JP2018171728A - Fiber-reinforced resin molding block and method of producing fiber-reinforced resin using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide fiber-reinforced resin molding blocks and a method of molding fiber-reinforced resin using the same capable of easily maintaining vacuum, preventing resin from leaking, and eliminating seal exchanging work by preventing breakage of a seal member.SOLUTION: Fiber-reinforced resin molding blocks of this invention are at least a pair of blocks facing one another to form a cavity, in which a groove is disposed in a substantially circumferential shape outside the cavity of one of the blocks and a seal member is provided to the groove. The other one of the blocks includes an engaging face formed of at least two faces: one face to be engaged with the seal member being in a substantially parallel direction to a block open/close direction and one face being in a substantially vertical direction to the block open/close direction. When the blocks are open where the seal member and the engaging face are completely apart from one another, a relation of L1≤L2 is satisfied between the shortest distance (L1 (mm)) between the seal member and the face of the substantially parallel direction; and the shortest distance (L2 (mm)) between the seal member and the face of the substantially vertical direction.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a fiber reinforced resin mold and a method for producing a fiber reinforced resin using the same, and more particularly to a fiber reinforced resin mold having an improved mold seal structure and a method for producing a fiber reinforced resin using the same.

  As a method of molding fiber-reinforced resin with excellent productivity, after placing the reinforcing fiber base in the mold cavity, injecting the matrix resin into the mold and impregnating the reinforcing fiber base, and curing the resin So-called RTM (Resin Transfer Molding) molding, in which a fiber-reinforced resin molded product is removed, is known. In RTM molding, when manufacturing relatively large fiber reinforced resin molded products or thick fiber reinforced resin molded products, a reinforcing fiber substrate laminate (for example, a plurality of reinforcing fiber substrates) is formed in a predetermined shape. To form a preform for a reinforcing fiber substrate laminate, which is a pre-molding body of the fiber reinforced resin, place the preform in a mold, and inject the matrix resin into the mold. A method of curing the resin impregnated in the material is often used.

  The sealing part of the conventional fiber reinforced resin molding die used the sealing material of the rectangle and the round section which are described in patent documents 1-3. These sealing materials are mounted in grooves provided so as to extend along the outer periphery of the cavity of one mold, are elastically deformed by being pressed from the other mold by clamping, and have a vacuum retaining property in the cavity. Two sealing functions of resin leakage resistance after resin injection were exhibited.

  Patent Documents 1 and 2 describe a resin injection molding apparatus that presses a protruding portion protruding from a groove of a sealing material with a flat portion or an inclined portion of the other mold. Patent Document 2 describes a resin injection molding apparatus in which a recess is provided in a protruding portion of a seal material and the seal material is pressed by a protrusion corresponding to the recess.

  Further, in recent years, as a method for improving the resin impregnation property to the base material, as disclosed in Patent Document 3, the cavity is reinforced with a thickness larger than the final fiber reinforced resin molded product. Gap RTM molding is used, in which resin is injected into the gap between the fiber substrate and the mold, then the cavity thickness is reduced, the resin is pressurized and fluidized, the substrate is impregnated with resin, and then cured. Yes. Patent Document 3 describes a method using a first sealing material that increases the degree of vacuum in the cavity and a second sealing material that prevents liquid resin from leaking out of the cavity.

  Further, as a method for improving the surface design of the fiber reinforced resin molded product, after the fiber reinforced resin molded product is cured in the RTM molding as disclosed in Patent Document 4, the fiber reinforced resin molded product is placed between the fiber reinforced resin molded product and the mold. An in-mold coating method may be used in which a void is provided and a resin is injected into the void and cured.

JP 2012-187923 A JP-A-7-186199 JP 2014-43071 A Japanese Patent No. 5846638

  However, in the method disclosed in Patent Document 3, since two sealing materials must be provided for vacuum and resin, there is a problem that productivity is lowered, and a space for providing a plurality of seal portions is required, so that the apparatus size is large. There was a growing problem.

  On the other hand, when the seal structure provided with a single seal material disclosed in Patent Documents 1 and 2 is used for gap RTM molding, it is necessary to change the thickness of the cavity. There was a need to do. At this time, in the method of pressing the sealing material disclosed in Patent Document 1 with the flat portion of the other mold, there are cases where it is difficult to maintain a vacuum or a resin leak occurs when repeatedly used. Further, in the method of pressing the substantially end portion of the sealing material disclosed in Patent Document 2 with the other type of inclined projection, there is a difference in deformation at both ends of the sealing material, and cracks occur at the groove end portion when repeatedly used. It is easy and cannot be said to withstand long-term use of the mold. In addition, there is a problem that it is easily damaged when the press pressure is increased.

  Therefore, with the conventional seal structure, even if the material of the seal material is improved, it cannot be used for repeated long-term use while simultaneously satisfying vacuum retention and resin leakage resistance with a single seal material, resulting in damage. As a result of the replacement of the sealing material and the cleaning of the resin, the operating rate of the mold is lowered, which is a factor of reducing the productivity of the RTM member.

  On the other hand, the in-mold coating method described in Patent Document 4 also has a problem that the above-mentioned problem arises because it is necessary to change the thickness of the cavity, and sufficient sealing performance cannot be obtained, and productivity is reduced. .

