesive is applied and bonded to the location that becomes the joining surface of each flat plate (step S2). As the adhesive, a carbon-based adhesive in which graphite resin, coke powder, and pitch powder are mixed with phenol resin is used. In a state where the bonded mold 3 is pressurized with a pressure of 2 to 5 kgf / cm 2 , the temperature is raised to 90 ° C. to 250 ° C. at a temperature rising rate of 13 to 100 ° C./hr (step S3). The shaping | molding die 3 is maintained at 90-250 degreeC in the pressurized state for 1 to 20 hours (step S4). It is allowed to cool at room temperature (step S5), processed into a jig shape by NC processing (step S6), surface-finished by sanding or the like (step S7), and a release film having the same configuration as in Example 1 is baked. Paint (step S8). The upper surface member 31, the side members 32 and 33, and the surface of the concave portion 35 of the mold 3 are also baked and coated so that PFA forms a layer having a thickness of 200 μm ± 30 μm as a release film.
ここで、ステップＳ３の昇温工程と、ステップＳ４の保温工程の条件は、それぞれの接合面の接着剤の発泡を防止して十分な接着強度を得るために重要である。接着剤として使用するフェノール系樹脂が充分に重合して接着が完成するためには、通常９０−１８０℃の温度となる時間が３時間以上確保されることが好ましい。 Here, the conditions of the temperature raising process in step S3 and the heat retaining process in step S4 are important for preventing the foaming of the adhesive on the respective joint surfaces and obtaining sufficient adhesive strength. In order for the phenolic resin used as the adhesive to be sufficiently polymerized to complete the adhesion, it is preferable that a time period of 90 to 180 ° C. is usually secured for 3 hours or more.
図８（Ａ）に示すように、成形型３の上面３１の２箇所に、縦断面が部分円形状である凹部３５が設けられている。凹部３５は、プリプレグ４０の載置位置の端部に一部が重なる位置に形成されている。凹部３５には、この形状と対応する脱型用治具３６が収容される。脱型用治具３６は、ポリテトラフルオロエチレン（ＰＴＦＥ）等の耐熱性樹脂で形成されている。脱型用治具３６は、成形型３の凹部３５に収容されて、部分的にプリプレグ４０と接した状態でオートクレーブ成形に用いられる。そしてオートクレーブ成形により完成したＣＦＲＰ５０を脱型する時は、ＣＦＲＰ５０に接していない脱型用治具３６の端部を、例えばプラスチック棒とミニハンマーを用いて軽く衝撃を与えることで、ＣＦＲＰ５０が成形型３から容易に取り外される。空気が脱型用治具３６とＣＦＲＰ５０の間に入り、プラスチック製のへらなどが挿入しやすくなって、一気に脱型作業をすることが可能となる。 As shown in FIG. 8 (A), concave portions 35 whose longitudinal cross sections are partially circular are provided at two locations on the upper surface 31 of the mold 3. The recess 35 is formed at a position that partially overlaps the end of the mounting position of the prepreg 40. The recess 35 accommodates a demolding jig 36 corresponding to this shape. The demolding jig 36 is made of a heat resistant resin such as polytetrafluoroethylene (PTFE). The demolding jig 36 is accommodated in the concave portion 35 of the mold 3 and is used for autoclave molding in a state where it is partially in contact with the prepreg 40. When removing the CFRP 50 completed by autoclave molding, the CFRP 50 is molded by applying a light impact to the end of the demolding jig 36 not in contact with the CFRP 50 using, for example, a plastic rod and a mini hammer. 3 is easily removed. Air enters between the demolding jig 36 and the CFRP 50, and a plastic spatula or the like can be easily inserted, so that demolding work can be performed at once.
（実施例４）
密度１．８８ｇ／ｃｍ３，開気孔率１１％，熱膨張率４．９×１０−６／Ｋ、熱伝導率１４０Ｗ／ｍＫの多孔質等方性黒鉛を用いて実施例２と同等の形状の基材を形成し、実施例１と同様にＰＦＡを離型膜として積層して成形型とした。この成形型は、実施例２の成形型２と同等の気密性を示し、また同様の耐久性試験において、離型膜の厚さや表面粗度の変化がほとんど認められず、良好な特性を示した。
Example 4
A shape equivalent to that of Example 2 using porous isotropic graphite having a density of 1.88 g / cm 3 , an open porosity of 11%, a thermal expansion coefficient of 4.9 × 10 −6 / K, and a thermal conductivity of 140 W / mK. A base material was formed, and PFA was laminated as a release film in the same manner as in Example 1 to obtain a molding die. This mold has the same airtightness as the mold 2 of Example 2, and in the same durability test, almost no change in the thickness of the release film and the surface roughness is observed, and it exhibits good characteristics. It was.
