JP5833460B2 - Mold and method for producing thermoplastic resin fiber reinforced composite material molded article - Google Patents
Mold and method for producing thermoplastic resin fiber reinforced composite material molded article Download PDFInfo
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本発明は、金型及び熱可塑性樹脂系繊維強化複合材料成形品の製造方法に関する。 The present invention relates to a mold and a method for producing a thermoplastic resin-based fiber reinforced composite material molded article.
マトリックス樹脂が強化繊維で強化された熱可塑性樹脂系繊維強化複合材料等の成形材料の成形方法としては、所望の形状のキャビティを有する金型による成形方法が挙げられる。特に、熱可塑性樹脂系繊維強化複合材料の成形では、高温の金型で成形材料を溶融成形し、該金型を冷却して成形材料を固化した後に、金型から成形品を取り出す手法が用いられ、金型の加熱、冷却を繰り返す必要がある。このような成形品の製造のハイサイクル化には、金型の加熱及び冷却を急速で行うことが重要である。 Examples of a molding method for a molding material such as a thermoplastic resin-based fiber reinforced composite material in which a matrix resin is reinforced with reinforcing fibers include a molding method using a mold having a cavity having a desired shape. In particular, in the molding of thermoplastic resin fiber reinforced composite materials, a method is used in which a molding material is melt-molded with a high-temperature mold, the mold is cooled, the molding material is solidified, and then the molded product is taken out from the mold. It is necessary to repeat heating and cooling of the mold. In order to increase the cycle of manufacturing such a molded article, it is important to rapidly heat and cool the mold.
加熱や冷却が効率的に行える金型としては、下記の金型が知られている。
（１）金型のキャビティ面に薄肉の金属殻が形成されており、該金属殻を高周波誘導加熱により直接加熱する金型（特許文献１）。
（２）金型のキャビティ面を加熱する加熱配管を加熱するために、発熱体及び該発熱体を高周波誘導加熱する誘導加熱コイルを設けた金型（特許文献２）。
（３）樹脂の転写性と流動性を高めるため、金型のキャビティ近傍に、高周波誘導加熱する誘導加熱コイルが設けられ、かつ金型内に冷水を流通して金型を冷却する冷却水路が形成された射出成形用金型（特許文献３）。
The following molds are known as molds that can efficiently perform heating and cooling.
(1) A metal mold in which a thin metal shell is formed on a cavity surface of a mold, and the metal shell is directly heated by high frequency induction heating (Patent Document 1).
(2) A mold provided with a heating element and an induction heating coil for high-frequency induction heating of the heating element in order to heat the heating pipe for heating the cavity surface of the mold (Patent Document 2).
(3) In order to improve the transferability and fluidity of the resin, an induction heating coil that performs high-frequency induction heating is provided in the vicinity of the cavity of the mold, and a cooling water passage that cools the mold by circulating cold water in the mold. A formed injection mold (Patent Document 3).
（１）の金型は、成形材料と接触する薄肉の金属殻を、高周波誘導により直接加熱するため、成形時において急速な加熱が可能である。しかし、キャビティ面の金属殻を直接高周波誘導加熱した場合、昇温速度は速くなり、ハイサイクル化に有効であったが、金型のキャビティ表面の誘導発熱は、コイルの配置やキャビティ面の凹凸に大きく依存することから、表面温度のバラツキは大変大きかった。プリプレグの成形には、プリプレグの加熱温度を適正温度範囲内に制御しなければならないが、（１）の金型では表面の温度分布が広く、プリプレグの未溶融状態と熱分解や熱変色が共存し、良好な成形品を得ることは、大変困難であった。また押し型に絶縁性が必須であり、型締め時に絶縁破壊するトラブルが起こりやすく量産型として問題があった。また冷却手段が空冷であるため、金属殻の冷却に時間がかかった。 Since the metal mold (1) directly heats the thin metal shell that comes into contact with the molding material by high frequency induction, rapid heating is possible during molding. However, when the metal shell on the cavity surface was directly subjected to high-frequency induction heating, the rate of temperature increase increased, which was effective for high cycles. However, induction heat generation on the cavity surface of the mold caused the coil placement and the unevenness of the cavity surface. The surface temperature variation was very large. For prepreg molding, the heating temperature of the prepreg must be controlled within an appropriate temperature range. However, the mold (1) has a wide surface temperature distribution, and the unmelted state of the prepreg and thermal decomposition and thermal discoloration coexist. However, it was very difficult to obtain a good molded product. In addition, insulation is indispensable for the pressing mold, and there is a problem as a mass-production mold because it is easy to cause troubles that cause dielectric breakdown during clamping. Further, since the cooling means is air cooling, it took time to cool the metal shell.
（２）の金型は、金型を温調配管により加熱するために、高周波誘導で温調配管を加熱するものである。熱媒体を高温に加熱するために、金型の加熱に適するが、成形後成形品を取り出す際に、金型を冷却するまで時間がかかり量産型としては要求に合わなかった。 The mold of (2) heats the temperature control pipe by high frequency induction in order to heat the mold by the temperature control pipe. Although it is suitable for heating a mold in order to heat the heating medium to a high temperature, it takes time until the mold is cooled when taking out a molded product after molding, and it was not suitable as a mass production mold.
（３）の金型は、高周波誘導により金型を直接加熱し、また金型内に冷水を流通することで金型を冷却するものである。しかし、該金型は、金型全体を加熱及び冷却するものであり、通常の金型の熱容量は高く、加熱、冷却に時間がかかる。また、発熱や冷却は、コイルや冷却管の配置に強く依存する。熱伝導率が低いため伝熱が均一化されず、温度分布を有し、温度に敏感なプリプレグの成形において良品を得るには問題があった。 In the mold (3), the mold is directly heated by high frequency induction, and the mold is cooled by circulating cold water in the mold. However, the mold heats and cools the entire mold, and the heat capacity of a normal mold is high, and it takes time for heating and cooling. Further, heat generation and cooling strongly depend on the arrangement of the coil and the cooling pipe. Since the heat conductivity is low, heat transfer is not uniform, and there is a problem in obtaining a good product in molding a prepreg having a temperature distribution and sensitive to temperature.
以上のように、（１）〜（３）の金型では、加熱、冷却サイクルの効率化はなされたが、金型の場所による温度分布が広く、従って、成形される樹脂の温度分布も広く、樹脂の流動ムラや黄変やヤケムラが発生し、良品を得ることは困難であった。特に、成形に厳密な温度管理が必要な熱可塑性樹脂の圧縮成形や内圧成形には使用できるものでなかった。また適正成形温度幅の狭いプリプレグ成形用に、温度分布が狭く、かつ短時間に加熱・冷却サイクルできる金型の強い開発要求があった。 As described above, in the molds (1) to (3), the efficiency of the heating and cooling cycle has been improved, but the temperature distribution depending on the location of the mold is wide, and therefore the temperature distribution of the molded resin is also wide. The resin flow unevenness, yellowing and discoloration unevenness occurred, and it was difficult to obtain a good product. In particular, it cannot be used for compression molding and internal pressure molding of thermoplastic resins that require strict temperature control for molding. In addition, there has been a strong demand for development of a mold that has a narrow temperature distribution and can be heated and cooled in a short time for molding a prepreg having a narrow proper molding temperature range.
本発明は、熱可塑性樹脂系繊維強化複合材料等の成形材料を成形する金型であって、キャビティ面の加熱及び冷却を急速に行って、かつ温度分布が均一であり、ハイサイクルに品質のよい成形品を製造できる金型の提供を目的とする。
また、本発明は、前記金型を用いたハイサイクルな熱可塑性樹脂系繊維強化複合材料成形品の製造方法の提供を目的とする。
The present invention is a mold for molding a molding material such as a thermoplastic resin-based fiber reinforced composite material, which rapidly heats and cools the cavity surface, has a uniform temperature distribution, and has high quality in a high cycle. It aims at providing the metal mold | die which can manufacture a good molded article.
Another object of the present invention is to provide a method for producing a high cycle thermoplastic resin fiber reinforced composite material molded article using the mold.