  Accordingly, the object of the present invention is to replace the sealing material by paying attention to the above-mentioned problems, making it easier to maintain a vacuum, preventing resin from leaking, and preventing damage to the sealing material as compared with the conventional sealing structure. An object of the present invention is to provide a fiber reinforced resin molding die that can save the labor of the above, and a method for molding a fiber reinforced resin using the same. Another object of the present invention is to provide a fiber reinforced resin mold suitable for RTM molding in which the thickness of the cavity changes as described above, and a fiber reinforced resin molding method using the same.

  As a result of repeated studies based on such problems, the present inventors have found that the sealing material is composed of at least two surfaces, that is, a surface that is substantially parallel to the mold opening / closing direction and a surface that is substantially perpendicular to the mold opening / closing direction. By providing the contact part in the fiber reinforced resin molding die, even when the thickness of the cavity is changed during molding or when such molding is repeated, the sealing material is not easily damaged, and it is easy to maintain a vacuum. It was found that the resin is difficult to leak.

The fiber-reinforced resin molding die of the present invention adopts the following configuration in order to solve the above-described problems. That is,
(1) At least a pair of molds facing each other and forming a cavity, and a fiber reinforced resin molding die having a groove provided in a substantially circumferential shape on the outer side of the cavity of one of the molds. The other mold has an abutting portion composed of at least two surfaces, a surface in a direction substantially parallel to the mold opening / closing direction and a surface in the direction perpendicular to the mold opening / closing direction. At the time of mold opening when the sealing material and the contact portion are completely separated, the shortest distance (L1 (mm)) between the sealing material and the substantially parallel surface and the shortest distance between the sealing material and the substantially vertical surface A fiber-reinforced resin mold in which the relationship of distance (L2 (mm)) is L1 ≦ L2.
(2) In the second mold closed state in which the sealing material, the substantially parallel surface and the substantially vertical surface are in contact, the cavity is sealed by the following (A), (B), and (C). The fiber-reinforced resin mold according to (1) above.
(A) One mold (B) The other mold (C) A clamp region in which a sealing material is sandwiched by one mold and the other mold in the mold opening / closing direction (3) The substantially parallel surface and the substantially vertical direction The fiber-reinforced resin mold according to (1) or (2) above, wherein an angle (α (degree)) formed by the surface is 80 ≦ α ≦ 135.
(4) The angle between the insertion direction of the sealing material into the groove and the mold opening / closing direction (β (degree)) is 15 ≦ β ≦ 75, according to any one of (1) to (3) above Fiber reinforced resin mold.
(5) The fiber reinforced resin mold according to any one of (1) to (4), wherein the shape of the bottom of the groove in a cross section perpendicular to the circumferential direction of the contact portion is a substantially semicircular shape. .
(6) The fiber-reinforced resin mold according to any one of (1) to (5), wherein the substantially vertical surface has a protrusion.
(7) A substrate placement step of placing a reinforcing fiber substrate in the cavity of the fiber-reinforced resin molding die according to any one of (1) to (6), and a resin injection impregnation step of injecting resin into the cavity A method for producing a fiber reinforced resin, comprising:
(8) An intermediate base material disposing step of disposing an intermediate base material in the cavity of the fiber reinforced resin molding die according to any one of (1) to (6), and reducing the thickness of the cavity to form the intermediate base material And a pressing step of pressing the fiber.
(9) A fiber-reinforced resin molded product placement step for placing a fiber-reinforced resin molded product in the cavity of the fiber-reinforced resin mold according to any one of (1) to (6) above, and a surface for injecting resin into the cavity A method for producing a fiber reinforced resin, comprising a resin injection step.

  According to the fiber reinforced resin molding die according to the present invention, even when the thickness of the cavity is changed during molding or when such molding is repeated, the sealing material is not easily damaged and the vacuum is easily maintained. Is difficult to leak.

It is a schematic sectional drawing which shows an example of the positional relationship of the component of the seal | sticker part of this invention. It is explanatory drawing which shows an example of the clamp area | region of the sealing material by which both surfaces were inserted | pinched by the type | mold opening / closing direction by one type | mold and the other type | mold of this invention. It is a schematic sectional drawing which shows an example of the relationship between the groove | channel and sealing material of this invention. It is a schematic sectional drawing of the RTM shaping | molding apparatus which shows an example at the time of applying the fiber reinforced resin shaping | molding die which concerns on the 1st embodiment of the manufacturing method of this invention to RTM shaping | molding. It is a schematic sectional drawing of the RTM shaping | molding apparatus which shows an example at the time of applying the fiber reinforced resin shaping | molding die which concerns on the 2nd embodiment of the manufacturing method of this invention to RTM shaping | molding. It is a schematic sectional drawing which shows an example of the state hold | maintained in the state where the thickness of a cavity is larger than the thickness of a fiber reinforced resin molded product in the RTM molding apparatus of FIG. It is a figure which shows an example of the structure of the seal | sticker part of this invention, and a series of processes from mold clamping to mold removal. It is a figure which shows another example of the structure of the seal | sticker part of this invention, and a series of processes from mold clamping to mold removal. It is a figure which shows another example of the structure of the seal | sticker part of this invention, and a series of processes from mold clamping to mold removal. It is a schematic sectional drawing which shows the example of the seal | sticker part which consists of the surface of a substantially parallel direction and the surface of a substantially perpendicular direction with the sealing material of this invention. It is a schematic sectional drawing which shows the relationship between the sealing material of the Example of this invention, and a contact part. It is a schematic sectional drawing which shows the relationship between the sealing material of a comparative example, and a contact part.

