JP3292498B2 - Method and apparatus for molding fiber-reinforced plastic molded article, method for producing molding material, and apparatus for producing the same - 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 a molding material for a fiber-reinforced plastic molded product, a molding method, and an apparatus for producing the same.

[0002]

2. Description of the Related Art In recent years, in the Japanese fiber reinforced plastic (hereinafter referred to as FRP) industry, a matched metal die method of press-forming between two dies is mainly used as a production means. However, SMC (Sheet moldin) consisting of reinforcing fiber, synthetic resin and thickener
Although the g compound method is often used, a molding die having two concaves and convexes is required, and a die having sufficient strength to withstand the pressure is required since it is pressed by a high-pressure press. Also, the preform mat is formed by preforming the reinforcing fibers in advance according to the shape of the mold to form a preform mat, and the synthetic resin is placed on the mold and the synthetic resin is sufficiently filled into the reinforcing fibers of the preform mat. Impregnation is difficult, expensive equipment is required, and it is difficult to handle multi-product moldings.

[0003]

A hand lay-up method in which a reinforcing fiber impregnated with a synthetic resin is pressed by hand onto a mold and a spray-up method in which a cut piece of the reinforcing fiber and a synthetic resin are sprayed on the mold are disclosed. About half of the FRP molded products are manufactured, but only by hand, the working environment is poor,
Due to the shortage of human resources, mass production is difficult. In view of the above, an object of the present invention is to provide a method and an apparatus that can easily produce a molding material and mold with a single female mold.

[0004]

In order to achieve the above object, the present invention provides a molding material in which a reinforcing fiber is impregnated with a thermosetting resin, defoamed, and covered with a thin synthetic resin sheet which is stretched up and down by heating at a low temperature. Is placed on a female mold filled with hot liquid, a lid is placed on the upper surface, and a low-temperature liquid or gas is gradually injected from the female mold into the synthetic resin sheet on the upper surface at a low pressure from the lid. A method for molding a fiber-reinforced plastic molded article is disclosed in which a hot liquid is withdrawn, a molding material is pressed against a female mold, and a thermosetting resin is cured and molded.

Further, the reinforcing fibers and the thermosetting resin are alternately dropped on a thin synthetic resin sheet which is stretched by low-temperature heating to have a desired thickness, and then pressed while moving a pressing roller to remove bubbles. A method for manufacturing a molding material is provided, which is covered with a thin synthetic resin sheet that is stretched on the upper surface by low-temperature heating.

A shooter for dropping reinforcing fibers is provided on a reciprocating base frame, nozzles for flowing down a thermosetting resin are provided on both sides of the shooter, and defoaming pressing rollers are rotatable on both sides of the base frame. A conveyor that moves in a direction perpendicular to the direction of movement of the base frame is installed below the base frame, and a coil of a thin synthetic resin sheet that is stretched by low-temperature heating placed on the conveyor on the entry side of the base frame is mounted on the base. An apparatus for manufacturing a molding material is provided in which a coil of a thin synthetic resin sheet that extends by low-temperature heating and that covers a reinforcing fiber is installed on the discharge side of a frame.

A fixing means for attaching a conduit having a valve for removing hot liquid to a lower surface of a female mold having a flange, and fixing a molding material and a lid having a conduit for introducing a low-temperature liquid or gas to the flange. Are provided in a large number of places to constitute a fiber reinforced plastic molded product manufacturing apparatus.

[0008]

The present invention is constructed as described above.
A thin synthetic resin sheet extending by low-temperature heating from a coil provided to the advance entry side rewound with the movement of the conveyor. Thereafter, the thermosetting resin is dropped from the synthetic resin nozzle by reciprocating the base frame in a direction orthogonal to the moving direction of the conveyor,
The reinforcing fiber is dropped from the shooter on top of it, and the thermosetting resin is dropped on top of it. The reinforcing fiber is stacked to a desired thickness, and is pressed with a pressing roller to impregnate the thermosetting resin and remove it at the same time. Do foam. Next, the conveyor is moved, the base frame is reciprocated at a position adjacent to the stacked reinforcing fibers to form a molding material having a desired shape, and the upper and lower thin synthetic resin sheets are rewound along with the movement of the conveyor, and the molding material is formed. Up and down
A molding material covered with a thin synthetic resin sheet stretched by the low-temperature heating is manufactured.