本発明は、前記課題を解決するために以下の構成を採用した。
〔１〕２０℃における熱伝導率が１００〜４５０Ｗ／ｍ／Ｋである非磁性金属材料により形成されたキャビティ面を有する一対のキャビティ型を具備し、前記一対の型のそれぞれに、内部に冷媒を流通して前記キャビティ型を冷却するための、該型内を貫通する冷却回路を有し、かつ前記一対のキャビティ型の外面にそれぞれ２０℃における固有抵抗値が４．０〜１００μΩ・ｃｍである高周波誘導により発熱する磁性体を密接し、かつ該磁性体の外面に誘導加熱コイルが設けられている金型。
〔２〕キャビティ型がアルミニウムまたはアルミニウム系合金により形成されている、前記〔１〕に記載の金型。
〔３〕キャビティ型表面が、窒化金属コート、炭化金属コート、金属メッキのいずれかで処理されたアルミニウムまたはアルミニウム系合金により形成されている、前記〔１〕に記載の金型。
〔４〕一対のキャビティ型それぞれの厚さが、５〜１５０ｍｍである前記〔１〕又は、〔２〕又は、〔３〕に記載の金型。
〔５〕前記〔１〕又は、〔２〕又は、〔３〕又は、〔４〕に記載の金型を用いた熱可塑性樹脂系繊維強化複合材料成形品の製造方法であって、
加圧チューブの周囲に巻き付けた熱可塑性樹脂系繊維強化複合材料を、該加圧チューブがキャビティの長手方向に沿うように、前記金型のキャビティ内に配置して該金型を閉じる配置工程と、
前記誘導加熱コイルに電流を通じて加熱板を高周波誘導加熱し、熱伝導によりキャビティ型を熱可塑性樹脂系繊維強化複合材料の成形温度に調節した後、前記加圧チューブを加圧して膨張させ、熱可塑性樹脂系繊維強化複合材料をキャビティ面に内側から密着させ、熱可塑性樹脂系繊維強化複合材料に内部から圧力をかけて内圧成形する成形工程と、
前記成形工程の後に、前記高周波誘導加熱を停止し、前記冷却回路に冷媒を流通させてキャビティ面を冷却し、前記熱可塑性樹脂系繊維強化複合材料を固化する冷却工程と、
前記冷却工程の後に、金型から熱可塑性樹脂系繊維強化複合材料成形品を取り出す取り出し工程と、
を有する熱可塑性樹脂系繊維強化複合材料成形品の製造方法。
〔６〕前記〔１〕又は、〔２〕又は、〔３〕又は、〔４〕に記載の金型を用いた熱可塑性樹脂系繊維強化複合材料成形品の製造方法であって、
前記金型のキャビティ内に熱可塑性樹脂系繊維強化複合材料を配置する配置工程と、
前記誘導加熱コイルに電流を通じて加熱板を高周波誘導加熱し、熱伝導によりキャビティ型を熱可塑性樹脂系繊維強化複合材料の成形温度に調節した後、金型で熱可塑性樹脂系繊維強化複合材料を圧縮成形する成形工程と、
前記成形工程の後に、前記高周波誘導加熱を停止し、前記冷却回路に冷媒を流通させてキャビティ面を冷却し、前記熱可塑性樹脂系繊維強化複合材料を固化する冷却工程と、
前記冷却工程の後に、金型から熱可塑性樹脂系繊維強化複合材料成形品を取り出す取り出し工程と、
を有する熱可塑性樹脂系繊維強化複合材料成形品の製造方法。
The present invention employs the following configuration in order to solve the above problems.
[1] A pair of cavity molds having a cavity surface formed of a nonmagnetic metal material having a thermal conductivity at 20 ° C. of 100 to 450 W / m / K is provided, and a refrigerant is provided in each of the pair of molds. And a cooling circuit penetrating through the mold for cooling the cavity mold, and the specific resistance value at 20 ° C. is 4.0 to 100 μΩ · cm on the outer surfaces of the pair of cavity molds, respectively. A mold in which a magnetic material that generates heat by high frequency induction is in close contact, and an induction heating coil is provided on the outer surface of the magnetic material.
[2] The mold according to [1], wherein the cavity mold is formed of aluminum or an aluminum-based alloy.
[3] The mold according to [1], wherein the cavity mold surface is formed of aluminum or an aluminum-based alloy treated by any one of a metal nitride coat, a metal carbide coat, and metal plating.
[4] The mold according to [1], [2], or [3], wherein each of the pair of cavity molds has a thickness of 5 to 150 mm.
[5] A method for producing a thermoplastic resin-based fiber reinforced composite material molded article using the mold according to [1], [2], [3], or [4],
A disposing step of disposing the thermoplastic resin fiber-reinforced composite material wound around the pressurizing tube in the cavity of the mold so that the pressurizing tube is along the longitudinal direction of the cavity and closing the mold; ,
High-frequency induction heating is performed on the heating plate through a current through the induction heating coil, and the cavity mold is adjusted to the molding temperature of the thermoplastic resin fiber reinforced composite material by heat conduction. A molding process in which a resin-based fiber reinforced composite material is closely adhered to the cavity surface from the inside, and an internal pressure molding is performed by applying pressure from the inside to the thermoplastic resin-based fiber reinforced composite material;
After the molding step, the high-frequency induction heating is stopped, the coolant is circulated through the cooling circuit to cool the cavity surface, and the thermoplastic resin-based fiber reinforced composite material is solidified;
After the cooling step, taking out the thermoplastic resin fiber reinforced composite material molded product from the mold,
A method for producing a thermoplastic resin-based fiber reinforced composite material molded article having
[6] A method for producing a thermoplastic resin-based fiber-reinforced composite material molded article using the mold according to [1], [2], [3], or [4],
An arranging step of arranging a thermoplastic resin-based fiber reinforced composite material in the cavity of the mold;
High-frequency induction heating is applied to the heating plate through a current through the induction heating coil, the cavity mold is adjusted to the molding temperature of the thermoplastic resin-based fiber reinforced composite material by heat conduction, and then the thermoplastic resin-based fiber reinforced composite material is compressed by the mold Molding process to mold;
After the molding step, the high-frequency induction heating is stopped, the coolant is circulated through the cooling circuit to cool the cavity surface, and the thermoplastic resin-based fiber reinforced composite material is solidified;
After the cooling step, taking out the thermoplastic resin fiber reinforced composite material molded product from the mold,
A method for producing a thermoplastic resin-based fiber reinforced composite material molded article having
本発明の金型は、キャビティ面の加熱及び冷却を急速に行うことができ、かつ温度分布が均一であり、これを用いると広い成形条件幅で成形品を製造できる。
また、本発明の製造方法によれば、ムラがなく高品質な熱可塑性樹脂系複合材料成形品をハイサイクルに製造できる。
The mold of the present invention can rapidly heat and cool the cavity surface, and has a uniform temperature distribution. By using this, a molded product can be produced with a wide range of molding conditions.
Moreover, according to the manufacturing method of the present invention, a high-quality thermoplastic resin composite material molded product without unevenness can be manufactured in a high cycle.
＜金型＞
本発明の金型は、２０℃における熱伝導率が１００〜４５０Ｗ／ｍ／Ｋである非磁性金属材料により形成されたキャビティ面を有する一対の型を具備し、前記一対の型のそれぞれに、内部に冷媒を流通して前記キャビティ型を冷却するために、該型内を貫通する冷却回路を有し、かつ前記一対のキャビティ型の外面にそれぞれ２０℃における固有抵抗値が４．０〜１００μΩ・ｃｍである高周波誘導により発熱する磁性体を密接し、かつ該磁性体の外面に誘導加熱コイルが設けられている金型である。
以下、本発明の金型の実施形態の一例を示して詳細に説明する。
<Mold>
The mold of the present invention includes a pair of molds having a cavity surface formed of a nonmagnetic metal material having a thermal conductivity of 100 to 450 W / m / K at 20 ° C., and each of the pair of molds includes: In order to cool the cavity mold by circulating a refrigerant inside, a cooling circuit penetrating through the mold is provided, and a specific resistance value at 20 ° C. is 4.0 to 100 μΩ on the outer surface of the pair of cavity molds, respectively. A mold in which a magnetic body that generates heat by high-frequency induction of cm is in close contact, and an induction heating coil is provided on the outer surface of the magnetic body.
Hereinafter, an example of an embodiment of a mold of the present invention will be shown and described in detail.
［第１実施形態］
本実施形態の金型１は、図１及び図２に示すように、相対移動可能な、直方体形状の一対の上型１０と下型２０を具備している。
上型１０は、キャビティ型１１の短手方向の中央に、キャビティ型１１の長手方向に沿ってキャビティ２６が形成されている。上型のキャビティ型１１と下型のキャビティ型２１が型締めで接触する。また、上型１０は、上型１０の長手方向に沿ってキャビティ型１１を貫通する複数本の冷却回路１４が並べて設けられている。また、上型１０の内部の冷却回路１４より更に外側（キャビティ型１１の反対側）には、磁性体（加熱板）１２を高周波誘導加熱する誘導加熱コイル１５が設けられている。
下型２０は、上型１０と同様に、キャビティ型２１の短手方向の中央に、キャビティ型２１の長手方向に沿ってキャビティ２６が形成されている。また、下型２０は、下型２０の長手方向に沿ってキャビティ型２１を貫通する複数本の冷却回路２４が並べて設けられており、下型２０の外側（キャビティ型２１の反対側）に、磁性体２２を高周波誘導加熱する誘導加熱コイル２５が設けられている。
上型誘導加熱コイルケース１３と下型誘導加熱コイルケース２３は、電気的に完全に絶縁されている本実施形態では、キャビティ型２１と１１が絶縁層となっている。
金型１は、図１（Ｂ）及び図２（Ｂ）に示すように、上型１０と下型２０を閉じることで、両端が開放された円柱状のキャビティ２６が形成される。
[First Embodiment]
As shown in FIGS. 1 and 2, the mold 1 of the present embodiment includes a pair of an upper mold 10 and a lower mold 20 that are relatively movable and have a rectangular parallelepiped shape.
In the upper mold 10, a cavity 26 is formed in the center of the cavity mold 11 in the short direction along the longitudinal direction of the cavity mold 11. The upper cavity die 11 and the lower cavity die 21 come into contact with each other by clamping. In addition, the upper mold 10 is provided with a plurality of cooling circuits 14 arranged side by side through the cavity mold 11 along the longitudinal direction of the upper mold 10. In addition, an induction heating coil 15 that performs high-frequency induction heating of the magnetic body (heating plate) 12 is provided on the outer side (the opposite side of the cavity mold 11) from the cooling circuit 14 inside the upper mold 10.