  The present invention relates to a fiber reinforced resin mold having a contact portion between a surface that is substantially parallel to the mold opening / closing direction and a sealing material that is substantially perpendicular to the mold opening / closing direction, and production of a fiber reinforced resin using the same. Is the method.

  Here, the mold open state of the pair of molds will be described with reference to FIG. 1 includes a mold 7 having a sealing material 2 outside the cavity 4, a surface 101 in a direction substantially parallel to the mold opening / closing direction 3 in contact with the sealing material 2, and a surface 102 in a direction substantially perpendicular to the mold opening / closing direction 3. The other mold 8 with the abutment 1 is shown. Further, as an example of the contact portion of the present invention, a substantially vertical surface 102 having protrusions 5 and a substantially parallel surface 101 smoothly connected to the substantially vertical surface 102 via a curved surface are illustrated. At this time, the mold open state of the pair of molds is determined based on the positional relationship between the mold contact portion 1 and the seal material 2, and the mold open state in which the seal material 2 and the contact portion 1 are completely separated from each other. The first mold closed state in which only the substantially parallel surface 101 of the part 1 is in contact, and the second mold closed state in which the seal material 2 and the substantially parallel surface 101 of the contact part 1 are in contact with the substantially vertical surface 102. Classify into three states.

Next, details of the embodiment of the present invention will be described.
[Contact part]
In the fiber reinforced resin molding die of the present invention, the contact portion of the mold with the sealing material is composed of at least two surfaces: a surface in the direction parallel to the mold opening / closing direction and a surface in the direction perpendicular to the mold opening / closing direction.

  There is no particular limitation on the angle formed between the plane in the substantially parallel direction and the mold opening / closing direction, but it is preferable that the angle is 0 degree or more and 30 degrees or less because the pressing amount of the sealing material hardly changes when the mold is closed and the sealing material is not easily damaged. In order to reduce damage to the sealing material due to rubbing with the abutting portion, it is more preferable that the angle is 0 degree or more and 10 degrees or less.

  In addition, the angle formed between the surface in the substantially vertical direction and the mold opening / closing direction is not particularly limited, but the resin leakage resistance of the cavity can be improved by increasing the pressing amount of the sealing material as the mold is closed. The angle is preferably 90 degrees or less.

  Further, the substantially parallel surface and the substantially vertical surface may be smoothly connected via a curved surface, or may be connected via a corner or a recess. There is no particular limitation on the angle (α (degrees)) formed by the substantially parallel surface and the substantially perpendicular surface, but when the resin in the cavity becomes a high pressure in the second mold closed state, the substantially parallel surface Is a backup that suppresses deformation of the seal material in the direction opposite to the cavity, so that 80 ≦ α ≦ 135 is preferable, and sufficient resin leakage is obtained without damaging the seal material when pressed. Therefore, it is more preferable that 90 ≦ α ≦ 105.

  In the fiber reinforced resin molding die of the present invention, when the mold is opened with the sealing material and the contact portion completely separated from each other, the shortest distance (L1 (mm)) between the sealing material and the surface in the substantially parallel direction and the sealing material in the substantially vertical direction. The relationship of the shortest distance (L2 (mm)) with respect to the surface is L1 ≦ L2. By adopting such a configuration, the surface in the substantially parallel direction is in contact with the sealing material in the closed state of the first mold, so that vacuum retention can be obtained while suppressing damage to the sealing material for the above-described reason. The degree of vacuum can be increased by evacuating the cavity until the mold is closed, which is preferable from the viewpoint of productivity. Further, in the second mold closed state, the surface in the substantially vertical direction comes into contact with the sealing material, and the pressing amount of the sealing material can be increased along with the mold closing. In addition, the sealing material is in the direction substantially perpendicular to the mold opening / closing direction. Since the resin is pressed and fixed in a direction substantially parallel to the mold opening / closing direction, resin leakage from the cavity can be prevented, which is preferable.

  In the fiber reinforced resin molding die of the present invention, the cross-sectional shape of the abutting portion of the die does not need to be constant. For example, even if the shape or size of a substantially parallel surface or a substantially vertical surface changes in the circumferential direction, good. Although there is no particular limitation on the dimension of the surface in the substantially parallel direction, the length in the mold opening / closing direction is 5 mm or more and 1000 mm because the vacuum degree of the cavity can be increased by securing the exhaust time in the cavity in the first mold closed state. It is preferable that the thickness is 10 mm or more and 300 mm or less because the sealing material can be pressed and fixed in the second mold closed state.

  In addition, the substantially parallel surface and the substantially vertical surface can have, for example, a curved shape or a protrusion as a change in the unevenness that falls within the surface. In particular, by providing the protrusion on the substantially vertical surface, the volume of the sealing material that is pushed away by contact with the protrusion is smaller than when there is no protrusion, so the strain generated in the sealing material in the second mold closed state is reduced, It is preferable because damage is easily prevented.

