JP5362596B2 - Paste composition method, pasting composite mold and pasting device - Google Patents

Description

  In the present invention, a reinforcing fiber fabric is impregnated with a thermoplastic resin by using a stationary mold and a movable mold that is opened and closed with respect to the stationary mold and is slid. The present invention relates to a paste composition method for producing an intermediate base material or a reinforced fiber fabric reinforced plastic, a paste composition mold and a paste composition apparatus.

  Carbon fiber fabric reinforced plastic (CFRP), in which a sheet or fabric with unidirectionally aligned carbon fibers is impregnated with thermosetting resin, has a specific strength and a specific elastic modulus compared to steel and glass fiber fabric reinforced plastic (GFRP). And has the mechanical characteristics of being light and strong. Therefore, carbon fiber reinforced plastics are widely used from the aviation industry such as aircraft and space equipment to the consumer equipment such as golf shafts and fishing rods. Recently, it has been attracting attention as a new material from the viewpoint of improving fuel efficiency by reducing the weight of automobiles. Reinforced plastics are also produced from reinforcing fibers such as glass fibers other than carbon fibers and aramid fibers.

  Such a reinforced fiber fabric reinforced plastic is generally produced by impregnating a matrix resin into a sheet or a reinforced fiber fabric in which reinforcing fibers are aligned in one direction to produce an intermediate substrate, that is, a prepreg, and laminating a required number of the prepregs. Manufactured by thermosetting in an autoclave. The manufacturing method or manufacturing apparatus of a prepreg is shown by the patent document 1, for example, and the nonpatent literature 1 is related with the thermosetting of a prepreg.

Japanese Patent Publication No. 2-26845

Advanced molding technology P328-334

  Generally, a prepreg manufacturing apparatus includes a pair of heating rolls. Accordingly, a resin-carrying sheet coated with a semi-cured resin is superimposed on both sides of a reinforcing fiber fabric such as carbon fiber, and the semi-cured resin of the resin-carrying sheet is applied to the reinforcing fiber fabric by clamping with the heating roll. When transferred and impregnated, a semi-cured sheet-like prepreg is obtained. In the prepreg manufacturing apparatus described in Patent Document 1, a resin pool control plate is provided at a nip point where a pair of heating rolls mesh. On the other hand, an autoclave device for thermosetting a laminated prepreg requires a function of heating the prepreg, a function of cooling, a function of pressurizing and depressurizing, and the like. It is shown in Patent Document 1.

  In the prepreg manufacturing apparatus described in Patent Document 1, since the resin pool control plate is provided at the nip point, when the reinforcing fiber fabric and the resin carrying sheet are overlapped and pressed by a pair of heating rolls, Resin accumulation generated between the reinforcing fiber fabric and the support sheet can be suppressed. In addition, since the autoclave device is configured to have the functions as described above, the prepreg is cut according to the part shape, the cut prepreg is laid up on the jig, and the prepreg stacked on the jig is stacked. A reinforced fiber woven reinforced plastic can be obtained through processes such as vacuum sealing and backing, and thermosetting with an autoplate. As described above, the reinforced fiber fabric reinforced plastic can be obtained by producing a prepreg and thermosetting it with an autoclave apparatus. However, the prepreg as an intermediate substrate is impregnated with a thermosetting resin. Therefore, it is necessary to strictly manage temperature, humidity, dirt, etc., and storage and management are costly. On the other hand, in order to obtain a product from a prepreg, there is a disadvantage that a large amount of cost is required for an apparatus for performing each process such as cutting, layup, backing, and thermosetting. For example, the construction cost of a freezer that stores prepreg at a low temperature of -18 ° C or lower, the construction cost of a layup room in which temperature, humidity, etc. are strictly controlled, the automatic cutting machine installed in the layup room, the automatic layup machine, Equipment costs such as molding jigs and vacuum pumps increase. Further, each of the above processes has a disadvantage that it takes time especially for impregnation and productivity is lowered. Furthermore, there is a problem that the obtained reinforced fiber fabric reinforced plastic is difficult to recycle.

  Therefore, according to the present invention, it is possible to obtain a prepreg impregnated with a thermoplastic resin in a short time with an inexpensive facility, that is, an intermediate base material or a reinforced fiber fabric reinforced plastic, and to easily recycle the intermediate base material or the reinforced fiber fabric. It is an object of the present invention to provide a method for pasting and molding plastic, a mold for pasting and molding, and a pasting and molding apparatus.

