JP2019025890A - Production method of molding - Google Patents

Abstract

To provide a production method of a molding having desired strength and profile from a raw material comprising a mixed material composed of a resin and a fiber.SOLUTION: The production method of a molding from a raw material comprising a mixed material composed of a resin and a fiber contains: a first molding step of forming a preform by heating the raw material using a mold to a first heating temperature at which the resin and the fiber are crosslinked; and a second molding step, after the first molding step, of heating the preform using the mold to a second heating temperature which is higher than the first heating temperature to crosslink the resin to each other to form a macromolecule so as to produce a molding.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a molded article.

  Conventionally, various production methods for producing carbon fiber reinforced plastic (CRPM) composed of carbon fiber and a resin material have been proposed (see, for example, Patent Document 1).

  Patent Document 1 is a method for producing a carbon fiber reinforced plastic as an example of a method for producing a carbon fiber reinforced plastic using a sheet-like material in which a carbon fiber called a prepreg is impregnated with a resin. In the production method of Patent Document 1, a sheet-shaped body is impregnated with a thermosetting resin composition, and then irradiated with light to heat the metal nanoparticles in the thermosetting resin composition, thereby thermosetting resin. Is cured.

JP 2013-91728 A

  Carbon fiber reinforced plastic is a material having both high strength and lightness, and is required to have a desired strength and shape. As a method for producing such a carbon fiber reinforced plastic, in addition to the method using a prepreg as described in Patent Document 1 described above, a mold was used based on a material made of a mixed material in which carbon resin and fiber were mixed. A method of manufacturing as a molded product by molding is conceivable. However, according to the manufacturing method using a metal mold, it is difficult to process the material, and the finished product is often porous and low in density, and produces a carbon fiber reinforced plastic having a desired strength and shape. Difficult to do.

  Thus, when manufacturing molded articles, such as carbon fiber reinforced plastic, using a metal mold | die, it can be said that there is still room for improvement regarding manufacturing a molded article having a desired strength and shape.

  Accordingly, an object of the present invention is to solve the above-described problem, and to provide a method for manufacturing a molded product that can manufacture a molded product having a desired strength and shape from a material made of a mixed material of resin and fiber. There is.

  In order to achieve the above object, a method for producing a molded product according to the present invention is a method for producing a molded product from a material using a mixed material in which a resin and a fiber are mixed. A first molding step for producing a preform by heating to a first heating temperature for crosslinking the resin and the fiber, and after the first molding step, the preform is transformed with the mold using the mold. And a second molding step for producing a molded product by heating to a second heating temperature higher than the first heating temperature and at which the resin is crosslinked and polymerized.

  According to the method for producing a molded article of the present invention, a molded article having a desired strength and shape can be produced.

Schematic perspective view of the molding apparatus of Embodiment 1 Longitudinal sectional view of the molding apparatus of Embodiment 1 Schematic of the material supplied to the molding apparatus of Embodiment 1 Plan view of preformed product and molded product of embodiment 1 Plan view of the fixing part of the preliminary mold and the fixing part of the main mold of the first embodiment Schematic for demonstrating the manufacturing method of the molded article of Embodiment 1. FIG. Schematic for demonstrating the manufacturing method of the molded article of Embodiment 1. FIG. Schematic for demonstrating the manufacturing method of the molded article of Embodiment 1. FIG. Schematic for demonstrating the manufacturing method of the molded article of Embodiment 1. FIG. Schematic for demonstrating the manufacturing method of the molded article of Embodiment 1. FIG. The figure which shows the example of the temperature change of the raw material at the time of implementing the manufacturing method of Embodiment 1, a preformed article, and a molded article Plan view showing a preformed product of Embodiment 2 Side view showing preformed product of embodiment 2 Plan view showing a molded product of the second embodiment Side view showing the molded product of the second embodiment Longitudinal sectional view showing a spare mold of the second embodiment Longitudinal sectional view showing the main mold of the second embodiment Plan view showing a molded product of Embodiment 3 Side view showing the molded product of the third embodiment The perspective view which shows the molded product of Embodiment 3. Plan view showing the first material of the third embodiment Plan view showing the second material of the third embodiment The perspective view which shows the preforming product of Embodiment 3 The perspective view which shows the simple metal mold | die of Embodiment 4. FIG. The perspective view which shows the raw material of Embodiment 4. The perspective view which shows the crude product of Embodiment 4. Schematic showing the results of the experiment according to Example 1 Schematic showing the results of the experiment according to Example 1 Longitudinal sectional view of the second molded product used in Example 1 Surface view of the first molded product Back view of the first molded product Longitudinal section of the first molded product Surface view of the second molded product Back view of the second molded product Longitudinal section of the second molded product Surface view of the third molded product Back view of the third molded product Longitudinal section of the third molded product Surface view of the fourth molded product Back view of the fourth molded product Longitudinal section of the fourth molded product Surface view of the fifth molded product Back view of the fifth molded product Longitudinal section of the fifth molded product Schematic showing the results of the experiment according to Example 2 Vertical sectional view of the fifth molded product used in Example 2 Surface view of a molded product having the same shape as the molded product created in Example 3 Rear view of a molded product having the same shape as the molded product created in Example 3 Longitudinal sectional view of a molded product having the same shape as the molded product created in Example 3 Surface view of a molded product having a shape similar to the molded product created in Example 3 Rear view of a molded product having a shape similar to the molded product created in Example 3 Longitudinal sectional view of a molded product having a shape similar to the molded product created in Example 3 Diagram showing destructive testing machine The graph which shows the result of having performed the destructive test using the destructive testing machine shown to FIG. 28A

  Hereinafter, exemplary embodiments of a method for manufacturing a molded article according to the present invention will be described with reference to the accompanying drawings. The present invention is not limited to the specific configurations of the following embodiments, and configurations based on similar technical ideas are included in the present invention.

(Embodiment 1)
A schematic configuration of a molding apparatus for manufacturing a molded article in the first embodiment will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic perspective view of a molding apparatus 2 according to the first embodiment, and FIG. 2 is a longitudinal sectional view of the molding apparatus 2. FIG. 2 is a longitudinal sectional view as seen from the Y direction in FIG. 1 (a state in which the molds are combined).

  The molding apparatus 2 according to the first embodiment is an apparatus that manufactures a molded product from a material made of a mixed material obtained by mixing resin and fibers using a mold. In particular, the molding apparatus 2 according to the first embodiment forms a carbon fiber reinforced plastic by hot press-molding a material 12 (FIG. 3) in which thermosetting “phenolic resin” and “carbon fiber” are mixed. Manufacturing goods.

