JP5417631B2 - Molding method of thermoplastic resin composite material molded product - Google Patents

Description

  The present invention relates to a method for molding a thermoplastic resin composite material molded by impregnating a reinforcing fiber material such as carbon fiber or glass fiber with a thermoplastic resin material such as polypropylene resin, polyamide 6 resin, or polyetherimide resin. About.

  Fiber reinforced composite materials are a combination of fiber materials and matrix materials, and are lightweight, rigid, and capable of diverse functional designs. They are widely used in aerospace, transportation, civil engineering, and exercise equipment. Used in the field. Currently, fiber reinforced plastic (FRP) in which a reinforcing fiber material such as carbon fiber or glass fiber is combined with a thermosetting resin material has become the mainstream.

However, due to advantages such as recyclability, short-time moldability, and improved impact resistance characteristics of molded products, technological development relating to molded products using a thermoplastic resin material as a matrix resin is being promoted. For example, in Patent Document 1, planar and concavo-convex plate-like bodies are superposed on the upper and lower surfaces of a material, inserted into a hot press machine, and a thermoplastic resin is melted, and then the material is superposed on the plate-like body. The method of taking out in the state, inserting in a cooling press board, cooling, and taking out a molded article is described. In Patent Document 2, the fiber reinforced thermoplastic composite material is placed in a female open mold, and the entire open mold is covered with a heat-resistant bag material, and then air between the bag material and the open mold is discharged and heated. A production method for obtaining a fiber-reinforced thermoplastic composite molded article by performing pressure molding is described.
JP-A-6-320655 JP 2004-276471 A

  In the thermoplastic resin composite material molded article described above, a thermoplastic resin material such as polypropylene resin, polyamide 6 resin, or polyetherimide resin is used as a reinforcing fiber material such as carbon fiber or glass fiber. There are problems of impregnating in a short time with good fiber dispersibility and whether to perform good forming without forming warp in a three-dimensional shape when forming.

  In Patent Document 1, since the shape of the plate-like body is processed to be uneven only on the material side, and the side corresponding to the press plate has a flat plate shape, the thickness of the plate-like body is not uniform during heating and cooling. Unevenness occurs in the heat transfer to the material, and heating and cooling in a uniform state are not performed. As a result, it is difficult to shorten the molding time, and a molding warp due to partial impregnation of the resin or the like is generated.

  Usually, the press disk of the press apparatus is formed in two planes, and the mold also has a structure in which the plate is in contact with the surface of the press disk and the material side is uneven in accordance with the shape of the molded product. For this reason, the mold is made with a metal such as iron so as not to be deformed in the uneven portion during pressing, and it takes time to heat and cool the mold itself.

  In the conventional molding method using a heating vacuum bag or the like as in Patent Document 2, it takes time to set the bag in the mold (mold) and take out the mold (mold) from the bag. Moreover, since a bag has a subject in heat resistance, it is difficult to form at a high temperature of 300 degrees or more. Furthermore, since such a bag is difficult to reuse, there is a problem that it is necessary to replace the bag for each molding process, and the cost burden is high.

  Therefore, an object of the present invention is to provide a molding method capable of molding a thermoplastic resin composite material molded article having almost no voids and good fiber dispersibility in a short time without generating molding warpage.

A molding method of a thermoplastic resin composite material molded article according to the present invention is a molding method of molding a thermoplastic resin composite material molded article using a molding material composed of a reinforcing fiber material and a thermoplastic resin material, The molding material is disposed between the molding dies using a pair of molding dies formed at a uniform thickness at the contact portion with the molding material, and the gas from the periphery of the molding material to the inside. Is set in a state of being pressed and pressed by the mold from both sides of the material to be evacuated, and the inside of the mold that holds the material to be pressed is set to a reduced pressure or a vacuum state. The molding material is placed between the heat press mold bodies using a pair of heat press mold bodies having contact surfaces formed so as to be in close contact with the contact surfaces of the mold dies. And hold the pressure inside or And heating and pressurizing treatment to the mold body, which is set in a state impregnated with the thermoplastic resin material which is melted inside the reinforcing fiber material, abut in close contact with the abutment surface of the mold body Using the pair of cooling press molds on which the surfaces are formed, the molding mold body heated and pressurized is placed between the cooling press mold bodies, the material to be molded is sandwiched, and the inside is decompressed or vacuumed cooling and pressure treatment to solidify the thermoplastic resin material inside the melted impregnation of the reinforcing fiber material to set the mold body, characterized in that molding. Furthermore, a plurality of the molds sandwiching the material to be molded are stacked to perform heating / pressurizing treatment and cooling / pressurizing treatment. Furthermore, before Symbol heating and pressing process, and performing a sequential heating and pressurizing treatment using a plurality of heated press mold body having different set temperatures. Further, the cooling / pressurizing process is characterized in that the cooling / pressurizing process is sequentially performed using a plurality of cooling press molds having different set temperatures. Further, the molding die is characterized in that the contact portion is formed in a thin shape. Furthermore, the mold is made of a carbon fiber carbon composite material. Further, the mold body is characterized in that a contact surface that contacts the material to be molded is subjected to a mold release process. Further, the molding material is characterized in that a release sheet material is provided at a portion in contact with the molding die. Further, the molding material is characterized in that the thermoplastic resin material serving as a matrix is unevenly distributed between the layers in which the reinforcing fiber materials are arranged. Further, the molding material includes a reinforcing fiber sheet material in which a plurality of reinforcing fibers are aligned in a predetermined direction and formed into a sheet shape, and a thermoplastic resin sheet material attached to one or both surfaces of the reinforcing fiber sheet material. A plurality of the thermoplastic resin reinforcing sheet materials that are configured are laminated and configured. Further, the reinforcing fiber sheet material and the thermoplastic resin sheet material are adhered by an adhesive thermoplastic resin material that melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material.

  The present invention has the above-described configuration, and heats and cools the molding material composed of the reinforcing fiber material and the thermoplastic resin material while heating and cooling the material, and the thermoplastic resin material is uniformly melt-impregnated and solidified. It is possible to form a thermoplastic resin composite material molded article having a good fiber dispersibility with almost no voids in a state in which molding warpage does not occur.

  That is, using a pair of molding dies formed at a uniform thickness at the contact portion with the molding material, the molding material is placed between them and the molding die is set in a pressure-contacted state. Since the mold is placed between a pair of heat press molds with contact surfaces formed so as to be in intimate contact with the contact surfaces, the heat from the heat press molds has a uniform thickness. Through the contact portion of the mold body, the entire material to be molded is uniformly conducted.

  Therefore, the thermoplastic resin material constituting the molding material is melted and impregnated more uniformly as a whole. Since the gas inside the molding material can be evacuated from both sides of the molding material, it is set in a state of being sandwiched and pressed by the mold from both sides. The gas in the molding material is exhausted, and the thermoplastic resin material is impregnated without generating voids. In addition, since the material to be molded is always in pressure contact with the abutting surface of the mold body, the arrangement of the reinforcing fiber material is not disturbed due to the flow during the impregnation of the thermoplastic resin material, and the dispersibility of the fibers is improved. Will be maintained.

  Next, a mold having a uniform thickness is formed by placing the heated and pressure-treated mold body between a pair of cooling press mold bodies having contact surfaces so as to be in close contact with the contact surface of the mold body. Cooling and pressurizing treatment is performed through the contact part of the mold body, so that the entire molding material can be cooled uniformly, and the thermoplastic resin material that has been melted and impregnated is solidified in the same way, and there is no unevenness. It becomes possible to mold, and a good molded product without molding warp can be manufactured.

  And each process can be performed efficiently by performing each of the heat treatment and the cooling process with separate press mold bodies, and the molding time is significantly shortened compared with the case where both processes are performed with one press mold body. It becomes possible.

  Further, a thermoplastic resin can be obtained by forming a space in which a gas inside the molding material is exhausted between the molding dies and setting the molding material in a pressure-contacted state and reducing the exhaust space to a reduced pressure or a vacuum state. When the material is melted and impregnated, the impregnation of the thermoplastic resin material into the reinforcing fiber material can be promoted to greatly reduce the impregnation time. Furthermore, voids in the obtained molded product can be reduced, and a high-quality molded product can be obtained.

  Further, by setting the inside of the mold body to a vacuum state or a reduced pressure state, a pressure state due to atmospheric pressure is generated on the entire outer surface of the mold body. Therefore, when the molding die is placed on the heating press die or the cooling press die, the molding material sandwiched by the molding die can be always kept in the pressure contact state, and the straightness and dispersion of the reinforcing fiber material can be maintained. It is possible to obtain a molded article with good quality and the like maintained.