The time from the start of the first mold closed state to the start of the second mold clamped state is not particularly limited. However, since the degree of vacuum of the cavity can be further increased during the mold closing by evacuation, it should be 1 second or longer. The cycle time is preferably 1000 seconds or less because the cycle time can be shortened to increase the productivity.
[Clamping area]
As shown in FIG. 2 (a), the fiber-reinforced resin molding die of the present invention has the sealing material 2 sandwiched in both the mold opening and closing direction 3 by one mold and the other mold when the second mold is closed. It can have a clamping area 6. For comparison, FIGS. 2B and 2C show a case where the clamp area is not provided. By providing the clamp region, the pressing amount of the sealing material can be increased as the mold is closed, and the resin leakage resistance is improved. That is, in the second mold closed state in which the seal material, the substantially parallel surface and the substantially vertical surface are in contact, the cavity has (A) one mold, (B) the other mold, and (C) Since the sealing material is sealed by the clamp region in which the sealing material is sandwiched in the mold opening and closing direction by the one mold and the other mold, the resin is difficult to leak even when the inside of the cavity is at a high pressure.

Although there is no particular limitation on the width of the clamp region, it is preferably 1 mm or more to prevent leakage due to deformation of the sealing material for high pressure resin of 0.5 MPa or more, and is sufficient for high pressure resin of 2 MPa or more. In order to exhibit sealing, it is more preferable that it is 5 mm or more. Moreover, it is preferable that it is 50 mm or less because a mold dimension can be made small, and it is more preferable that it is 20 mm or less because a reaction force of the sealing material becomes small and a clamping force can be reduced.
[groove]
Here, FIG. 3 shows an example of the relationship between the groove 9 provided on the outer side of the cavity 4 of one mold 7 of the fiber-reinforced resin mold of the present invention and the sealing material 2. In FIG. 3, the sealing material 2 is inserted into the groove 9 in the direction of the insertion direction 10.

  In the fiber reinforced resin molding die of the present invention, there is no particular limitation on the cross-sectional shape of the groove, but since the processing is easy when the groove is three-dimensionally formed in the die, it is perpendicular to the circumferential direction of the contact portion. It is preferable that the shape of the bottom of the groove in the cross section is a substantially semicircular shape.

There is no particular limitation on the angle (β (degrees)) between the insertion direction of the sealing material into the groove and the mold opening / closing direction, but the sealing material is defined by the substantially vertical surface and the substantially parallel surface in the second mold closed state. Is preferably pressed and fixed, and it is possible to suppress the dropping of the sealing material and the insertion of the resin between the sealing material and the groove.
[Sealant]
There is no particular limitation on the cross-sectional shape of the sealing material, but by making it solid, it is possible to prevent the resin from being inserted between the sealing material and the groove because the pressing of the sealing material due to high resin pressure is suppressed. This is preferable. On the other hand, it is preferable to make the sealing material hollow because the followability of the sealing material to the contact portion is improved and the durability is also increased.

  The specific material of the sealing material is not particularly limited, and the preferable material of the sealing material is preferably a silicone-based or fluorine-based material, although it varies depending on the compatibility with the resin. That is, since such a material has excellent releasability with respect to the resin, the sealing material can be prolonged.

Further, the hardness of the sealing material is preferably in the range of A10 to 90 in terms of durometer hardness and Shore A based on, for example, ISO 7691, and more preferably in the range of A30 to 70. When it is hard, the resin can be prevented from entering between the groove and the sealing material, while when it is soft, the design range of the crushing allowance is wide and easy to use industrially. From the balance of both, the above range is preferable.
[Type]
In the fiber-reinforced resin molding die of the present invention, it is preferable that one die provided with a groove and the other die having a contact portion have a smaller linear expansion coefficient than that of the sealing material, and preferably the linear expansion coefficient is 30 × 10. It is in the range of ^-6 or less. The range of the linear expansion coefficient is preferably included in at least a part of the temperature range of −20 to 300 ° C. Since the molding in the present invention is resin molding and is different from die casting or the like, it is sufficient that the linear expansion coefficient in the above range can be expressed only in the resin molding temperature range.

  In the fiber reinforced resin molding die of the present invention, it is preferable that the finished surface of the groove of one mold provided with the groove does not have a tool mark in order to suppress damage to the sealing material. Further, the surface roughness of the finished surface is preferably maintained at a certain value or less, and Ra: 2.5 (μm) or less is preferable.

  The fiber reinforced resin molding die of the present invention as described above can be applied to, for example, RTM molding, a prepreg obtained by impregnating a fiber reinforcing material made of long fibers such as reinforcing fibers, or a fiber reinforcing material made of short fibers such as reinforcing fibers. It can also be used for press molding of an intermediate substrate such as a sheet mold compound (SMC) impregnated with a resin.

  The fiber reinforced resin mold of the present invention is also suitably used when it is desired to mold the fiber reinforced resin in a short time. The viscosity of the resin injected when molding in a short time is preferably low, for example, 2000 cP or less because it is easy to impregnate the reinforcing fiber substrate. If the injected resin has a low viscosity, the resin may reach the sealing material when the mold is clamped, which often leads to resin leakage, but the fiber-reinforced resin mold of the present invention has high vacuum retention and resin leakage resistance. Therefore, even if the resin reaches the sealing material, it can be molded in a short time without causing resin leakage.

  Since the fiber-reinforced resin mold of the present invention is not easily damaged even if it is repeatedly used, it is possible to use the seal material mounted in the groove repeatedly as it is for a plurality of RTM moldings and press moldings. is there.