  FIG. 3 shows an example of the material 12 in which a phenol resin and carbon fiber are mixed. The material 12 is a mixed material in which phenol resin and carbon fiber are collected in a solid state at room temperature. In FIG. 3, the state before the raw material 12 is compressed with a metal mold | die is shown. In a state after being compressed by the mold, the material 12 becomes a porous material having a large number of voids inside.

  As an apparatus for processing / molding the material 12 shown in FIG. 3, the molding apparatus 2 shown in FIGS. 1 and 2 includes a preliminary mold (first mold) 4 and a main mold (second mold) 6. With. The preliminary mold 4 is a mold for making a preform 14 from the material 12. The present mold 6 is a mold for making a molded product 16 based on the preformed product 14 made by the preliminary mold 4. In FIG. 1, both the preformed product 14 and the molded product 16 are illustrated. Hereinafter, the respective configurations of the reserve mold 4 and the main mold 6 will be described.

  The preliminary mold 4 is a mold configured to heat the raw material 12 in a compressed state so as to make a preformed product 14 from the raw material 12. Hot press molding of the material 12 is performed by the preliminary mold 4.

  As shown in FIGS. 1 and 2, the reserve mold 4 includes a movable portion 4 a and a fixed portion 4 b. The movable part 4a disposed above is configured to be movable up and down with respect to the fixed part 4b disposed below. 1 shows a state in which the movable part 4a and the fixed part 4b are separated from each other, and FIG. 2 shows a state in which the movable part 4a and the fixed part 4b are in contact with each other.

  The movable part 4a has a convex core 5a protruding downward from the bottom surface thereof. On the other hand, the fixed portion 4b has a concave cavity 5b that is recessed downward from the upper surface thereof. The shape of the core 5a corresponds to the shape of the cavity 5b, and the core 5a can be disposed in the cavity 5b as shown in FIG.

  In the state shown in FIG. 2, a cavity 8 is formed in the cavity 5b. The cavity 8 is an arrangement region (preliminary molding region) for arranging the material 12 to make the preform 14. The three-dimensional shape of the cavity 8 is substantially the same as the three-dimensional shape of the preform 14 shown in FIG.

  The present mold 6 is a mold configured to heat the preform 14 in a compressed state so that the preform 16 is formed from the preform 14. With this die 6, hot press molding of the preformed product 14 is performed.

  The metal mold 6 includes a movable portion 6a disposed above and a fixed portion 6b disposed below. The movable part 6a has a core 7a, and the fixed part 6b has a cavity 7b.

  As shown in FIG. 2, in a state where the core 7a is disposed in the cavity 7b, a cavity 10 is formed in the cavity 7b. The cavity 10 is an arrangement region (main forming region) for arranging the preformed product 14 to make the molded product 16. The three-dimensional shape of the cavity 10 is substantially the same as the three-dimensional shape of the molded product 16 shown in FIG.

  Each of the preformed product 14 and the molded product 16 shown in FIG. 1 is a plate-like member extending in the A direction. Each of the preformed product 14 and the molded product 16 has a width in the B direction orthogonal to the A direction.

  The outer shape of the preformed product 14 and the molded product 16 in plan view will be described with reference to FIGS. 4A and 4B.

  FIG. 4A is a plan view of the preform 14 and the molded product 16. FIG. 4B is a plan view of the fixing portion 4 b of the preliminary mold 4 corresponding to the preformed product 14 and the fixing portion 6 b of the main mold 6 corresponding to the molded product 16.

  4A and 4B, the horizontal length A1 and the vertical length B1 of the preform 14 are the horizontal length of the cavity 5b shown in FIG. 4B. A1 and length B1 in the vertical direction are the same. Similarly, the lateral length A2 and the longitudinal length B2 of the molded product 16 shown in FIG. 4A are the same as the lateral length A2 and the longitudinal length B2 of the cavity 7b shown in FIG. 4B, respectively. is there.

  In such a configuration, the length A1 is set shorter than the length A2, and the length B1 is set shorter than the length B2 (for example, about 80%). Further, as shown by a dotted line in FIG. 4B, the outer shape of the horizontal section of the cavity 5b in plan view is set smaller than the outer shape of the horizontal section of the cavity 7b, and fits inside the cavity 7b. As a result, as indicated by the dotted line in FIG. 4A, the outer shape of the horizontal section of the preformed product 14 in plan view is smaller than the outer shape of the horizontal section of the molded product 16 and fits inside the molded product 16.

  According to such a size setting, the outer shape of the horizontal section of the preform 14 shown in FIG. 4A is smaller than the outer shape of the horizontal section of the cavity 7b in the main mold 6 shown in FIG. 4B. Therefore, when the preform 14 made from the preform 4 is transferred to the cavity 7b of the main mold 6, the preform 14 can be easily placed in the cavity 7b. Further, since the preform 14 is molded as having a high strength as described later and is not easily deformed, the preform 14 is surely arranged in the cavity 7b by setting the outer diameter as described above. be able to.

  Since the molded product 16 is made by compressing the preformed product 14 in the thickness direction, as shown in FIG. 4A, the horizontal outer shape becomes larger in both the vertical and horizontal directions. On the other hand, as shown in FIG. 1, the thickness C2 of the molded product 16 is smaller than the thickness C1 of the preformed product 14 (for example, about 40%).

  The molded product 16 having the above-described shape can be used for a connecting rod for automobiles, for example. By applying carbon fiber reinforced plastic to such applications, it is possible to improve the safety and convenience by applying a material having both strength and lightness.

  5A-5E and FIG. 6 show an example of a method of making a preform 14 from the raw material 12 using the molding apparatus 2 having the above-described configuration and making a molded product 16 (carbon fiber reinforced plastic) from the preform 14. It explains using.

  5A to 5E are schematic longitudinal sectional views for explaining a method for producing a carbon fiber reinforced plastic by the molding apparatus 2. FIG. 6 is a diagram showing temperature changes of the raw material 12, the preformed product 14, and the molded product 16 in the series of steps shown in FIGS. 5A-5E.

  First, the raw material 12 is prepared and arrange | positioned to the backup metal mold | die 4 (step S1). Specifically, the material 12 shown in FIG. 3 is prepared. As described above, the material 12 is made of a mixed material of phenol resin and carbon fiber. The material 12 can be prepared, for example, by preparing each of the phenol resin and the carbon fiber and mixing them together.

