JP5671314B2 - Lamination method and forming method of textile base material and thermoplastic resin - Google Patents

Description

The present invention relates to a forming method for forming a fiber reinforced resin member such as an automobile or an aircraft into a three-dimensional shape using a forming die and a laminated material used for such a forming method.

Conventionally, as a method of molding a fiber reinforced resin using carbon fiber as a reinforcing fiber, a flat laminated product is placed on a mold, the mold is evacuated, and the resin is injected into the flat laminated product. A resin transfer molding method in which a resin is diffused and impregnated is known.

Patent Document 1 discloses a forming method capable of automatically and accurately producing a flat laminated molded product having a three-dimensional shape suitable for use in this resin transfer molding method. It was.

However, the forming method disclosed in Patent Document 1 uses a flat laminated molded product made of reinforced fibers and a thermosetting resin, and its moldability is limited. Moreover, once cured, there is a problem that it cannot be recycled because it cannot be dissolved by heat or dissolved in a solvent.

On the other hand, in Patent Document 2, a thermoplastic resin material is attached to at least one surface of a fabric base material including a plurality of reinforcing fiber bundles, and then the relative strength of the plurality of reinforcing fiber bundles constituting the fabric base material is determined. By giving variation to the position, it is possible to follow a complicated shape with excellent deformability, and a flat laminate molded product, a fiber reinforced resin molded product using a reinforced fiber fabric that has excellent shape retention, and Their manufacturing method has been disclosed.

Japanese Patent Laid-Open No. 2003-21447 JP 2007-56441 A

In a molding method in which a laminated molding material obtained by laminating a reinforcing fiber fabric disclosed in Patent Document 2 as a molding raw material is heated to a melting temperature and then compressed with a molding die at a solidification temperature, the thermoplastic resin is completely converted into carbon fibers. There is a problem that it is difficult to impregnate, and a sufficient molded product strength cannot be obtained.
In view of the problems in the prior art described above, the present invention provides a method for laminating a textile base material and a thermoplastic resin, and a forming shape, which can shape a strong molded product into a three-dimensional shape with a high degree of freedom in shape. It aims to provide a method .

Method of laminating the textile substrate and the thermoplastic resin of the present invention includes the steps of holding the fabric substrate containing reinforcing fiber bundles of a plurality of between full I Lum shape thermoplastic resin, between a thermoplastic resin It is characterized by comprising a step of depressurizing and a step of heating the thermoplastic resin sandwiching the carbon fibers with near infrared rays and then cooling to adhere the thermoplastic resin to both side surfaces of the textile substrate.

A full I Lum shape thermoplastic resin was wound thermoplastic resin between the thermoplastic resin from the step of holding the carbon fiber is cooled after heating in the near infrared, it is continuously performed until the step of winding the roller It is good.

  The forming method of the present invention comprises a step of laminating a plurality of laminates of the textile substrate of the present invention and a thermoplastic resin, and a mold having a thermoplastic resin melting temperature by preheating the laminated laminates with near infrared rays. And a step of cooling the mold after the mold having a thermoplastic resin melting temperature is clamped and compressed.

Furthermore, the forming method of the present invention includes a step of raising a forming mold to a thermoplastic resin melting temperature, and a laminated molded material obtained by laminating a plurality of laminated materials of the textile base material and the thermoplastic resin of the present invention. And a step of pre-heating and placing in the mold, a step of clamping and pressurizing the mold, and a step of opening the mold by releasing the mold after cooling the mold to the solidification temperature.

By this forming method of the present invention, the molding die is heated to the melting temperature of the thermoplastic resin material to completely impregnate the thermoplastic resin into the carbon fibers and strengthened by fiber lamination to obtain sufficient molded product strength. It becomes possible to mold a thermoplastic resin material. In addition, it can be prevented by preheating that the cycle time becomes excessive due to the long heating time.

If the reinforcing fiber bundle is a carbon fiber bundle, a light and high-strength molded product can be obtained.

The preheating process is a process of heating with near infrared rays, detecting the temperature with a far infrared temperature sensor, adjusting the intensity of the near infrared rays, and raising the temperature to a predetermined temperature. It can be heated and heated to the center, and the far-infrared sensor can detect the accurate temperature without contact.
By adjusting the near-infrared intensity with a continuous voltage drop and raising the temperature to a predetermined temperature, the molecules to be preheated can be heated with the near infrared rays, and the preheated object can be efficiently heated to the center.