The fiber-reinforced resin molding die of the present invention is less likely to cause damage to the sealing material even when the thickness is changed by sealing the cavity, and can have both high vacuum retention and resin leakage resistance. You can get a good product. Furthermore, since the trouble of replacing the sealing material can be saved and the resin burr near the sealing material can be easily removed, the cycle time can be shortened and the productivity is improved. In addition, even when the thickness of the cavity changes, there is no damage to the sealing material, and high vacuum retention and high resin leakage resistance can be expressed repeatedly, so that RTM molding and press molding can be performed while changing the cavity thickness. It is possible to improve the resin impregnation property to the reinforced fiber base material, improve the surface design of the fiber reinforced resin molded product, and use the same RTM mold for multiple fiber reinforced resin molded products with different thicknesses. It becomes possible to manufacture with.
[Production method]
Hereinafter, the manufacturing method of the fiber reinforced resin of the present invention may be simply referred to as “the manufacturing method of the present invention”.
(First aspect)
The first aspect of the method for producing a fiber reinforced resin of the present invention includes a base material arranging step of arranging a reinforced fiber base material in the cavity of the fiber reinforced resin mold of the present invention, and a resin injection impregnation for injecting the resin into the cavity. Process.

  A first aspect of the production method of the present invention will be described with reference to the drawings. The present invention is not limited to the invention described in the drawings.

  FIG. 4 shows an example in which the fiber reinforced resin mold according to the first embodiment of the production method of the present invention is applied to RTM molding. In FIG. 4, an RTM molding device 1001 shows an RTM molding device as a fiber-reinforced resin molding die according to the first aspect of the manufacturing method of the present invention, and an upper mold 701 is provided with a groove in the present invention. The lower mold 801 indicates the other mold having the contact portion in the present invention, which is clamped by the press mechanism 11. A cavity 4 for forming a predetermined shape is formed between the lower mold 701 and the upper mold 801, and a seal portion 15 is provided around the cavity. A reinforcing fiber substrate 12 is disposed in the cavity 4. The upper mold 701 is provided with a resin supply path 13 and a resin injection port 14 for supplying resin. In addition, the thickness of the cavity 4 is adjusted by the mold position adjusting mechanism 17.

  In the first aspect of the production method of the present invention, the reinforcing fiber base material is placed in the cavity (base material placement step). The reinforced base material may be a preform formed in advance. The upper mold is clamped with respect to the lower mold in a state where the reinforcing fiber base is disposed in the cavity (clamping process). Subsequently, a resin for constituting the fiber reinforced resin from the resin supply path is injected through a resin injection port opened at an appropriate position with respect to the reinforcing fiber base, and impregnated into the reinforcing fiber base (resin Injection impregnation step). After the resin impregnation, the resin is cured and a predetermined fiber-reinforced resin molded product is produced.

In the RTM molding device as the fiber reinforced resin molding die as described above, a seal portion is provided around the cavity. Here, some examples of the seal portion in the present invention are shown in FIG. FIG. 10 is a view showing the first mold closed state.
(Second embodiment)
A second aspect of the method for producing a fiber reinforced resin of the present invention includes an intermediate substrate arranging step of arranging an intermediate substrate in a cavity of the fiber reinforced resin molding die of the present invention, and reducing the thickness of the cavity to the intermediate Pressing the substrate.

  A second aspect of the production method of the present invention will be described with reference to the drawings. The present invention is not limited to the invention described in the drawings.

  FIG. 5 shows an example when the fiber-reinforced resin mold according to the second embodiment of the production method of the present invention is applied to press molding. In FIG. 5, a press molding apparatus 1002 shows a press molding apparatus as a fiber reinforced resin molding die according to the second aspect of the manufacturing method of the present invention, and an upper mold 701 is provided with a groove in the present invention. The lower mold 801 indicates the other mold having the contact portion in the present invention, which is clamped by the press mechanism 11. A cavity 4 for forming a predetermined shape is formed between the lower mold 701 and the upper mold 801, and a seal portion 15 is provided around the cavity. An intermediate substrate 18 is disposed in the cavity 4. The thickness of the cavity 4 is adjusted by the mold position adjusting mechanism 17.

  In the second aspect of the production method of the present invention, an intermediate substrate such as a prepreg or SMC is arranged in the cavity (intermediate substrate arrangement step). The intermediate substrate may be a preform shaped in advance.

  The upper mold is clamped with respect to the lower mold in a state where the intermediate substrate is disposed in the cavity (clamping process). In the mold clamping process, the mold position adjusting mechanism maintains the thickness of the cavity larger than the thickness of the fiber reinforced resin molded product to be produced.

  Next, the intermediate substrate is pressurized by reducing the thickness of the cavity (pressing process).

After pressurization, the resin is cured and a predetermined fiber reinforced resin molded product is produced. In the press molding apparatus as the fiber reinforced resin molding die as described above, the first of the manufacturing method of the present invention is provided around the cavity. A seal portion similar to that described in the embodiment is provided.
(Third embodiment)
A third aspect of the method for producing a fiber reinforced resin according to the present invention includes a fiber reinforced resin molded product arrangement step of arranging a fiber reinforced resin molded product in a cavity of a fiber reinforced resin molding die, and a surface resin injecting the resin into the cavity. Injection step.

  A third aspect of the production method of the present invention will be described with reference to the drawings. The present invention is not limited to the invention described in the drawings.

  The 3rd aspect of the manufacturing method of this invention can be implemented using the structure similar to the fiber reinforced resin molding apparatus which concerns on the 1st aspect of the manufacturing method of this invention (FIG. 4).

  In the third aspect of the production method of the present invention, a fiber reinforced resin molded product is arranged in the cavity (fiber reinforced resin molded product arranging step).