As shown in FIG. 5A, the prepared material 12 is disposed in the cavity 5 b of the fixing part 4 b of the preliminary mold 4. The temperature of the material 12 as it is placed in the cavity 5b is a normal temperature _{T 0} (Fig. 6).

  Next, preforming is performed (step S2). Specifically, as shown in FIG. 5B, the movable part 4a of the preliminary mold 4 is moved downward to press the material 12 between the movable part 4a and the fixed part 4b. Heating the movable part 4a and the fixed part 4b with a heat source (not shown) heats the pressurized material 12 (hot press molding). Thereby, the preformed product 14 is made.

Preform 14 is adapted to heat the material 12 as shown in FIG. 6 at a predetermined Atsushi Nobori rate, ultimately made by heating up to a first heating temperature T _1.

First heating temperature T ₁ of the phenolic resin and the carbon fibers constituting the blank 12 is set to a temperature that cross-linking. By heating to such a temperature, the phenol resin and the carbon fiber are chemically bonded, and the preform 14 having a predetermined strength is produced.

When molding a mixed material consisting of resin and fibers by heating, the resin and fibers are easily separated systematically, resulting in a large number of voids inside the final product, which reduces the density of the product. , Easy to reduce strength. On the other hand, according to the above method, the resin 12 and the fiber are surely cross-linked by heating to the _first heating temperature T1 while heating the material 12 at a predetermined temperature increase rate. Thereby, a chemical bond can be formed and strength can be improved, removing gas contained in material 12 (including gas generated from material 12 itself by heating) efficiently.

The first heating temperature T ₁ described above is set to be equal to or higher than the first crosslinking start temperature at which the phenol resin and the carbon fiber start to be crosslinked. The first heating temperatures T ₁ is set to be less than the second cross-linking starting temperature for starting the polymerization by crosslinking one another thermosetting resin (phenol resin) to each other after crosslinking the carbon fiber. According to such a temperature setting, it is possible to allow the preform 14 to be further processed while giving the preform 14 a predetermined strength.

For example, if the phenolic resin and the carbon fiber, the first cross-linking starting temperature is about 135 degrees, for the second cross-linking starting temperature is about 150 degrees, the first heat temperatures T ₁ described above for example, 135 More than 150 degrees and less than 150 degrees are set.

  As shown in FIG. 6, the (average) temperature increase rate in the preforming step S2 is set slower than the (average) temperature increase rate in the main forming step S4 described later. According to such setting, the preformed product 14 can be made while efficiently removing the gas contained in the material 12, and the density of the preformed product 14 can be improved.

  In particular, when the material 12 is hot press-molded, the temperature rises from the surface side of the material 12 toward the center, and thus the internal temperature of the material 12 may vary. On the other hand, since the temperature increase rate of the material 12 is set slower in the preforming step S2, the material 12 can be heated more uniformly, and the density of the preformed product 14 made from the material 12 is more uniform. Can be

  Next, the preformed product 14 is moved (step S3). Specifically, the preformed product 14 made of the preliminary mold 4 is moved from the preliminary mold 4 to the main mold 6 as shown in FIG. 5C. A transport means (not shown) may be used for moving the preformed product 14. Thereafter, the preformed product 14 is placed in the cavity 7 b of the fixed portion 6 b of the mold 6.

As the preliminary mold 4 moves to the main mold 6, the temperature of the preform 14 decreases. As shown in FIG. 6, the temperature of the preform 14 is lowered to a first lower temperature T ₃ than the heating temperature T ₁ of the aforementioned.

  Next, main molding is performed (step S4). Specifically, as shown in FIG. 5D, the movable part 6a of the main mold 6 is moved downward to pressurize the preform 14 between the movable part 6a and the fixed part 6b. The movable part 6a and the fixed part 6b are heated by a heat source (not shown) to heat the pressurized preform 14 (hot press molding). Thereby, the molded product 16 is produced.

As shown in FIG. 6, the molded article 16, while heating the preform 14 from the temperature T ₃ at a predetermined Atsushi Nobori rate, ultimately made by heating to a second heating temperature T _2.

Second heating temperature T ₂ is set to a temperature at which polymerization and crosslinking each other phenolic resins and phenolic resins among crosslinked with carbon fibers.

Second heating temperature T _2, the phenolic resin together monomolecular is set to more than the second cross-linking starting temperature to begin cross-linking. In order to prevent polymerization phenol resin is decomposed, a second heating temperature T ₂ is set to a temperature lower than the decomposition temperature of the polymer of phenolic resin begins to decompose. For example, if the phenolic resin and the carbon fiber, the second cross-linking starting temperature is about 150 degrees, because the decomposition initiation temperature is about 180 degrees, the second heating temperature T _2, for example, 150 degrees or more 160 degrees Set to

In addition, immediately before reaching the _second heating temperature T2, there is a state in which the phenol resin and the carbon fiber instantaneously gel and the shape is likely to change. At this time, the preformed product 14 can be processed into a molded product 16 having a desired shape by applying pressure to the preform 6.

  In addition, since the processing is started from the preform 14 having a predetermined strength, the main molding step S4 can be performed quickly and easily.

  Next, the molded product 16 is taken out (step S5). Specifically, as shown in FIG. 5E, the molded product 16 is taken out from the main mold 6. The temperature of the removed molded product 16 gradually decreases as shown in FIG.

  According to the manufacturing method, a carbon fiber reinforced plastic molded product 16 having a desired strength and shape can be manufactured from the material 12 which is a mixed material of carbon fiber and phenol resin.

As described above, the manufacturing method according to the first embodiment is a method for manufacturing a molded article 16 of carbon fiber reinforced plastic from the material 12 made of a mixed material in which a phenol resin and carbon fiber are mixed. The manufacturing method of the first embodiment includes a preforming step S2 (first forming step) and a main forming step S4 (second forming step). Preforming step S2 is a material 12, using a pre-mold 4, by heating to a first heating temperature T ₁ of of crosslinking the phenol resin and the carbon fiber is a step of making the preform 14. This molding step S4, after the preforming step S2, the preform 14, using the present mold 6, the high and phenolic resins each other than the first heating temperature T ₁ is to polymerized by crosslinking In this step, the molded product 16 is made by heating to a heating temperature T _{2 of 2} .