  In the preheating process, the laminated molding material is placed and placed in the mold in the process of raising the temperature to the melting temperature, heated with near infrared rays, the temperature is detected with a far infrared temperature sensor, the intensity of near infrared rays is adjusted, and the predetermined temperature is reached. By being the step of raising the temperature, the molecule to be preheated can be heated to the middle core with near infrared rays, and the accurate temperature can be detected in a non-contact manner by the far infrared sensor. Moreover, the laminated molding material in the process of raising the temperature to the melting temperature is placed in a mold that has been heated, so that the time can be efficiently reduced and preheated.

The fiber reinforced resin molded product produced by the above forming method of the present invention can be applied to various applications because it can be manufactured with high strength, light weight, efficiency and low cost, and also can be shaped with complex shapes. It becomes.

According to the laminating method and the forming method of the textile base material and the thermoplastic resin according to the present invention, a strong molded product is shaped into a three-dimensional shape efficiently with a high degree of freedom in shape using a forming raw material. be able to.

(A) It is a conceptual diagram of the laminated material obtained by the lamination | stacking method of the textile base material of this invention, and a thermoplastic resin . (B) It is another conceptual diagram of the laminated material obtained by the lamination | stacking method of the textile base material and thermoplastic resin of this invention. (C) It is explanatory drawing of the textile base material used by this invention. (A) Explanatory drawing of the lamination | stacking method of the textile base material and thermoplastic resin of this invention, (b) Other explanatory drawing of the lamination | stacking method of the textile base material and thermoplastic resin of this invention, (c) Of this invention It is other explanatory drawing of the lamination | stacking method of a textile base material and a thermoplastic resin. It is an isometric view explanatory drawing of the lamination | stacking method of the textile base material and thermoplastic resin of this invention. It is explanatory drawing of the shaping apparatus used with the shaping method of 1st embodiment of this invention.

As shown in FIGS. 1 (a) and 1 (b) , a laminated material 1 obtained by the method of laminating a textile base material and a thermoplastic resin of the present invention has both sides of a textile base material 3 including a plurality of reinforcing fiber bundles 2. The film-like thermoplastic resin 4 is adhered to the substrate.
This laminated material 1 sandwiches a fabric substrate 3 including a plurality of reinforcing fiber bundles 2 between film-shaped thermoplastic resins 4 and depressurizes between the thermoplastic resins 4 to be heated by a near infrared radiation device 5.・ Cooled.

More specifically, as shown in FIGS. 2 (a) to 2 (c), a step of sandwiching a woven base material 3 including a plurality of reinforcing fiber bundles 2 between the thermoplastic resin 4 in the form of a film, and the thermoplastic resin The laminated material 1 can be manufactured by the process of depressurizing between 4 and the process of heating and cooling the thermoplastic resin 4 holding the woven fabric base 3 including the reinforcing fiber bundle 2 with the near infrared radiation device 5. .

Near infrared rays emitted by the near-infrared radiation device 5 heats the fabric substrate 3 comprising a reinforcing fiber bundle 2 passes through the full I Lum shaped heat thermoplastic resin 4 directly in the above process. Heat conduction occurs in heated fabric substrate 3 carafe I Lum shaped heat thermoplastic resin 4, full I Lum shaped heat thermoplastic resin 4 is pasted contract and the front and back of the fabric substrate 3.
In this case passes through the transparent full I Lum shaped heat thermoplastic resin 4 to heat the inside of the fabric substrate 3 directly high efficiency by using a near-infrared. Moreover, the heating efficiency is also high compared with far infrared rays.

Depressurizing between thermoplastic resin 4 from the step of holding the fabric substrate 3 comprising a reinforcing fiber bundle 2 unwound thermoplastic resin 4 was full I Lum form between the thermoplastic resin 4 as shown in FIG. 3 Production efficiency can be improved by performing the process of heating the thermoplastic resin 4 with the near-infrared radiation device 5 after the process and then cooling it with the fan 6 and winding it around the roller 7.
As shown in FIG. 3, the step of reducing the pressure between the thermoplastic resins 4 can be performed using a pressure reducing device 88 between the thermoplastic resins 4 holding the woven fabric base 3.

Excipient type method of the present invention, FIG. 1 (a) (b) full I Lum shaped heat thermoplastic resin 4 on both sides of the plurality of fabric substrate 3 comprising a reinforcing fiber bundle 2 of is affixed shown stacked This is done using material 1.