  In order to achieve the above object, the present invention is applied to a fixed mold and a movable mold that is opened and closed with respect to the fixed mold and is slidably driven. Then, the moving side mold is driven to the first position to clamp the mold on the fixed side mold. By this clamping, a pair of cavities are formed between these molds. Therefore, a matrix resin to be paired is formed by injection filling with a thermoplastic resin. The moving mold is opened by a predetermined amount and moved to the second position. In this second position, the matrix resin to be paired is aligned while remaining in the respective molds. Or it is opposite. A reinforcing fiber woven fabric, which is a sheet or woven fabric in which reinforcing fibers are aligned in one direction, is inserted between opposing matrix resins, and a heating element is interposed between the matrix resin remaining in the mold and the inserted reinforcing fiber woven fabric. Insert. At this time, a carbon heater or a halogen heater is preferably applied to the heating body. Once inserted, the distance between the matrix resin and the reinforcing fiber fabric is reduced, and both the matrix resin and the reinforcing fiber fabric are heated. The heating element inserted after heating to a predetermined temperature or for a predetermined time is retracted, and the moving side mold is clamped to the fixed side mold. Then, the matrix resin made of the thermoplastic resin in the heated state is pressed against the reinforcing fiber fabric in the same manner, and the matrix resin sticks to the reinforcing fiber fabric or penetrates between the reinforcing fiber fabrics. .

  Thus, in order to achieve the above object, the invention described in claim 1 includes a fixed mold and a movable mold that is opened and closed with respect to the fixed mold and is slidably driven. A molding step of injecting and filling molten thermoplastic resin into the configured cavity to mold the first and second matrix resins to be paired, and the first and second matrix resins molded in the molding step are solidified to some extent After that, the moving mold is opened, and the first and second matrix resins are opposed to each other at a predetermined interval, and a reinforcing fiber fabric is inserted between the matrix resins opposed by the positioning step. Inserting the heating element between the matrix resin and the reinforcing fiber woven fabric inserted by the inserting step and the reinforcing fiber woven fabric and the matrix fiber resin. First and second matrix resins by heating both the Lix resin, retracting the heating body after the heating step, and clamping the movable mold against the fixed mold And an impregnation step of impregnating the reinforcing fiber fabric.

The invention according to claim 2 is the sticking composition method according to claim 1, wherein the heating step includes an interval between the heating body and the reinforcing fiber fabric during the positioning step or an insertion step, and the heating body. It is comprised so that the space | interval of a matrix resin may be narrowed. According to a third aspect of the present invention, in the method of pasting and combining the present invention according to the first or second aspect, a halogen heater or a carbon heater is used in the heating step, and the invention according to the fourth aspect is In the sticking synthetic | combination method of any one of Claims 1-3, it is comprised so that carbon fiber may be used for a reinforcing fiber fabric.

According to a fifth aspect of the present invention, there is provided a fixed mold, and a movable mold that is slidably driven while being opened and closed with respect to the fixed mold, and the movable mold is a first mold. When the mold is clamped to the fixed mold at the position, a cavity in which a matrix resin made of a thermoplastic resin is molded is formed between the molds, and the movable mold is the second mold. The cavity component formed on the movable mold is opposed to the cavity component formed on the fixed mold, and the movable mold is disposed at the opposed position. And a first mold opening position where the distance between the fixed mold and the fixed side mold is increased, and a second mold opening position which is narrower than the first mold opening position, In the second position, it is inserted with the cavity component. Heating body is adapted to be inserted into and between the reinforcing fiber fabric and other cavities components that are inserted between the reinforcing fiber fabric, the stationary-side the movable mold at the second position It is configured so that the mold can be clamped. The invention according to claim 6 is a stationary mold, a movable mold that is opened and closed with respect to the stationary mold and is slidably driven, and a heating body comprising a halogen heater or a carbon heater. When the moving mold is clamped to the fixed mold at the first position, a matrix made of a thermoplastic resin is paired between the molds. When the cavity in which the resin is molded is configured and the moving side mold is moved to the second position, the cavity component formed in the moving side mold is formed in the fixed side mold. A first mold opening position where the distance between the movable mold and the fixed mold is larger and a first mold opening position which is narrower than the first mold opening position. It is configured to be able to take 2 mold opening positions In the first mold opening position, the heating element is inserted between the cavity component and the inserted reinforcing fiber fabric and between the inserted reinforcing fiber fabric and another cavity component. In addition, the movable side mold can be clamped to the fixed side mold at the second position.