According to the above method, the preforming step S2 for crosslinking the phenol resin and the carbon fiber and the main molding step S4 for crosslinking the phenol resins to form a polymer are performed separately. According to such a method, a preform 14 having a predetermined strength is produced while venting the gas contained in the material 12 in the preforming step S2, and the main molding step based on the preform 14 is made. In S4, the molded product 16 having a desired shape can be formed. Without dividing the preforming step S2 and the full-forming step S4, compared to the case of continuously heating to a second heating temperature T _2, it is possible to improve the density remove the gas contained in the material 12 effectively The molded product 16 having a desired strength and shape can be manufactured.

As described above, since the material 12 is porous with a lot of voids inside, when the material 12 is simply hot press-molded, a lot of gas is contained inside the molded product to be produced. As a result, the density may decrease, and the desired strength may not be obtained. According to the manufacturing method of the first embodiment On the contrary, by heating the material 12 in the preforming step S2 to the first heating temperature T ₁ of while heating at a predetermined Atsushi Nobori rate, phenolic resin and carbon The fibers are cross-linked. Thereby, the preform 14 having a predetermined strength can be made while accurately extracting the gas contained in the material 12. In addition the molding step S4, by heating the preform 14 to the second heating temperature T _2, are polymerized by crosslinking the phenol resin together unimolecular. In this way, by forming the molded product 16 as the final molded product based on the preform 14 having a high density, the molded product 16 having both desired strength and shape can be manufactured.

  Further, in the first embodiment, the average temperature increase rate in the pre-forming step S2 is set to a value slower than the average temperature increase rate in the main forming step S4. For this reason, the gas contained in the raw material 12 can be extracted more accurately, and the preformed product 14 and the molded product 16 having a high density can be produced.

  Further, unlike the manufacturing method of carbon fiber reinforced plastic using prepreg as in Patent Document 1, the manufacturing method in Embodiment 1 is a manufacturing method by hot press molding using a mold. Since it is the manufacturing method using a metal mold | die, the manufacturing cost of carbon fiber reinforced plastics can be reduced.

  Furthermore, the manufacturing method in the first embodiment uses different molds (preliminary mold 4 and main mold 6) in the preliminary molding step S2 and the main molding step S4. Further, the material 12 is moved from the preliminary mold 4 to the main mold 6 between the preliminary molding step S2 and the main molding step S4.

  According to the above method, by performing the preforming step S2 and the main molding step S4 with separate molds, the sizes of the preformed product 14 and the molded product 16 produced in the step can be made different. Thereby, the external shape of the preformed product 14 and the molded product 16 described with reference to FIGS. 4A and 4B can be set, and a desired shape suitable for each step can be obtained.

Furthermore, according to the manufacturing method in the first embodiment, the temperature change region of each mold can be reduced, and the productivity in mass production can be improved. Specifically, as shown in FIG. 6, the temperature change range of the pre-mold 4 in preforming step S2 is in the range of from room temperature T ₀ to the first heating temperature T _1, the present in the present molding step S4 temperature change range of the die 6 is in the range from a temperature T ₃ to a second heating temperature T _2. When the continuous preliminary shaping step S2 and the full-forming step S4 using the same mold, the temperature change range of the die is wide range of from room temperature T ₀ to the second heating temperature T _2. On the other hand, since each temperature change region of the preliminary mold 4 and the main mold 6 shown in FIG. 6 is a small range, the heating time required for one molding can be shortened in each mold. Thereby, the tact time required for one molding at the time of mass production can be shortened, and the productivity can be improved.

  As a general resin molding method, a method is known in which a material obtained by heating and melting a material made of a thermoplastic resin is flowed into a mold to make a molded product. However, in the case of carbon fiber reinforced plastic, since the raw material 12 containing not only resin but also carbon fiber is used, sufficient fluidity cannot be obtained even when heated. Therefore, it is very difficult to produce a carbon fiber reinforced plastic by applying a conventional general method as it is. On the other hand, the manufacturing method of Embodiment 1 is a method of making the preform 14 and the carbon fiber plastic molded product 16 by press molding the material 12 instead of flowing it. Thus, a carbon fiber plastic having a desired strength and shape can be produced by a method completely different from a conventional general resin molding method.

  In addition, since the conventional general resin molding method is to flow the resin, the resin is poured into one mold. On the other hand, the manufacturing method of the first embodiment is a manufacturing method using two molds, that is, the preliminary mold 4 and the main mold 6, and is greatly different from the concept of a conventional general resin molding method. Is.

  As described above, according to the manufacturing method of the first embodiment, it is possible to easily perform press molding of a carbon fiber reinforced plastic, which has been considered to be very difficult in the past, and has few defective products and excellent reliability. A method for producing a reinforced plastic can be provided.

  The configuration of the preformed product 14 and the molded product 16 and the manufacturing method thereof according to the first embodiment have been described above, but various modifications are possible. For example, the shapes of the preformed product 14 and the molded product 16 are not limited to the shapes shown in FIGS. 1 and 4A, and various modifications are possible. Specific modifications thereof will be described with reference to the following second and third embodiments. In the second and third embodiments, differences from the first embodiment will be mainly described, and the description overlapping with the first embodiment will be omitted.

(Embodiment 2)
A preform 34 in Embodiment 2 according to the present invention is shown in FIGS. 7A and 7B, and a molded product 36 is shown in FIGS. 8A and 8B. 7A is a plan view of the preform 34, and FIG. 7B is a side view of the preform 34. FIG. FIG. 8A is a plan view of the molded product 36, and FIG. 8B is a side view of the molded product 36.

  The molded article 36 shown in FIGS. 8A and 8B is used as a connecting rod (connecting rod) of an automobile. Such connecting rods are generally made of metal or the like and have a problem of hindering the acceleration of the automobile because of the high specific gravity. If a molded product 36 made of carbon fiber reinforced plastic is used for such a connecting rod, a significant weight reduction can be achieved while maintaining the required strength of the connecting rod, and the acceleration of the vehicle can be achieved while ensuring safety. Can be improved.

  As shown in FIGS. 7A and 7B, the preform 34 includes a central portion 34a and both end portions 34b. The central portion 34a is a plate-shaped portion and has a thickness X1 as shown in FIG. 7B. Both end portions 34b are portions formed in an annular shape at both ends of the central portion 34a, and form a cylindrical cavity 34c. As shown in FIG. 7B, both end portions 34b have a thickness X2.

  By processing the preform 34 shown in FIGS. 7A and 7B by the same method as the main molding step S4 described in the first embodiment, the molded product 36 shown in FIGS. 8A and 8B can be produced.

