JP3326541B2 - Molding method of fiber reinforced resin material - 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 molding a fiber reinforced resin material formed by a plurality of thermoplastic resin sheets including a fiber reinforced resin sheet.

[0002]

2. Description of the Related Art As for fiber-reinforced resin materials used for motorcycle cowlings and hulls of small boats, thermosetting resins are generally easier to mold than thermoplastic resins.
Since the viscosity at the time of molding is low, the impregnation property is good and the strength is easy to come out, so conventionally, fiber reinforced resin materials reinforced with short fibers using a thermosetting resin as a matrix are generally used,
In recent years, as the reuse of resources has been considered in connection with resources and environmental issues, thermoplastic resins can be reused more than thermosetting resins, so in such applications, Fiber-reinforced resin materials reinforced with continuous fibers have been used to increase the strength of a thermoplastic resin as a matrix.

In order to form such a fiber-reinforced resin material, a plurality of fiber-reinforced resin sheets in which reinforcing fibers are solidified in a resin matrix are put into a mold in a state of being stacked, and a laminate is formed by joining the sheets together. A molding method is adopted in which the shaping of the laminate according to the mold is performed at the same time, but in this case, the fiber-reinforced resin material using a thermosetting resin as a matrix is At the time of disposition, since the sheet itself has tackiness (adhesiveness) and closely adheres to the mold, it is not necessary to particularly provide a means for fixing the sheet to the mold.

However, in a fiber-reinforced resin material having a thermoplastic resin as a matrix, since there is no tackiness (adhesiveness) itself, an upright surface in the mold (a surface almost perpendicular to an overhanging surface). and in its periphery, as to <br/> shown in Figure 5, the fiber-reinforced resin material 1 consisting of superimposed sheets that will fall down into the mold can not be in close contact with the mold 2 often occurs.

[0005] Therefore, in order to prevent the falling to such fiber-reinforced resin sheet mold, conventionally, as to <br/> shown in FIG. 6 (A), the entrance periphery of each sheet type 2 in sequentially or fixed by a fixing member 6 such as an adhesive tape, shown to <br/> so on in FIG. 6 (B), the inlet peripheral already mold 2 by a fixing member 6 such as an adhesive tape at the inlet around the mold 2 or welded overlapping another sheet 1b, and 1c with respect to fixed sheet 1a, or, although not shown, means such as a superimposed sheets or welded to the inlet peripheral types by thermal iron is facilities Have been.

[0006]

However, according to the conventional means for preventing the fiber-reinforced resin sheet from falling into the mold as described above, if the respective sheets are fixed in order by an adhesive tape or the like, the adhesive tape or the like is not used. A large amount of work is required and the work is complicated, and in the case where another sheet is overlapped and welded on the sheet already fixed by the fixing member, the already fixed sheet itself may shift when the second and subsequent sheets are fixed. (Since the surface of the mold is smooth and the release agent is applied, the first sheet is likely to be misaligned.) The work is difficult, and when the number of laminated sheets increases, the first sheet Since the weight applied to the fixed fixing member increases and the fixing member comes off, a large number of fixing members are required.

Further, in a method in which a superposed sheet is welded around the entrance of a mold by a hot iron, the tip of the iron touches the mold, and when the thickness of the superimposed sheets is small, the mold is damaged. The use of a hot iron by scorching or melting the mold causes the surface of the mold to become rough, and once the sheet is welded to the mold, it becomes impossible to correct its position or (orientation) angle.

An object of the present invention is to eliminate the disadvantages of the conventional method of molding a fiber-reinforced resin material as described above, and more specifically, to arrange the laminated thermoplastic resin sheets in a mold. In this case, it is not necessary to use a fixing member such as an adhesive tape, and the work of arranging in the mold is easy, and it is possible to correct the position when arranging in the mold without adversely affecting the mold itself. It is an object of the present invention to provide a method of molding a fiber-reinforced resin material that can effectively prevent falling into a mold.

[0009]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems and to achieve the object, the present invention provides a fiber reinforced resin in which at least a plurality of thermoplastic resin sheets including a fiber reinforced resin sheet are stacked. In a molding method for forming a material into a fiber-reinforced resin material which is formed into a certain shape and integrated by heating the material in a mold, when the fiber-reinforced resin material is arranged in the mold, Outer layer
First, pre-shape only the sheet that matches the mold, and then
By overlapping other sheets on each other and fixing them together,
The stacked sheets are fixed to each other in advance so as to maintain the shape along the mold.