  The upper mold is clamped with respect to the lower mold in a state where the fiber-reinforced resin molded product is arranged in the cavity (clamping process). In the mold clamping process, the thickness of the cavity is kept larger than the thickness of the fiber-reinforced resin molded article disposed in the cavity by the mold position adjusting mechanism.

  Subsequently, if necessary, the inside of the cavity is evacuated through a vacuum suction port (not shown), and the degree of vacuum in the cavity is increased. Next, a resin for coating the fiber reinforced resin molded product is injected from the resin supply path through a resin inlet that is opened at an appropriate position with respect to the fiber reinforced resin molded product. At least a part is coated (surface resin injection step).

  After coating, the resin is cured, and a fiber-reinforced resin molded article with improved surface design is produced.

  In the RTM molding apparatus as the fiber reinforced resin molding die as described above, a seal portion similar to that described in the first aspect of the manufacturing method of the present invention is provided around the cavity.

Hereinafter, preferred embodiments of the production method of the present invention will be described.
(First preferred embodiment)
The process of the RTM shaping | molding of the 1st preferable embodiment based on the 1st aspect of the manufacturing method of this invention is demonstrated.

  The structure of the seal portion and the series of steps from clamping to demolding according to the first preferred embodiment of the production method of the present invention will be described with reference to FIG. A groove for inserting the sealing material 2 is provided around the cavity 4 of the upper mold 701 so as to extend along the outer periphery of the cavity 4. In this groove, as shown in FIG. Thus, the sealing material 2 is mounted. Further, the contact portion of the lower mold 801 with the sealing material 2 is provided with a contact portion 1 composed of a substantially parallel surface 101 and a substantially vertical surface 102 along the outer periphery of the cavity. The part 1 comes into contact with the sealing material 2 by clamping. The sealing material is made of a material such as rubber that can be elastically deformed and elastically restored.

  In the substrate arranging step, the reinforcing fiber substrate 12 is arranged in the cavity 4. The reinforced base material may be a preform formed in advance.

  In the mold clamping process, first, as shown in FIG. 7B, the sealing material 2 comes into contact with the surface 101 in the substantially parallel direction by clamping the upper mold 701, the inside of the cavity 4 is sealed, and a vacuum suction port (not shown) is provided. Then, the exhaust in the cavity 4 can be started (first mold closed state). In the mold clamping process, the second mold can be closed by further closing the mold and bringing the sealing material 2 into contact with the substantially vertical surface 102. The pressing amount of the sealing material can be arbitrarily adjusted from the relationship between the dimensions of the groove and the sealing material and the thickness of the cavity, and sufficient vacuum retention can be obtained without damaging the sealing material by being pressed more than necessary. it can.

  In the resin injection process, as shown in FIG. 7C, the resin 16 may reach the sealing material 2 particularly when the viscosity of the resin is small. Even when the resin reaches the sealing material, the substantially vertical surface presses the sealing material, and the substantially parallel surface serves as a backup to suppress deformation of the sealing material in the direction opposite to the cavity. Sufficient resin leakage resistance can be obtained without damaging the seal material by pressing it more than necessary.

After the resin impregnation, the resin is cured and a predetermined fiber-reinforced resin molded product is produced.
(Second preferred embodiment)
Furthermore, the process of the RTM shaping | molding of the 2nd preferable embodiment based on the 1st aspect of the manufacturing method of this invention is demonstrated.

  In the second preferred embodiment of the production method of the present invention, the reinforcing fiber substrate is disposed in the cavity in the substrate disposing step. The reinforced base material may be a preform formed in advance.

  After performing a base-material arrangement | positioning process, a mold clamping process is implemented. In the mold clamping step, as shown in FIG. 7B, the sealing material 2 comes into contact with the surface 101 in the substantially parallel direction by clamping the upper mold 701, and the fiber for forming the thickness of the cavity 4 by the mold position adjusting mechanism 17 In the state shown in FIG. 6 which is kept larger than the thickness of the reinforced resin molded product, the space between the lower mold 801 and the upper mold 701 is hermetically sealed, and the vacuum in the cavity 4 is maintained.

  Subsequently, the resin for constituting the fiber reinforced resin from the resin supply path 13 is interposed between the reinforcing fiber base 12 and the mold via the resin inlet 14 opened at an appropriate position with respect to the reinforcing fiber base 12. The resin is injected into the voids (resin injection impregnation step).

  Then, the reinforcing fiber base material is impregnated with the pressurized resin by reducing the thickness of the cavity during the injection of the resin and / or after the injection of the resin. At this time, the sealing material is further pressed by the substantially vertical surface, but the pressing amount of the sealing material can be arbitrarily adjusted based on the relationship between the dimensions of the groove and the sealing material and the thickness of the cavity, and the sealing material is pressed more than necessary. Thus, sufficient resin leakage resistance can be obtained without causing damage.

After the resin impregnation, the resin is cured and a predetermined fiber-reinforced resin molded product is produced.
(Third preferred embodiment)
Moreover, the process of the RTM shaping | molding of the 3rd preferable embodiment based on the 1st aspect of the manufacturing method of this invention is demonstrated. In the third preferred embodiment of the production method of the present invention, a molded product having a thickness different from that of the first preferred embodiment can be produced using the same apparatus configuration as that of the first preferred embodiment.

  In the substrate arranging step, the reinforcing fiber substrate is arranged in the cavity. The reinforced base material may be a preform formed in advance.

