JP3221225B2 - Composite molded body manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing composite molded articles of various shapes based on a composition formed by a blader.

[0002]

2. Description of the Related Art Conventionally, there has been known a production method in which a molded article is formed by impregnating a thermosetting resin or a thermoplastic resin into a composition formed by a blader.

[0003]

A molded article produced by impregnating a composition with a thermosetting resin has a high elastic modulus but a fragile property, while a molded article impregnated with a thermoplastic resin. The manufactured molded article has a property that it has a low elastic modulus but has toughness. A composite molded body having a high elastic modulus and a high toughness, which combines these two properties, has conventionally been manufactured by hand, and therefore, the productivity is low and the manufactured composite molded body is expensive. Has become.

[0004] It is an object of the present invention to solve the above-mentioned problems and to provide a method for manufacturing a composite molded article that can be automated.

[0005]

SUMMARY OF THE INVENTION In order to achieve the above-mentioned object, the present invention firstly forms a composition comprising a thermosetting prepreg yarn around a mandrel, and then heat-treats the composition. After forming a composition comprising a thermoplastic prepreg yarn around a mandrel and a step of forming a curable composition layer, the step of performing a heat treatment to form a thermoplastic composition layer is appropriately combined, at least, A composite molded article comprising one thermosetting composition layer and at least one thermoplastic composition layer is manufactured. Second, a thermosetting prepreg yarn is provided around a mandrel. The composition composed of the filament and the composition composed of the thermoplastic prepreg yarn are appropriately formed, and then heat-treated to provide at least one thermosetting composition layer and at least one thermosetting composition layer. Third, a thermoplastic resin composition layer is formed by winding a thermoplastic tape around a mandrel. In No. 4, the thermosetting composition layer was formed by winding a thermosetting tape around a mandrel.

[0006]

Embodiments of the present invention will be described below, but the present invention is not limited to these embodiments unless it departs from the gist of the present invention.

First, a blade as an example used in the method of manufacturing a composite molded article of the present invention will be described with reference to FIG. 1 which is a front view of the blade and FIG. 2 which is a side view thereof. In FIGS. 1 and 2 and FIG. 3 to be described later, a square portion indicated by a dotted line above the bobbin carrier C is a thread guide portion c of the bobbin carrier C to be described later.
3 is omitted.

The blader B is formed in a curved upper plate U having a predetermined radius of curvature L and disposed in a substantially cylindrical machine base Fb having a horizontal axis and an opening e on one side. A bobbin carrier C traveling along the track, a driving device D for causing the bobbin carrier C to travel along the track,
It is composed of a yarn guide member G, a mandrel support device M, and the like.

Hereinafter, each of the above-described devices and members will be described. First, referring to FIG. 3, which is an enlarged front view of a driving device D for causing the bobbin carrier C including the section II of FIG. 2 and the section II of FIG. And a drive device D for causing the bobbin carrier C to travel along the track will be described.

As shown in FIG. 2, a curved upper plate U is provided with a suitable fixing member arranged at a predetermined interval on a machine frame f1 arranged in a substantially cylindrical machine base Fb. f2, f
A known track is formed in the upper plate U in the circumferential direction. f3 is a hollow bolt attached to the machine frame f1 by a nut f4, and a gear d1 is fitted to the hollow bolt f3 via an appropriate bearing f5.
An impeller d2 having a groove into which an engagement shaft c1 of a bobbin carrier C described later fits is fixed to the gear d1 so as to be able to rotate integrally with the gear d1.

Y is a yarn that is unwound from a bobbin mounted on a bobbin carrier C and travels toward a composition point Z on a mandrel m cantilevered by a mandrel support device M, and y is a substantially cylindrical member. Frame F of the machine base Fb
b ′ is unwound from a bobbin carrier C arranged substantially horizontally, guided in a substantially right angle direction by a guide roller f6 attached to the machine base Fb, inserted into the hollow bolt f3, and then placed on the mandrel m. This is a middle yarn or a reinforcing yarn heading toward the composition point Z (hereinafter, simply referred to as “middle yarn”).

The gear d is driven by a suitable driving means such as a motor.
By rotating the wheel 1 to rotate the impeller d2,
The bobbin carrier C is configured to move along an orbit by moving an engagement shaft c1 of the bobbin carrier C fitted in a groove formed in the impeller d2. By running the bobbin carrier C along the track formed in the curved upper plate U as described above, a large number of yarns Y are interlaced to form the composition b on the mandrel m. If necessary, a yarn formed from a bobbin carrier C disposed substantially horizontally on the frame Fb 'of the machine base Fb, and a yarn for medium yarn y being unwound from the bobbin carrier C traveling along the track. A composition b is formed by entanglement with the article Y.