Similar to the upper mold 10, the lower mold 20 has a cavity 26 formed at the center in the short direction of the cavity mold 21 along the longitudinal direction of the cavity mold 21. In addition, the lower mold 20 is provided with a plurality of cooling circuits 24 that pass through the cavity mold 21 along the longitudinal direction of the lower mold 20, and is arranged outside the lower mold 20 (on the opposite side of the cavity mold 21). An induction heating coil 25 is provided for high-frequency induction heating of the magnetic body 22.
In this embodiment in which the upper induction heating coil case 13 and the lower induction heating coil case 23 are electrically completely insulated, the cavity molds 21 and 11 are insulating layers.
As shown in FIGS. 1 (B) and 2 (B), the mold 1 closes the upper mold 10 and the lower mold 20 to form a cylindrical cavity 26 having both ends opened.
型の取り付け板や側板を形成する材料としては、高周波誘導により加熱されない絶縁物を用いる。また熱伝導度も低い無機物が特に好ましい。
取り付け板や側板を形成する材料の具体例としては、例えば、セラミック、耐熱強化プラスチック、無機断熱材、コンクリートが挙げられる。
As a material for forming the mold mounting plate and side plate, an insulator that is not heated by high frequency induction is used. An inorganic substance having a low thermal conductivity is particularly preferable.
Specific examples of the material for forming the mounting plate and the side plate include ceramic, heat-resistant reinforced plastic, inorganic heat insulating material, and concrete.
キャビティ２６の形状は、目的の成形品の形状に応じて決定すればよく、本実施形態では、短手方向に沿った断面形状が半円形状である。 The shape of the cavity 26 may be determined according to the shape of the target molded product, and in the present embodiment, the cross-sectional shape along the short direction is a semicircular shape.
成形工程において、成形性がよく、かつ良好な成形品を得るには、キャビティ型のキャビティ面の温度分布はできるだけ均一であることが重要である。特に、急速加熱、急速冷却を意図した本発明に使用される金型においては、均一な温度分布は必須の要求項目である。 In the molding process, it is important that the temperature distribution on the cavity surface of the cavity mold is as uniform as possible in order to obtain a molded product with good moldability and good quality. In particular, in a mold used in the present invention intended for rapid heating and rapid cooling, a uniform temperature distribution is an essential requirement.
本発明者等が鋭意検討した結果、加熱源である加熱板をキャビティ面から離して配置し、２０℃における熱伝導率が１００〜４５０Ｗ／ｍ／Ｋ、好ましくは１５０〜４００Ｗ／ｍ／Ｋである材料がキャビティの材質として好ましいことが分かった。熱伝導率が１００Ｗ／ｍ／Ｋ未満では、伝熱に時間がかかり、急速加熱や急速冷却が達成されなく、また４５０Ｗ／ｍ／Ｋを超えると、加熱板からの温度分布が解消できず、キャビティ面での温度分布が広くなり好ましくない。また本発明では、加熱源として、誘導加熱コイルによる誘導加熱を使用することから、温度制御の面から、キャビティの材質は、誘導加熱しにくいことが必要であり、非磁性金属材料が好ましい。２０℃における熱伝導率が１５０〜４５０Ｗ／ｍ／Ｋの材料としては、アルミニウム、アルミニウム合金、銅、銅合金が挙げられる。特にアルミニウムやアルミニウム合金は熱伝導率が高く、キャビティの加工性がよく好ましい。アルミニウム合金としては、アルミニウムと亜鉛、銅、マグネシウム、ケイ素、マンガンなどからなる合金が挙げられる。キャビティの耐磨耗性の面から表面硬度が高い方が、型として耐用年数が長くなり好ましい。このため本発明には、アルミニウム単体より、銅とマグネシウムや、亜鉛とマグネシウムとなどとの合金が特に好ましい。 As a result of intensive studies by the present inventors, a heating plate as a heating source is arranged away from the cavity surface, and the thermal conductivity at 20 ° C. is 100 to 450 W / m / K, preferably 150 to 400 W / m / K. A material has been found to be preferred as the cavity material. If the thermal conductivity is less than 100 W / m / K, it takes time for heat transfer, rapid heating and rapid cooling cannot be achieved, and if it exceeds 450 W / m / K, the temperature distribution from the heating plate cannot be eliminated, The temperature distribution on the cavity surface becomes wide, which is not preferable. In the present invention, induction heating using an induction heating coil is used as a heating source, and therefore, from the viewpoint of temperature control, the material of the cavity needs to be difficult to be induction heated, and a nonmagnetic metal material is preferable. Examples of the material having a thermal conductivity of 150 to 450 W / m / K at 20 ° C. include aluminum, an aluminum alloy, copper, and a copper alloy. In particular, aluminum and aluminum alloys are preferable because of high thermal conductivity and good cavity workability. Examples of the aluminum alloy include alloys made of aluminum and zinc, copper, magnesium, silicon, manganese and the like. A higher surface hardness is preferable in terms of wear resistance of the cavity because the service life of the mold becomes longer. Therefore, in the present invention, an alloy of copper and magnesium, zinc and magnesium, or the like is more preferable than aluminum alone.
また、キャビティ面は、成形する材料により磨耗や腐蝕や離型性の面から硬度や耐食性が要求される。本発明において、キャビティ型で温度分布が均一化するから、キャビティ型をメッキやコーティングすることが出来る。メッキとしては、クロムメッキや無電解ニッケルメッキなどが例示される。またコーティングとしては、ＴｉＮ，ＴｉＣＮ，ＴｉＡｌＮ，ＣｒＮ，ＡｌＣｒＮなどの窒化金属コートや炭化金属コートが例示される。 In addition, the cavity surface is required to have hardness and corrosion resistance in terms of wear, corrosion, and releasability depending on the material to be molded. In the present invention, since the temperature distribution is uniform in the cavity mold, the cavity mold can be plated or coated. Examples of plating include chrome plating and electroless nickel plating. Examples of the coating include a metal nitride coating and a metal carbide coating such as TiN, TiCN, TiAlN, CrN, and AlCrN.
加熱源となる磁性体１２と２２は、それぞれキャビティ型１１と誘導加熱コイルのケース１３、キャビティ型２１と誘導加熱コイルのケース２３の間に配置される。磁性体１２と２２は、２０℃における固有抵抗値（以下、単に「ρ」という。）が４．０〜１００μΩ・ｃｍの磁性金属材料からなる。すなわち、上型の磁性体１２と下型の磁性体２２は、ρが４．０〜１００μΩ・ｃｍの磁性金属材料により形成されている。前記磁性金属材料のρが４．０μΩ・ｃｍ以上であれば、高周波誘導により加熱され、密着したキャビティ型に急速に伝熱される。また、前記磁性金属材料のρが１００μΩ・ｃｍ以下であれば、充分な電流が流れるため、急速に加熱できる。磁性体（加熱板）１２と２２を形成する磁性金属材料のρは、５．０〜９０μΩ・ｃｍが好ましく、６．０〜８０μΩ・ｃｍがより好ましい。 The magnetic bodies 12 and 22 serving as heating sources are disposed between the cavity mold 11 and the induction heating coil case 13 and between the cavity mold 21 and the induction heating coil case 23, respectively. The magnetic bodies 12 and 22 are made of a magnetic metal material having a specific resistance value (hereinafter, simply referred to as “ρ”) at 20 ° C. of 4.0 to 100 μΩ · cm. That is, the upper magnetic body 12 and the lower magnetic body 22 are made of a magnetic metal material having a ρ of 4.0 to 100 μΩ · cm. If ρ of the magnetic metal material is 4.0 μΩ · cm or more, the magnetic metal material is heated by high-frequency induction, and is rapidly transferred to the closely attached cavity mold. In addition, if ρ of the magnetic metal material is 100 μΩ · cm or less, a sufficient current flows, so that heating can be performed rapidly. The ρ of the magnetic metal material forming the magnetic bodies (heating plates) 12 and 22 is preferably 5.0 to 90 μΩ · cm, and more preferably 6.0 to 80 μΩ · cm.
本発明でいう磁性体とは、磁石に吸い付くような強い磁性を示す強磁性体をさし、磁界Ｈと磁化の強さＩとの関係を示す磁化曲線は、直線的ではなく、強いＨでＩは一定の値Ｉｓに飽和し、この飽和磁界強さが、０．１（Ｗｂ／ｍ2）以上、特に０．５（Ｗｂ／ｍ2）以上の強磁性材料が好ましい。例えば、鉄、ニッケル、コバルトなどから選ばれた1種以上の原子を質量にして５０％以上を含む金属や合金が上げられる。加熱板１２と２２を形成する磁性金属材料は、具体的には鋼鉄、炭素鋼、軟鋼、珪素鋼、ＭＫ鋼、ステンレス鋼、ニッケル、四三酸化鉄などが上げられる。特に、強磁性体である鋼やニッケルが好ましい。 The magnetic material referred to in the present invention refers to a ferromagnetic material exhibiting strong magnetism that is attracted to a magnet, and the magnetization curve indicating the relationship between the magnetic field H and the magnetization intensity I is not linear but strong H. I is saturated to a constant value Is, and a ferromagnetic material having a saturation magnetic field strength of 0.1 (Wb / m 2 ) or more, particularly 0.5 (Wb / m 2 ) or more is preferable. For example, a metal or alloy containing 50% or more of one or more kinds of atoms selected from iron, nickel, cobalt and the like can be raised. Specific examples of the magnetic metal material forming the heating plates 12 and 22 include steel, carbon steel, mild steel, silicon steel, MK steel, stainless steel, nickel, and iron trioxide. In particular, steel and nickel which are ferromagnetic materials are preferable.