As shown in FIG. 1C, the woven fabric base 3 is a bi-directional woven fabric formed by weaving a plurality of reinforcing fiber bundles 2 aligned in one direction so as to be parallel to each other in two orthogonal directions. The bi-directional woven fabric has the advantage that it is easy to be deformed due to a change in the relative position between the reinforcing fiber bundles 2 and is easily deformed into a three-dimensional shape, and that it is easy to obtain a laminated molding material that is mechanically pseudo-isotropic with a small number of sheets. .

The reinforcing fiber bundle 2 may be a carbon fiber bundle, a graphite fiber bundle, a glass fiber bundle, an aramid fiber bundle, or the like, and is preferably a carbon fiber bundle. By using the carbon fiber bundle, the mechanical properties of the fiber reinforced resin molded product as the final product can be improved.

The resin material 4 adhering to the surface of the woven fabric base 3 is mainly composed of a thermoplastic resin capable of obtaining the action of bonding the layers of the woven fabric base 3. Examples of the thermoplastic resin include polyamide, polysulfone, polyetherimide, polyphenylene ether, polyimide, and polyamideimide . When the resin material 4 has a thermoplastic resin as a main component, the laminate 1 is laminated, and the handleability when the layers of the fabric base material 3 are bonded after being deformed into a three-dimensional shape is improved. Productivity is improved. The main component is a component having the largest ratio among the components constituting the resin material 4.

Hereinafter, the forming method according to the first embodiment of the present invention will be described in detail with reference to FIG.

First, the laminated material 1 is laminated, and the laminated molding material 9 preliminarily compression-molded with a preliminary lamination mold (not shown) is preheated with the preliminary heating mold 10.

In the preheating, the laminated molding material 9 placed on the heating plate 11 in the preheating mold 10 is heated by near infrared radiation from the upper part by the near infrared radiation device 5 and laminated by a far infrared temperature sensor (not shown). The temperature of the molding material 9 is detected, the intensity of near infrared rays by the near infrared radiation device 5 is adjusted, and the laminated molding material 9 is heated to a predetermined temperature.

On the other hand, the forming die 12 which is a shaping die having a three-dimensional shape is preheated to raise the temperature to the melting temperature of the laminated material 1. Next, the laminated molding material 9 is accommodated in a preheated molding die 12, and the laminated molding material 9 is compressed by the molding die 12. As a result, the resin material 4 adhering to the fabric base material 3 is softened, the layers of the laminated molding material 9 are bonded, and the shape is maintained.

Thereafter, the mold 12 is rapidly cooled to the solidification temperature, and the mold is opened and released. The laminated material 1 is laminated by the above steps and shaped into a three-dimensional shape.

The temperature at which the laminated molding material 9 is heated is a temperature at which the resin material 4 is softened to bond the layers of the laminated molding material 9 together. When the laminated molding material 9 is heated while being pressed, the fabric base materials 3 including the plurality of reinforcing fiber bundles 2 constituting the laminated molding material 9 are strongly pressed against each other, and the softened resin materials 4 are opposed to each other. It penetrates between the single yarns of the reinforcing fiber bundles 2 constituting the fabric base material including the reinforcing fiber bundles 2. Next, by cooling the laminated molding material 9, the resin material 4 adheres to the woven fabric base 3 including a plurality of reinforcing fiber bundles 2 facing each other, and bonds the layers of the laminated molding material 9 together.

By thus deforming the laminated molding material 9 into a three-dimensional shape and bonding the layers, a three-dimensional shaped product having no wrinkles can be manufactured. In addition, since the layer of the laminated molding material 9 is bonded to the molded body, the molded body has high rigidity and excellent shape retention and can be handled efficiently.

The mold 12 includes a product part mold 13 and a heat storage board 14, and raises the mold temperature of the mold 12 by heat conduction from the heater 15 and the heat storage board 14 provided in the product part mold 13. The molding die 12 includes a cooling water passage 16 for water cooling, and the molding die 12 is rapidly cooled by passing water through the cooling water passage 16. The cooling water flow path 16 can efficiently extract and lower water by applying air. That is, after the mold temperature of the mold 12 reaches a predetermined cooling temperature, the cooling of the mold 12 is finished by stopping water flow in the cooling water passage 16 and applying air. After taking out, the temperature rise of the mold 12 can be efficiently started again.