（比較例１）
かさ密度１．６６〜１．７４ｇ／ｃｍ３，開気孔率１９〜３０％、平均気孔半径１０〜１００μｍ、熱膨張率４．４×１０−６／Ｋ、熱伝導率１５０Ｗ／ｍＫの押し出し黒鉛（異方性黒鉛）を基材とし、実施例１と同様にＰＦＡを離型膜として積層して成形型とした。しかしながらこの成形型は、気密性を維持することができず、オートクレーブ成形法に用いることができなかった。このことから、気密性を維持するためには、開気孔率が１８％以下であることが重要であり、この値を超える黒鉛材料は気密性が維持できず、オートクレーブ成形に用いる成形型には適さないことが明らかとなった。
(Comparative Example 1)
Extruded graphite having a bulk density of 1.66 to 1.74 g / cm 3 , an open porosity of 19 to 30%, an average pore radius of 10 to 100 μm, a thermal expansion coefficient of 4.4 × 10 −6 / K, and a thermal conductivity of 150 W / mK (Anisotropic graphite) was used as a base material, and PFA was laminated as a release film in the same manner as in Example 1 to form a mold. However, this mold cannot maintain airtightness and cannot be used in an autoclave molding method. Therefore, in order to maintain the airtightness, it is important that the open porosity is 18% or less, and the graphite material exceeding this value cannot maintain the airtightness. It became clear that it was not suitable.
以上、実施例において本発明の具体例を詳細に説明したが、これらは例示にすぎず、特許請求の範囲を限定するものではない。特許請求の範囲に記載の技術には、以上に例示した具体例を様々に変形、変更したものが含まれ、本発明の要旨を逸脱しない範囲の設計変更等も含まれる。例えば実施例では、ＰＦＡを離型膜として用いる場合について説明したが、離型性を向上させる任意のフッ素系樹脂を利用することができる。また、離型膜の膜厚も、５０μｍ以上５００μｍ以下の任意の厚さとすることができる。さらに、脱型用治具の形状は、部分円状に限らず、くさび形、多角形など、任意に形成することができる。 As mentioned above, although the specific example of this invention was described in detail in the Example, these are only illustrations and do not limit a claim. The technology described in the claims includes various modifications and changes of the specific examples illustrated above, and includes design changes and the like within a scope that does not depart from the gist of the present invention. For example, in the embodiment, the case where PFA is used as the release film has been described, but any fluorine-based resin that improves the release property can be used. The film thickness of the release film can also be set to an arbitrary thickness of 50 μm or more and 500 μm or less. Further, the shape of the demolding jig is not limited to a partial circle, and can be arbitrarily formed such as a wedge shape or a polygonal shape.
１、２、３・・・成形型
１０、２０、３０・・・基材
１１、２１、３４・・・離型膜
１４・・・真空引き用アダプタ
１５・・・真空ホース
１６・・・真空計
２２・・・金属製の基台
３１・・・上面部材
３２，３３・・・側面部材
３５・・・凹部
３６・・・脱型用治具
３７・・・補強部材
４０・・・プリプレグ
４１・・・カウルプレート
４２・・・離型フィルム
４３・・・ブリーザー
４４・・・バッグフィルム
４５・・・シールテープ
５０・・・ＣＦＲＰ
1, 2, 3 ... Mold 10, 20, 30 ... Base material 11, 21, 34 ... Release film 14 ... Vacuum pulling adapter 15 ... Vacuum hose 16 ... Vacuum Total 22 ... Metal base 31 ... Upper surface members 32, 33 ... Side members 35 ... Recess 36 ... Demolding jig 37 ... Reinforcing member 40 ... Prepreg 41 ... Cowl plate 42 ... Release film 43 ... Breaser 44 ... Bag film 45 ... Seal tape 50 ... CFRP
Claims (3)
当該基材の表面に形成された、フッ素系樹脂からなる離型膜とを、備えており、
前記基材は、熱伝導率が１３Ｗ／ｍＫよりも大きく２００Ｗ／ｍＫ未満であり、
且つ前記離型膜の膜厚が５０μｍ以上５００μｍ以下であることを特徴とする成形型。 A mold for molding a composite material, comprising a base material made of porous isotropic graphite having an open porosity of 18% or less;
A release film made of a fluorine-based resin formed on the surface of the substrate,
The base material has a thermal conductivity of greater than 13 W / mK and less than 200 W / mK,
And the film thickness of the said release film is 50 micrometers or more and 500 micrometers or less, The shaping | molding die characterized by the above-mentioned.