高周波誘導加熱された磁性金属材料から、２０℃における熱伝導率が１００〜４５０Ｗ／ｍ／Ｋ、好ましくは１５０〜４００Ｗ／ｍ／Ｋである非磁性金属材料により形成されたキャビティ型１１と２１に伝熱される。磁性金属材料は、誘導加熱コイル１５と２５の配置による磁界の強弱により、発熱度合いが異なり、位置に依存して大きな温度分布を有する。しかし、上型と下型のキャビティ型を通して伝熱されたキャビティ面における温度分布は大変小さくなる。熱伝導率が１００Ｗ／ｍ／Ｋ未満では、磁性金属材料をより高温にする必要があり、省エネルギーの面から好ましくない。また４５０Ｗ／ｍ／Ｋを超えると熱効率はよくなるが、本発明ではキャビティ型と加熱板を密着させているので、キャビティ型の熱伝導率が極端に高いと、キャビティ型の表面温度は、加熱板の温度分布をそのまま拾って、キャビティ面での温度分布の均一化が不十分となり好ましくない。 Cavity molds 11 and 21 formed of a nonmagnetic metal material having a thermal conductivity at 20 ° C. of 100 to 450 W / m / K, preferably 150 to 400 W / m / K, from a magnetic metal material heated at high frequency induction. Heat is transferred. The magnetic metal material has different degrees of heat generation due to the strength of the magnetic field due to the arrangement of the induction heating coils 15 and 25, and has a large temperature distribution depending on the position. However, the temperature distribution on the cavity surface transferred through the upper and lower cavity cavities becomes very small. When the thermal conductivity is less than 100 W / m / K, the magnetic metal material needs to be heated to a higher temperature, which is not preferable from the viewpoint of energy saving. In addition, the thermal efficiency is improved when it exceeds 450 W / m / K. However, since the cavity mold and the heating plate are in close contact with each other in the present invention, if the thermal conductivity of the cavity mold is extremely high, the surface temperature of the cavity mold This is not preferable because the temperature distribution on the cavity surface is not sufficiently uniformized.
本発明に使用されるキャビティ面への伝熱距離となるキャビティ型の厚さは、特に限定されないが、５〜１５０ｍｍ、好ましくは、１０〜１２０ｍｍである。５ｍｍ未満では、キャビティ面の温度分布の均一化が不十分で好ましくなく、また１５０ｍｍを超えると、キャビティ面の加熱に時間がかかり好ましくない。キャビティ型の厚さは、成形する際の温度分布と加熱速度の要求度により選択される。なお、本発明における熱伝導率は、ＪＩＳ Ａ１４１２−２付属書Ａの平板比較法に準拠して測定される。 The thickness of the cavity mold that becomes the heat transfer distance to the cavity surface used in the present invention is not particularly limited, but is 5 to 150 mm, preferably 10 to 120 mm. If it is less than 5 mm, the temperature distribution on the cavity surface is not sufficiently uniform, and if it exceeds 150 mm, it takes time to heat the cavity surface. The thickness of the cavity mold is selected depending on the temperature distribution and the required heating rate during molding. In addition, the thermal conductivity in this invention is measured based on the flat plate comparison method of JIS A1412-2 appendix A.
キャビティ型１１と２１に配置された冷却回路１４と２４は、その内部に冷媒を流通させ、熱伝導によりキャビティ面を冷却するものであり、キャビティ型を長手方向に貫通するように配管されている。また、冷却回路１４と２４は、それぞれがキャビティ型に貫通するように穴加工され、型の外表面で連結されている。冷媒が熱伝導率の高いキャビティ型内を直接流れるから、急速に冷却される。 The cooling circuits 14 and 24 arranged in the cavity molds 11 and 21 circulate the refrigerant therein and cool the cavity surface by heat conduction, and are piped so as to penetrate the cavity mold in the longitudinal direction. . In addition, the cooling circuits 14 and 24 are drilled so as to penetrate through the cavity mold and are connected to each other on the outer surface of the mold. Since the refrigerant flows directly in the cavity mold having a high thermal conductivity, the refrigerant is rapidly cooled.
本実施形態の冷却回路１４と２４は、キャビティ型に貫通孔を開け、図１０に示したように金型表面で隣接する貫通孔を配管でつなぐことで敷設される。キャビティ内は、貫通孔とすることが冷却時の熱交換性から好ましいが、この貫通孔中にも配管することができる。この配管は、ρが５．０μΩ・ｃｍ以下の非磁性金属材料により形成されることが好ましい。前記ρが５．０μΩ・ｃｍ以下の非磁性金属材料により冷却回路１４と２４が形成されていることにより、冷却回路１４と２４は、加熱板１２と２２より誘導加熱コイルからの遠距離であることと合わせて、材質的にも加熱板１２と２２に比べて高周波誘導による加熱効率が著しく低くなる。そのため、高周波誘導により、加熱板１２と２２を加熱し、それからの伝熱で加熱されるキャビティ型１１と２１の加熱時に、その高周波誘導により冷却回路１４と２４が同時に加熱されることを防止することができ、冷却回路１４と２４の温度が低いまま保たれるので、その後のキャビティ型１１と２１の冷却を速やかに高効率で行える。 The cooling circuits 14 and 24 of this embodiment are laid by making a through hole in a cavity mold and connecting adjacent through holes on the mold surface with piping as shown in FIG. The inside of the cavity is preferably a through hole from the viewpoint of heat exchange at the time of cooling, but piping can also be provided in this through hole. This pipe is preferably formed of a nonmagnetic metal material having a ρ of 5.0 μΩ · cm or less. Since the cooling circuits 14 and 24 are formed of a nonmagnetic metal material having ρ of 5.0 μΩ · cm or less, the cooling circuits 14 and 24 are far from the induction heating coil than the heating plates 12 and 22. At the same time, the heating efficiency by high frequency induction is remarkably lower than the heating plates 12 and 22 in terms of material. Therefore, the heating plates 12 and 22 are heated by high-frequency induction, and the cooling circuits 14 and 24 are prevented from being simultaneously heated by the high-frequency induction when the cavity molds 11 and 21 heated by heat transfer from the heating plates 12 and 22 are heated. Since the temperature of the cooling circuits 14 and 24 is kept low, the subsequent cooling of the cavity molds 11 and 21 can be performed quickly and with high efficiency.
冷却回路１４と２４を形成する非磁性金属材料のρは、４．０μΩ・ｃｍ以下がより好ましい。 The ρ of the nonmagnetic metal material forming the cooling circuits 14 and 24 is more preferably 4.0 μΩ · cm or less.
また、冷却回路１４と２４は、キャビティ型１１と２１の冷却効率の点から、熱伝導度の高い非磁性金属材料から形成されていることが好ましい。 The cooling circuits 14 and 24 are preferably formed from a nonmagnetic metal material having high thermal conductivity from the viewpoint of cooling efficiency of the cavity molds 11 and 21.
冷却回路１４と２４を形成する非磁性金属材料としては、特に制限はないが、例えば、銅、アルミニウム等が挙げられる。なかでも、銅が好ましい。 The nonmagnetic metal material forming the cooling circuits 14 and 24 is not particularly limited, and examples thereof include copper and aluminum. Of these, copper is preferable.
冷却回路１４と２４の断面形状及び断面積は、適宜設定できる。
冷却回路１４と２４の本数は、キャビティ型１１と２１を急速に冷却するのに充分な本数であればよく、上型１０の強度を考慮しつつ適宜設定できる。冷却回路１４と２４は、キャビティ型１１と２１全体を均一に冷却できるように、複数本を平行にかつ等間隔に設けることが好ましい。
The cross-sectional shape and cross-sectional area of the cooling circuits 14 and 24 can be set as appropriate.
The number of the cooling circuits 14 and 24 is sufficient if it is sufficient to rapidly cool the cavity molds 11 and 21, and can be appropriately set in consideration of the strength of the upper mold 10. A plurality of cooling circuits 14 and 24 are preferably provided in parallel and at equal intervals so that the entire cavity molds 11 and 21 can be uniformly cooled.
コイルケース１３と２３中に敷設された誘導加熱コイル１５と２５は、電流を通じることで発生する磁界により、加熱板１２と２２を高周波誘導加熱するものである。
誘導加熱コイル１５と２５は、加熱板１２と２２を高周波誘導加熱して伝熱によりキャビティ型１１と２１を加熱できるものであればよく、一般には外側が絶縁された集束された銅線が用いられる。
The induction heating coils 15 and 25 laid in the coil cases 13 and 23 are for induction heating of the heating plates 12 and 22 by a magnetic field generated by passing a current.
The induction heating coils 15 and 25 only need to be capable of heating the cavity molds 11 and 21 by high-frequency induction heating of the heating plates 12 and 22 and heat transfer, and generally used are concentrated copper wires whose outer sides are insulated. It is done.