Next, the bobbin carrier C will be described with reference to FIG. 4 which is a front view of the bobbin carrier C. In FIG. 4, c2 is an upper flange, and the upper flange c
2, a mast c4 having a U-shaped cross section and a spindle c5 having a thread guide portion c3 rotatably disposed at the distal end thereof are provided upright. A bobbin c6 around which the yarn Y is wound is inserted into the spindle c5, and a flyer c8 having a bearing c7 is rotatably fitted to the tip of the spindle c5.

A not-shown slit extending in the vertical direction is provided at the tip of the spindle c5, and a pair of hook members c9, c having a substantially triangular tip are provided in the slit.
9 'is arranged, and the lower ends of the hook members c9, c9' are pivotally supported by a shaft (not shown) attached to the spindle c5. The hook members c9 and c9 'are constantly urged in directions away from each other by an elastic member such as a compression spring disposed between the hook members c9 and c9', and the bobbin c6 or the flyer c8 is hooked by the hook members c9 and c9 '.
, The hook members c9 and c9 'rotate in a direction approaching each other, and the bobbin c6 or the flyer c8 can be mounted on the spindle c5. Bobbin c6 or flyer c8 is spindle c5
When the hook members c9 and c9 'are attached to the bobbin c, the hook members c9 and c9' expand in the directions away from each other.
6 or the flyer c8 is prevented from falling out of the spindle c5.

Reference numeral c6 'denotes a cylindrical bobbin cover, which is attached to the upper flange c2. When the bobbin carrier C is inclined or inverted, the cylindrical bobbin cover c6 'is pulled out or hangs down the yarn Y wound on the bobbin c6, and is wound on the adjacent bobbin. Entangled with a thread or a braider B
This prevents troubles such as entanglement with other members.

A tension washer c11 and a guide roller c1 are arranged in order from below on a substantially U-shaped frame c10 of a thread guide portion c3 arranged at the tip of the mast c4.
2, a slack removing member c13 and a guide roller c14 are arranged. A guide c15 having a guide roller c15 'is attached to the tip of the slack removing member c13, and the other end of the slack removing member c13 is connected to a coil spring c.
One end of the coil spring c16 is attached.
Is attached to the frame c10. The slack removing member c13 is pivotally supported on the frame c10 via a shaft member c17 'attached to a bearing member c17 disposed on the frame c10, and is always counterclockwise in FIG. 4 by the coil spring c16. It is urged to rotate. Therefore, when the yarn Y unwound from the bobbin c6 becomes slack, the slack removing member c13 rotates counterclockwise about the shaft member c17 'in FIG. 4 so as to absorb the slack of the yarn Y. Is configured.

Through holes c18 and c19 through which the thread Y is inserted are formed in the frame c10 adjacent to the tension washer c11 and the guide roller c14. The substantially U-shaped frame c10 is configured to be rotatable clockwise about an axis c20 disposed on the mast c4, and the bobbin c6 or the fryer c8 is connected to the spindle c20.
When the frame c10 is mounted on the spindle c5, a space is created above the spindle c5 by rotating the frame c10 clockwise, and the spindle c5 is provided with a bobbin c6 or a flyer c8.
Attach. After attaching the bobbin c6 or the flyer c8 to the spindle c5, the frame c10 is rotated counterclockwise to be arranged at a position as shown in FIG. In addition, the frame c10 is locked by an appropriate locking means.
As long as the locking means is not released, it is configured to be held at the position shown in FIG.

In FIG. 4, c21 is a substantially elliptical lower flange, and c22 is disposed between the upper flange c2 and the lower flange c21 which are fitted and slid on a track formed on the upper plate U. It is a guide part. The bobbin carrier C is configured to run along a track while being held substantially perpendicular to the upper plate U by sandwiching the upper plate U between the upper flange c2 and the lower flange c21.

Next, the yarn guide member G will be described with reference to FIGS. The yarn guide member G extends substantially horizontally from the intermediate frame Fb ″ of the machine base Fb.
The first thread guide member g1 having a substantially annular shape and attached to the front end of a frame g2 'erected on a floor member Fr arranged at a predetermined distance from the first thread guide member g1. It is constituted by a second thread guide member g2, which is also substantially annular and is attached.