  In the mold clamping step, the thickness of the cavity is kept smaller or larger than the thickness of the fiber reinforced resin molded product produced in the first preferred embodiment by the mold position adjusting mechanism. At this time, since the first mold closed state shown in FIG. 7B or the second mold closed state shown in FIG. 7C is maintained, the inside of the cavity is hermetically sealed.

Subsequently, a resin injection impregnation step is performed, and after the resin impregnation, a fiber reinforced resin molded product having a thickness smaller or larger than the thickness of the fiber reinforced resin molded product of the first embodiment is produced.
(Fourth Preferred Embodiment)
In addition, a fourth preferred embodiment of the production method of the present invention according to the second aspect of the production method of the present invention will be described.

  The structure of the seal portion and the series of steps from clamping to demolding according to the fourth preferred embodiment of the production method of the present invention will be described with reference to FIG. A groove for inserting the sealing material 2 is provided around the cavity 4 of the upper mold 701 so as to extend along the outer periphery of the cavity 4. In this groove, as shown in FIG. Thus, the sealing material 2 is mounted. Further, the contact portion of the lower mold 801 with the sealing material 2 is provided with a contact portion 1 composed of a substantially parallel surface 101 and a substantially vertical surface 102 along the outer periphery of the cavity. The part 1 comes into contact with the sealing material 2 by clamping. The sealing material is made of a material such as rubber that can be elastically deformed and elastically restored.

  After the intermediate base material 18 such as prepreg or SMC is placed in the cavity 4 in the base material placement step, a mold clamping step is performed. In the mold clamping process, the thickness of the cavity is kept larger than the thickness of the fiber-reinforced resin molded product to be manufactured by the mold position adjusting mechanism. At this time, the mold is kept in the first mold closed state shown in FIG. 8B or the second mold closed state shown in FIG. 8C, and the inside of the cavity is hermetically sealed.

  Next, if necessary, the inside of the cavity is evacuated through a vacuum suction port (not shown), the degree of vacuum in the cavity is increased, and at the same time, the intermediate substrate is preheated.

  Subsequently, in the pressing step, the reinforcing fiber base material is impregnated with the pressurized resin by reducing the thickness of the cavity.

  In the pressing step, as shown in FIG. 8C, the resin 16 contained in the intermediate base material may reach the sealing material 2 particularly when the viscosity of the resin is small. Even when the resin reaches the sealing material, the substantially vertical surface presses the sealing material, and the substantially parallel surface serves as a backup to suppress deformation of the sealing material in the direction opposite to the cavity. Sufficient resin leakage resistance can be obtained without damaging the seal material by pressing it more than necessary.

After the resin impregnation, the resin is cured and a predetermined fiber-reinforced resin molded product is produced.
(Fifth Preferred Embodiment)
Furthermore, the 5th preferable embodiment of the manufacturing method of this invention based on the 3rd aspect of the manufacturing method of this invention is demonstrated.

  The structure of the seal part and the series of steps from clamping to demolding according to the fifth preferred embodiment of the manufacturing method of the present invention will be described with reference to FIG. A groove for inserting the sealing material 2 is provided around the cavity 4 of the upper mold 701 so as to extend along the outer periphery of the cavity 4. In this groove, as shown in FIG. Thus, the sealing material 2 is mounted. Further, the contact portion of the lower mold 801 with the sealing material 2 is provided with a contact portion 1 composed of a substantially parallel surface 101 and a substantially vertical surface 102 along the outer periphery of the cavity. The part 1 comes into contact with the sealing material 2 by clamping. The sealing material is made of a material such as rubber that can be elastically deformed and elastically restored.

  In the fiber reinforced resin molded product arrangement step, the fiber reinforced resin molded product 19 is arranged in the cavity 4. As the fiber reinforced resin molded article, for example, the fiber reinforced resin molded article produced by the first aspect and the second aspect of the production method of the present invention may be used. Moreover, after producing the fiber reinforced resin molded product according to the first aspect of the production method of the present invention, the subsequent surface resin injection step may be performed without taking the fiber reinforced resin molded product into the cavity.

  Subsequently, as shown in FIG. 6, the mold position adjusting mechanism 17 holds the cavity 4 in a state where the thickness of the cavity 4 is larger than the thickness of the fiber reinforced resin molded product. It is evacuated and the degree of vacuum in the cavity is increased.

  Subsequently, the resin for improving the surface design of the fiber reinforced resin molded product from the resin supply path 13 is passed through the resin injection port 14 opened at an appropriate position with respect to the fiber reinforced resin molded product. It is injected into the gap between the mold and the mold (surface resin injection process).

  In the surface resin injection step, as shown in FIG. 9B, the sealing material 2 comes into contact with the surface 101 in the substantially parallel direction by clamping the upper die 701, and the thickness of the cavity 4 is made larger than the thickness of the fiber-reinforced resin molded product. In a state where it is kept large, the space between the lower mold 801 and the upper mold 701 is hermetically sealed, and the vacuum retention and resin leakage resistance in the cavity are maintained.

  Furthermore, in the surface resin injection process, as shown in FIG. 9C, the resin 16 may reach the sealing material 2 particularly when the viscosity of the resin is small. Even when the resin reaches the sealing material, the substantially vertical surface presses the sealing material, and the substantially parallel surface serves as a backup to suppress deformation of the sealing material in the direction opposite to the cavity. Sufficient resin leakage resistance can be obtained without damaging the seal material by pressing it more than necessary.

  Then, the injected resin is cured, and a fiber-reinforced resin molded product having excellent surface design is produced.