[Example]
A plurality of square laminates 1 each having a size of 100 mm × 100 mm having a resin material 4 mainly composed of polyphenylene sulfide resin (PPS) attached to the surface were prepared on both side surfaces of the bidirectional woven fabric base 3. Each laminated material 1 has a fiber axis direction of approximately 0 ° and 90 ° when the directions of the sides of the square are set to 0 ° and 90 °, respectively.
A laminated molded material 9 in which the laminated materials 1 were laminated was obtained.
[Comparative example]

The laminated molding material 9 is placed on a heating plate 11, the laminated molding material 9 is heated by near infrared radiation from the upper part by a near infrared radiation device 5, and the temperature of the laminated molding material 9 is detected by a far infrared temperature sensor. The intensity of near infrared rays by the infrared radiation device 5 was adjusted, and the laminated molding material 9 was heated and preheated to 260 ° C.

The intensity of the near infrared ray was adjusted by the continuous drop of the conduction voltage to the near infrared radiation device 5 and preheated.

On the other hand, it consists of a product part mold 13 and a heat storage board 14, and the mold temperature of the mold 12 is raised by heat conduction from the heater 15 and the heat storage board 14 provided in the product part mold 13 to 260 ° C. The laminated mold 9 preheated to 260 ° C. is stored in the mold 12 preheated to 260 ° C., and the flat plate provided by the mold 12 is pressed while the mold clamping time in the molten state is 7 minutes. It was made to deform | transform into the shape of a flat plate-shaped laminated molded product. Thereafter, the molding die 12 is rapidly cooled to 80 ° C. by passing water through the cooling water passage 16, the cooling die is clamped for 3 minutes, and air is applied to the cooling water passage 16 efficiently. Water was extracted and dropped to obtain a flat laminated molded product solidified by cooling.

[Comparative example]

A plurality of square forming raw materials having a size of 100 mm × 100 mm in which a resin material 4 mainly composed of polyphenylene sulfide resin (PPS) was adhered to one surface of the bidirectional fabric base material 3 were prepared. Each forming raw material had a fiber axis direction of approximately 0 ° and 90 ° when the directions of the square sides were 0 ° and 90 °, respectively.
A laminated molding material 9 is obtained by laminating the respective molding raw materials 1a with the uppermost reinforcing fiber woven fabric having the resin material 4 adhering side down and the other resin material 4 adhering side up. It was.
The laminated molded material 9 was obtained in the same manner as in the example to obtain a flat laminated molded product.
When the bending strength of the molded product obtained in each of the example and the comparative example was measured, it was confirmed that the comparative example molded product was 316 Mpa, whereas the example molded product had a bending strength of 633 Mpa.

DESCRIPTION OF SYMBOLS 1 ... Laminated material, 2 ... Reinforcement fiber bundle, 3 ... Textile base material, 4 ... Resin material, 9 ... Laminated molding material, 10 ... Preheating type, 5 ... Near-infrared radiation device, 12 ... mold, 13 ... product part mold, 14 ... heat storage board, 16 ... cooling water passage, 15 ... heater.

Claims (5)

  A process of sandwiching a textile substrate including a plurality of reinforcing fiber bundles between a thermoplastic resin made into a film, a process of reducing the pressure between thermoplastic resins, and a thermoplastic resin sandwiching carbon fibers in the near infrared A method for laminating a woven fabric base material and a thermoplastic resin, comprising: heating and then cooling to adhere a thermoplastic resin to both side surfaces of the woven fabric base material. A process in which a film-like thermoplastic resin is unwound and the carbon fiber is sandwiched between the thermoplastic resins, and the thermoplastic resin is heated with near infrared rays and then cooled and wound up on a roller. A method for laminating the textile substrate and the thermoplastic resin described in 1. The method for laminating a textile substrate and a thermoplastic resin according to claim 1 or 2 , wherein the reinforcing fiber bundle is a carbon fiber bundle. A plurality of laminates in which film-like thermoplastic resins are bonded to both side surfaces of a fabric base material including a plurality of reinforcing fiber bundles obtained by the method of laminating a textile base material and a thermoplastic resin according to claim 1 or claim 2. A step of laminating, a step of preheating the multi-layered laminate with near-infrared rays and putting it into a mold having a thermoplastic resin melting temperature, and a step of cooling the mold after clamping the mold having a thermoplastic resin melting temperature. A forming method characterized by comprising: A fabric comprising a plurality of reinforcing fiber bundles obtained by heating a shaping mold to a thermoplastic resin melting temperature, and a method of laminating a fabric substrate and a thermoplastic resin according to claim 1 or 2. Preheating a laminated molding material in which a plurality of laminated materials each having a film-like thermoplastic resin bonded to both sides of the base material are laminated, placing and placing them in a molding die, clamping and pressing the molding die, and a molding die Forming the mold by opening the mold and releasing the mold.

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