  As described above, according to the present invention, the molding process for molding the first and second matrix resins to be paired and the alignment process for causing the first and second matrix resins to face each other at a predetermined interval are opposed to each other. An insertion step of inserting a reinforcing fiber fabric between the matrix resins, a heating step of inserting a heating body between the reinforcing fiber fabric and the matrix resin to heat both the reinforcing fiber fabric and the matrix resin, Since the base material or the reinforced fiber fabric reinforced plastic is molded from the impregnation process in which the matrix resin is pressed against the reinforcing fiber fabric and bonded or impregnated, these steps move with the fixed mold. Since it is implemented with a side mold, it is possible to obtain an intermediate substrate or reinforced fiber woven plastic with inexpensive equipment. That. Also, both the reinforcing fiber fabric and the matrix resin are heated and the moving side mold is clamped to the fixed side mold and bonded or impregnated. Can be obtained. At this time, according to the invention using carbon heaters or halogen heaters during the heating process, these heaters are excellent in thermal responsiveness. Can do. Further, according to another invention, during the heating step, the distance between the matrix resin and the heating body and the distance between the heating body and the reinforcing fiber fabric are reduced, so that the heating can be performed in a shorter time with further energy saving. Furthermore, according to the present invention, since the matrix resin is made of a thermoplastic resin, recycling is easy.

  Further, according to the present invention, the reinforced fiber fabric reinforced plastic can be directly molded as described above. However, since the matrix resin is made of a thermoplastic resin, the intermediate substrate obtained as described above is heated and deformed. Then, a desired shape or a necessary number of intermediate substrates can be stacked to form a reinforcing fiber woven reinforced plastic having a desired thickness.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the shaping | molding apparatus which concerns on embodiment of this invention, The (a) is sectional drawing which shows the state by which the movement side metal mold was clamped in the 1st position, The (a) is a 2nd position. Sectional drawing shown in a state where the mold is opened, (c) is an enlarged sectional view of an essential part at the beginning of mold clamping for impregnation.

  Embodiments of the present invention will be described below. As shown in FIGS. 1A and 1B, the molding die or molding apparatus according to the present embodiment is roughly composed of a fixed mold 1 and a movable mold 11. It is configured. The fixed-side mold 1 is attached to a fixed plate (not shown) in a conventionally known manner. In addition, the movable mold 11 is attached to the movable mold 10 that is opened and closed with respect to the fixed mold 1, in other words, the movable mold 11 is slidable in the vertical direction in the illustrated embodiment. . More specifically, although not shown in FIG. 1, for example, a support frame extends upward from the upper part of the movable platen 10, and a support arm extends from the upper end portion toward the fixed platen. A hydraulic piston / cylinder unit is attached to this support arm, and its rod is connected to the moving side mold 11. As a result, when hydraulic oil is supplied to or discharged from the hydraulic piston / cylinder unit, the movable mold 11 is slidably driven in the vertical direction in FIG.

  A sprue 2 is formed across the mold 1 in the stationary mold 1 configured as described above. A recess 3 having a predetermined depth for molding one matrix resin is formed on the parting surface P side above the sprue 2. Further, a core 4 having a predetermined height for molding the other matrix resin is formed on the parting surface P side below the sprue 2. These thermoplastic matrix resins are bonded or impregnated into the reinforcing fiber fabric as described later.

  On the parting surface P side of the moving-side mold 11, a core 13 that forms a pair with the concave portion 3 is formed at an upper position thereof. The core 13 and the recess 3 constitute a first cavity K1 for molding one matrix resin. The core 13 protrudes slightly from the parting surface P so as to fit into the recess 3. Therefore, the matrix resin to be molded is slightly pulled in from the parting surface P. Accordingly, the reinforcing fiber fabric described later can be positioned, and also serves as a relief portion of the solid reinforcing fiber fabric during mold clamping. On the lower parting surface P side, a recess 14 that cooperates with the core 4 of the fixed mold 1 is formed. The recess 14 and the core 4 are the same size as the recess 3 and the core 13, respectively, and the recess 14 and the core 4 form a second cavity K2 for molding the other matrix resin. Gates 5 and 15 communicating with the sprue 2 are opened in the first and second cavities K1 and K2, respectively.

