JP2020142457A - Production method of fiber reinforced resin molded article, and mold used for production method - Google Patents

Abstract

To provide a production method of a fiber reinforced resin molded article and a mold that allows a resin to easily flow into between a fiber base material and an insert member.SOLUTION: A fiber reinforced resin molded article is produced by using a mold 1 comprising: a first mold 10 provided with a recess 11a into which an insert member 40 can be inserted, and a holding mechanism 20 capable of holding the insert member 40 in the recess 11a; a second mold 30 on which a fiber base material 50 can be disposed so as to face the insert member 40; the insert member 40; and the fiber base material 50. The mold 1 can be clamped while being provided with a gap L between the fiber base material 50 and the insert member 40. The gap L becomes a passage of a resin R to allow the resin R to easily flow into between the insert member 40 and the fiber base material 50.SELECTED DRAWING: Figure 2

Description

The present invention relates to a method for producing a fiber-reinforced resin molded product and a molding die used in the method for producing the same.

Fiber-reinforced resin molded products have higher strength than other general resin molded products, and are lighter and more rigid than general metal materials, so they are used in various applications such as automobiles and aircraft. Has been done. In such applications, it may be requested to supply a fiber-reinforced resin molded product in which a fiber-reinforced resin and a metal member or the like (hereinafter referred to as “insert member”) are integrated.

As an example of a method for producing a fiber-reinforced resin molded product, Patent Documents 1 and 2 disclose a method for producing a fiber-reinforced resin molded product by filling a mold in which an insert member and a fiber base material are arranged with a resin.

In Patent Document 1, first, an insert member having a recess, a multi-layered fiber base material laminated so as to sandwich the insert member, and a positioning member that penetrates the fiber base material and can be inserted into the recess of the insert member are prepared. To do. The positioning member includes an insertion portion that is inserted into the recess of the insert member and a protruding portion that protrudes from the insertion portion. In addition, a first mold having a recess into which the protruding portion can be inserted and a second mold facing the first mold are prepared. Next, the insertion portion of the positioning member is inserted into the recess of the insert member. Then, the fiber base material is arranged in the second mold so that the protruding portion of the positioning member protruding from the insert member faces the recess of the first mold. Next, the first mold and the second mold are brought close to each other and the mold is fastened so that the protruding portion of the positioning member is inserted into the recess of the first mold. Next, the resin material is injected between the first mold and the second mold. The resin injected into the mold is filled while penetrating into the fiber base material. In this way, the fiber reinforced resin molded body is molded. The positioning member is taken out from the insert member after the mold is opened.

Further, in Patent Document 2, among the upper and lower dies for forming the resin molded body, the insert member is held by a permanent magnet with respect to the upper die, and the protrusion provided on the lower surface of the insert member is provided on the lower side. A technique is disclosed in which a resin is injected into the upper and lower molds after the insert member and the long fiber mat material are integrated by penetrating the long fiber mat material (fiber base material) arranged in the mold.

Japanese Unexamined Patent Publication No. 2011-14369 Japanese Unexamined Patent Publication No. 4-107113

By the way, in the manufacturing method of Patent Document 1, the insert member is sandwiched between the fiber base materials. Therefore, when the mold is fastened, the fiber base material and the insert member are pressed against the first mold and the second mold so as to be in close contact with each other. Therefore, there is no gap between the fiber base material and the insert member, and it is difficult for the resin to flow into the fiber base material. If the resin is not sufficiently distributed between the fiber base material and the insert member, the bonding strength between the fiber base material and the insert member may decrease. This also applies to the manufacturing method of Patent Document 2 in which the insert member and the long fiber matte material are integrated and then the resin is injected into the upper and lower dies.

Therefore, the problem to be solved by the present invention is to make the method for manufacturing the fiber-reinforced resin molded body and the molding die easy for the resin to flow between the insert member and the fiber base material.

In order to solve the above problems, the method for producing a fiber-reinforced resin molded product of the present invention includes a recess into which an insert member can be inserted and a first mold provided with a holding mechanism capable of holding the insert member in the recess. Using a second mold capable of arranging the fiber base material so as to face the insert member, the insert member, and the fiber base material, the insert member is inserted into the recess and the holding mechanism is used. The step of arranging the fiber base material in the second mold so as to face the recess, and the step of arranging the fiber base material in the second mold, and the first mold so that a gap is formed between the fiber base material and the insert member. A configuration including a step of mold-clamping the second mold and a step of filling a resin between the mold-clamped first mold and the second mold was adopted.

In this way, the first mold and the second mold can be molded so that a gap is formed between the fiber base material and the insert member. Since the resin filled in the mold can pass through this gap, the resin easily flows between the fiber base material and the insert member.