誘導加熱コイル１５と２５の形状、大きさ、位置及び数は、加熱板１２と２２を高周波誘導加熱して伝熱によりキャビティ型１１と２１を急速に加熱できる範囲であれば特に限定されない。
誘導加熱コイル１５と２５は、本実施形態では、型本体の内部で加熱板１２と２２の外側（キャビティ型１１と２１の反対側のコイルケース１３と２３内）に設けられている。誘導加熱コイル１５と２５を敷設するコイルケースは、誘導加熱しくい材質であることが好ましく、樹脂製、セラミック製、石綿製、木網セメント板製、非磁性金属製などが挙げられる。これらの中では、断熱性が高い樹脂製や石綿製、木網セメント板が好ましい。
The shape, size, position, and number of the induction heating coils 15 and 25 are not particularly limited as long as the heating molds 12 and 22 can be heated by high-frequency induction heating and the cavity molds 11 and 21 can be rapidly heated by heat transfer.
In the present embodiment, the induction heating coils 15 and 25 are provided outside the heating plates 12 and 22 inside the mold body (inside the coil cases 13 and 23 opposite to the cavity molds 11 and 21). The coil case in which the induction heating coils 15 and 25 are laid is preferably made of an induction heating material, and examples thereof include resin, ceramic, asbestos, wood cement board, and nonmagnetic metal. In these, the product made from resin with high heat insulation, asbestos, and a wood-mesh cement board is preferable.
下型２０は、上型１０と基本的に同じ仕様の型や材質が使用できる。成形する製品により、上型のキャビティ１１と下型のキャビティ２１の厚さは異なることもある。その熱容量バランスを考慮して、キャビティ１１と２１の温度が等しく昇温するように加熱板１２と２２や加熱コイル１５と２５の容量が選択されることが好ましい。また冷却工程でキャビティ１１とキャビティ２１の温度が等しくなるように、冷却管（冷却孔）１４と２４を敷設することが好ましい。 The lower mold 20 can use a mold or material having basically the same specifications as the upper mold 10. Depending on the product to be molded, the thickness of the upper mold cavity 11 and the lower mold cavity 21 may be different. In consideration of the heat capacity balance, it is preferable to select the capacities of the heating plates 12 and 22 and the heating coils 15 and 25 so that the temperatures of the cavities 11 and 21 are equally increased. Further, it is preferable to lay cooling pipes (cooling holes) 14 and 24 so that the temperatures of the cavity 11 and the cavity 21 become equal in the cooling step.
本発明の成形用型では、積層型の層間に絶縁層は特に必要がない。ただ加熱コイル１５と２５のそれぞれのコイル間の絶縁性は保たれなければならない。またコイルケース１３と２３は、熱的のみならず電気的にも絶縁性を有する材質が好ましい。材質としては、樹脂製、セラミック製、石綿製、木網セメント板などが挙げられる。 In the molding die of the present invention, an insulating layer is not particularly required between the layers of the laminated mold. However, the insulation between each of the heating coils 15 and 25 must be maintained. The coil cases 13 and 23 are preferably made of a material that is electrically insulating as well as thermally. Examples of the material include resin, ceramic, asbestos, and wood cement board.
金型１は、誘導加熱コイル１５，２５に電流を通じることにより、高周波誘導により加熱板１２，２２を加熱して、伝熱によりキャビティ型１１，２１を急速に加熱できる。また、誘導加熱コイル１５，２５の電流を停止して加熱板１２，２２の高周波誘導加熱を停止した後、冷却回路１４，２４に冷媒を流通させることで、キャビティ型１１，２１を急速に冷却できる。そのため、キャビティ型１１，２１の急速な加熱と冷却を繰り返しながら成形材料を成形することで、ハイサイクルに成形品を製造できる。 The metal mold 1 can rapidly heat the cavity molds 11 and 21 by heat transfer by passing current through the induction heating coils 15 and 25 to heat the heating plates 12 and 22 by high-frequency induction. Also, after the current of the induction heating coils 15 and 25 is stopped and the high frequency induction heating of the heating plates 12 and 22 is stopped, the coolant is circulated through the cooling circuits 14 and 24, thereby rapidly cooling the cavity molds 11 and 21. it can. Therefore, a molded product can be manufactured in a high cycle by molding the molding material while repeating rapid heating and cooling of the cavity molds 11 and 21.
なお、本実施形態の金型１における誘導加熱コイル１５，２５を設ける位置は、加熱板１２，２２を高周波誘導加熱できる位置であればよく、型本体１０，２０の内部に設ける積層位置の態様には限定されない。例えば、加熱板１２，２２とコイルケース１３，２３の間に断熱板や空間を設けることができる。この場合においても、キャビティ型の加熱速度を向上させるために、加熱板１２，２２をキャビティ型１１，２１に密着するように設置する。 In addition, the position where the induction heating coils 15 and 25 are provided in the mold 1 of the present embodiment may be a position where the heating plates 12 and 22 can be induction-heated by high frequency. It is not limited to. For example, a heat insulating plate or a space can be provided between the heating plates 12 and 22 and the coil cases 13 and 23. Even in this case, in order to improve the heating speed of the cavity mold, the heating plates 12 and 22 are installed in close contact with the cavity molds 11 and 21.
キャビティ型１１，２１の冷却速度を向上させるために、冷却回路１４，２４は、キャビティ型１１，２１内のキャビティ面近傍に設置することが好ましい。
また、冷却回路は、金型本体の長手方向に沿って設ける態様には限定されず、金型の短手方向に沿って設けてもよい。ただし、冷却回路は、キャビティ面の冷却効率の点から、キャビティが形成されている向きに沿って設けることが好ましい。
In order to improve the cooling rate of the cavity molds 11 and 21, the cooling circuits 14 and 24 are preferably installed in the vicinity of the cavity surface in the cavity molds 11 and 21.
Further, the cooling circuit is not limited to the aspect provided along the longitudinal direction of the mold body, and may be provided along the short direction of the mold. However, the cooling circuit is preferably provided along the direction in which the cavity is formed from the viewpoint of cooling efficiency of the cavity surface.
［第２実施形態］
次に、本発明の金型の他の実施形態例を示して詳細に説明する。
本実施形態の金型２は、図３（Ａ）に示すように、相対移動可能な一対の上型と下型を具備する。金型２は、上型と下型がそれぞれ直方体形状であり、図３（Ｂ）に示すように、上型と下型を閉じることで、キャビティ型３１，４１に発現する密閉空間として３６，４６が形成される。すなわち、金型２により、立体状の成形品を製造できる。
[Second Embodiment]
Next, another embodiment of the mold of the present invention will be shown and described in detail.
As shown in FIG. 3A, the mold 2 of this embodiment includes a pair of an upper mold and a lower mold that are relatively movable. In the mold 2, each of the upper mold and the lower mold has a rectangular parallelepiped shape. As shown in FIG. 3B, the upper mold and the lower mold are closed to form 36, 36, 46 is formed. That is, a three-dimensional molded product can be manufactured by the mold 2.
キャビティ型３１，４１の長手方向に沿ってキャビティ型３１，４１を貫通する複数本の冷却回路３７，４７が、キャビティ面３６，４６に密着するように並べて設けられている。また、キャビティ型３１，４１の外側（金型表面側）には、加熱板３２，４２を高周波誘導加熱して、熱伝導によりキャビティ型３１，４１を加熱する誘導加熱コイル３８，４８が、コイルケース３３，４３中に設けられている。更に成形機への取り付け板３４，４４と側板３５，４５が取り付けられている。誘導加熱コイル３８，４８や、加熱板３２，４２は、電気的に完全に絶縁されている必要があり、コイルケース３３，４３に電気絶縁が施されている。 A plurality of cooling circuits 37 and 47 penetrating the cavity molds 31 and 41 along the longitudinal direction of the cavity molds 31 and 41 are provided side by side so as to be in close contact with the cavity surfaces 36 and 46. In addition, induction heating coils 38 and 48 for heating the cavity molds 31 and 41 by high-frequency induction heating and heating the cavity molds 31 and 41 are provided outside the cavity molds 31 and 41 (on the mold surface side). It is provided in the cases 33 and 43. Further, attachment plates 34 and 44 and side plates 35 and 45 to the molding machine are attached. The induction heating coils 38 and 48 and the heating plates 32 and 42 need to be electrically completely insulated, and the coil cases 33 and 43 are electrically insulated.
キャビティ型３１と４１により形成されるキャビティ３６，４６の形状は、目的の成形品の形状に応じて決定すればよく、本実施形態ではその断面形状は矩形である。
キャビティ型３１，４１の材質としては、第１実施形態のキャビティ型１１で挙げた材質と同じ材質が挙げられ、好ましい態様も同じである。
加熱板３２，４２は、ρが４．０〜１００μΩ・ｃｍの磁性金属材料からなり、第１実施形態の加熱板１２，２２と同じものが挙げられ、好ましい態様も同じである。
The shape of the cavities 36 and 46 formed by the cavity molds 31 and 41 may be determined according to the shape of the target molded product, and in the present embodiment, the cross-sectional shape is rectangular.
Examples of the material of the cavity molds 31 and 41 include the same materials as those described for the cavity mold 11 of the first embodiment, and the preferred aspects are also the same.