  In addition, by stacking a plurality of molds sandwiching the material to be molded and performing heating / pressurizing treatment and cooling / pressurizing treatment, a plurality of thermoplastic resin composite material molded products can be molded at once, The molding time can be shortened. When a plurality of mold dies are stacked, the mold dies can be efficiently put into a vacuum state or a reduced pressure state if the exhaust spaces of the respective mold bodies are combined into one and set in a vacuum state or a reduced pressure state.

  In addition, by performing sequential heating / pressurization processing using a plurality of heating press mold bodies having different set temperatures, or by sequentially performing cooling / heating processing using a plurality of cooling press mold bodies having different set temperatures, Heating / pressurizing treatment or cooling / pressurizing treatment can be performed. Therefore, it becomes possible to control the heating or cooling of the thermoplastic resin material, smoothly impregnating into the reinforcing fiber material and preventing rapid shrinkage of the thermoplastic resin material, etc., and good fiber straightness A high-quality thermoplastic resin composite material molded article can be obtained.

  In addition, since the contact portion of the mold body is formed in a thin shape, the thermal conductivity of the mold body during heating and cooling is improved, and the molding time can be shortened.

  In addition, by forming the mold from a carbon fiber carbon composite material, there is almost no thermal deformation during heating and cooling, and excellent thermal conductivity, so molding of thermoplastic resin composite material with almost no molding warpage The product can be molded.

  In addition, the molded product can be molded by removing the contact surface of the molding die that comes into contact with the molding material or by providing a release sheet material at the portion of the molding material that comes into contact with the molding die. Can be easily removed from the body.

  If a thermoplastic resin material that is a matrix is unevenly distributed between layers in which reinforcing fiber materials are arranged as the molding material, the thermoplastic resin material is distributed along the layer direction. During the pressure treatment, the thermoplastic resin material is simultaneously heated and melt impregnated in a direction perpendicular to the layer direction, so that a smooth impregnation treatment can be performed. Since the thermoplastic resin material is impregnated from both sides of the layer, the air inside the layer is efficiently exhausted along the arrangement direction of the reinforcing fiber material, and almost no air remains inside the layer.

  Further, the material to be molded is composed of a reinforcing fiber sheet material in which a plurality of reinforcing fibers are aligned in a predetermined direction and formed into a sheet shape, and a thermoplastic resin sheet material attached to one or both surfaces of the reinforcing fiber sheet material If a plurality of the thermoplastic resin reinforced sheet materials that are used are laminated, it is possible to use a molding material that is easy to manufacture and excellent in mechanical properties and drapeability during molding.

  Hereinafter, embodiments according to the present invention will be described in detail. The embodiments described below are preferable specific examples for carrying out the present invention, and thus various technical limitations are made. However, the present invention is particularly limited in the following description. Unless otherwise specified, the present invention is not limited to these forms.

  In the molding method according to the present invention, a material composed of at least a reinforcing fiber material and a thermoplastic resin material is used as a material to be molded. Reinforcing fiber materials are high strength used for FRP such as carbon fiber, glass fiber, ceramic fiber, aramid fiber, polyoxymethylene fiber, aromatic polyamide fiber, PBO (polyparaphenylene benzobisoxazole) fiber, metal fiber, etc. A material in which a plurality of reinforcing fibers such as inorganic fibers and organic fibers having a high elastic modulus are bundled. A plurality of various fiber bundles may be combined. The fineness is not particularly limited.

  Examples of thermoplastic resin materials include polypropylene, polyethylene, polystyrene, polyamide (nylon 6, nylon 66, nylon 12, etc.), polyacetal, polycarbonate, acrylonitrile-butadiene-styrene copolymer (ABS), polyethylene terephthalate, polybutylene terephthalate, poly Examples include ether imide, polyether sulfone, polyphenylene sulfide, polyether ketone, and polyether ether ketone. Further, two or more of these thermoplastic resins may be mixed and used as a polymer alloy.

  The thermoplastic resin material may be in any form such as liquid, powder, granular, fiber, fabric, or sheet, and is not particularly limited.

  As a form of the molding material, for example, a prepreg sheet in which a reinforcing fiber material is impregnated with a thermoplastic resin material may be used. However, as a form of the molding material suitable for the molding method according to the present invention, a material in which the thermoplastic resin material is unevenly distributed between the layers in which the reinforcing fiber materials are arranged is particularly preferable. Specific examples of such molding materials will be described below.

  FIG. 1 is a schematic diagram showing a part of a thermoplastic resin multilayer reinforcing sheet material 1 which is an example of a molding material used in the present invention. The thermoplastic resin multilayer reinforcing sheet material 1 is a thermoplastic resin formed by adhering a thermoplastic resin sheet material 4 to one side of a reinforcing fiber sheet material 3 formed into a sheet shape by arranging a plurality of reinforcing fibers 3f. In the state where the reinforcing sheet materials 21 to 24 are laminated, the thermoplastic resin sheet material 4 and the thermoplastic resin fiber bundle 5 for integration are integrated. In FIG. 1, the thermoplastic resin reinforcing sheet materials 21 to 24 are laminated so that the reinforcing fibers of the respective thermoplastic resin reinforcing sheet materials are arranged in different axial directions. Each thermoplastic resin reinforcing sheet material is stitched and integrated by stitching using the thermoplastic resin fiber bundle 5 for integration.

  The reinforcing fiber sheet material 3 is formed by, for example, arranging a plurality of reinforcing fiber bundles that are bundled so that the plurality of reinforcing fibers are not separated by a sizing agent or the like into a sheet shape. As the reinforcing fiber 3f, as described above, high-strength and high-modulus inorganic fiber or organic fiber used for FRP such as carbon fiber, glass fiber, and ceramic fiber can be used.

  The thermoplastic resin sheet material 4 serves as a base material (matrix) resin, and the above-described thermoplastic resin material is used. Also, two or more of these thermoplastic resin materials may be mixed to form a polymer alloy and used as a base material (matrix) resin.

  The thermoplastic resin fiber bundle 5 for integration uses thermoplastic resin fibers made of the same material as the used matrix resin. The same material may have the same main chemical composition, and the molecular weight, crystallinity, type of compound, and the like may be different. Since the resin is heated and melted when a molded product is obtained, the thermoplastic resin sheet material 4 and the thermoplastic resin fiber bundle 5 for integration are melt-mixed and the base material (matrix) if the main polymer has the same chemical composition. ).

  Furthermore, when the thermoplastic resin sheet material 4 is a polymer alloy, it is desirable to use a thermoplastic resin fiber bundle for integration with the polymer alloy resin, but it was mixed to obtain the polymer alloy resin. You may use the thermoplastic resin fiber bundle for integration by any one kind of thermoplastic resin. Although the mixing ratio of the thermoplastic resin constituting the polymer alloy is slightly changed locally by heating and melting to obtain a molded product, the thermoplastic resin for integration with the thermoplastic resin sheet material 4 serving as a base material (matrix). Since the resin fiber bundle 5 is melt-mixed and the shape of the fiber disappears, it is possible to obtain a molded product in which the uniform dispersibility and the surface smoothness of the reinforcing fiber are improved without deterioration of the mechanical properties.

  The thermoplastic resin multilayer reinforcing sheet material 1 in FIG. 1 is formed by laminating four sheets of thermoplastic resin reinforcing sheet materials 21 to 24, but the number of laminated sheets is not limited to four, and two sheets It is sufficient if the number of stacked layers is the above. At this time, the thermoplastic resin reinforcing sheet material may be laminated in the same direction or in different directions. In the case of FIG. 1, the thermoplastic resin reinforcing sheet material 21 is in the 0 degree direction, the thermoplastic resin reinforcing sheet material 22 is in the 45 degree direction, the thermoplastic resin reinforcing sheet material 23 is in the 90 degree direction, and the thermoplastic resin reinforcing sheet material 24 is − The fiber is reinforced in the 45 degree direction.

  FIG.2 and FIG.3 is a schematic diagram which shows a part of the thermoplastic resin reinforcement sheet material 2 used for a thermoplastic resin multilayer reinforcement sheet material. The thermoplastic resin reinforcing sheet material 2 in FIG. 2 has a reinforcing fiber bundle 3t, in which a plurality of reinforcing fibers 3f are bundled by a sizing agent or the like, formed in a single-sided sheet-like reinforcing fiber sheet material 3 in the width direction. The thermoplastic resin sheet material 4 is attached. The thermoplastic resin sheet material 4 may be attached to both surfaces of the reinforcing fiber sheet material 3. Further, the reinforcing fiber sheet material 3 may be attached to both surfaces of the thermoplastic resin sheet material 4.