  As shown in FIGS. 8A and 8B, the molded product 36 includes a central portion 36a and both end portions 36b. The central portion 36a is a plate-shaped portion and has a thickness X3 as shown in FIG. 8B. Both end portions 36b are portions formed in an annular shape at both ends of the central portion 36a, and form a cylindrical cavity 36c. As shown in FIG. 8B, both end portions 36b have a thickness X4.

  The thicknesses X3 and X4 of the molded product 36 shown in FIGS. 8A and 8B are smaller than the thicknesses X1 and X2 of the preform 34, respectively.

  FIGS. 9 and 10 show the configuration of the preliminary mold 24 for manufacturing the preform 34 shown in FIGS. 7A and 7B and the main mold 26 for manufacturing the molded article 36 shown in FIGS. 8A and 8B. It explains using.

  FIG. 9 is an enlarged vertical sectional view of a pre-mold 24 for making a preform 34 from the same material 12 as in the first embodiment, and FIG. 10 is for making a mold 36 from the preform 34. FIG. 3 is an enlarged vertical sectional view of the present mold 26.

  As shown in FIG. 9, the reserve mold 24 forms a cavity 28 between the upper movable part 24a and the lower fixed part 24b in contact with each other. The cavity 28 has substantially the same shape as the preform 34 described above. In order to form the cavity 28 having such a shape, unevenness is provided on each of the bottom surface 24c of the movable portion 24a and the top surface 24d of the fixed portion 24b. In particular, the upper surface 24d of the movable part 24b is provided with two columnar protrusions 29 extending upward and spaced apart in the horizontal direction. By providing the protrusions 29, cavities 34c are formed at both ends 34b of the preform 34 shown in FIGS. 7A and 7B.

  As shown in FIG. 10, the present mold 26 forms a cavity 30 between the upper movable portion 26a and the lower fixed portion 26b in contact with each other. The cavity 30 has substantially the same shape as the molded product 36 described above. In order to form the cavity 30 having such a shape, unevenness is provided on each of the bottom surface 26c of the movable portion 26a and the upper surface 26d of the fixed portion 26b. In particular, two columnar protrusions 31 are provided on the upper surface 26d of the movable portion 26b so as to extend upward and be spaced apart in the horizontal direction. By providing the protrusions 31, cavities 36c are formed at both ends 36b of the molded product 36 shown in FIGS. 8A and 8B.

  If the shapes of the bottom surface 24c and the upper surface 24d in the preliminary mold 24 and the shapes of the bottom surface 26c and the upper surface 26d in the main mold 26 are appropriately changed, the shape is not limited to the shapes shown in FIGS. A carbon fiber plastic having a desired shape can be manufactured.

(Embodiment 3)
A molded product 46 according to the third embodiment of the present invention is shown in FIGS. 11A-11C.

  FIG. 11A is a plan view of the molded product 46, FIG. 11B is a side view of the molded product 46, and FIG. 11C is a perspective view of the molded product 46.

  The molded product 46 shown in FIGS. 11A to 11C is used as a connecting rod for an automobile, similarly to the molded product 36 of the second embodiment.

  The molded product 46 according to the third embodiment includes a honeycomb portion 48 that constitutes a central portion, and both end portions 50.

  In the molded product 36 of the second embodiment described above, the central portion 36a is a plate having a substantially constant thickness (FIG. 8B), whereas in the molded product 46 of the third embodiment, the honeycomb portion 48 constitutes the central portion. The point to do is different.

  As shown in FIGS. 11A and 11C, a honeycomb shape 52 is formed on the surface of the honeycomb portion 48. The honeycomb shape 52 is a rib shape for strength reinforcement. 11A and 11C, only the front surface side of the honeycomb portion 48 is illustrated, but the honeycomb shape 52 is also formed on the back surface of the honeycomb portion 48.

  In order to form the honeycomb shape 52, the shape of the bottom surface 24c and the top surface 24d of the preliminary mold 24 of the second embodiment and the shape of the bottom surface 26c and the top surface 26d of the main mold 26 correspond to the honeycomb shape 52. What is necessary is just to form the unevenness | corrugation to perform.

  The molded product 46 and its preform (not shown) shown in FIGS. 11A-11C can be made by a manufacturing method similar to the manufacturing method of the first and second embodiments described above.

  According to the manufacturing methods of Embodiments 1 and 2, since most of the gas has already been extracted at the stage of the preform, a fine shape such as the honeycomb shape 52 has a high strength without reducing the strength. Can be molded.

  By providing the honeycomb portion 48 having such a honeycomb shape 52, the strength of the molded product 46 can be further improved as compared with the molded product 36 of the second embodiment. Thereby, even higher strength can be realized in a carbon fiber reinforced plastic that requires particularly high strength.

  12A and 12B will be described as examples of materials for manufacturing the molded product 46 having the honeycomb shape 52 described above. FIG. 12A shows the first material 60, and FIG. 12B shows the second material 62.

  In the manufacturing method of the third embodiment, a preformed product is made by placing two types of materials, a first material 60 and a second material 62, in a preliminary mold and press-molding. Further, the preform 46 is put into a main mold and press-molded to produce a molded product 46.

  A first material 60 shown in FIG. 12A is a sheet-like member in which a mixed material of carbon fiber and phenol resin is in a semi-gel state. A first material 60 shown in FIG. 12A includes an inner portion 64 and an outer portion 66. By cutting the sheet-like mixed material, the inner portion 64 and the outer portion 66 are separated. The inner portion 64 has a shape that can be accommodated in the cavity (not shown) of the preliminary mold described above. On the other hand, the outer portion 66 has an outer shape larger than the cavity of the spare mold and cannot be accommodated in the cavity. The outer portion 66 is originally a portion that is discarded as waste material. However, in the manufacturing method according to the third embodiment, the outer portion 66 that is waste material is finely crushed so as to be in a form that can be accommodated in the cavity of the preliminary mold. Use (not shown).

  A second material 62 shown in FIG. 12B is a member made of a mixed material of carbon cloth, phenol resin, and a curing agent in a sheet shape. The carbon cloth is woven with carbon fibers. The second material 62 shown in FIG. 12B includes an inner portion 68 and an outer portion 70. By cutting the sheet-like mixed material, the inner portion 68 and the outer portion 70 are separated. The outer portion 70 is a portion that is originally discarded as waste material in the same manner as the outer portion 66 of the first material 60 described above. However, when the outer portion 70 is crushed into fine pieces, the outer portion 70 can be accommodated in the cavity of the preliminary mold. Use as a form.