The first yarn guide member g1 and the second yarn guide member g2 are yarns that oscillate with the lateral movement of the bobbin carrier C running meandering along a track formed in the upper plate U. The yarn Y is guided by a first yarn guide member g1 and a second yarn guide member g2 arranged at a predetermined interval, and the composition point Z is maintained at a substantially constant position by regulating the swing. By maintaining the composition point Z at a substantially constant position in this manner, a stable composition can be realized without the yarn Y to be composed being entangled in an irregular state in the vicinity of the composition point Z. A composition b having a uniform and stable shape can be manufactured.

Next, the bobbin carrier C as described above is used.
A composite molded body manufacturing apparatus to which the method of the present invention for manufacturing a composite molded body using a blader B traveling along a track will be described with reference to FIG. 5, which is an overall configuration diagram of the apparatus.

The composite molded article manufacturing apparatus shown in FIG. 5 includes a mandrel support device M, a braider B1 for forming a composition b1 around a cylindrical mandrel m with a thermosetting prepreg yarn, and a thermosetting prepreg yarn. A thermosetting molding heat treatment apparatus H1 having a heater h1 ′ and a heater power source h1 ″ for performing a heat treatment on the composition b1 formed of the strips to form a thermosetting composition layer, and a thermosetting composition layer surrounding the thermosetting composition layer. A heater h2 'and a heater power source h2''for forming a thermoplastic composition layer by performing a heat treatment on the braider B2 forming the composition b2 with the thermoplastic prepreg yarn and the composition b2 comprising the thermoplastic prepreg yarn. And a thermoplastic molding heat treatment device H2 having

With the above-described composite molded article manufacturing apparatus, for example, a composition b1 composed of a thermosetting prepreg yarn coated with a thermosetting resin powder in a braider B1.
Is subjected to a heat treatment by a thermosetting molding heat treatment apparatus H1,
A thermosetting composition layer is formed by melting and curing the thermosetting resin powder, and then a composition b2 is formed around the thermosetting composition layer using a thermoplastic prepreg yarn with a braider B2. Thereafter, the thermoplastic prepreg yarn is melted and cured by heating with a thermoplastic molding heat treatment device H2 to form a thermoplastic composition layer, the inner layer is a thermosetting composition layer, and the outer layer is a thermoplastic composition layer. Is produced. Needless to say, a thermosetting composition layer or a thermoplastic composition layer is further formed around the composite molded body b3 by a similar method as appropriate to form a multi-layer composite molded body W3.
Can be manufactured, but the outermost layer of the composite molded body W is
In consideration of external force, impact force, etc. applied to the composite molded body W,
It is preferable that the thermoplastic composition layer has a low elasticity but a toughness.

FIG. 6, which is an overall configuration diagram of a composite molded article manufacturing apparatus similar to FIG. 5, shows a mandrel supporting apparatus M, a braider B1 for forming a composition b1 around a cylindrical mandrel m with a thermosetting prepreg yarn. A braider B2 for forming a composition b2 from thermoplastic prepreg yarn, a thermosetting molding heat treatment apparatus H1, and a thermoplastic molding heat treatment apparatus H2 arranged in this order around the composition b1, and the inner layer is a thermosetting prepreg yarn. The composition consisting of the composition b1 composed of the filament and the composition composed of the composition b2 whose outer layer is composed of the thermoplastic prepreg yarn is subjected to a heat treatment by a thermosetting molding heat treatment apparatus H1 and a thermoplastic molding heat treatment apparatus H2, respectively. A composite molded article W is manufactured by forming a thermosetting composition layer and a thermoplastic composition layer.

FIG. 7, which is an overall configuration diagram of a composite molded article manufacturing apparatus similar to FIG. 5, shows a thermo-woven fabric made of thermoplastic prepreg yarns in place of the second braider B2 shown in FIG. A taping device T for winding a thermoplastic tape made of a nonwoven fabric made of a plastic tape or a thermoplastic prepreg fiber is disposed.

As the taping device T, various known taping devices T can be used. The one shown in FIG. 7 is a gear t2 and a gear t2 attached to the output shaft of the motor t1. A drum body t in which a rack t3 to be screwed is rotatably supported by a suitable bearing provided on the outer periphery.
4. It comprises a spindle t5 inclined with respect to the mandrel m attached inside the drum body t4, and a bobbin t7 wound with a thermoplastic tape t6 rotatably inserted on the spindle t5. The motor t1 is driven to rotate the gear t2, and the rack t3 screwed to the gear t2 rotates the drum body t4 provided on the outer periphery around the mandrel m, thereby pulling out the thermoplastic tape t6 from the bobbin t7. A thermoplastic tape t6 is wound around a composition b1 composed of a braider B1 using a thermosetting prepreg yarn.