[0009] This molding material is placed on a female mold filled with hot liquid, and a lid is put on it and fixed by fixing means, and then a low-temperature hot liquid or gas is supplied at a low pressure from a conduit provided on the lid. And at the same time, by gradually withdrawing the warm liquid from the female mold, the molding material is deformed along the female mold, and after the withdrawal of the warm liquid and the supply from the upper part are completed, the molding material is pressed against the female mold. Then, the thermosetting resin is cured to complete the molding.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, a method and an apparatus for producing a molding material for a fiber-reinforced plastic molded product will be described in detail with reference to FIGS. The coil 3 wound a thin synthetic resin sheet 2 extending by low-temperature heating in the advance entry side belt conveyor 1 moves horizontally installed, with the synthetic resin sheet 2 to the movement of the belt conveyor 1, unwound the belt The upper surface of the conveyor 1 moves together with the belt conveyor 1. On the other hand, above the belt conveyor 1 is provided with a base frame 4 which reciprocates and the lift in the direction perpendicular to the moving direction and the horizontal plane of the belt conveyors 1. The base frame 4 is provided with mounting plates 5 on both sides.
Press rollers 6 and 7 are rotatably mounted at both ends of the roller 5, respectively, and a shooter 9 for supplying reinforcing fibers such as glass fibers by fixing key-shaped mounting arms 8 and 8 at the center is provided.
7 is supported above. Then, synthetic resin nozzles 10 and 11 for supplying a thermosetting resin to both sides (on the pressing rollers 6 and 7 side) of the shooter 9 are attached via support plates 12 and 13.

A coil 15 wound with a thin synthetic resin sheet 14 which is stretched by low-temperature heating is installed above the discharge side of the shooter 9, and is placed on the upper surface of a mat-shaped molding material 18 via guide rolls 16 and 17. Thinned by low temperature heating
The synthetic resin sheet 14 is supplied.

The embodiment of the apparatus according to the present invention is configured as described above, and the manufacturing method will be described with reference to this embodiment. The synthetic resin sheet 2 is rewound by moving the belt conveyor 1 to a state shown in FIGS. In this state, the base frame 4 is moved in a direction orthogonal to the moving direction of the belt conveyor 1,
A relatively long (50 mm or more) cut piece of reinforcing fiber such as glass fiber is dropped from the shooter 9 onto the synthetic resin sheet 2. At this time, the thermosetting resin flows down from the synthetic resin nozzles 10 and 11. Then, by moving the base frame 4 back and forth, reinforcing fibers are placed on the thermosetting synthetic resin,
On top of this, reinforcing fibers are stacked in a sandwich shape such as a thermosetting synthetic resin to a desired thickness. At this time, the base frame 4
Is gradually raised so that the pressing rollers 6 and 7 are positioned at positions corresponding to the thickness, and the reinforcing fibers are pressed along with the movement of the base frame 4 to sufficiently impregnate the reinforcing fibers with the synthetic resin. Degas.

When the synthetic resin is formed to a desired thickness, the belt conveyor 1 is moved by the width of the shooter 9, the base frame 4 is reciprocated again, and the same operation is repeated to form the molding material 18. As shown in the right side of FIG. 1, the molding material 18 adjusts the reciprocating distance of the base frame 4 so that
It is formed into a shape according to the shape at the time of molding, which is a subsequent step.
The molding material 18 is formed to the desired thickness and shape, and after the defoaming is completed, the belt conveyor 1 is moved to form the molding material 1.
8 moves the synthetic resin sheet 2 carrying the cover the upper surface of the thin synthetic resin sheet 14 unwound by the molding material 18 extending through the low-temperature heat from the coil 15, low temperature vertical
Covering with thin synthetic resin sheets 2 and 14 that are stretched by heating prevents air from entering.

Then, as the belt conveyor 1 moves,
When the molding material 18 is separated from the belt conveyor 1 and moves on a support stand (not shown), the movement of the belt conveyor 1 is stopped, cut off from the cutting line 19, and moved to the next molding step. Although it has been described that the base frame 4 is moved up and down, since the positions of the pressing rollers 6 and 7 are problematic,
The object can be achieved if at least the pressing rollers 6, 7 can be moved up and down.

Next, a molding method and a molding apparatus are shown in FIGS.
It will be described based on FIG. The female mold 20 has a flange 21 on the outer periphery of the upper end.
And a conduit 23 having a valve 22 for withdrawing a hot liquid of 50 ° C. or more filled in the mold on the lower surface. And
The mat-shaped molding material 18 covered with the thin synthetic resin sheets 14 and 2 extending above and below by low-temperature heating is placed on the flange 21, and the lid 24 is placed from above. A conduit 26 having a valve 25 through which a low-temperature (50 ° C. or higher) liquid or gas flows is attached to the top of the lid 24. Then, the cover 24 is fixed to the flange 2 by fixing means 27 such as a vise provided at a plurality of places.
It is designed to be fixed at 1.