  In the third embodiment, in particular, in order from the bottom, two inner portions 68, one outer portion 70 chopped, one inner portion 64, one outer portion 66 chopped, one inner portion 64 The outer portion 70 is cut into two pieces and the inner portion 68 is laminated. The laminate thus formed is press-molded in a preliminary mold (not shown) to produce a preform 72 as shown in FIG. The preformed product 72 is further placed in a metal mold (not shown) and press-molded, whereby a molded product 46 as shown in FIGS. 11A-11C can be made.

  Not limited to the above-described lamination pattern, a laminate obtained by combining the first material 60 and the second material 62 in an arbitrary pattern may be press-molded with a preliminary mold.

  According to the manufacturing method described above, the outer portion 66 of the first material 60 and the outer portion 70 of the second material 62 that are originally discarded are used as a material for making a preform by finely crushing them. Can do. By using such waste material, the manufacturing cost of the molded product 46 can be reduced.

  Furthermore, since the second material 62 using the carbon cloth shown in FIG. 12B has higher strength than the first material 60, the inner portion 68 of the second material 62 is arranged at the upper and lower end portions to form a molded product. By manufacturing 46, the surface strength of the molded product 46 can be improved. On the other hand, since the second material 62 is expensive, the cost can be reduced while maintaining the surface strength by the second material 62 by arranging the first material 60 inside.

(Embodiment 4)
A method for manufacturing a molded article according to Embodiment 4 of the present invention will be described with reference to FIGS.

  FIG. 14 shows a simple mold 80, and FIG. 15 shows a material 82 put into the simple mold 80. A simple mold 80 shown in FIG. 14 is a mold for forming a material to be put into the preliminary mold 4 shown in FIG. 1 and the like based on the material 82 shown in FIG. The fourth embodiment differs from the first embodiment in that a simple mold 80 is used in addition to the preliminary mold 4 and the main mold 6 described above.

  A simple mold 80 shown in FIG. 14 includes a movable portion 84 and a fixed portion 86. The movable portion 84 has a core 84A, and the fixed portion 86 has a cavity 86A. FIG. 14 shows a state where the core 84A of the movable part 84 and the cavity 86A of the fixed part 86 do not face each other, but the core 84A faces the cavity 86A when in use.

  A material 82 shown in FIG. 15 is a material to be put into the reserve mold 4 shown in FIG. The material 82 is a portion that is originally discarded as a waste material, like the outer portion 66 of the first material 60 shown in FIG. 12A. A material 82 shown in FIG. 15 includes a first material 82A, a second material 82B, and a third material 82C. The first material 82A, the second material 82B, and the third material 82C are cut into different shapes, but all are cut from the same sheet-like material. Specifically, by cutting a sheet-like base material obtained by impregnating a long carbon fiber with a phenol resin, it is divided into a first material 82A, a second material 82B, a third material 82C, and the like.

  Each of the materials 82 shown in FIG. 15 is finely crushed into sliced shapes and put into the cavities 86A of the fixing portion 86 of the simple mold 80 shown in FIG. By pressing the material 82 using the movable portion 84 and the fixed portion 86, a crude product 88 as shown in FIG. 16 is produced.

  Thereafter, the crude product 88 is used as the raw material 12 to be put into the reserve mold 4 shown in FIG. That is, the preformed product 14 and the molded product 16 described above can be manufactured using the crude product 88 as the material 12.

Example 1
Next, Example 1 will be described. Example 1 is an experiment for verifying the dimensional accuracy of a plurality of molded products created by the method described in the third embodiment.

  17A and 17B are schematic diagrams showing the results of the experiment according to Example 1. FIG. As shown in FIGS. 17A and 17B, in Example 1, the first molded product 90 and the second molded product 92 created by the method described in Embodiment 3 are used.

  The first molded product 90 has honeycomb surfaces 90A and 90B on both sides. The second molded product 92 has a honeycomb surface 92A on one side and a flat surface 92B on the other side.

  As shown in FIGS. 17A and 17B, two test bars 94 are inserted into both end portions 90C of the first molded product 90 and both end portions 92C of the second molded product 92, respectively. Each of the test bars 94 includes an insertion portion 94A and a head 94B. The insertion portion 94 </ b> A is a portion that is inserted into both end portions 90 </ b> C of the first molded product 90 and both end portions 92 </ b> C of the second molded product 92. The head 94B is a portion having a larger diameter than the insertion portion 94A.

  As shown in FIGS. 17A and 17B, two test bars 94 are inserted through the first molded product 90 and the second molded product 92 at the same time. Even if there is a slight difference between the size of the first molded product 90 and the size of the second molded product 92, it becomes difficult to insert the two test bars 94 at the same time. , 92 can be formed to have substantially the same dimensions.

  Here, a longitudinal sectional view of the second molded product 92 is shown in FIG. As shown in FIG. 18, the inner layer of the second molded product 92 includes carbon fibers 96 and a phenol resin 98. In each layer in the thickness direction P1 of the second molded product 92, it can be seen that the carbon fibers 96 extend from the end portion toward the end portion without being substantially divided in the lateral direction. By arranging the carbon fibers 96 in this manner, the high strength of the second molded product 92 can be realized.

(Example 2)
Next, Example 2 will be described. In the same manner as in Example 1, Example 2 is an experiment in which dimensional accuracy is verified for a plurality of molded products created by the method described in the third embodiment. In the first embodiment, two molded products 90 and 92 are used, whereas in the second embodiment, five molded products 100, 102, 104, 106, and 108 are mainly used.

  Each of the five molded articles 100, 102, 104, 106, 108 is shown in FIGS. 19A-23C. Specifically, the first molded product 100 is shown in FIGS. 19A-19C, the second molded product 102 is shown in FIGS. 20A-20C, the third molded product 104 is shown in FIGS. 21A-21C, and FIGS. The fourth molded product 106 is shown in 22C, and the fourth molded product 108 is shown in FIGS. 23A-23C. In these drawings, A corresponds to a front view, B corresponds to a back view, and C corresponds to a longitudinal sectional view.

  As shown in FIGS. 19A to 19C, the first molded product 100 has honeycomb surfaces 100A and 100B on both surfaces, and further has both end portions 100C. The honeycomb surface 100A and the honeycomb surface 100B have honeycomb shapes having substantially the same pattern.