The composite molding manufacturing apparatus shown in FIG. 7 has a composition b1 in which the inner layer is composed of thermosetting prepreg yarn and a thermoplastic tape t7 layer in which the outer layer is wound by a taping device T. Forming a pre-composite molded body,
Thereafter, similarly to the composite molded article manufacturing apparatus shown in FIG. 6, a heat treatment is performed by a thermosetting molding heat treatment apparatus H1 and a thermoplastic molding heat treatment apparatus H2, and a thermosetting composition layer and a thermoplastic layer, respectively. Is formed, and the composite molded body W is manufactured.

The blader B3 shown in FIG. 8 is a self-propelled gripping mandrel m having various shapes such as a T-shape, an H-shape, a cross shape or a tetra-pot shape, instead of the above-described mandrel support device M. A mandrel m supported by a mandrel support device r1 disposed at the tip of the self-propelled articulated robot R is appropriately controlled in position and orientation by manipulating the mandrel m. It is configured so that a composition can be formed around the periphery of the body.

FIG. 9 shows the self-propelled articulated robot R described above.
Is a plan view of a composite molded body manufacturing apparatus disposed in front of two braiders B3 and B3 ′ arranged side by side so that the axes of the substantially cylindrical machine base Fb are parallel to each other, and H3 is This is a molding device, which will be described later, which is disposed approximately in the middle of the front surfaces of the two bladers B3 and B3 '. As shown in FIGS. 8 and 9, the self-propelled articulated robot R is driven on wheels r3 and r3 so that it can run on rails r2 and r2 ′ arranged on the floor.
r3 ', and as shown by a solid line, a two-dot chain line and a dotted line in Fig. 9, a configuration in which the blader B3, the molding device H3, and the blader B3' can be moved to respective positions. Have been. Note that the rails r2, r
2 'may be omitted so that the self-propelled articulated robot R can freely move on the floor surface.

FIG. 10 is a perspective view of a main part of the molding apparatus H3. The molding apparatus H3 has a vertical frame Fh, and the side walls h3 of the vertical frame Fh on the side of the blades B3 and B3 '.
Is provided with guide members h6 having vertical grooves h4 'and h5' having substantially U-shaped bent portions h4 and t5 formed at both ends in the horizontal direction. Grooves h4 ', h of guide member h6
The convex portions h7 ′ and h8 ′ of the upper hot press h7 and the lower hot press h8 are inserted into 5 ′, and the upper hot press h7 and the lower hot press h8 are disposed on the side wall h3, respectively. Vertical cylinder h9, h
The distal ends of ten piston rods h9 'and h10' are attached. Therefore, by operating the vertical cylinders h9 and h10 to move the piston rods h9 ′ and h10 ′ up and down, the upper hot press h is moved along the guide member h6.
7 and the lower hot press h8 can be joined or separated from each other.

The upper hot press h7 and the lower hot press h8 are configured as a kind of split mold. In FIG. 10, a T-shaped composition is formed around the T-shaped mandrel m by the above-mentioned bladers B3 and B3 '. Since the composition example is shown, when the upper hot press h7 and the lower hot press h8 are joined, the T-shaped mandrel m in which the composition is composed by the upper hot press h7 and the lower hot press h8 is fitted. The upper hot press h7 and the lower hot press h8 are respectively provided with T-shaped concave portions h11 and h12 so as to form a compatible T-shaped hollow portion. In the vicinity of the T-shaped concave portions h11 and h12 of the upper hot press h7 and the lower hot press h8, heaters h13 and h14 that can appropriately adjust the temperature are provided.

Next, two bladers B as described above are used.
3, B3 ', self-propelled articulated robot R and molding device H3
The means for producing a composite molded article by the composite molded article production apparatus comprising the above will be described with reference to FIG. 9 and FIG.

One of the two bladers B3 and B3 '
Self-propelled articulated robot R using two bladers B3
A composition b composed of a thermosetting prepreg yarn is formed around a T-shaped mandrel m gripped by a robot, and then the position of the self-propelled articulated robot R is appropriately controlled to obtain a thermosetting prepreg yarn. The composition b composed of the strips is subjected to T-shaped recesses h11 of the upper hot press h7 and the lower hot press h8,
The thermosetting composition layer is formed by mounting in h12 and applying appropriate heat.