[0010] Note that the fixing between the sheets in the above molding method, ultrasonic, high frequency, in addition to the welding of matrixes by hot air or the like, temporarily fixed by Tucker matrix the same material, the reinforcing fibers and similar material fibers Can be performed by means such as temporary fixing.

[0011]

According to the molding method as described above, the fiber-reinforced resin material in a state in which a plurality of thermoplastic resin sheets are overlapped, for example, at a portion corresponding to the vicinity of the periphery from the entrance of the mold. Since the shape is surely maintained, the part is securely locked to the mold, and does not fall into the mold.

[0012]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a molding method of a fiber-reinforced resin material according to the present invention.

FIGS. 1 and 2 show an embodiment of a method for molding a fiber reinforced resin material, in which the fiber reinforced resin material is arranged in a mold prior to heat molding with the mold. The material 1 is arranged in the mold 2 in a state where the respective sheets are superimposed, and is heated in the mold 2 so that
It is formed into a shape along the mold 2 and is formed in a state where the matrices of the respective sheets are fused and integrated.

Each of the sheets 1a, 1b, and 1 of the fiber-reinforced resin material 1 arranged on the mold 2 as superposed sheets.
1c has a matrix made of thermoplastic resin such as polyetheretherketone, polyetherketone, polyphenylenesulfide, polyamideimide, thermoplastic polyimide, etc., and has long continuous reinforcing fibers such as carbon fiber and glass fiber embedded therein. Fiber reinforced resin sheet.

[0015] Such fiber-reinforced resin material 1, when placed in the mold, as is shown in Fig 2, in the vicinity of the inlet of the mold 2, each sheet 1a, 1b, 1c is along the mold 2 Each of the sheets 1a, 1
The b and 1c are previously fixed to each other by the tucker 3 at a plurality of locations around the vertical portion 2a and the horizontal portion 2b around the corner of the entrance so that the shape is maintained.

In the pretreatment molding for disposing the fiber reinforced resin material 1 in the mold 2 as described above, the sheet 1a on the side in contact with the mold 2 is put in the mold 2 in advance and heated. The pre-shaped sheet 1 is subjected to pre-shaping to such an extent that at least the shape near the entrance of the mold 2 is maintained.
a. Overlay the other sheets 1b and 1c on a.
By temporarily fixing at a plurality of locations by a tucker 3 made of a thermoplastic resin of the same material as the matrix of the fiber-reinforced resin material 1 in a portion in contact with the vertical portion 2a and the horizontal portion 2b around the corner of the entrance of the mold 2, it is intended to be shaped to be shown in FIG.

According to the pretreatment molding of the fiber reinforced resin material 1 as in the above embodiment, the other sheets 1b and 1c are superimposed on the preformed sheet 1a,
Since the base surface 1a is stable and the deviation is small, the fiber direction of the sheets 1b and 1c to be superimposed is easily directed to a predetermined direction, the variation in the thickness due to the deviation is reduced, and a product can be manufactured with high accuracy. .

Further, even after the tuckers 3 are driven in to fix the sheets together, the sheets are not completely adhered to each other, so that it is possible to make corrections. It is not integrated with the matrix of No. 1 and remains as a foreign substance.

FIGS. 3 and 4 show another method of molding the fiber-reinforced resin material 1 similar to that of the above-described embodiment, except for the specific fixing means of the superposed sheets 1a, 1b, 1c. FIG. 3 shows each of the sheets 1a, 1a by ultrasonic waves, high frequency waves, hot air and the like.
FIG. 4 shows an embodiment in which the matrices b and 1c are welded to each other. In FIG. 4, the sheets are sewn with fibers of the same material as the reinforcing fibers embedded in each of the sheets 1a, 1b and 1c. A temporarily fixed embodiment is shown.

[0020] In the embodiment shows in FIG. 3, for example, if the welding is performed by ultrasonic welding, welding surface 4 between the sheets
And the welding horn does not heat up as much as the tip of a hot iron, so even if the sheets are welded to each other using the mold 2 as an anvil, there is little thermal effect on the mold 2 It is.