  The thermoplastic resin reinforcing sheet material is a reinforcing fiber sheet material formed by aligning a plurality of reinforcing fiber bundles that are bundled so that a plurality of reinforcing fibers are not scattered by a sizing agent or the like in a sheet shape. It is formed by attaching a thermoplastic resin sheet material to one side or both sides. For this reason, the aligned state of the reinforcing fiber bundle is maintained and does not come apart, and also in each reinforcing fiber constituting the reinforcing fiber bundle, due to the effect that the sizing agent or the like adheres, The reinforcing fibers are not scattered, the fiber orientation disorder is suppressed, and fluff is hardly generated.

  Here, adhesion means that the thermoplastic resin sheet material is thermally fused to one surface or both surfaces of the reinforcing fiber sheet material or a plurality of portions, or does not affect the mechanical properties when the molded product is formed. For example, the reinforcing fiber sheet material and the thermoplastic resin sheet material are integrated so as not to be separated by, for example, thinly applying and bonding an adhesive. When the thermoplastic resin sheet material is heat-sealed to the reinforcing fiber sheet material, the thermoplastic resin sheet material may be slightly impregnated in the surface portion of the reinforcing fiber sheet material, but even in that case, the draping property as a sheet is It is enough and it can be said that it is in the state of adhesion.

  The thermoplastic resin reinforcing sheet material 2 in FIG. 3 has a narrow width heat in which a narrow-width thermoplastic resin sheet material 4 is attached to one side of a narrow-width reinforcing fiber sheet material 3 in which a plurality of reinforcing fibers 3f are aligned. By using the plastic resin reinforcing sheet material 2H, a plurality of the narrow thermoplastic resin reinforcing sheet material 2H are arranged in a sheet shape in the width direction. In this way, by aligning a plurality of the narrow thermoplastic resin auxiliary sheet materials 2H in the width direction and the thickness direction, a reinforced thermoplastic resin reinforcing sheet material is obtained. Further, by weaving using the narrow thermoplastic resin reinforcing sheet material 2H as a woven yarn, for example, it is possible to obtain a thermoplastic resin reinforcing sheet material in which two directions of 0 degrees and 90 degrees are reinforced in advance.

  Also in the narrow thermoplastic resin reinforcing sheet material 2H in FIG. 3, the narrow thermoplastic resin sheet material 4 is attached to one side of the narrow reinforcing fiber sheet material 3, but the narrow reinforcing fiber sheet A narrow-width thermoplastic resin sheet material may be adhered to both surfaces of the sheet material. Furthermore, a narrow reinforcing fiber sheet material may be attached to both surfaces of the narrow thermoplastic resin sheet material.

  By making the thickness of the reinforcing fiber sheet material 3 within 10 times the diameter of the reinforcing fiber 3f, the distance that the thermoplastic resin sheet material flows between the reinforcing fibers for impregnation becomes shorter when forming a molded product. A carbon fiber representative as a reinforcing fiber of the composite material has a single yarn diameter of 0.005 to 0.007 mm. Therefore, the thickness of the reinforcing fiber sheet material 3 is 0.05 to 0.07 mm or less. With such a thickness, it is expected that the thermoplastic resin sheet material will be impregnated into the reinforcing fiber bundle in about several seconds, and a molding process can be realized in a short time. In addition, by shortening the distance that flows between the reinforcing fibers of the thermoplastic resin sheet material, the disturbance of orientation of the reinforcing fibers due to the resin flow is suppressed, the uniform dispersibility of the reinforcing fibers is improved, and there are few voids Can be obtained.

  In order to make the thickness of the reinforcing fiber sheet material 3 within 10 times the diameter of the reinforcing fiber 3f, there are a method using a fiber bundle with a small number of bundles, a method of opening the fiber bundle, and the like. The method by opening can make a fiber bundle having a large number of bundles (thick fiber bundle) into a thin and wide state. Since the thick fiber bundle has a relatively low material cost, it is possible to obtain a low-cost molded product. In addition, the form of the spread yarn is stabilized by the effect of the sizing agent used in the state of the raw yarn.

  The thickness or weight of the thermoplastic resin sheet material 4 attached to the reinforcing fiber sheet material 3 is the basis weight of the reinforcing fiber sheet material (fiber weight per unit area), the fiber volume content when forming a molded product, and the like. Decided in relation.

  FIG. 4 is a schematic view showing a part of a thermoplastic resin reinforcing sheet material 11 which is still another example used for the thermoplastic resin multilayer reinforcing sheet material. The thermoplastic resin reinforcing sheet material 11 has a thermoplastic resin on one side formed on a reinforcing fiber sheet material 12 in the form of a plurality of reinforcing fiber bundles 12t in which a plurality of reinforcing fibers 12f are converged by a sizing agent or the like in the width direction. Adhesive thermoplastic resin material 14 that adheres sheet material 13 and melts or softens at a temperature lower than the melting temperature of thermoplastic resin sheet material 13 does not adhere to reinforcing fiber sheet material 12 of thermoplastic resin sheet material 13. It is configured to adhere to the surface of the surface. Note that the adhesive thermoplastic resin material 14 may be attached to the surface of the reinforcing fiber sheet material 12 on which the thermoplastic resin sheet material 13 is not attached. Further, the thermoplastic resin sheet material may be attached to both surfaces of the reinforcing fiber sheet material. In this case, the adhesive thermoplastic resin material is adhered to the surface of one or both of the thermoplastic resin sheet materials to which the reinforcing fiber sheet material is not adhered. Further, the reinforcing fiber sheet material may be adhered to both surfaces of the thermoplastic resin sheet material. In this case, the adhesive thermoplastic resin material is adhered to the surface of one or both of the reinforcing fiber sheet materials to which the thermoplastic resin sheet material is not adhered.

  Since the adhesive thermoplastic resin material 14 is attached to the surface, when the thermoplastic resin reinforcing sheet material is cut and laminated in the required direction, the adhesive thermoplastic resin material melts or softens. By heating or heating and pressurizing at a temperature to be applied, the respective layers of the laminated thermoplastic resin reinforcing sheet material can be bonded and integrated with the adhesive thermoplastic resin material. In other words, it becomes easier to handle the laminated thermoplastic resin reinforced sheet material, and it is laminated while maintaining the reinforcing fiber reinforcement direction and the reinforcing fiber alignment state when installed in the mold for molding. It becomes possible to easily install the thermoplastic resin reinforcing sheet material in the mold.

  The reinforcing fiber sheet material constituting the thermoplastic resin reinforcing sheet material is often formed using a reinforcing fiber bundle in which a plurality of reinforcing fibers are bundled so as not to be scattered by a sizing agent or the like. In this case, since the base material (matrix) resin is a thermoplastic resin, it is desirable to use a sizing agent in consideration of adhesiveness to the base material resin and the like as the sizing agent for bundling the reinforcing fiber bundle. And, by the effect that the sizing agent or the like adheres, it is possible to move each reinforcing fiber, shift each reinforcing fiber, etc. A reinforcing fiber sheet material excellent in drapeability can be obtained.

  Considering the adhesion between the reinforcing fiber and the base resin, when using a reinforcing fiber bundle that does not adhere to the sizing agent or has a very small amount attached, or remove the sizing agent that adheres to the reinforcing fiber bundle. In some cases, a reinforcing fiber sheet material is used. Even in this case, it is possible to prevent the reinforcing fibers from being scattered by attaching the reinforcing fiber sheet material and the thermoplastic resin sheet material. In particular, if the number of reinforcing fibers arranged in the thickness direction is reduced by opening the reinforcing fiber bundle or the like, it is possible to further suppress the dispersion of the reinforcing fibers.

  The adhesion of the reinforcing fiber sheet material 12 and the thermoplastic resin sheet material 13 in FIG. 4 is a form in which the thermoplastic resin sheet material is thermally fused to one surface or both surfaces of the reinforcing fiber sheet material or a plurality of portions, or molding. There is a form in which a reinforcing fiber sheet material and a thermoplastic resin sheet material are bonded to each other by thinly applying an adhesive that does not affect the mechanical properties and the like when it becomes a product. In addition, when the thermoplastic resin sheet material is heat-sealed to the reinforcing fiber sheet material, the thermoplastic resin sheet material may be slightly impregnated in the surface layer portion of the reinforcing fiber sheet material. It can be said that it has sufficient properties and is in the form of adhesion.