At this time, the method for producing the fiber-reinforced resin molded product according to the present invention can adopt a configuration in which the facing surface of the insert member with the fiber base material and the fiber base material are adhered to each other via the resin.

By doing so, the production of a fiber-reinforced resin molded product in which the facing surface of the insert member with the fiber base material is adhered to the fiber base material via the resin flowing into the gap between the fiber base material and the insert member. Becomes possible.

Further, a first mold having a recess into which the insert member can be inserted, a holding mechanism capable of holding the insert member in the recess, and a second mold capable of arranging a fiber base material so as to face the insert member. It is possible to adopt a configuration in which the first mold and the second mold can be molded so as to provide a mold and a gap between the insert member and the fiber base material.

The concave portion of the first mold of the molding mold faces the second mold. Therefore, the fiber base material can be arranged on the second mold so as to face the insert member in the recess. Therefore, it is possible to mold the first mold and the second mold so as to form a gap between the fiber base material and the insert member.

At this time, the holding mechanism can adopt a configuration in which the insert member is a magnetic material having a magnetic force capable of attracting the insert member into the recess.

In this way, if the insert member is a magnetic material, it can be attracted into the recess by magnetic force.

Further, the first mold can adopt a configuration including a nest provided with the recess and a storage groove capable of accommodating the nest.

In this way, it becomes possible to prepare a plurality of nests according to the shape of each of several types of insert members and replace the nests to manufacture various fiber-reinforced resin molded bodies. Since it is possible to change to various insert members by simply replacing the nest without changing the mode of the first mold, it is possible to prevent an increase in the manufacturing cost of the first mold.

By providing a step of molding so that a gap is formed between the fiber base material and the insert member, a method for manufacturing a fiber reinforced resin molded body in which resin easily flows between the fiber base material and the insert member, and a molding die. It becomes possible to do.

(A) is a cross-sectional view of a molding die according to the first embodiment of the present invention, and (b) is a cross-sectional view in which an insert member and a fiber base material are arranged in (a). (A) is a cross-sectional view of a molding die after mold clamping, (b) is a cross-sectional view of a molding die filled with resin, and (c) is a first mold and a second mold from the state of (b). Cross-sectional view of a molding die with the mold open Sectional drawing of the molding die which concerns on 2nd Embodiment Sectional drawing of the molding die which concerns on 3rd Embodiment Sectional drawing of the molding die which concerns on 4th Embodiment

Hereinafter, the first embodiment of the present invention will be described with reference to the drawings.

FIG. 1 shows a molding die 1 for manufacturing a fiber-reinforced resin molded body by filling the fiber base material 50 arranged inside together with the insert member 40 with the resin R. The molding die 1 includes a first mold 10 having a recess 11a into which a metal insert member 40 can be inserted, a holding mechanism 20 capable of holding the insert member 40 in the recess 11a, and a first mold 10. A second mold 30 facing in the vertical direction is provided. The first mold 10 includes a surface 11 facing the second mold 30. The second mold 30 includes a facing surface 31 facing the facing surface 11.

The insert member 40 is a metal member made of a magnetic material. The insert member 40 includes a surface 40a facing the first mold 10, a side surface 40b, and a surface 40c facing the second mold 30. Although the insert member 40 is shown to have a rectangular parallelepiped shape, the insert member 40 is not limited to this and may have various shapes. The fiber base material 50 is a general fiber material used as a core material of a fiber reinforced resin, and is made of, for example, glass fiber or carbon fiber. The facing surface 50a of the fiber base material 50 with the first mold 10 forms a surface parallel to the facing surface 11 of the first mold 10. The resin R is preferably one having a lower viscosity than a general one, and for example, an epoxy resin which is a thermosetting resin can be adopted. By adopting a so-called two-component curing type epoxy resin, it is possible to adjust the viscosity to be suitable for filling in the mold.

The recess 11a is recessed upward in the drawing from the facing surface 11 of the first mold 10. The inner surface of the recess 11a has a shape along the facing surface 40a and the side surface 40b of the insert member 40. Its inner surface is formed from a bottom surface 11b and a side wall surface 11c rising downward from the bottom surface 11b. Further, the depth of the recess 11a is equal to the thickness of the insert member 40 in the vertical direction. When the insert member 40 is inserted into the recess 11a, the facing surface 40a of the insert member 40 and the bottom surface 11b of the recess 11a come into contact with each other, and the side surface 40b of the insert member 40 and the side wall surface 11c of the recess 11a come into contact with each other. Therefore, the position of the insert member 40 inserted into the recess 11a is determined in the left-right direction. At this time, the facing surface 40c of the insert member 40 inserted into the recess 11a is located on the same plane as the facing surface 11 of the first mold 10.