  As shown in FIGS. 20A-20C, the second molded product 102 has honeycomb surfaces 102A and 102B on both sides, and further has both end portions 102C. The honeycomb surface 102A and the honeycomb surface 102B have a honeycomb shape with substantially the same pattern.

  As shown in FIGS. 21A-21C, the third molded product 104 has a honeycomb surface 104A on one side, an R surface 104B on the other side, and further has both end portions 104C. As shown in FIG. 21C, the R surface 104B is formed of a curved surface that is smoothly curved while slightly protruding downward.

  As shown in FIGS. 22A-22C, the fourth molded product 106 has a honeycomb surface 106A on one side, an R surface 106B on the other side, and further has both end portions 106C. As shown in FIG. 22C, the R surface 106B is formed of a curved surface that is smoothly curved while slightly protruding downward.

  As shown in FIGS. 23A-23C, the fifth molded article 108 has a honeycomb surface 108A on one side, a sine curve surface 108B on the other side, and further has both end portions 108C. As shown in FIG. 23C, the sine curve surface 108B is configured by a curved surface curved so as to draw a sine curve in its cross section.

  The two test bars 110 are inserted into the five molded products 100, 102, 104, 106, 108 described above in the same manner as in the first embodiment. The inserted state is shown in FIG.

  As shown in FIG. 24, the molded products 100, 102, 104, 106, and 108 are arranged in order from the top, and two test bars 110 are simultaneously inserted so as to penetrate the respective end portions. From this, it can be seen that the dimensions of the respective molded products 100, 102, 104, 106, and 108 can be molded to substantially the same dimensions.

  Here, the example of the longitudinal cross-sectional view of the 5th molded article 108 is shown in FIG. As shown in FIG. 25, the inner layer of the fifth molded article 108 includes carbon fibers 111 and a phenol resin 112. In each layer in the thickness direction P2 of the fifth molded article 108, it can be seen that the carbon fibers 111 extend from the end portion toward the end portion without being substantially divided in the lateral direction. By arranging the carbon fibers 111 in this way, the high strength of the fifth molded product 108 can be realized.

(Example 3)
Next, Example 3 will be described. Example 3 shows the result of actually creating a molded product having a honeycomb surface on one side and a sine curve surface on the other side, similar to the fifth molded product 108 described in Example 2. Particularly in Example 3, a molded product 120 having the same shape as the fifth molded product 108 and a molded product 122 having a shape similar to the fifth molded product 108 were produced. 26A-26C show the molded product 120, and FIGS. 27A-27C show the molded product 122. FIG. In these drawings, A corresponds to a front view, B corresponds to a back view, and C corresponds to a longitudinal sectional view.

  As shown in FIGS. 26A-26C, the molded product 120 has a honeycomb surface 120A on one side, a sine curve surface 120B on the other side, and further has both end portions 120C. As shown in FIG. 26C, the honeycomb surface 120A forms three grooves 121A, 121B, and 121C so as to be aligned in the width direction X1 of the molded product 120.

  As shown in FIGS. 27A-27C, the molded product 122 has an uneven surface 122A on one side, a sine curve surface 122B on the other side, and further has both end portions 122C. As shown in FIG. 27C, the concave and convex surface 122A forms two grooves 123A and 123B so as to be aligned in the width direction X2 of the molded product 122.

  The dimension in the width direction X1 of the molded product 120 and the dimension in the width direction X2 of the molded product 122 are substantially the same. On the other hand, three grooves 121A, 121B, and 121C are formed on the honeycomb surface 120A of the molded product 120, and two grooves 123A and 123B are formed on the uneven surface 122A of the molded product 122.

  As a result of the inventors conducting a strength test on the molded product 120 and the molded product 122, it was concluded that the molded product 122 has higher strength than the molded product 120. This is because the number of grooves 123A and 123B formed on the uneven surface 122A of the molded product 122 is smaller than that of the molded product 120, so that the carbon fibers existing in the vicinity of the uneven surface 122A are not divided in the width direction X2. This is thought to be due to the fact that it is easy to ensure strength.

  Moreover, the molded product 122 of Example 3 described above is made from a composite laminated base material of a carbon cloth sheet base material and an SMC sheet base material. Specifically, 6-7 sheets of carbon cloth sheet base material and 5 sheets of SMC sheet base material (thickness 1.5-2.5 mm), which are alternately arranged in the preliminary mold 4, are produced. . By molding from such a material, it is possible to extend the carbon fiber without further division compared to the case of making a laminate from only the carbon cloth sheet base material or only the SMC sheet base material. A molded article 122 can be made.

  Although explanation is omitted in other examples, the strength of the molded product is greatly improved by molding from a composite laminated substrate of a carbon cloth sheet substrate and an SMC sheet substrate in the same manner as the molded product 122 of Example 3. Can be improved.

  In addition, according to the cross-sectional shape of the uneven surface 122A and the cross-sectional shape of the sine curve surface 122B shown in FIG. 27C, the carbon fibers can be arranged in the molded product 122 without being divided in the lateral direction. The strength of the molded product 122 can be drastically improved by setting the shape of the front and back surfaces and selecting the materials described above.

  The result of the bending fracture test of the molded product 122 made in this way will be described with reference to FIGS. 28A and 28B.

  FIG. 28A is a diagram showing a bending fracture tester 130. FIG. 28B is a graph showing an example of a result of a bending fracture test performed using a bending fracture tester 130.

  A bending fracture testing machine 130 shown in FIG. 28A is a machine that applies a predetermined external force (test force) to the molded product 122 by pressing the molded product 122 disposed below downward.

  In the graph shown in FIG. 28B, the vertical axis represents the test force (unit: N) of the bending fracture tester 130, and the horizontal axis represents the vertical displacement (unit: mm) of the bending fracture tester 130. Regarding the results shown in FIG. 28B, main items are shown in Table 1 below.

  As shown in Table 1, the test force at the proportional limit was 254.00 N, and the displacement was 1.48 mm. The test force at the yield point and the maximum point was 804.00 N, and the displacement was 2.73 mm. The elastic modulus was 683.3 MPa.

  Among the above results, in particular, the test force at the yield point of the molded product 122 is 804 N, which indicates that a very high yield strength can be realized with respect to the yield strength of the molded product 122.

  According to the method described above, by using the simple mold 80 in addition to the preliminary mold 4 and the main mold 6, it is possible to manufacture a molded product 16 having a more desired shape.