  FIG. 5 is a schematic view showing a part of a thermoplastic resin reinforcing sheet material 11 which is still another example used for the thermoplastic resin multilayer reinforcing sheet material. The thermoplastic resin reinforcing sheet material 11 has a thermoplastic resin sheet on one surface of a reinforcing fiber sheet material 12 in which a plurality of reinforcing fiber bundles 12t, in which a plurality of reinforcing fibers 12f are bundled with a sizing agent, are arranged in a width direction. The material 13 is made to adhere by the thermoplastic resin material 14 for adhesion | attachment which fuse | melts or softens at the temperature lower than the melting temperature of the said thermoplastic resin sheet material. The thermoplastic resin sheet material 13 may be attached to both surfaces of the reinforcing fiber sheet material 12. Further, the reinforcing fiber sheet material 12 may be attached to both surfaces of the thermoplastic resin sheet material 13.

  In FIG. 5, the reinforcing fiber sheet material 12 and the thermoplastic resin sheet material 13 are bonded together by the bonding thermoplastic resin material 4 and integrated so as not to be separated, whereby the reinforcing fiber sheet material 12 and the thermoplastic resin sheet are integrated. The material 13 is adhered. That is, since the reinforcing fiber sheet material and the thermoplastic resin sheet material are adhered without being heated to the melting temperature of the thermoplastic resin sheet material, the form of the reinforcing fiber sheet material and the form of the thermoplastic resin sheet material are maintained. Yes. Therefore, the drapeability of the thermoplastic resin reinforced sheet material, the straight state of the reinforcing fiber, the uniform dispersed state, and the like are excellent sheet materials.

  FIG. 6 is a schematic view showing a part of a thermoplastic resin reinforcing sheet material 11 which is still another example used for the thermoplastic resin multilayer reinforcing sheet material. In the thermoplastic resin reinforcing sheet material 11, the narrow thermoplastic resin sheet material 13 is melted on one surface of the narrow reinforcing fiber sheet material 12 in which a plurality of reinforcing fibers 12f are aligned. The narrow thermoplastic resin reinforced sheet material 1H is used in the width direction by using the narrow thermoplastic resin reinforced sheet material 11H formed by adhering with an adhesive thermoplastic resin material 14 that melts or softens at a temperature lower than the temperature. Are arranged in a plurality of sheets. Thus, the thermoplastic resin reinforcement sheet material 11 reinforced in one direction is obtained by aligning a plurality of the narrow thermoplastic resin auxiliary sheet materials 1H in the width direction and the thickness direction. Further, by weaving using the narrow thermoplastic resin reinforcing sheet material 1H as a woven yarn, for example, it is possible to obtain a thermoplastic resin reinforcing sheet material in which two directions of 0 degrees and 90 degrees are reinforced in advance.

  Also in the narrow thermoplastic resin reinforcing sheet material 1 </ b> H in FIG. 6, the narrow thermoplastic resin sheet material 13 is adhered to one surface of the narrow reinforcing fiber sheet material 12 by the adhesive thermoplastic resin material 14. However, a narrow thermoplastic resin sheet material may be adhered to both surfaces of the narrow reinforcing fiber sheet material by an adhesive thermoplastic resin material. Further, a narrow reinforcing fiber sheet material may be attached to both surfaces of a narrow-shaped thermoplastic resin sheet material by an adhesive thermoplastic resin material.

  In FIGS. 5 and 6, the thermoplastic resin reinforcing sheet material 11 is not attached to the surface of the thermoplastic resin reinforcing sheet material 11. A thermoplastic resin material for adhesion may be distributed and adhered to the surface.

  The thermoplastic resin reinforced sheet material is adhered to one or both sides of the adhesion amount per unit area of the adhesive thermoplastic resin material for bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material. Different adhesion amounts per unit area of the adhesive thermoplastic resin material, and the adhesive thermoplastic resin material and the thermoplastic resin reinforcing sheet material for adhering the reinforcing fiber sheet material and the thermoplastic resin sheet material. The thermoplastic resin material for adhesion adhered to one side or both sides can be made different.

  The adhesion amount per unit area of the adhesive thermoplastic resin material for adhering the reinforcing fiber sheet material and the thermoplastic resin sheet material to the adhesive thermoplastic resin material attached to one or both surfaces of the thermoplastic resin reinforcing sheet material More than the amount of adhesion per unit area, or the adhesive force of the adhesive thermoplastic resin material that bonds the reinforcing fiber sheet material and the thermoplastic resin sheet material is adhered to one or both surfaces of the thermoplastic resin reinforced sheet material. By selecting a material larger than the adhesive strength of the adhesive thermoplastic resin material, the adhesive strength between the reinforcing fiber sheet material and the thermoplastic resin sheet material is made larger than the adhesive strength between the thermoplastic resin reinforced sheet materials. A thermoplastic resin multilayer reinforcing sheet material can be obtained.

  Thereby, the shift | offset | difference between each lamination | stacking of a thermoplastic resin reinforcement sheet material is realizable, making the reinforcement fiber sheet material adhere to the thermoplastic resin sheet material. In other words, the thermoplastic resin multilayer reinforcing sheet material is easy to handle, in which a plurality of thermoplastic resin reinforcing sheet materials are bonded and integrated, and the thermoplastic resin multilayer reinforcing sheet material is installed in a mold for molding. Sometimes, in the curved surface shape part of the inner surface of the mold body, the adhesion between the layers of the thermoplastic resin reinforcing sheet material is locally removed without impairing the alignment state and dispersion state of the reinforcing fibers, and the thermoplastic resin reinforcement The thermoplastic resin multilayer reinforcing sheet material can be adapted to the mold shape while shifting the respective layers of the sheet material, and is further excellent in drapeability. That is, it is possible to obtain a laminated molded product having a complicated shape with high quality.

  Here, the adhesion force means that the reinforcing fiber sheet material and the thermoplastic resin sheet material, or the reinforcing fiber sheet material and the reinforcing fiber sheet material, or the thermoplastic resin sheet material and the thermoplastic resin sheet are used. It represents the force with which the material adheres, and a large adhesion means that the force to adhere is strong. Note that the reinforcing fiber sheet material and the thermoplastic resin sheet material adhere to each other when the reinforcing fiber sheet material and the thermoplastic resin sheet material are used in normal handling, for example, handling the sheet material, lifting, cutting the sheet material, etc. Refers to a state in which peeling does not occur.

  The thickness or weight of the thermoplastic resin sheet material 13 to be adhered to the reinforcing fiber sheet material 12 is related to the basis weight of the reinforcing fiber sheet material (fiber weight per unit area), the fiber volume content when formed into a molded product, and the like. Can be decided.

  The reinforcing fiber sheet material 12 is formed, for example, by arranging a plurality of reinforcing fiber bundles 12t that are bundled so that the plurality of reinforcing fibers 12f are not separated by a sizing agent or the like into a sheet shape. Further, as described above, the reinforcing fiber 12f has high strength and high elastic modulus used for FRP such as carbon fiber, glass fiber, ceramic fiber, aramid fiber, PBO (polyparaphenylene benzobisoxazole) fiber, and metal fiber. Inorganic fibers and organic fibers.

  By making the thickness of the reinforcing fiber sheet material 12 within 10 times the diameter of the reinforcing fiber 12f, the distance that the thermoplastic resin sheet material flows between the reinforcing fibers for impregnation becomes shorter when forming a molded product. A carbon fiber representative as a reinforcing fiber of the composite material has a single yarn diameter of 0.005 to 0.007 mm. Therefore, the thickness of the reinforcing fiber sheet material 13 is 0.05 to 0.07 mm or less. With such a thickness, it is expected that the thermoplastic resin BR> V material will be impregnated in the reinforcing fiber bundle in about several seconds, and a molding process can be realized in a short time. In addition, by shortening the distance that flows between the reinforcing fibers of the thermoplastic resin sheet material, the disturbance of orientation of the reinforcing fibers due to the resin flow is suppressed, the uniform dispersibility of the reinforcing fibers is improved, and there are few voids Can be obtained.