A groove portion 11d recessed upward is provided on the bottom surface 11b of the recess 11a. The holding mechanism 20 is a magnet (permanent magnet) fixed in the groove 11d, and has an attractive force capable of attracting the insert member 40 by its magnetic force. The insert member 40 inserted into the recess 11a is sucked by the suction force of the holding mechanism 20 and is held so that the facing surface 40a and the bottom surface 11b of the recess 11a do not fall in contact with each other. Therefore, the position of the insert member 40 inserted into the recess 11a is determined in the vertical direction shown in the drawing.

In the second mold 30, the fiber base material 50 can be arranged at a position facing the recess 11a. Although omitted in the drawing, the second mold 30 may have a configuration for positioning the fiber base material 50 in the left-right direction.

When the insert member 40 is held in the recess 11a of the first mold 10 and the fiber base material 50 is placed on the second mold 30, the insert member 40 and the fiber base material 50 are formed. , A gap L is formed. The size of this gap L may be 1 mm or less.

The configuration of the molding die 1 of the first embodiment is as described above, and a method of manufacturing a fiber-reinforced resin molded body using the molding die 1 will be described with reference to FIGS. 1 and 2.

The above-mentioned first mold 10, the second mold 30, the insert member 40, and the fiber base material 50 are prepared. Next, as shown in FIG. 1B, the insert member 40 is inserted into the recess 11a. Then, the insert member 40 is held in the recess 11a by the holding mechanism 20. At this time, the insert member 40 is positioned in the left-right direction and the up-down direction as described above. Next, the fiber base material 50 is arranged on the second mold 30 so as to face the recess 11a and the insert member 40. As described above, since the facing surface 50a of the fiber base material 50 is a surface parallel to the facing surface 11 of the first mold 10, it is parallel to the facing surface 40c of the insert member 40.

Next, as shown in FIG. 2A, the first mold 10 is lowered, and the first mold 10 and the second mold 30 are molded. When the mold is fastened, a gap L is formed between the facing surface 40c of the insert member 40 and the facing surface 50a of the fiber base material 50.

Next, as shown in FIG. 2B, the resin R is filled between the first mold 10 and the second mold 30 that have been molded. At this time, the resin R poured into the mold is filled in the mold so that the gap L is used as a flow path. Therefore, the resin R is more likely to flow between the fiber base material 50 and the insert member 40 as compared with the method for manufacturing the fiber-reinforced resin molded product without providing such a gap L.

Next, the first mold 10 is further lowered so that the gap L becomes smaller. Then, the resin R between the fiber base material 50 and the insert member 40 is pressed into the fiber base material 50. By this step, the resin R penetrates into the fiber of the fiber base material 50. After that, the resin R is cured by heating from the mold (when a thermoplastic resin is used for the resin R, it is cured by lowering the temperature).

Next, the first mold 10 is raised to open the mold. Here, the suction force of the holding mechanism 20 is smaller than the bonding force between the resin R and the insert member 40. Therefore, as shown in FIG. 2C, when the first mold 10 is separated from the second mold 30, the insert member 40 is integrated with the fiber base material 50 and is taken out from the recess 11a.

By forming a gap L between the facing surface 40c of the insert member 40 and the facing surface 50a of the fiber base material 50 in this way, the facing surface 40c of the insert member 40 and the facing surface 50a of the fiber base material 50 are formed. In the meantime, the resin R is sufficiently distributed, and the insert member 40 and the fiber base material 50 are more firmly adhered to each other.

Next, the second embodiment of the present invention will be described.

As shown in FIG. 3, the side wall surface 11c of the recess 11a is provided with a pair of groove portions 11e recessed in the left-right direction in the drawing. In the groove portion 11e, a holding mechanism 20 having a holding portion 21 capable of contacting the insert member 40 and an urging portion 22 capable of pressing the holding portion 21 against the insert member 40 is housed. The insert member 40 inserted into the recess 11a is pressed against the holding portion 21 from the left-right direction. By this pressing force, the holding mechanism 20 can hold the insert member 40 in the recess 11a. This pressing force is smaller than the bonding force between the insert member 40 and the fiber base material 50. Therefore, when the first mold 10 is separated from the second mold 30 after the resin R is filled in the mold, the insert member 40 is taken out from the recess 11a together with the fiber base material 50.

The insert member 40 of the first embodiment is a metal member made of a magnetic material, but the insert member 40 of the second embodiment is not limited to the magnetic material member. By providing the holding mechanism 20 as described above, the insert member 40 can be held in the recess 11a even if the insert member 40 is not a magnetic member.