  The cores 4 and 13 protrude outward from the parting surface P as described above, but the total volume of the protruding portions is substantially equal to the volume when the carbon fiber fabric described later is compressed. It has become.

  A mold clamping device for opening and closing the movable plate 10, and thus the movable mold 11 with respect to the fixed mold 1, is not shown in FIG. 1, but the movable mold 11 is driven to the first position. In this case, the mold can be clamped even when driven to the second position. In addition, the first stage mold opening (insert mode) that is largely opened at the second position and the second stage mold opening (heating mode) narrower than that can be performed.

  Next, a molding example using the molding apparatus will be described. The moving side mold 11 is slidably driven to the first position. Then, clamp the mold. Then, the first cavity K1 is formed by the recess 4 of the fixed mold 1 and the core 13 of the movable mold 11 and the first cavity K1 is formed by the core 4 of the fixed mold 1 and the concave 14 of the movable mold 11. Two cavities K2 are formed. FIG. 1A shows a state where the moving side mold 11 is driven to the first position and the first and second cavities K1 and K2 are configured.

  Although not shown in the drawing, a thermoplastic resin in a molten state is injected from a conventionally known injection unit. The molten resin is filled from the sprue 2 into the first and second cavities K1 and K2 through the gates 5 and 15, respectively. Thereby, the first and second matrix resins M1 and M2 are molded substantially simultaneously. Waiting for the solidification of the first and second matrix resins M1 and M2 to some extent, the moving mold 11 is opened to the first stage. The first matrix resin M1 remains on the stationary mold 1 and the second matrix resin M2 remains on the moving mold 11 and is opened.

  The moving mold 11 is driven to the second position. Then, the second matrix resin M2 remaining in the movable mold 11 is opposed to the first matrix resin M1 remaining in the fixed mold 1. This state is the insert mode as shown in FIG. A carbon fiber fabric W is inserted between these matrix resins K1 and K2. Further, between the first matrix resin K1 and the carbon fiber woven fabric W and between the carbon fiber woven fabric W and the second matrix resin K2, planar heating elements H and H made of a carbon heater or a halogen heater are inserted. To do. The mold opening amount of the moving side mold 11 is narrowed. By this heating mode, the distance between the first and second matrix resins K1, K2 and the heating bodies H, H is narrowed. Further, when the mold opening amount is narrowed, the distance between the carbon fiber fabric W and the heating elements H and H is also narrowed as necessary.

  The heating elements H, H are energized to heat the first and second matrix resins K1, K2 and the carbon fiber fabric W. Since the first and second matrix resins K1 and K2 made of thermoplastic resin are not deformed and the heat resistance temperature of the carbon fiber fabric W is as high as 280 ° C. or higher, the first and second matrix resins K1 and K2, When heated to a temperature higher than K2, the heating elements H and H are retracted. Then, the moving mold 11 is clamped with respect to the fixed mold 1. When the mold is clamped, the parting surfaces P and P of the fixed side mold 1 and the movable side mold 11 are in contact with each other, but the state immediately before that is shown enlarged in FIG. When the mold is clamped, the volume of the carbon fiber fabric W is reduced because it contains air, but the volume reduction of the first and second matrix resins K1, K2 is small. Since the total volume of the core 4 of the stationary mold 1 and the core 13 of the movable mold 11 is configured to be substantially equal to the volume of the carbon fiber fabric W when pressurized, further clamping is performed. Then, the first and second matrix resins K1 and K2 lose their escape and are pushed between the fibers of the carbon fiber fabric W. The leading ends of the first and second matrix resins K1 and K2 that are pushed in pass through the carbon fiber fabric W and merge. By merging, the carbon fiber fabric W is embedded between the first and second matrix resins K1 and K2. Thereby, the first and second matrix resins K1 and K2 are bonded or impregnated into the carbon fiber fabric W. When the moving mold 11 is opened, although not shown in FIG. 1, the ejector pin protrudes, and the carbon fiber woven plastic is protruded as conventionally known. Thereafter, molding is performed in the same manner.