  In order to make the thickness of the reinforcing fiber sheet material 12 within 10 times the diameter of the reinforcing fiber 12f, there are a method using a fiber bundle with a small number of bundles, a method of opening the fiber bundle, and the like. The method by opening can make a fiber bundle having a large number of bundles (thick fiber bundle) into a thin and wide state. Since the thick fiber bundle has a relatively low material cost, it is possible to obtain a low-cost molded product. In addition, the form of the spread yarn is stabilized by the effect of the sizing agent used in the state of the raw yarn.

  The thermoplastic resin sheet material 13 becomes a base material (matrix) resin, and the above-described thermoplastic resin material is used. Further, two or more of these thermoplastic resins may be mixed to form a polymer alloy and used as a base material (matrix) resin.

  The adhesive thermoplastic resin material 14 is a material that bonds and integrates the reinforcing fiber sheet material 12 and the thermoplastic resin sheet material 13, and melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material that is configured. The reinforcing fiber sheet material and the thermoplastic resin sheet material, and the reinforcing fiber sheet material or the thermoplastic resin sheet material and the thermoplastic resin capable of bonding the release sheet material are used. The adhesive thermoplastic resin material 14 adheres to at least one of the reinforcing fiber sheet material 12 and the thermoplastic resin sheet material 13. Preferably, it is desirable that the reinforcing fiber sheet material 12 and the thermoplastic resin sheet material 13 adhere to the surface of one or both surfaces of the thermoplastic resin sheet material 13 and are evenly dispersed. As a result, the reinforcing fiber sheet material 12 and the thermoplastic resin sheet material 13 are securely bonded, and the thermoplastic resin sheet material is adhered to the reinforcing fiber sheet material, or a plurality of thermoplastic resin reinforcing sheet materials are laminated. To make the united and integrated.

  The adhesive thermoplastic resin material 14 may be in either a powder shape or a fiber shape. Furthermore, in the case of a fiber shape, forms such as a state in which long fibers or short fibers are scattered and a fabric state such as a woven fabric, a knitted fabric, and a non-woven fabric can be used.

  Further, as the adhesive thermoplastic resin material 14, a resin having a melting point in the range of 80 to 250 degrees is preferable, and for example, polyamide, copolymer polyamide, polyurethane, or the like is selected. In particular, the copolymerized polyamide has a low melting point and good adhesiveness with a thermoplastic resin sheet material as a base material, and is preferable as an adhesive thermoplastic resin material. Furthermore, it is desirable to select a thermoplastic resin material for bonding that is compatible with the thermoplastic resin sheet material to be formed. Thereby, when the adhesive thermoplastic resin material is melted in the thermoplastic resin material serving as the base material, the adhesive thermoplastic resin material can be well present in the thermoplastic resin material serving as the base material.

  The adhesion amount per unit area of the adhesive thermoplastic resin material 14 is preferably within 3% of the weight per unit area of the reinforcing fiber sheet material, and more preferably within the range of 0.5 to 2%. More preferred. By reducing the amount of the adhesive thermoplastic resin material 4 used, it is possible to reduce the influence on the mechanical properties and thermal properties of the composite material molded product from which the adhesive thermoplastic resin material is obtained.

  Desirably, the adhesive thermoplastic resin material 14 is distributed on the surface of one or both surfaces of at least one of the reinforcing fiber sheet material 12 and the thermoplastic resin sheet material 13, and is further distributed uniformly on the surface. It is more desirable. Thereby, even if the thermoplastic resin material for adhesion is 3% or less, more preferably in the range of 0.5 to 2%, the reinforcing fiber sheet material and the thermoplastic resin sheet material can be reliably adhered, that is, adhered. By attaching the reinforcing fiber sheet material to the thermoplastic resin sheet material, it is possible to maintain the form of each fiber bundle constituting the reinforcing fiber sheet material, that is, the state in which the reinforcing fibers are straightly arranged or uniformly dispersed In addition, the form of the thermoplastic resin sheet material maintains the form as a sheet, and the sheet material is excellent in handling.

  FIG. 7 is a schematic view showing a part of another thermoplastic resin multilayer reinforcing sheet material 15 which is a molding material used in the present invention. The thermoplastic resin multilayer reinforcing sheet material 15 was laminated by bonding the four thermoplastic resin reinforcing sheet materials 11A, 11B, 11C, and 11D shown in FIG. 4 or FIG. 5 by the adhesive thermoplastic resin material. It is configured. In FIG. 7, the thermoplastic resin reinforcing sheet materials 11A, 11B, 11C and 11D are laminated so that the reinforcing fibers of the respective thermoplastic resin reinforcing sheet materials are arranged in different axial directions.

  FIG. 8 is a schematic view showing a part of still another thermoplastic resin multilayer reinforcing sheet material 15 which is a molding material used in the present invention. The thermoplastic resin multilayer reinforcing sheet material 15 is made of the same material as the thermoplastic resin sheet material in a state in which the four thermoplastic resin reinforcing sheet materials 11A, 11B, 11C and 11D shown in FIG. They are integrated by a thermoplastic resin fiber bundle 16 for integration. In FIG. 8, the thermoplastic resin reinforcing sheet materials 11A, 11B, 11C and 11D are laminated so that the reinforcing fibers of the respective thermoplastic resin reinforcing sheet materials are arranged in different axial directions. Each thermoplastic resin reinforcing sheet material is stitched and integrated by stitching using the thermoplastic resin fiber bundle 16 for integration.

  The thermoplastic resin multilayer reinforcing sheet material 15 of FIGS. 7 and 8 is formed by stacking four sheets of thermoplastic resin reinforcing sheet materials 11A, 11B, 11C, and 11D, but the number of stacked sheets is limited to four. What is necessary is just a lamination | stacking number of sheets of 2 or more. At this time, the reinforcing direction of the thermoplastic resin reinforcing sheet material may be laminated in the same direction or in different directions. In the case of FIGS. 7 and 8, the thermoplastic resin reinforcing sheet material 11A is in the 0 degree direction, the thermoplastic resin reinforcing sheet material 11B is in the 45 degree direction, the thermoplastic resin reinforcing sheet material 11C is in the 90 degree direction, and the thermoplastic resin reinforcing sheet material. 11D is fiber reinforced in the -45 degree direction.

  As a molding material used in the present invention, a thermoplastic resin material serving as a matrix is unevenly distributed between layers in which reinforcing fiber materials are arranged. In addition to the above-described thermoplastic resin multilayer reinforcing sheet material, the reinforcing fiber material It is also possible to use a material in which a powdered or short fiber thermoplastic resin material is distributed between the layers in which the layers are arranged, or a material in which a thermoplastic resin material formed on a nonwoven fabric or fabric is laminated between the layers. it can.

  Next, an embodiment according to the present invention will be described. FIG. 9 is a cross-sectional view showing a state in which the molding material 1 is installed between the pair of molding dies 100 and 101. The pair of molds 100 and 101 are formed by processing thin plates having the same thickness. In this example, the step portions 100a and 101a are formed by bending so that the central portion is recessed downward. The material of the molds 100 and 101 is preferably a material that is small in thermal deformation during heating / cooling and has good thermal conductivity, such as a metal material such as iron or a carbon fiber carbon composite material called CC composite. Among them, a carbon fiber carbon composite material is particularly preferable.

  In this example, a thin plate is used as the molding die. However, it is only necessary that the contact portion with which the molding material 1 contacts has a uniform thickness, and the thickness other than the contact portion is different. May be. Further, it is only necessary to make the thickness uniform so that the thermal conductivity is uniform at the contact portion of the mold body with the material to be molded, and the thermal conductivity can be increased by reducing the thickness.

  In the molding material 1, the thermoplastic resin material is unevenly distributed between the layers made of the reinforcing fiber material. In this example, the thermoplastic reinforcing sheet material 2 made of the reinforcing fiber sheet material 3 and the thermoplastic resin sheet material 4 is used. A plurality of stacked layers are excellent in drapability, and are arranged so that the layer direction is along the mold surfaces of the mold bodies 100 and 101. Then, around the molding material 1, an exhaust space 102 is formed between the peripheral portions 100 b and 101 b of the mold bodies 100 and 101, and the peripheral portion of the molding material 1 is opened without being sealed. .

  The pair of molding dies 100 and 101 holding the molding material 1 is set in a state in which the molding material 1 is press-contacted at a predetermined interval by a locking tool (not shown). If the molding material 1 can be clamped in a stable pressure contact state at a predetermined interval by the weight of the molding die 101, the locking tool may not be used.