The heating plates 32 and 42 are made of a magnetic metal material having ρ of 4.0 to 100 μΩ · cm, and the same ones as the heating plates 12 and 22 of the first embodiment can be mentioned, and the preferred modes are also the same.
冷却回路３７，４７は、その内部に冷媒を流通させ、熱伝導によりキャビティ型３１，４１を冷却してキャビティ面３６，４６を冷却するものであり、第１実施形態の冷却回路１４，２４と同じものが挙げられ、好ましい態様も同じである。 The cooling circuits 37 and 47 circulate the refrigerant therein, cool the cavity molds 31 and 41 by heat conduction, and cool the cavity surfaces 36 and 46, and the cooling circuits 14 and 24 of the first embodiment. The same thing is mentioned, A preferable aspect is also the same.
誘導加熱コイル３８，４８は、電流を通じることで加熱板３２，４２を高周波誘導加熱して、伝熱により密着したキャビティ型３１，４１を成形温度まで急速に加熱するものであり、第１実施形態の誘導加熱コイル１５，２５と同じものが挙げられ、好ましい態様も同じである。 The induction heating coils 38 and 48 heat the heating plates 32 and 42 by high-frequency induction heating by passing an electric current, and rapidly heat the cavity molds 31 and 41 adhered by heat transfer to the molding temperature. The same thing as the induction heating coils 15 and 25 of a form is mentioned, A preferable aspect is also the same.
取り付け板３４，４４や側板３５，４５に用いることができる材料としては、無機物等の絶縁物、２０℃における固有抵抗値が５．０μΩ・ｃｍ以下の非磁性体である誘導加熱されにくい金属材料等が挙げられる。 Examples of materials that can be used for the mounting plates 34 and 44 and the side plates 35 and 45 include insulators such as inorganic substances, and non-magnetic materials that are nonmagnetic materials having a specific resistance value at 20 ° C. of 5.0 μΩ · cm or less. Etc.
金型２は、誘導加熱コイル３８，４８に電流を通じることで、高周波誘導により加熱板３２，４２を加熱して、伝熱によりキャビティ型３１，４１を急速に加熱できる。また、誘導加熱コイル３８，４８の電流を停止して加熱板３２，４２の高周波誘導加熱を停止した後、冷却回路３７，４７内に冷媒を流通させることで、キャビティ型３１，４１を冷却してキャビティ面３６，４６を急速に冷却できる。そのため、キャビティ面３６，４６の急速な加熱と冷却を繰り返しながら成形材料を成形することで、ハイサイクルに成形品を製造できる。 The mold 2 can rapidly heat the cavity molds 31 and 41 by heat transfer by passing current through the induction heating coils 38 and 48 to heat the heating plates 32 and 42 by high-frequency induction. Further, after the current of the induction heating coils 38 and 48 is stopped to stop the high frequency induction heating of the heating plates 32 and 42, the coolant is circulated in the cooling circuits 37 and 47, thereby cooling the cavity molds 31 and 41. Thus, the cavity surfaces 36 and 46 can be rapidly cooled. Therefore, a molded product can be manufactured in a high cycle by molding the molding material while repeating rapid heating and cooling of the cavity surfaces 36 and 46.
なお、本実施形態の金型２においては、誘導加熱コイルを設ける位置は、加熱板３２，４２を高周波誘導加熱できる位置であればよく、型本体の内部に設ける積層位置の態様には限定されない。例えば、加熱板３２，４２とコイルケース３３，４３の間に断熱板や空間を設けることができる。この場合においても、キャビティ型の加熱速度を向上させるために、加熱板３２，４２をキャビティ型３１，４１に密着するように設置する。コイルケース３３，４３は、加熱板３２，４２や取り付け板３４，４４と電気絶縁性を有することが必要であり、樹脂製やセラミック製が好ましい。 In the mold 2 of this embodiment, the position where the induction heating coil is provided may be a position where the heating plates 32 and 42 can be induction-heated by high frequency, and is not limited to the form of the stacking position provided inside the mold body. . For example, a heat insulating plate or a space can be provided between the heating plates 32 and 42 and the coil cases 33 and 43. Even in this case, the heating plates 32 and 42 are installed in close contact with the cavity molds 31 and 41 in order to improve the heating speed of the cavity molds. The coil cases 33 and 43 are required to have electrical insulation with the heating plates 32 and 42 and the mounting plates 34 and 44, and are preferably made of resin or ceramic.
＜熱可塑性樹脂系繊維強化複合材料成形品の製造方法［第１実施形態］＞
本発明の熱可塑性樹脂系繊維強化複合材料成形品の製造方法は、本発明の金型を用いた製造方法であって、下記工程を有する。
配置工程：金型のキャビティ内に熱可塑性樹脂系繊維強化複合材料を配置し、金型を閉じる。なお、予め、熱可塑性樹脂系繊維強化複合材料を溶融させておき、キャビティ内に配置してもよい。この態様は、後述する第２実施形態においても採用可能である。
成形工程：誘導加熱コイルに電流を通じて磁性体（加熱板）を高周波誘導加熱し、加熱板から伝熱でキャビティを均一に加熱する。熱可塑性樹脂系繊維強化複合材料を加熱し、必要に応じて溶融させ、更に内部から圧力をかけることによって内圧成形する。なお、「必要に応じて溶融させ」るのは、配置工程で、溶融していない熱可塑性樹脂系繊維強化複合材料を配置した場合のことである。この態様は、後述する第２実施形態においても同様である。
冷却工程：前記成形工程の後に、前記加熱板の高周波誘導加熱を停止し、キャビティ型内の冷却回路に冷媒を流通させてキャビティ面を冷却し、熱可塑性樹脂系繊維強化複合材料を固化する。
取り出し工程：前記冷却工程の後に、金型から熱可塑性樹脂系繊維強化複合材料成形品を取り出す。
<Method for Manufacturing Thermoplastic Resin Fiber Reinforced Composite Material Molded Product [First Embodiment]>
The manufacturing method of the thermoplastic resin fiber-reinforced composite material molded article of the present invention is a manufacturing method using the mold of the present invention, and includes the following steps.
Arranging step: A thermoplastic resin fiber reinforced composite material is disposed in the cavity of the mold, and the mold is closed. The thermoplastic resin fiber reinforced composite material may be melted in advance and placed in the cavity. This aspect can also be adopted in a second embodiment described later.
Molding process: A magnetic substance (heating plate) is induction-heated by high-frequency induction through an induction heating coil, and the cavity is uniformly heated by heat transfer from the heating plate. The thermoplastic resin fiber reinforced composite material is heated, melted as necessary, and further subjected to internal pressure molding by applying pressure from the inside. In addition, “melting as necessary” refers to a case where a thermoplastic resin-based fiber reinforced composite material that has not been melted is placed in the placement step. This aspect is the same in the second embodiment described later.
Cooling step: After the molding step, high-frequency induction heating of the heating plate is stopped, the coolant is circulated through the cooling circuit in the cavity mold to cool the cavity surface, and the thermoplastic resin fiber reinforced composite material is solidified.
Removal step: After the cooling step, the thermoplastic resin-based fiber reinforced composite material molded product is removed from the mold.
以下、本発明の熱可塑性樹脂系繊維強化複合材料成形品の製造方法の実施形態の一例として、前述の金型１を用いた製造方法について説明する。 Hereinafter, the manufacturing method using the above-mentioned metal mold | die 1 is demonstrated as an example of embodiment of the manufacturing method of the thermoplastic resin fiber reinforced composite material molded article of this invention.
配置工程では、図４および図６に示すように、加圧チューブ５１の周囲に巻き付けられた熱可塑性樹脂系繊維強化複合材料Ｘを、加圧チューブ５１がキャビティ１６，２６の長手方向に沿うように、キャビティ２６内に配置し、金型１を閉じる。
この状態でチューブ内にガスを送入して加圧チューブ５１を膨張させることで熱可塑性樹脂系繊維強化複合材料Ｘを内側からキャビティ面１６，２６に密着させて、さらに加圧することができるようになっている。
In the arranging step, as shown in FIGS. 4 and 6, the thermoplastic resin fiber reinforced composite material X wound around the pressurizing tube 51 is placed so that the pressurizing tube 51 extends along the longitudinal direction of the cavities 16 and 26. Then, it is placed in the cavity 26 and the mold 1 is closed.
In this state, gas is fed into the tube and the pressure tube 51 is expanded, so that the thermoplastic resin fiber reinforced composite material X can be brought into close contact with the cavity surfaces 16 and 26 from the inside and further pressurized. It has become.
熱可塑性樹脂系繊維強化複合材料Ｘは、マトリックス樹脂が強化繊維で強化された繊維強化複合材料からなる公知の熱可塑性樹脂系繊維強化複合材料を用いることができる。なお、熱可塑性樹脂系繊維強化複合材料を溶融させた状態でキャビティの上に載置しても構わない。 As the thermoplastic resin fiber reinforced composite material X, a known thermoplastic resin fiber reinforced composite material made of a fiber reinforced composite material in which a matrix resin is reinforced with reinforced fibers can be used. The thermoplastic resin fiber reinforced composite material may be placed on the cavity in a melted state.