Next, the T on which the thermosetting composition layer is formed
The letter-shaped mandrel m is taken out from the upper hot press h7 and the lower hot press h8, and placed in the other braider B3 ', and the composition b is formed around the thermosetting composition layer by the thermoplastic prepreg yarn. Thereafter, in the same manner as described above, the position of the self-propelled articulated robot R is appropriately controlled, and the composition in which the thermoplastic prepreg yarn is formed around the thermosetting composition layer is again placed on the top. T-shaped recess h of hot press h7 and lower hot press h8
11. The thermoplastic composition layer is formed by mounting in h12 and applying an appropriate heat. In this manner, the composite molded article W on which the thermosetting composition layer and the thermoplastic composition layer are formed can also be manufactured. Of course, after the composition b composed of a thermosetting prepreg yarn or the composition b composed of a thermoplastic prepreg yarn is further appropriately formed on the thermoplastic composition layer by the bladers B3 and B3 ′, the molding apparatus is used. By performing heat treatment with H3, it is possible to produce a composite molded article composed of multiple layers of a thermosetting composition layer and a thermoplastic composition layer.

The above-described method for producing a composite molded article is merely an example, and a thermoplastic composition layer having a low elasticity but a toughness can be formed as the innermost layer, and a thermosetting prepreg yarn can be formed. A thermosetting tape made of non-woven fabric or a thermosetting tape made of non-woven fabric made of thermosetting prepreg fiber is wound around a mandrel m using a taping device T, and then subjected to a heat treatment to obtain a thermosetting tape. Layers can also be formed. Further, by using a plurality of self-propelled articulated robots R, for example, one self-propelled articulated robot R may form a composition b composed of a thermoplastic prepreg yarn with a braider B3 ′, One self-propelled articulated robot R may be configured to continuously produce a composite molded article by, for example, composing a composition b composed of a thermosetting prepreg yarn using a braider B3.

[0036]

Since the present invention is configured as described above, it has the following effects. A high elastic modulus composed of a thermosetting composition layer and a thermoplastic composition layer, and furthermore, it is possible to improve the productivity of a tough composite molded product and to automate the production of such a composite molded product. it can.

[Brief description of the drawings]

FIG. 1 is a front view of a braider as an example used in a method of manufacturing a composite molded article according to the present invention.

FIG. 2 is a side view of the blader of FIG. 1;

FIG. 3 is an enlarged front view of a driving device for causing a bobbin carrier including a section taken along a line II of FIG. 2 to travel along a track.

FIG. 4 is a front view of an exemplary bobbin carrier used in the blader shown in FIG.

FIG. 5 is an overall configuration diagram of a composite molded body manufacturing apparatus for producing a composite molded body.

FIG. 6 is an overall configuration diagram of another embodiment of a composite molded body manufacturing apparatus for producing a composite molded body.

FIG. 7 is an overall configuration diagram of still another embodiment of a composite molded body manufacturing apparatus for producing a composite molded body.

FIG. 8 is a side view of a blade or the like used in still another embodiment of a composite molded body manufacturing apparatus for producing a composite molded body.

FIG. 9 is a plan view of a composite molded body manufacturing apparatus for manufacturing a composite molded body using the blader or the like shown in FIG. 8;

FIG. 10 is a perspective view of a main part of a molding apparatus used in a composite molded body manufacturing apparatus for producing the composite molded body shown in FIG.

[Explanation of symbols]

 B: Blader C: Bobbin carrier H1: Thermosetting molding heat treatment apparatus H2: Thermoplastic molding heat treatment device H3 Molding device M Mandrel support device R Self-propelled articulated robot T・ ・ ・ ・ ・ ・ ・ ・ ・ Taping device W ・ ・ ・ ・ ・ ・ ・ ・ ・ Composite molded body Y ・ ・ ・ ・ ・ ・ ・ ・ ・ Thread m ・ ・ ・ ・ ・ ・ ・ ・ ・ Mandrel

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B29C 70/00-70/88

Claims (4)

(57) [Claims] A composition comprising a thermosetting prepreg yarn formed around a mandrel, followed by heat treatment to form a thermosetting composition layer, and a composition formed from a thermoplastic prepreg yarn around the mandrel. After the composition is formed, the composition is subjected to heat treatment to form a thermoplastic composition layer, as appropriate, so that at least one thermosetting composition layer and at least one thermoplastic composition layer A method for producing a composite molded article, comprising producing a composite molded article comprising: 2. A composition comprising a thermosetting prepreg yarn and a composition comprising a thermoplastic prepreg yarn are respectively appropriately formed around a mandrel, and then heat-treated to obtain at least one layer of thermosetting. A method for producing a composite molded article, comprising producing a composite molded article comprising a conductive composition layer and at least one thermoplastic composition layer. 3. The method according to claim 1, wherein the thermoplastic composition layer is formed by winding a thermoplastic tape. 4. The method according to claim 1, wherein the thermosetting composition layer is formed by winding a thermosetting tape.