  In addition, in order to improve the mold release property of the molded product after the molding process, it is preferable to perform a mold release process for applying a known mold release agent to the contact surfaces of the mold bodies 100 and 101 with respect to the molding material 1. Good. Moreover, in order to improve mold release property, you may make it provide a release sheet material in the contact part with respect to the shaping | molding die body of a to-be-molded material. As the release sheet material, a release film such as a polyolefin resin sheet, a thermosetting polyimide resin sheet, a fluororesin sheet, or a release paper can be selected.

  FIG. 10 is an explanatory diagram illustrating a process of molding the molding material 1 set between the mold bodies 100 and 101. First, as described with reference to FIG. 9, the material 1 to be molded is set between the pair of molds 100 and 101 and set in a state in which it is pressed at a predetermined interval (FIG. 10A).

  Next, the molds 100 and 101 holding the material 1 to be molded are set in the hot press machine 103 (FIG. 10B). The hot press mold bodies 104 and 105 have a mold surface formed in the same shape as the mold bodies 100 and 101, and the lower heat press mold body 104 is in close contact with the contact surface of the mold body 100. A step portion is formed on the mold surface so that the upper heated press die 105 is in close contact with the contact surface of the mold 101.

  The heating press molds 104 and 105 are heated in advance to a predetermined heating temperature by a built-in heater, and the molds 100 and 101 set between the heating press molds 104 and 105 are moved from both sides in the vertical direction, that is, Heating / pressurizing treatment is performed by pressing from both sides in the thickness direction of the molding material. What is necessary is just to set a heating temperature and a press pressure suitably according to the material of a to-be-molded material.

  When heat is applied by heating with a hot press mold body, the heat press mold body and the mold body are in close contact with each other, so that heat conduction is good and the mold body is formed with a uniform thickness. The conducted heat is applied almost uniformly to the entire molding material. Therefore, the entire material to be molded is heated substantially in the same state, and the thermoplastic resin sheet material 4 arranged substantially parallel to the contact surface of the molding die is heated almost simultaneously and melted, and the reinforcing fibers on both sides The entire sheet material 3 is impregnated.

  Then, as each of the reinforcing fiber sheet materials 3 is gradually impregnated with the thermoplastic resin material from both sides, the internal air flows and is exhausted from the peripheral portion of the molding material 1 to the exhaust space 102. For this reason, the air inside the reinforcing fiber sheet material 3 is efficiently exhausted and impregnated with the thermoplastic resin material without remaining inside.

  After performing the heating / pressurizing treatment, the molds 100 and 101 are taken out from the heating press and set in the cooling press 106 (FIG. 10C). The cooling press mold bodies 107 and 108 are formed in the same shape as the mold bodies 100 and 101, and the lower cooling press mold body 107 is in contact with the contact surface of the mold body 100. Similarly, a step portion is formed on the mold surface so that the upper heating press mold 108 is in close contact with the contact surface of the mold 101.

  The cooling press mold bodies 107 and 108 are set in advance to a predetermined cooling temperature (for example, a normal temperature state) by a cooling device (not shown), and the molding mold bodies 100 and 101 set between the cooling press mold bodies 107 and 108. Is subjected to cooling / pressurizing treatment by pressing from both sides in the vertical direction, that is, from both sides in the thickness direction of the molding material. What is necessary is just to set a cooling temperature and a press pressure suitably according to the material of a molding material.

  The thermoplastic resin material melt-impregnated inside the molding material 1 is solidified in the pressurized state by cooling while being pressurized by the cooling press mold. At that time, since the thicknesses of the molds 100 and 101 are set to be uniform as described above, the thermal conductivity with respect to the entire molding material 1 becomes substantially uniform, and the entire molding material 1 is almost the same. Cooling. Therefore, the thermoplastic resin material can be cooled and solidified without unevenness and finished into a molded product A having no molding warp (FIG. 10D).

  FIG. 11 is a process explanatory diagram relating to another embodiment for forming the molding material 1 using the molding dies 100 and 101. In this example, a ring-shaped seal member 110 is bonded and fixed to the peripheral edge of the mold 100 over the entire circumference. A pipe 109 connected to an air suction device (not shown) communicates with the mold body 101.

  First, the molding material 1 is set on the molding die 100, the molding die 101 is set on the upper surface of the molding material 1, and the molding die 100 and 101 are locked by a locking tool (not shown). It sets so that the material 1 may be clamped in the state pressed (FIG. 11 (a)). At that time, the seal member 110 is compressed by both molds, and the inside is kept airtight. The pipe 109 is attached so as to communicate with the exhaust space 102 formed at the peripheral edge portions of the mold bodies 100 and 101, and the air suction after the inside of both mold bodies is set in an airtight state by the seal member 110. The apparatus is operated to set the inside to a vacuum or a reduced pressure state (FIG. 11 (b)). In this case, the reduced pressure state is a pressure state close to vacuum, for example, a pressure state of 10 Torr or less.

  Then, the molds 100 and 101 set in a vacuum or reduced pressure state are set in the heating press machine 103 similar to the embodiment described with reference to FIG. 10, and a heating / pressurizing process is performed (FIG. 11C). The thermoplastic resin material in the molding material is melted and impregnated by heating, but since the inside of the molding die is in a vacuum or reduced pressure state, the molten thermoplastic resin material is sucked and reinforced fiber sheet material Impregnation into the inside of the glass is promoted, and the impregnation treatment can be performed in a short time without air remaining inside.

  And after performing a heating and pressurizing process, it sets to the cooling press machine 106 similar to embodiment described in FIG. 10, and performs a cooling and pressurizing process (FIG.11 (d)). The thermoplastic resin material melt-impregnated by cooling is solidified without unevenness and can be finished into a molded product A without molding warp (FIG. 11 (e)).

  When the seal member 110 is attached to the molding die, as shown in FIG. 12, grooves 100c and 101c are formed in the peripheral portions of the molds 100 and 110, and the seal member 110 is fitted into the grooves 100c and 101c. By setting the airtight state, an airtight structure can be realized more reliably inside the mold body.

  FIG. 13 is a process explanatory diagram relating to an embodiment for molding a plurality of molding materials at a time. In this example, four plate-shaped mold bodies 111 are used, the molding materials 1A, 1B, and 1C are installed between the mold bodies 111, and the mold body 111 is locked with a locking tool (not shown). Then, each material to be molded is set so as to be pressed at a predetermined interval (FIG. 13A).

  Then, the mold body 111 is installed between the heat press mold bodies 104 ′ and 105 ′ of the heat press machine 103 (FIG. 13B). The heating press molds 104 ′ and 105 ′ have a flat mold surface, and are in contact with the mold 111 in a state of being in close contact with each other, and are subjected to heating / pressurizing treatment. Since the thickness of the contact portion of the molding body 111 with respect to the molding material is all set uniformly, the thermal conductivity from the heating press mold bodies 104 ′ and 105 ′ to each molding material becomes substantially uniform, The entire thermoplastic resin material inside each molding material is melted and impregnated almost simultaneously.

  Next, the mold 111 is placed between the cooling press molds 107 ′ and 108 ′ of the cooling press machine 106 for the heated and pressurized mold 111 (FIG. 13C). The cooling press mold bodies 107 ′ and 108 ′ have a flat mold surface, and contact with the mold body 111 in close contact with each other to perform cooling and pressurizing processes. The melt-impregnated thermoplastic resin material is solidified and molded uniformly by cooling / pressurizing treatment, and each molding material is finished into a molded product B having no molding warpage.

  In this way, by using a plurality of molding bodies having the same shape, it becomes possible to mold a plurality of molding materials at once, and production efficiency can be greatly improved. And the impregnation of the molten thermoplastic resin material can be promoted by setting a seal member as shown in FIG.

  In the above-described embodiment, one heating press and one cooling press are used. However, a plurality of heating presses or cooling presses may be used for molding. In that case, the heating temperature of each heating press is set to be different, and the heating / pressurizing treatment is repeated from a lower heating temperature to a higher heating temperature in order, so that the thermoplastic resin material inside the molding material A melt impregnation process can be performed reliably. In addition, the cooling temperature of each cooling press machine is set to be different and the cooling and pressurizing treatment is repeated from a high cooling temperature to a low cooling temperature in order to solidify the thermoplastic resin material impregnated inside the molding material. Can be performed reliably.