基材を構成する、開気孔率１８％以下の多孔質等方性黒鉛からなる複数の部材を炭素系接着剤によって接着する工程と、
前記基材を、２〜５ｋｇｆ／ｃｍ２の圧着力で加圧した状態で、１３〜１００℃／ｈｒの昇温速度で９０〜２５０℃まで昇温する工程と、
前記基材を９０〜２５０℃で１〜２０時間維持する工程と、
前記基材を放冷する工程と、
前記基材に離型膜を焼付け塗装する工程と、
を備えることを特徴とする成形型の製造方法。 A manufacturing method of a mold for molding a composite material,
A step of adhering a plurality of members made of porous isotropic graphite having an open porosity of 18% or less, constituting a base material, with a carbon-based adhesive;
A step of heating the substrate to 90 to 250 ° C. at a temperature rising rate of 13 to 100 ° C./hr in a state where the substrate is pressed with a pressure of 2 to 5 kgf / cm 2 ;
Maintaining the substrate at 90-250 ° C. for 1-20 hours;
Cooling the substrate;
Baking and painting a release film on the substrate;
The manufacturing method of the shaping | molding die characterized by providing.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2016081281A JP2017189939A (en) | 2016-04-14 | 2016-04-14 | Mold and method of manufacturing mold |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2016081281A JP2017189939A (en) | 2016-04-14 | 2016-04-14 | Mold and method of manufacturing mold |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2017189939A true JP2017189939A (en) | 2017-10-19 |
Family
ID=60086422
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2016081281A Pending JP2017189939A (en) | 2016-04-14 | 2016-04-14 | Mold and method of manufacturing mold |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2017189939A (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02269014A (en) * | 1989-04-11 | 1990-11-02 | Ibiden Co Ltd | Graphite mold for plastic molding |
| JP2000238045A (en) * | 1998-12-25 | 2000-09-05 | Fusoo Kk | Plastic molding tool and manufacture thereof |
| JP2000355018A (en) * | 1999-06-16 | 2000-12-26 | Toyo Tanso Kk | Mold for resin molding |
| JP2002067045A (en) * | 2000-09-04 | 2002-03-05 | Toyota Motor Corp | Graphite mold for molding urethane foam |
-
2016
- 2016-04-14 JP JP2016081281A patent/JP2017189939A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02269014A (en) * | 1989-04-11 | 1990-11-02 | Ibiden Co Ltd | Graphite mold for plastic molding |
| JP2000238045A (en) * | 1998-12-25 | 2000-09-05 | Fusoo Kk | Plastic molding tool and manufacture thereof |
| JP2000355018A (en) * | 1999-06-16 | 2000-12-26 | Toyo Tanso Kk | Mold for resin molding |
| JP2002067045A (en) * | 2000-09-04 | 2002-03-05 | Toyota Motor Corp | Graphite mold for molding urethane foam |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US10518487B2 (en) | Artificial defect material and manufacturing method of FRP structure | |
| CA2662476C (en) | Forming-molding tool and process for producing preforms and fiber reinforced plastics with the tool | |
| JP5044220B2 (en) | Carbon foam composite tool and method for using the carbon foam composite tool | |
| JP4808720B2 (en) | Apparatus, system and method for manufacturing composite parts | |
| US20100186899A1 (en) | Thermoplastic mandrels for composite fabrication | |
| US20110175262A1 (en) | Molding die and molding method | |
| US10821683B2 (en) | Method for molding flame-retardant bending beam integrated with three-dimensional nylon air duct and production mould thereof | |
| JP2007521987A5 (en) | ||
| JP2010540294A (en) | Molding method of molding material | |
| JP6273804B2 (en) | Manufacturing method of fiber reinforced plastic molding | |
| JP2007118598A (en) | Method and apparatus for manufacturing preform | |
| US11426958B2 (en) | 3D printed end cauls for composite part fabrication | |
| CN103958142A (en) | Preform manufacturing method and fiber-reinforced plastic molding manufacturing method | |
| JP2009274248A (en) | Method for manufacturing frp | |
| JP4941811B2 (en) | Manufacturing method of preform and FRP molded body | |
| JP2017189939A (en) | Mold and method of manufacturing mold | |
| JP6717105B2 (en) | Method for producing fiber-reinforced resin molding | |
| US11642816B2 (en) | Fluoroelastomer covered elastomeric tooling for composite manufacturing | |
| JP3834628B2 (en) | Resin filler for manufacturing fiber reinforced composite material and fiber reinforced composite material manufacturing method using the same | |
| JP2007176163A (en) | Manufacturing process of fiber-reinforced plastic | |
| JP3870299B2 (en) | Method for joining and molding modified polytetrafluoroethylene molded product | |
| Louis et al. | Effects of Release Materials and Temperature Ramp Rates on the Surface Finish of Carbon-Fiber Composite Components | |
| JPH03174360A (en) | Jig material for molding and molding method |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A621 | Written request for application examination |
Free format text: JAPANESE INTERMEDIATE CODE: A621 Effective date: 20190104 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A821 Effective date: 20190104 |
|
| A977 | Report on retrieval |
Free format text: JAPANESE INTERMEDIATE CODE: A971007 Effective date: 20191018 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20191126 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20200122 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A821 Effective date: 20200122 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20200630 |
|
| A02 | Decision of refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A02 Effective date: 20210105 |