Further, in the embodiment is shown in Figure 4, the fiber-reinforced resin material 1 after heat molding fibers 5 that are used to temporarily fixed
Since the reinforcing effect is exhibited in the inside, the strength of the product is improved. In particular, since the reinforcing material 5 enters so as to penetrate between the layers, delamination can be effectively prevented.

Each of the stacked sheets 1a, 1
The specific fixing between b and 1c is not limited to the above-described embodiment, and the above-described units may be appropriately combined with each other. It is also possible to combine the fixing techniques described above.

Further, in each of the above embodiments, all the sheets 1a, 1b, 1c of the fiber reinforced resin material 1 are described as being fiber reinforced resin sheets. It does not apply only to such a thing, for example, the sheet to be preformed is not a fiber reinforced resin sheet, and may be a resin film equivalent to a matrix resin of the fiber reinforced resin sheet. In this case, a resin layer is formed on the surface layer of the product, and the smoothness of the surface is improved.

Furthermore, the molding method of the present invention can be applied to the hybridization of fiber-reinforced resin sheets having different molding temperatures (materials). A sheet made of resin is arranged, and an outer plate member is manufactured by laminating and molding a sheet made of inexpensive and highly moldable polypropylene as a matrix resin inside the sheet, or on both sides of a sheet made of polyamide as a matrix resin. The present invention can also be applied as a pretreatment for heat molding in the case of manufacturing a low-cost and lightweight fuel tank with high gas barrier properties by laminating and molding sheets using polyethylene as a matrix resin.

[0025]

According to the method for molding a fiber-reinforced resin material of the present invention as described above, a fixing member such as an adhesive tape is required when the laminated thermoplastic resin sheets are arranged in a mold. Without disturbing the mold itself.
The position of the sheet with respect to the mold can be corrected, and moreover, it is possible to effectively prevent the superimposed sheet from falling into the mold.

[Brief description of the drawings]

FIG. 1 shows a method for molding a fiber-reinforced resin material according to the present invention.
Sectional drawing which shows the state which arrange | positioned the fiber reinforced resin material in the type | mold.

FIG. 2 is a partially enlarged cross-sectional view of a main part (portion A in FIG. 1) showing one embodiment of the present invention.

FIG. 3 is a partially enlarged cross-sectional view of a main part (A in FIG. 1) showing another embodiment of the present invention.

FIG. 4 is a partially enlarged sectional view of a main part (A in FIG. 1) showing still another embodiment of the present invention.

FIG. 5 is a cross-sectional view showing a state in which a fiber-reinforced resin material arranged in a mold is collapsed in a conventional method of molding a fiber-reinforced resin material.

FIG. 6 shows a conventional fiber-reinforced resin material molding method.
5 is a partially enlarged cross-sectional view of a main part, showing a part corresponding to FIG.

[Explanation of symbols]

 Reference Signs List 1 fiber reinforced resin material 1a thermoplastic resin sheet (fiber reinforced resin sheet) 1b thermoplastic resin sheet (fiber reinforced resin sheet) 1c thermoplastic resin sheet (fiber reinforced resin sheet) 3 tucker 5 reinforcing fiber (for temporary fixing)

──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Naoshi Morita 2500 Shinkai, Iwata City, Shizuoka Prefecture Inside Yamaha Motor Co., Ltd. (56) References JP-A-2-276625 (JP, A) (58) Fields investigated ( Int.Cl. ⁷ , DB name) B29C 70/06

Claims (3)

(57) [Claims] 1. A fiber formed by integrating a plurality of thermoplastic resin sheets, including at least a fiber-reinforced resin sheet, in a state of being superposed into a mold and heating the fiber-reinforced resin material into a predetermined shape and integrated. In the molding method for forming a reinforced resin material, only the sheet to be the outer layer portion of the fiber reinforced resin material is first placed when placing the fiber reinforced resin material in the mold.
After pre-shaping according to the mold, another sheet is
A method of molding a fiber-reinforced resin material, wherein the stacked sheets are fixed to each other in advance so as to maintain the shape along the mold by fixing them together. 2. The method for molding a fiber-reinforced resin material according to claim 1 , wherein the fixing of the sheets is performed by temporary fixing with a tucker of the same material as the matrix. Wherein between the sheets fixed, claim 1, characterized in that by temporary fixing by fibers of the reinforcing fiber equivalent material
The method for molding a fiber-reinforced resin material according to item 1.