Next, a third embodiment of the present invention will be described.

As shown in FIG. 4, the recess 11a is provided with an intake passage 12 that opens to the bottom surface 11b and extends from the opening to the outside through the inside of the first mold 10. The intake passage 12 is connected to an intake device (not shown) outside the first mold 10. The intake device is capable of sucking through the opening through the intake passage 12, and has a suction force capable of sucking the insert member 40 inserted in the recess 11a. The insert member 40 inserted into the recess 11a is held in the recess 11a by this intake device. This suction force is smaller than the bonding force between the insert member 40 and the fiber base material 50. Therefore, when the first mold 10 is separated from the second mold 30 after the resin R is filled in the mold, the insert member 40 is taken out from the recess 11a together with the fiber base material 50.

The insert member 40 according to the third embodiment is not limited to the magnetic member as in the second embodiment. By providing the intake passage 12 as described above, the insert member 40 can be held in the recess 11a even if the insert member 40 is not a magnetic member.

Next, a fourth embodiment will be described.

As shown in FIG. 5, the first mold 10 includes an accommodating groove 13 recessed upward in the drawing and a nest 14 accommodating in the accommodating groove 13. The nest 14 is detachably held in the accommodating groove 13. The nest 14 includes a recess 11a into which the insert member 40 can be inserted. The recess 11a is recessed so as to correspond to the contour of the insert member 40, and the bottom surface 11b of the recess 11a is provided with a groove portion 11d that is recessed upward. The holding mechanism 20 is held in the groove 11d.

Various nests 14 in which the shape of the inner surface of the recess 11a is changed can be prepared, and the nests 14 can be replaced and used according to the mode of the fiber reinforced resin molded product.

Although the embodiment of the present invention has been described, the scope of the present invention is not limited to the above embodiment, and various modifications can be applied.

The groove portion 11d of the first embodiment of FIG. 1 is shown in such a manner that it is recessed upward from the bottom surface 11b, but the present invention is not limited to this. For example, it may be a cavity provided inside the first mold 10 so as to face the recess 11a with the bottom surface 11b interposed therebetween. This cavity is open to the outside of the first mold 10, and a holding mechanism 20 which is a magnetic material can be inserted from the outside, and the holding mechanism 20 can be arranged at a position facing the insert member 40. it can.

In each of the above-described embodiments, a configuration is shown in which the first mold 10 is lowered when the first mold 10 and the second mold 30 are molded, but the first mold 10 is lowered. Instead, the second mold 30 may be raised to perform mold clamping. Similarly, the first mold 10 may be lowered and the second mold 30 may also be raised to perform mold clamping.

10 1st mold 11 Facing surface 11a Recess 13 Accommodating groove 14 Nesting 20 Holding mechanism 30 2nd mold 40 Insert member 50 Fiber base material L Gap R Resin

Claims (5)

A first mold (10) provided with a recess (11a) into which the insert member (40) can be inserted, a holding mechanism (20) capable of holding the insert member (40) in the recess (11a), and the insert member. Using the second mold (30) in which the fiber base material (50) can be arranged so as to face (40), the insert member (40), and the fiber base material (50),
A step of inserting the insert member (40) into the recess (11a) and holding it by the holding mechanism (20).
A step of arranging the fiber base material (50) in the second mold (30) so as to face the recess (11a), and
A step of molding the first mold (10) and the second mold (30) so that a gap (L) is formed between the fiber base material (50) and the insert member (40).
A method for producing a fiber-reinforced resin molded product, comprising a step of filling a resin (R) between the first mold (10) and the second mold (30) that have been molded. The fiber-reinforced resin according to claim 1, wherein the facing surface (40c) of the insert member (40) with the fiber base material (50) and the fiber base material (50) are bonded to each other via the resin (R). A method for manufacturing a molded product. A first mold (10) provided with a recess (11a) into which the insert member (40) can be inserted, and
A holding mechanism (20) capable of holding the insert member (40) in the recess (11a),
A second mold (30) capable of arranging the fiber base material (50) so as to face the insert member (40), and
With
For molding in which the first mold (10) and the second mold (30) can be molded so that a gap (L) is formed between the insert member (40) and the fiber base material (50). Mold. The molding die according to claim 3, wherein the holding mechanism (20) is a magnetic material having a magnetic force capable of attracting the insert member (40) into the recess (11a). The first mold (10) according to claim 3 or 4, wherein the first mold (10) includes a nest (14) provided with the recess (11a) and a storage groove (13) capable of accommodating the nest (14). Mold for molding.

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