[Example 1]
A concave thermoplastic multilayer reinforced molded product was manufactured by the molding process described with reference to FIG. 10 using the following materials.
<Materials used>
(Reinforcing fiber bundle)
Carbon fiber bundle manufactured by Mitsubishi Rayon Co., Ltd .; TR50S-15K, fiber diameter of about 7 μm, number of fibers of 15000 (thermoplastic resin)
Polyamide resin Mitsubishi Chemical Corporation; nylon 6 resin film, film thickness 20 μm

<Manufacturing process>
(1) One reinforcing fiber bundle TR50S-15K is set at an interval of 20 mm, and each reinforcing fiber bundle is reduced to a width by a known method (see Japanese Patent Publication No. 2007-518890) in which a large number of fibers are opened simultaneously. The fiber was opened to 20 mm.
(2) Each reinforcing fiber spread yarn opened to a width of 20 mm was vibrated in the width direction to obtain a reinforcing fiber sheet material having no gap between the reinforcing fiber spread yarns. The obtained reinforcing fiber sheet material had a width of about 320 mm and a fiber basis weight (fiber weight per unit area) of about 50 g / m ² .
(3) The obtained reinforcing fiber sheet material was continuously bonded while heating the thermoplastic resin sheet material. At this time, the heating temperature was controlled at about 270 ° C. A thermosetting polyimide resin film (product name: Upilex S, thickness: 25 μm, manufacturer: Ube Industries, Ltd.) was supplied as a release film together with the reinforcing fiber sheet material. The speed at which the thermoplastic resin reinforcing sheet material was bonded to the reinforcing fiber sheet material was 10 m / min.
(4) After heating, it was cooled and the release film was peeled off from the substrate to obtain a thermoplastic resin reinforced sheet material in which the thermoplastic resin sheet material adhered to one side of the reinforced fiber sheet material.
(5) Cut out a 320 mm square sheet in which fibers are arranged in the 0 degree direction, 90 degree direction, 45 degree direction, and -45 degree direction from the obtained thermoplastic resin reinforced sheet material with the fiber direction as 0 degree direction. , [(45 ° / 0 ° / −45 ° / 90 °) ₃ ] A laminated sheet material laminated on _S was produced.
(6) After the laminated sheet material was installed on an iron concave mold (lower mold) having a thickness of 1 mm, an iron convex mold (upper mold) having a thickness of 1 mm was installed. A mold release agent (Frekote 44-NC; manufactured by Henkel) was sprayed on the mold surface of the mold body as a mold release treatment. Thereafter, the pair of molding dies on which the laminated sheet material was installed were set in a hot press machine. The mold was placed on the lower mold of the hot press mold that had been heated to 270 ° C. in advance, and the upper mold was immediately lowered to apply pressure. At this time, the lower mold of the hot press mold body is shaped so that the concave mold body can be installed in close contact, and the upper mold of the hot press mold body is shaped so as to be able to press the convex mold mold in close contact. Yes. Heating / pressurizing treatment was performed for 5 minutes at a pressure of 2 MPa.
(7) After the heating / pressurizing treatment, the molding die was taken out from the heating press and set in a cooling press. A pair of molds were placed on the lower mold of the cooling press mold that had been cooled to about 20 degrees by water cooling in advance, and the upper mold of the cooling press mold was immediately lowered and pressurized. Like the hot press mold, the cooling press mold body has a shape that allows the concave mold body to be placed in close contact with the lower mold, and the upper mold of the cooling press body has a shape that allows the convex mold body to be in close contact with pressure. It has become. Cooling and pressurizing treatment was performed for 3 minutes at a pressurizing pressure of 2 MPa. Thereafter, the molding die was taken out from the cooling press machine to obtain a thermoplastic resin composite material molded product.

<Evaluation>
The obtained thermoplastic resin composite material molded article was finished into a concave-shaped molded article having a thickness of about 1.2 mm and a fiber volume content of about 60%, in which no molding warp occurred. When a part of the molded product was cut and the cross section was observed, it was confirmed that the thermoplastic resin was uniformly impregnated in the fiber bundle and that the fibers were uniformly dispersed. Further, in the curved shape and the corner shape of the molded product, the molding process has been performed with a good shape along the mold surface of the molding die.

[Example 2]
Molding was performed using the laminated sheet material obtained in (1) to (5) of Example 1.

<Manufacturing process>
(1) A laminated sheet material laminated on 320 mm square [(45 ° / 0 ° / −45 ° / 90 °) ₃ ] _{S according} to (1) to (5) of Example 1 was manufactured.
(2) After placing the laminated sheet material on the iron concave mold (lower mold) having a thickness of 1 mm, the iron convex mold (upper mold) having a thickness of 1 mm is installed, and the peripheral edges of the upper and lower molds The space between the parts was sealed with a heat-resistant rubber sealing member to form an airtight structure. In addition, (Frekote 44-NC; manufactured by Henkel) was sprayed on the surface of the mold body as a mold release treatment. Thereafter, air in the mold was sucked (exhausted), and the mold was set in a reduced pressure state of 10 Torr or less.
(3) The concavo-convex mold body in which the laminated sheet material was installed and the inside was in a reduced pressure state was set in a heating press. The mold was placed on the lower mold of the hot press mold that had been heated to 270 ° C. in advance, and the upper mold was immediately lowered to apply pressure. At this time, as in the case of Example 1, the lower mold of the hot press mold body has a shape that allows the concave mold body to be installed in close contact, and the upper mold of the hot press mold body has the convex mold mold in close contact. The shape can be pressurized. A heating / pressurizing treatment for 3 minutes was performed at a pressure of 2 MPa. Even during the heating / pressurizing process by the heating press, the air in the mold was continuously sucked (discharged), and the mold was maintained at a reduced pressure of 10 Torr or less.
(4) After the heating / pressurizing treatment, the mold was taken out from the heating press while the inside was in a reduced pressure state, and set in a cooling press. The forming die was placed on the lower die of the cooling press die that had been cooled to about 20 degrees by water cooling in advance, and the upper die was immediately lowered to pressurize. At this time, as in Example 1, the lower mold of the cooling press mold was shaped so that the concave mold could be placed in close contact with the upper mold, and the upper mold of the cooling press mold was pressed against the convex mold. It has a shape that can be done. Cooling and pressurizing treatment was performed for 3 minutes at a pressurizing pressure of 2 MPa. Even during the cooling and pressurizing treatment of the mold body by the cooling press, the air in the mold body was continuously sucked (discharged), and the mold body was maintained at a reduced pressure of 10 Torr or less.
(5) Then, after removing the molding die from the cooling press machine and returning the reduced pressure state in the molding die to the atmospheric pressure state, a thermoplastic resin composite material molded product was obtained from the molding die.

<Evaluation>
The obtained thermoplastic resin composite material molded article was finished into a concave-shaped molded article having a thickness of about 1.2 mm and a fiber volume content of about 60% and in which no molding warp occurred. When a part of the molded product was cut and the cross section was observed, the fiber bundle was uniformly impregnated with the thermoplastic resin even though the heating / pressurization time was shortened. In addition, it was confirmed that the fibers were uniformly dispersed. Further, in the curved shape and the corner shape of the molded product, the molding process has been performed with a good shape along the mold surface of the molding die.

[Example 3]
A flat plate-shaped thermoplastic resin multilayer reinforced molded article was produced by the molding method described in FIG. 13 using the following materials.
<Materials used>
(Reinforcing fiber bundle)
Carbon fiber bundle manufactured by Mitsubishi Rayon Co., Ltd .; MR60H-24K, fiber diameter of about 5.4 μm, number of fibers of 24,000 (thermoplastic resin)
Polyetherimide (PEI) resin film manufactured by Mitsubishi Plastics, Inc .; Superior UT, thickness 15 μm
(Resin used for adhesive thermoplastic resin)
Copolymer polyamide resin powder manufactured by Toray Industries, Inc .; CM842P48, low melting point (115 ° C) resin