  The present invention can be implemented in various ways. For example, when a plurality of pairs of matrix resins are simultaneously molded by a fixed side mold and a moving side mold, a plurality of products can be obtained simultaneously. Since the carbon fiber woven plastic obtained as described above is impregnated with a thermoplastic resin, it is regarded as an intermediate material, and a plurality of sheets are thermocompressed and carbon fiber woven reinforced plastic having a predetermined thickness. You can also get Also, the shape can be changed. In addition to plain woven, twill, or satin woven fabrics such as glass fibers other than carbon fibers, polyaramid fibers, boron fibers, etc., non-woven fabrics can also be applied, and the above fibers are aligned in a sheet form in one direction. A sheet or a sheet knitted in a mesh shape can also be applied. The base material or the reinforced fiber fabric reinforced plastic can be obtained from these fabrics in the same manner.

1 Fixed side mold 11 Moving side mold
3 Recess 4 Core 13 Core 14 Recess M1 First matrix resin K2 Second matrix resin H Heating element W Carbon fiber fabric

Claims (6)

A cavity formed by a fixed mold and a movable mold that is opened and closed with respect to the fixed mold and slidably driven is injected and filled with a molten thermoplastic resin to form a pair. A molding step of molding the first and second matrix resins;
An alignment step of opening the moving mold after the first and second matrix resins molded in the molding step are solidified to some extent, and making the first and second matrix resins face each other at a predetermined interval;
An insert step of inserting a reinforcing fiber fabric between the matrix resins opposed by the positioning step;
A heating step of heating both the reinforcing fiber woven fabric and the matrix resin by inserting a heating body between the reinforcing fiber woven fabric inserted by the insert step and each matrix resin;
Impregnation by retracting the heating body after the heating step, clamping the moving mold to the stationary mold, and bonding or impregnating the first and second matrix resins to the reinforcing fiber fabric by clamping A method for pasting and forming an intermediate base material or a reinforced fiber fabric reinforced plastic comprising a process. In the sticking synthetic | combination method of Claim 1, the said heating process narrows the space | interval of the said heating body and reinforcement fiber fabric at the time of the said alignment process or insert process, and the space | interval of the said heating body and matrix resin. A method for pasting and forming an intermediate base material or a reinforced fiber fabric reinforced plastic. 3. The method for pasting and forming a laminated composite of a base material or a reinforced fiber fabric reinforced plastic according to claim 1, wherein a halogen heater or a carbon heater is used in the heating step. 4. A method for pasting and forming a reinforcing fiber fabric-reinforced plastic according to claim 1, wherein carbon fibers are used for the reinforcing fiber fabric. It consists of a fixed mold and a movable mold that is slid and driven with respect to the fixed mold.
When the moving-side mold is clamped to the fixed-side mold at the first position, a cavity in which a matrix resin made of a thermoplastic resin is molded is formed between these molds, When the moving mold is moved to the second position, the cavity component formed on the moving mold is opposed to the cavity component formed on the fixed mold. In this position, a first mold opening position where the distance between the movable mold and the fixed mold is large and a second mold opening position which is narrower than the first mold opening position may be adopted. As well as being able to
In the second position, a heating element is inserted between the cavity component and the reinforcing fiber fabric to be inserted, and between the inserted reinforcing fiber fabric and another cavity component,
An intermediate base material or a reinforcing fiber fabric reinforced plastic pasting mold for molding, wherein the moving side mold can be clamped to the fixed side mold even at the second position. A pasting and forming apparatus comprising a fixed side mold, a moving side mold that is slidably driven with respect to the fixed side mold, and a heating body made of a halogen heater or a carbon heater. ,
When the moving-side mold is clamped to the fixed-side mold at the first position, a cavity in which a matrix resin made of a thermoplastic resin is molded is formed between these molds, When the moving mold is moved to the second position, the cavity component formed on the moving mold is opposed to the cavity component formed on the fixed mold. In this position, a first mold opening position where the distance between the movable mold and the fixed mold is large and a second mold opening position which is narrower than the first mold opening position may be adopted. Configured to be able to
In the first mold opening position, the heating element is inserted between the cavity component and the reinforcing fiber fabric to be inserted, and between the inserted reinforcing fiber fabric and another cavity component. At the second position, the intermediate mold or the reinforcing fiber fabric reinforced plastic pasting and forming apparatus is configured such that the movable mold can be clamped to the fixed mold in the second position.

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