  In the present invention, the first to fifth embodiments can be implemented in any combination.

Hereinafter, the present invention will be described more specifically with reference to examples.
(1) Sealing part and sealing material As a sealing material, a silicone extruded product (hardness A50, tensile strength 9.1 MPa, elongation at cutting 400%) manufactured by Nippon Chemical Equipment Co., Ltd. was used. Table 1 shows the configuration of the seal portion and the seal material. FIG. 11 shows the relationship between the embodiment and FIG. 12 shows the relationship between the sealing material and the contact portion for the comparative example.

(2) RTM shaping | molding The RTM shaping | molding apparatus of the structure shown in FIG. 5 was prepared, and RTM shaping | molding was performed. A carbon fiber woven fabric (woven structure: plain weave, woven fabric weight: 330 g / m ² , reinforcing fiber: T700S-12K) manufactured by Toray Industries, Inc. was used as the reinforcing fiber substrate. As the resin, a two-component epoxy resin (main agent: manufactured by Momentive, curing agent: manufactured by Toray Industries, Inc., acid anhydride curing agent) was used.
(Examples 1-7)
After the configurations of the seal part and the seal material were as shown in Table 1 and FIG. 11, the above-described base material placement process, mold clamping process, resin injection process, pressure impregnation process, and demolding process were performed. In the pressure impregnation step, the cavity thickness was reduced by 2 mm.

When the sealing material was removed from the groove and observed, it was confirmed that the surface was free of cracks, scuffing, peeling, whitening, and no damage. In Example 6 only, traces of the resin entering and solidifying between the sealing material and the substantially vertical surface were observed, but no resin leakage to the outside of the cavity occurred.
(Comparative Examples 1-5)
After making the structure of the sealing part and the sealing material as shown in Table 1, the above-described base material arranging process, mold clamping process, resin injection process, pressure impregnation process, and demolding process were performed. In the pressure impregnation step, the cavity thickness was reduced by 2 mm.

  When the sealing material was removed from the groove and observed, in Comparative Examples 2, 3, and 5, the surface was cracked, swollen, peeled, whitened, and the sealing material was damaged. Further, in Comparative Examples 1 and 4, resin resin leakage occurred.

DESCRIPTION OF SYMBOLS 1 Contact part 101 Surface in substantially parallel direction 102 Surface in substantially vertical direction 2 Seal material 3 Mold opening / closing direction 4 Cavity 5 Protrusion 6 Clamp region 7 One mold 701 Upper mold 8 Other mold 801 Lower mold 9 Groove 10 Insertion direction 1001 RTM molding device 1002 Press molding device 11 Press mechanism 12 Reinforced fiber base material 13 Resin supply path 14 Resin inlet 15 Seal portion 16 Resin 17 Mold position adjusting mechanism 18 Intermediate base material 19 Fiber reinforced resin molded product

Claims (9)

  It is at least a pair of molds that face each other to form a cavity, and is a fiber reinforced resin molding mold in which a groove is provided in a substantially circumferential shape outside the cavity of one mold, and a sealing material is provided in the groove. The other mold has an abutting portion consisting of at least two surfaces of a surface in a direction substantially parallel to the mold opening / closing direction and a surface in a direction substantially perpendicular to the mold opening / closing direction. At the time of mold opening in which the contact portions are completely separated, the shortest distance (L1 (mm)) between the sealing material and the substantially parallel surface and the shortest distance (L2) between the sealing material and the substantially vertical surface. (Mm)) is a fiber reinforced resin mold in which the relationship of L1 ≦ L2. In the second mold closed state where the sealing material, the substantially parallel surface and the substantially vertical surface are in contact, the cavity is sealed by the following (A), (B), and (C). The fiber-reinforced resin mold according to claim 1.
(A) One mold (B) The other mold (C) Clamp region in which the sealing material is sandwiched between the one mold and the other mold in the mold opening / closing direction   The fiber reinforced resin mold according to claim 1 or 2, wherein an angle (α (degree)) formed by the plane in the substantially parallel direction and the plane in the substantially vertical direction is 80 ≦ α ≦ 135.   The fiber reinforced resin mold according to any one of claims 1 to 3, wherein an angle (β (degree)) formed by an insertion direction of the sealing material into the groove and the mold opening / closing direction is 15 ≦ β ≦ 75.   The fiber reinforced resin mold according to any one of claims 1 to 4, wherein a shape of a bottom portion of the groove in a cross section perpendicular to a circumferential direction of the contact portion is a substantially semicircular shape.   The fiber-reinforced resin molding die according to any one of claims 1 to 5, wherein the substantially vertical surface has a protrusion.   A fiber reinforced resin comprising: a base material arranging step of arranging a reinforcing fiber base material in a cavity of the fiber reinforced resin molding die according to claim 1; and a resin injection impregnation step of injecting resin into the cavity. Manufacturing method.   An intermediate base material placement step of placing an intermediate base material in the cavity of the fiber-reinforced resin mold according to any one of claims 1 to 6, and a pressing step of pressurizing the intermediate base material by reducing the thickness of the cavity. A method for producing a fiber reinforced resin, comprising:   A fiber reinforced resin molded product arrangement step of arranging a fiber reinforced resin molded product in the cavity of the fiber reinforced resin molding die according to any one of claims 1 to 6, and a surface resin injection step of injecting a resin into the cavity. The manufacturing method of fiber reinforced resin.

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