<Manufacturing process>
(1) The reinforcing fiber bundles MR60H-24K are set at intervals of 24 mm, and a number of the reinforcing fiber bundles are widened by a known method (see Japanese Patent Publication No. 2007-518890). The fiber was opened to about 24 mm.
(2) Each reinforcing fiber spread yarn opened to a width of 24 mm was vibrated in the width direction to obtain a reinforcing fiber sheet material having no gap between the reinforcing fiber spread yarns. The obtained reinforcing fiber sheet material had a width of about 310 mm and a fiber basis weight (fiber weight per unit area) of about 40 g / m ² .
(3) Copolymerized polyamide resin powder, which is an adhesive thermoplastic resin material, was uniformly dispersed and adhered to one surface of a PEI resin film, which is a thermoplastic resin sheet material, using a powder spraying device. The amount of dispersion was about 0.4 g / m ² , which was about 1% of the weight of the reinforcing fiber bundle.
(4) The thermoplastic resin sheet material to which the adhesive thermoplastic resin material adhered was continuously bonded to one surface of the obtained reinforcing fiber sheet material while heating. At this time, the heating temperature was controlled at about 150 ° C. Release paper (manufactured by Lintec) was supplied together with the reinforcing fiber sheet material. The speed at which the thermoplastic resin reinforcing sheet material was bonded to the reinforcing fiber sheet material was 10 m / min.
(5) Cut out a 320 mm square sheet in which fibers are arranged in the 0 degree direction, 90 degree direction, 45 degree direction, and -45 degree direction from the obtained thermoplastic resin reinforced sheet material with the fiber direction as 0 degree direction. , [(45 ° / 0 ° / −45 ° / 90 °) ₃ ] A laminated sheet material laminated on _S was produced.
(6) A laminated sheet material is placed on a flat plate mold made of CC composite having a thickness of 1 mm, and an iron flat plate mold having a thickness of 1 mm is placed on the upper surface thereof, and then another laminated sheet material is placed on the upper surface. Then, the peripheral portions of the uppermost molding die and the lowermost molding die were sealed with a heat-resistant rubber sealing member to form an airtight structure. A release sheet material (thermosetting polyimide film; Ube Industries, Ltd., thickness 50 μm) was provided between the laminated sheet material and the mold. Thereafter, the air in the mold was sucked (discharged), and the inside of the mold was set to a reduced pressure state of 10 Torr or less.
(7) The mold body in which the laminated sheet material was installed and the inside was in a reduced pressure state was set in a heating press. The molding die was placed on the lower die of the hot press die that had been heated to 370 ° C. in advance, and the upper die was immediately lowered to apply pressure. At this time, the mold surfaces of the upper and lower molds of the hot press mold body are formed in a flat shape so as to be in close contact with and pressurize the mold body. A heating / pressurizing treatment for 3 minutes was performed at a pressure of 2 MPa. Even during the heating and pressurizing treatment of the mold by the hot press machine, the air in the mold was continuously sucked (discharged), and the mold was maintained at a reduced pressure of 10 Torr or less.
(8) After the heating / pressurizing treatment, the mold body was taken out from the heating press while the inside was in a reduced pressure state, and set in a cooling press. The molding die was placed on the lower die of the cooling press die that had been cooled to about 20 ° C. in advance by water cooling, and the upper die was immediately lowered to pressurize. At this time, similarly to the hot press mold body, the upper and lower mold surfaces of the cold press mold body are formed in a flat shape so as to be in close contact with the mold body and pressurize. Cooling and pressurizing treatment was performed for 3 minutes at a pressurizing pressure of 2 MPa. Even during the cooling and pressurizing treatment of the mold body by the cooling press, the air in the mold body was continuously sucked (discharged), and the mold body was maintained at a reduced pressure of 10 Torr or less.
(9) Then, after removing the molding die from the cooling press machine and returning the reduced pressure state in the molding die to the atmospheric pressure state, three thermoplastic resin composite material molded products were obtained from the molding die.

<Evaluation>
The obtained thermoplastic resin composite material molded product was finished into a flat plate-shaped molded product having a thickness of about 0.9 mm and a fiber volume content of about 60% and having no molding warp. After cutting a part of the molded product and observing the cross section, it was confirmed that the thermoplastic resin impregnation into the bundle and the dispersibility of the carbon fiber were good despite being a heat resistant resin. did it. And, it was possible to obtain a molded product with good quality even under molding conditions in which the heating / pressurizing time was shortened.

It is a schematic diagram which shows a part of thermoplastic resin multilayer reinforcement sheet material which is a molding material used in this invention. It is a schematic diagram which shows a part of thermoplastic resin reinforcement sheet material used for a thermoplastic resin multilayer reinforcement sheet material. It is a schematic diagram which shows a part of another thermoplastic resin reinforcement sheet material used for a thermoplastic resin multilayer reinforcement sheet material. It is a schematic diagram which shows a part of another thermoplastic resin reinforcement sheet material used for a thermoplastic resin multilayer reinforcement sheet material. It is a schematic diagram which shows a part of another thermoplastic resin reinforcement sheet material used for a thermoplastic resin multilayer reinforcement sheet material. It is a schematic diagram which shows a part of another thermoplastic resin reinforcement sheet material used for a thermoplastic resin multilayer reinforcement sheet material. It is a schematic diagram which shows a part of another thermoplastic resin multilayer reinforcement sheet material which is a molding material used in this invention. It is a schematic diagram which shows a part of another thermoplastic resin multilayer reinforcement sheet material which is a molding material used in this invention. It is a schematic sectional drawing which shows the state which set the to-be-molded material to the shaping | molding die. It is process explanatory drawing regarding embodiment which concerns on this invention. It is process explanatory drawing regarding another embodiment which concerns on this invention. It is sectional drawing which shows the modification regarding attachment of the sealing member of FIG. It is process explanatory drawing regarding another embodiment which concerns on this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Thermoplastic resin multilayer reinforcement sheet material 2 Thermoplastic resin reinforcement sheet material 3 Reinforcement fiber sheet material 4 Thermoplastic resin sheet material
11 Thermoplastic resin multilayer reinforcing sheet material
12 Thermoplastic resin reinforced sheet material
13 Reinforcing fiber sheet material
14 Thermoplastic resin sheet material
100 Mold
101 Mold body
102 Exhaust space
103 Heating press
104 Heating press mold
105 Hot press mold
106 Cooling press machine
107 Cooling press mold
108 Cooling press mold
109 Piping
110 Seal member
111 Mold

Claims (11)

A molding method for molding a molded article of a thermoplastic resin composite material using a molding material composed of a reinforcing fiber material and a thermoplastic resin material, wherein the molding is formed to have a uniform thickness at a contact portion with the molding material. The molding material is disposed between the molding dies using a pair of molding dies, and the molding is performed from both sides of the molding material so that the internal gas can be exhausted from the periphery of the molding material. Set in a state of being clamped and pressed by a mold body, setting the inside of the mold body for clamping the material to be molded to a reduced pressure or vacuum state, and making contact with the contact surface of the mold body The molding in which the molding die is placed between the heating press molds using a pair of heating press molds formed with a surface, the molding material is sandwiched, and the inside is set to a reduced pressure or vacuum state before and heating and pressurizing treatment to the formed body Said thermoplastic resin material which is melted inside the reinforcing fiber material impregnated, using said pair of cooling press type body contact surface is formed so as to be in intimate contact with the abutment surface of the mold body the cooling press type The mold that has been heated / pressurized between the bodies is placed , the material to be molded is sandwiched, and the mold that is set in a reduced pressure or vacuum state is cooled / pressurized to reinforce the reinforcement. A method for molding a molded article of a thermoplastic resin composite material , wherein the thermoplastic resin material melt-impregnated inside a fiber material is solidified and molded. 2. The molding method according to claim 1, wherein a plurality of the molds sandwiching the molding material are stacked to perform heating / pressurizing treatment and cooling / pressurizing treatment. 3. The molding method according to claim 1, wherein the heating / pressurizing process is performed by sequentially using a plurality of heating press molds having different set temperatures. The molding method according to any one of claims 1 to 3, wherein the cooling / pressurizing process is performed sequentially using a plurality of cooling press molds having different set temperatures. The molding method according to claim 1, wherein a contact portion of the molding die is formed in a thin shape. The molding method according to claim 1, wherein the molding die is made of a carbon fiber carbon composite material. The molding method according to any one of claims 1 to 6, wherein the molding die is subjected to a mold release treatment on an abutting surface that abuts on the molding material. The molding method according to any one of claims 1 to 6, wherein a release sheet material is provided on a portion of the molding material that is in contact with the mold body. The molding method according to any one of claims 1 to 8, wherein the molding material includes the thermoplastic resin material serving as a matrix unevenly between layers in which the reinforcing fiber materials are arranged. The molding material is composed of a reinforcing fiber sheet material in which a plurality of reinforcing fibers are aligned in a predetermined direction and formed into a sheet shape, and a thermoplastic resin sheet material attached to one or both sides of the reinforcing fiber sheet material. The molding method according to claim 9, wherein a plurality of the thermoplastic resin reinforced sheet materials are laminated. 11. The reinforcing fiber sheet material and the thermoplastic resin sheet material are attached by an adhesive thermoplastic resin material that melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material. The forming method as described.