強化繊維としては、炭素繊維、アラミド繊維、ナイロン繊維、高強度ポリエステル繊維、ガラス繊維、ボロン繊維、アルミナ繊維、窒化珪素繊維等の各種の無機繊維または有機繊維等が挙げられる。強化繊維の形態は特に限定されるものではなく、一方向に引き揃えた状態、織物、編み物、不織布、チョップされた短繊維形状等いずれの状態であっても使用できる。 Examples of the reinforcing fibers include carbon fibers, aramid fibers, nylon fibers, high-strength polyester fibers, glass fibers, boron fibers, alumina fibers, silicon nitride fibers, and various inorganic fibers or organic fibers. The form of the reinforcing fiber is not particularly limited, and the reinforcing fiber can be used in any state such as a state in which the reinforcing fibers are aligned in one direction, a woven fabric, a knitted fabric, a nonwoven fabric, or a chopped short fiber shape.
マトリックス樹脂としては、公知の熱可塑性樹脂（ポリアミド、アクリロニトリル・ブタジエン・スチレン共重合体（ＡＢＳ）、アクリロニトリル・エチレンプロピレンゴム・スチレン共重合体（ＡＥＳ）、アクリロニトリル・スチレン・アクリルゴム共重合体（ＡＳＡ）、ポリエチレンテレフタレート、ポリブチレンテレフタレート（ＰＢＴ）、ポリカーボネート、ポリメチルメタクリレート、ポリエーテルスルフォン、ポリフェニレンエーテル、ポリフェニレンスルフィド、ポリエーテルエーテルケトン、ポリエーテルケトンケトン、ポリイミド、ポリテトラフルオロエチレン、ポリエーテル、ポリオレフィン、液晶ポリマー、ポリアリレート、ポリスルフォン、ポリアクリロニトリルスチレン、ポリスチレン、ポリアクリロニトリル、ポリ塩化ビニル等）等が挙げられる。 Examples of matrix resins include known thermoplastic resins (polyamide, acrylonitrile / butadiene / styrene copolymer (ABS), acrylonitrile / ethylene propylene rubber / styrene copolymer (AES), acrylonitrile / styrene / acrylic rubber copolymer (ASA)). ), Polyethylene terephthalate, polybutylene terephthalate (PBT), polycarbonate, polymethyl methacrylate, polyether sulfone, polyphenylene ether, polyphenylene sulfide, polyether ether ketone, polyether ketone ketone, polyimide, polytetrafluoroethylene, polyether, polyolefin, Liquid crystal polymer, polyarylate, polysulfone, polyacrylonitrile styrene, polystyrene, polyacrylonitrile, Polyvinyl chloride) and the like.
成形工程では、誘導加熱コイル１５，２５に電流を通じて加熱板１２，２２を高周波誘導加熱し、伝熱することでキャビティ型１１，２１を加熱し、キャビティ面１６，２６を成形温度に調節し、図７に示すように、チューブ内にガスを送入して加圧チューブ５１を加圧して膨張させ、加圧チューブ５１に巻き付けた熱可塑性樹脂系繊維強化複合材料Ｘをキャビティ面１６，２６に密着させる。これにより、熱可塑性樹脂系繊維強化複合材料Ｘが未溶融の場合でも、高温のキャビティ面１６，２６により溶融され、加圧チューブ５１とキャビティ面１６，２６に挟まれた状態で、内部から圧力がかかって円筒状に溶融成形される。 In the molding process, the heating plates 12 and 22 are induction-heated by induction through the induction heating coils 15 and 25, and the cavity molds 11 and 21 are heated by heat transfer to adjust the cavity surfaces 16 and 26 to the molding temperature. As shown in FIG. 7, gas is fed into the tube to pressurize and expand the pressure tube 51, and the thermoplastic resin fiber reinforced composite material X wound around the pressure tube 51 is applied to the cavity surfaces 16 and 26. Adhere closely. Thereby, even when the thermoplastic resin-based fiber reinforced composite material X is not melted, it is melted by the high-temperature cavity surfaces 16 and 26 and is pressed between the pressure tube 51 and the cavity surfaces 16 and 26 from the inside. Is melted and formed into a cylindrical shape.
キャビティ面１６，２６の加熱温度は、熱可塑性樹脂系繊維強化複合材料Ｘが充分に溶融する温度であればよく、用いる熱可塑性樹脂系繊維強化複合材料Ｘの種類によっても異なるが、８０〜４００℃が好ましく、１２０〜３００℃がより好ましい。加熱板の温度は、伝熱するキャビティ型の厚さによるが、キャビティ型より５〜５０℃高いことが好ましく、より好ましくは１０〜３０℃、特に１０〜２０℃高いことが好ましい。 The heating temperature of the cavity surfaces 16 and 26 may be a temperature at which the thermoplastic resin-based fiber reinforced composite material X is sufficiently melted, and varies depending on the type of the thermoplastic resin-based fiber reinforced composite material X to be used. ° C is preferred, and 120 to 300 ° C is more preferred. The temperature of the heating plate depends on the thickness of the cavity mold that transfers heat, but is preferably 5 to 50 ° C. higher than the cavity mold, more preferably 10 to 30 ° C., and particularly preferably 10 to 20 ° C.
成形工程の後、冷却工程において、誘導加熱コイル１５，２５の電流を停止し、加熱板１２，２２の高周波誘導加熱を停止する。そして、冷却回路１４，２４の内部に冷媒を流通させ、熱伝導によりキャビティ面１６，２６を冷却し、円柱状に成形された状態で熱可塑性樹脂系繊維強化複合材料Ｘを固化する。 After the forming process, in the cooling process, the current of the induction heating coils 15 and 25 is stopped, and the high frequency induction heating of the heating plates 12 and 22 is stopped. And a refrigerant | coolant is distribute | circulated inside the cooling circuits 14 and 24, the cavity surfaces 16 and 26 are cooled by heat conduction, and the thermoplastic resin fiber reinforced composite material X is solidified in the state shape | molded in the column shape.
冷却工程では、キャビティ面１６，２６の温度を、熱可塑性樹脂系繊維強化複合材料Ｘが固化するのに充分な温度まで冷却すればよい。冷却工程では、用いる熱可塑性樹脂系繊維強化複合材料Ｘの種類によっても異なるが、ハイサイクルな成形品の製造が容易な点から、キャビティ面１６，２６を３０〜２００℃まで冷却することが好ましく、７０〜１６０℃まで冷却することがより好ましい。 In the cooling process, the temperature of the cavity surfaces 16 and 26 may be cooled to a temperature sufficient for the thermoplastic resin fiber reinforced composite material X to solidify. In the cooling step, although depending on the type of thermoplastic resin fiber reinforced composite material X to be used, it is preferable to cool the cavity surfaces 16 and 26 to 30 to 200 ° C. from the viewpoint of easy production of a high cycle molded product. It is more preferable to cool to 70 to 160 ° C.
冷却回路１４，２４の内部に流通させる冷媒としては、水、オイル（例えば、松村石油（株）製バーレルサーム＃４００、綜研テクニックス（株）製ＮｅｏＳＫ−ＯＩＬ１４００等）等が挙げられる。冷媒の温度は、１０〜１００℃が好ましい。 Examples of the refrigerant circulated in the cooling circuits 14 and 24 include water, oil (for example, Barrel Therm # 400 manufactured by Matsumura Oil Co., Ltd., NeoSK-OIL1400 manufactured by Soken Technics Co., Ltd.), and the like. The temperature of the refrigerant is preferably 10 to 100 ° C.
冷却工程において熱可塑性樹脂系繊維強化複合材料Ｘを固化した後、加圧チューブ５１の加圧を停止し、加圧チューブ５１を抜き取り、金型１から成形品を取り出す。
以上の工程により、図８に例示した円筒状の熱可塑性樹脂系繊維強化複合材料成形品５０が得られる。
After the thermoplastic resin fiber reinforced composite material X is solidified in the cooling step, the pressurization of the pressurizing tube 51 is stopped, the pressurizing tube 51 is pulled out, and the molded product is taken out from the mold 1.
The cylindrical thermoplastic resin fiber reinforced composite material molded article 50 illustrated in FIG. 8 is obtained by the above process.
金型１では、ρが４．０〜１００μΩ・ｃｍの磁性金属材料により加熱板１２，２２が形成されているため、加熱板１２，２２を高周波誘導加熱により短時間で急速に加熱できる。一方、ρが５．０μΩ・ｃｍ以下の非磁性金属材料により冷却回路１４，２４が形成されているので、キャビティ面１６，２６を高周波誘導加熱する際に冷却回路１４，２４が同時に加熱されることが防止されている。そのため、冷却回路１４，２４は温度が低いまま保たれているので、冷却工程におけるキャビティ面１６，２６の冷却が効率的に行える。 In the mold 1, since the heating plates 12 and 22 are formed of a magnetic metal material having ρ of 4.0 to 100 μΩ · cm, the heating plates 12 and 22 can be rapidly heated in a short time by high frequency induction heating. On the other hand, since the cooling circuits 14 and 24 are formed of a nonmagnetic metal material having ρ of 5.0 μΩ · cm or less, the cooling circuits 14 and 24 are simultaneously heated when the cavity surfaces 16 and 26 are subjected to high-frequency induction heating. It is prevented. Therefore, since the cooling circuits 14 and 24 are kept at a low temperature, the cavity surfaces 16 and 26 can be efficiently cooled in the cooling process.