The embodiment of the present apparatus is constructed as described above. After filling the female mold 20 with the hot liquid of 50 ° C. or higher, the mat-shaped molding material 18 is placed on the flange 21, The molding material 18 is fixed so as not to move by covering with the lid 24 and fixing with fixing means 27, 27. Next, the valve 25 is opened and the molding material 1 is supplied from the conduit 26.
8 on the synthetic resin sheet 14 on the upper surface
(0 ° C. or higher) liquid or gas is injected at a low pressure, and at the same time, the lower valve 22 is opened and the hot liquid is gradually discharged from the conduit 23. Due to the discharge of the hot liquid and the injection from above, the molding material 18 gradually descends, and the upper and lower synthetic resin sheets 14 and
2 descends while being stretched by heating, makes the lower synthetic resin sheet 2 along the inner surface of the female mold 20 in a state where the hot liquid is completely removed, and presses it with a low-pressure liquid or gas from the upper surface, The thermosetting resin constituting the molding material 18 is cured and molded. After the molding, the product is extracted from the female mold 20 after the liquid on the upper surface is discharged.

[0017]

According to the method and the apparatus for producing a molding material, since the synthetic resin is impregnated and defoamed by a mechanical operation, a stable quality material can be obtained. Further, since the molding material is formed by reciprocating the shooter or the like, the molding material according to the shape of the molded product can be obtained by adjusting the reciprocating distance. In the molding method and apparatus, since the molding die is only a female mold, it can be manufactured at low cost.
Further, since extremely low pressure is used, equipment costs are low and mechanization is easy. Further, since a synthetic resin sheet is used, a release agent is not required.

[0018]

[Brief description of the drawings]

FIG. 1 is a partially cutaway plan view of one embodiment of a method and an apparatus for producing a molding material for a fiber-reinforced plastic molded product according to the present invention.

FIG. 2 is a front view of FIG. 1;

FIG. 3 is a plan view of a molding method and apparatus.

FIG. 4 is a longitudinal sectional view of FIG. 3;

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 belt conveyor 2 synthetic resin sheet 3 coil 4 base frame 5 mounting plate 6 pressing roller 7 pressing roller 8 mounting arm 9 shooter 10 nozzle for synthetic resin 11 nozzle for synthetic resin 12 support plate 13 support plate 14 synthetic resin sheet 15 coil 16 Guide Roll 17 Guide Roll 18 Molding Material 19 Cutting Line 20 Female 21 Flange 22 Valve 23 Conduit 24 Lid 25 Valve 26 Conduit 27 Fixing Means

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 39/02-39/40 B29C 43/02-43/54 B29C 33/02-33/04 B29C 70 / 04-70/56 B29B 11/14-11/16 B29B 15/08-15/14 C08J 5/08

Claims (4)

(57) [Claims] 1. A molding material impregnated with a thermosetting resin in a reinforcing fiber, defoamed, and covered with a thin synthetic resin sheet extending vertically by low-temperature heating is placed on a female mold filled with hot liquid. The lid is placed on the upper surface, and while the low-temperature liquid or gas is injected from the lid onto the synthetic resin sheet on the upper surface at a low pressure, the hot liquid is gradually withdrawn from the female mold, and the molding material is pressed against the female mold and thermoset. A method for molding a fiber-reinforced plastic molded article, characterized by curing and molding a conductive resin. 2. A method in which a reinforcing fiber and a thermosetting resin are alternately dropped on a thin synthetic resin sheet stretched by low-temperature heating to a desired thickness, and then defoamed by pressing while moving a pressing roller. A method for producing a molding material, characterized in that an upper surface is covered with a thin synthetic resin sheet that is stretched by heating at a low temperature. 3. A shooter for dropping reinforcing fibers on a reciprocating base frame, a synthetic resin nozzle for flowing down a thermosetting resin on both sides of the shooter, and defoaming pressing rollers on both sides of the base frame. rotatably the provided established the moving conveyor beneath the base frame in a direction perpendicular to the moving direction of the base frame, a thin synthetic resin sheet extending by low-temperature heating for placing on the conveyor advances the entry side of the base frame An apparatus for manufacturing a molding material, characterized in that a coil of a thin synthetic resin sheet, which extends by low-temperature heating and covers a reinforcing fiber, is provided on a discharge side. 4. A fixing means for attaching a conduit having a valve for extracting hot liquid to a lower surface of a female mold having a flange, and fixing the molding material and a lid having a conduit for introducing a low-temperature liquid or gas to the flange. Is provided at a large number of places, a manufacturing apparatus for a fiber-reinforced plastic molded product.