  The present invention has been described with reference to the above-described first to fourth embodiments, but the present invention is not limited to the above-described first to third embodiments. For example, in the first to third embodiments, the case where the carbon fiber reinforced plastic is molded based on the material 12 in which the phenol resin and the carbon fiber are mixed is described. However, the present invention is not limited to such a case. Manufacture molded products other than carbon fiber reinforced plastics from materials mixed with any resin (for example, thermosetting resin including epoxy resin, cyanate resin, maleimide resin, etc.) and not only phenol resin and carbon fiber It may be the case. In addition, manufacturing cost can be reduced by using a phenol resin especially among thermosetting resins. Moreover, not only two types of resin and fiber but other materials may be further mixed. However, when the carbon fiber reinforced plastic is molded from the raw material 12 in which the phenol resin and the carbon fiber are mixed as in Embodiment 1-3, the desired strength and shape of the carbon fiber reinforced plastic that requires particularly high strength. Can be realized.

  In Embodiment 1-4, the case where the preliminary molding step S2 and the main molding step S4 are performed separately with a time interval using two molds, the preliminary mold 4 and the main mold 6, has been described. It is not limited to such a case. The preforming step S2 and the main molding step S4 may be executed with the same mold using one mold. Even in this case, by performing the preliminary molding step S2 and the main molding step S4 separately with a time interval, a molded product of carbon fiber reinforced plastic can be produced as in the first embodiment. However, as in the first embodiment, the pre-molded product 14 and the molded product are divided into the two molds of the preliminary mold 4 and the main mold 6 and the preforming step S2 and the main molding step S4 are performed separately. The size of 16 can be changed to a desired shape suitable for each step. In addition, since the temperature change region of each mold can be reduced compared to the case of continuously molding with one mold, the heating / cooling time in each mold can be shortened, and once The tact time required for the molding can be shortened and the productivity can be improved.

  In Embodiment 1-4, the outer shape of the horizontal section of the cavity 5b for placing the material 12 shown in FIG. 4B is set smaller than the outer shape of the horizontal section of the cavity 7b for placing the preformed product 14. However, the present invention is not limited to such a case. You may set each external shape substantially the same. Even in such a case, the preform can be placed in the cavity of the present mold. However, as in the first embodiment, the preform 14 can be reliably disposed in the cavity 7b when the outer shape of the horizontal section of the cavity 5b is set smaller than the outer shape of the horizontal section of the cavity 7b.

  Further, in Embodiment 1-4, the case where one molded product 16 is made based on one preformed product 14 has been described. However, the present invention is not limited to such a case, and a plurality of preformed products are combined to form one molded product 16. You may make it make a molded article. In this case, a plurality of reserve molds may be provided for one main mold 6. According to such a method, molded products having various specifications can be made. However, when one molded product 16 is made based on one preform 14 as in Embodiment 1-3, the manufacturing process can be simplified.

  Although the present disclosure has been fully described in connection with preferred embodiments with reference to the accompanying drawings, various variations and modifications will be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present disclosure as set forth in the appended claims. In addition, combinations of elements and changes in the order in each embodiment can be realized without departing from the scope and spirit of the present disclosure.

  It is to be noted that, by appropriately combining any of the various embodiments and modifications, the effects possessed by them can be produced.

  The present invention is applicable to any method for producing a molded product.

2 Molding equipment 4 Preliminary mold (first mold)
4a Movable part 4b Fixed part 5a Core 5b Cavity 6 This mold (2nd mold)
6a Movable part 6b Fixed part 7a Core 7b Cavity 8 Cavity (arrangement area)
10 cavity (arrangement area)
12 Material 14 Preliminary product 16 Molded product 24 Preliminary mold (first mold)
24a Movable part 24b Fixed part 26 Main mold (second mold)
26a Movable portion 26b Fixed portion 26c Bottom surface 26d Top surface 28 Cavity 30 Cavity 31 Protrusion 34 Preliminary product 34a Center portion 34b Both ends 36 Molded product 36a Center portion 36b Both ends 46 Molded product 48 Honeycomb portion 50 Both ends 52 Honeycomb shape 60 First Material 62 second material 64 inner part 66 outer part 68 inner part 70 outer part 72 preform 80 simple mold 82 material 82A first material 82B second material 82C third material 84 movable part 84A core 86 Fixed portion 86A Cavity 88 Crude product 90 First molded product 90A, 90B Honeycomb surface 90C Both ends 92 Second molded product 92A Honeycomb surface 92B Flat surface 92C Both ends 94 Test rod 94A Insertion portion 94B Head 96 Carbon fiber 98 Phenolic resin 100 First molded product 100A, 100B Honeycomb surface 100C Both ends Part 102 Second molded product 102A, 102B Honeycomb surface 102C Both ends 104 Third molded product 104A Honeycomb surface 104B R surface 104C Both ends 106 Fourth molded product 106A Honeycomb surface 106B R surface 106C Both ends 108 Fifth molding Product 108A Honeycomb surface 108B Sine curve surface 108C Both ends 110 Test rod 111 Carbon fiber 112 Phenol resin 120 Molded product 120A Honeycomb surface 120B Sine curve surface 120C Both ends 121A, 121B, 121C Groove 122 Molded product 122A Uneven surface 122B Sine curve surface 122C Both ends 123A, 123B Groove 130 Bending fracture tester

Claims (5)

A method for producing a molded product from a material made of a mixed material in which resin and fiber are mixed,
A first molding step for producing a preform by heating the material to a first heating temperature for crosslinking the resin and the fiber using a mold;
After the first molding step, the preform is heated using a mold to a second heating temperature higher than the first heating temperature and at which the resins are crosslinked and polymerized. A second molding step for producing a molded article,
The manufacturing method of the molded article containing this. The mold used in the first molding step is a first mold, and the mold used in the second molding step is a second mold different from the first mold,
The method of manufacturing a molded product according to claim 1, further comprising a step of moving the material from the first mold to the second mold between the first molding step and the second molding step. .   The manufacturing area of the molded product according to claim 2, wherein the arrangement area of the material in the first mold is set to have an outer shape of a horizontal section smaller than the arrangement area of the preform in the second mold. Method.   The molding according to any one of claims 1 to 3, wherein a temperature rising rate of the material in the first molding step is set slower than a temperature rising rate of the preform in the second molding step. Product manufacturing method.   The method for producing a molded product according to any one of claims 1 to 4, wherein the fiber is a carbon fiber, and the molded product is a carbon fiber reinforced plastic.