加熱板１２，２２の温度は、加熱コイル１５，２５に誘導される磁界の強さと時間に依存する。その磁界の強さは、コイルの配置と電流に依存する。コイル配置による加熱板面上の磁界の強さの分布は避けられず、それに伴い加熱板に温度分布として現れる。加熱板上の温度分布を樹脂成形に要求される１０℃以内に抑制することは困難であった。しかし、この加熱板に密着した、２０℃における熱伝導率が１００〜４５０Ｗ／ｍ／Ｋ、好ましくは２００〜４００Ｗ／ｍ／Ｋである非磁性金属材料に伝熱通過する本発明により、伝熱過程で平均化され、キャビティ面１６，２６において温度分布は１０℃以下に制御できる。 The temperature of the heating plates 12 and 22 depends on the strength and time of the magnetic field induced in the heating coils 15 and 25. The strength of the magnetic field depends on the coil arrangement and current. The distribution of the strength of the magnetic field on the surface of the heating plate due to the coil arrangement is unavoidable and appears as a temperature distribution on the heating plate. It was difficult to suppress the temperature distribution on the heating plate within 10 ° C. required for resin molding. However, according to the present invention which transfers heat to a nonmagnetic metal material having a thermal conductivity at 20 ° C. of 100 to 450 W / m / K, preferably 200 to 400 W / m / K, which is in close contact with the heating plate, In the process, the temperature distribution can be controlled to 10 ° C. or less at the cavity surfaces 16 and 26.
なお、本発明の熱可塑性樹脂系繊維強化複合材料成形品の製造方法は、前述の金型１を用いる方法には限定されず、用いる金型は、前述した冷却回路及び誘導加熱コイルを有するものであれば、キャビティの形状は限定されない。 In addition, the manufacturing method of the thermoplastic resin fiber reinforced composite material molded article of the present invention is not limited to the method using the mold 1 described above, and the mold used includes the cooling circuit and the induction heating coil described above. If so, the shape of the cavity is not limited.
＜熱可塑性樹脂系繊維強化複合材料成形品の製造方法［第２実施形態］＞
以下、熱可塑性樹脂系繊維強化複合材料成形品の他の製造方法について説明する。該方法は、本発明の金型を用いた製造方法であって、下記工程を有する。
配置工程：金型のキャビティ内に熱可塑性樹脂系繊維強化複合材料を配置し、金型を閉じる。
成形工程：誘導加熱コイルに電流を通じて加熱板を高周波誘導加熱し、伝熱によりキャビティ型を成形温度まで加熱する。キャビティ内の熱可塑性樹脂系繊維強化複合材料を加熱し、必要に応じて溶融させ、次いで加圧して、金型内で圧縮成形する。
冷却工程：前記成形工程の後に、前記加熱板の高周波誘導加熱を停止し、キャビティ型内の冷却回路に冷媒を流通させてキャビティ面を冷却し、熱可塑性樹脂系繊維強化複合材料を固化する。
取り出し工程：前記冷却工程の後に、金型から熱可塑性樹脂系繊維強化複合材料成形品を取り出す。
<Method for Manufacturing Molded Article of Thermoplastic Resin Fiber Reinforced Composite Material [Second Embodiment]>
Hereinafter, another method for producing a thermoplastic resin-based fiber reinforced composite material molded product will be described. The method is a manufacturing method using the mold of the present invention and includes the following steps.
Arranging step: A thermoplastic resin fiber reinforced composite material is disposed in the cavity of the mold, and the mold is closed.
Molding process: A heating plate is induction-heated by high-frequency induction through an induction heating coil, and the cavity mold is heated to a molding temperature by heat transfer. The thermoplastic resin fiber reinforced composite material in the cavity is heated, melted as necessary, and then pressurized and compression molded in the mold.
Cooling step: After the molding step, high-frequency induction heating of the heating plate is stopped, the coolant is circulated through the cooling circuit in the cavity mold to cool the cavity surface, and the thermoplastic resin fiber reinforced composite material is solidified.
Removal step: After the cooling step, the thermoplastic resin-based fiber reinforced composite material molded product is removed from the mold.
以下、本発明の熱可塑性樹脂系繊維強化複合材料成形品の製造方法の実施形態の一例として、前述の金型２を用いた製造方法について説明する。 Hereinafter, the manufacturing method using the above-mentioned metal mold | die 2 is demonstrated as an example of embodiment of the manufacturing method of the thermoplastic resin fiber reinforced composite material molded article of this invention.
配置工程では、図９（Ａ）に示すように、熱可塑性樹脂系繊維強化複合材料Ｙを金型２の下型のキャビティ４６表面に配置し、金型を閉じる。次いで成形工程において、誘導加熱コイル３８，４８に電流を通じて加熱板３２，４２を高周波誘導加熱して、伝熱によりキャビティ型３１，４１を加熱するとともに金型を加圧し、図９（Ｂ）に示すように、上型と下型により熱可塑性樹脂系繊維強化複合材料Ｙを、必要に応じて溶融させ圧縮成形する。これにより、熱可塑性樹脂系繊維強化複合材料成形品Ｚを得ることができる。 In the arranging step, as shown in FIG. 9A, the thermoplastic resin fiber reinforced composite material Y is arranged on the surface of the lower mold cavity 46 of the mold 2 and the mold is closed. Next, in the molding process, the heating plates 32 and 42 are induction-heated by induction through the induction heating coils 38 and 48 by high-frequency induction, the cavity molds 31 and 41 are heated by heat transfer, and the molds are pressurized, as shown in FIG. As shown, the thermoplastic resin-based fiber reinforced composite material Y is melted and compression-molded as necessary using an upper mold and a lower mold. Thereby, the thermoplastic resin fiber-reinforced composite material molded product Z can be obtained.
本発明の熱可塑性樹脂系繊維強化複合材料成形品の製造方法では、誘導加熱コイル３８，４８に電流を通じて加熱板３２，４２を高周波誘導加熱して、伝熱によりキャビティ型３１，４１を加熱した後に熱可塑性樹脂系繊維強化複合材料Ｙを配置して圧縮成形を行ってもよい。 In the method for producing a thermoplastic resin-based fiber reinforced composite material molded product of the present invention, the heating plates 32 and 42 are induction-heated by induction through the induction heating coils 38 and 48, and the cavity molds 31 and 41 are heated by heat transfer. Later, the thermoplastic resin-based fiber reinforced composite material Y may be placed and compression molded.
キャビティ面３６，４６の加熱温度は、用いる熱可塑性樹脂系繊維強化複合材料Ｙの種類によっても異なるが、８０〜４００℃が好ましく、１２０〜３００℃がより好ましい。なお伝熱元の加熱板３２，４２は、キャビティ面より１０〜３０℃高く加熱される。 The heating temperature of the cavity surfaces 36 and 46 varies depending on the type of the thermoplastic resin fiber reinforced composite material Y to be used, but is preferably 80 to 400 ° C, more preferably 120 to 300 ° C. The heating plates 32 and 42 that are the heat transfer sources are heated 10 to 30 ° C. higher than the cavity surface.
熱可塑性樹脂系繊維強化複合材料Ｙは、熱可塑性樹脂系繊維強化複合材料成形品の製造方法［第１実施形態］で使用したものと同じ、マトリックス樹脂が強化繊維で強化された繊維強化複合材料からなる公知の熱可塑性樹脂系繊維強化複合材料を用いることができる。 The thermoplastic resin-based fiber reinforced composite material Y is the same fiber reinforced composite material in which the matrix resin is reinforced with reinforced fibers as used in the method of manufacturing a thermoplastic resin-based fiber reinforced composite material molded product [first embodiment]. A known thermoplastic resin-based fiber reinforced composite material can be used.
成形工程の後、冷却工程において、誘導加熱コイル３８，４８の電流を停止し、加熱板３２，４２の高周波誘導加熱を停止する。そして、キャビティ型３１，４１に配管された冷却回路３７，４７の内部に冷媒を流通させ、熱伝導によりキャビティ面３６，４６を冷却し、熱可塑性樹脂系繊維強化複合材料Ｙを固化する。 In the cooling process after the forming process, the current of the induction heating coils 38 and 48 is stopped, and the high frequency induction heating of the heating plates 32 and 42 is stopped. And a refrigerant | coolant is distribute | circulated inside the cooling circuits 37 and 47 piped by the cavity type | molds 31 and 41, the cavity surfaces 36 and 46 are cooled by heat conduction, and the thermoplastic resin type fiber reinforced composite material Y is solidified.
冷却回路３７，４７の内部に流通させる冷媒としては、冷却水、冷却オイル等が挙げられる。冷媒の温度は、１０〜１００℃が好ましい。 Examples of the refrigerant that circulates inside the cooling circuits 37 and 47 include cooling water and cooling oil. The temperature of the refrigerant is preferably 10 to 100 ° C.
冷却工程の後、取り出し工程において、金型２を開き、金型２から熱可塑性樹脂系繊維強化複合材料成形品を取り出す。これにより、平板状の熱可塑性樹脂系繊維強化複合材料成形品が得られる。 After the cooling step, in the take-out step, the mold 2 is opened, and a thermoplastic resin fiber-reinforced composite material molded product is taken out from the mold 2. Thereby, a plate-shaped thermoplastic resin fiber reinforced composite material molded product is obtained.
金型２は、金型１と同様に、ρが４．０〜１００μΩ・ｃｍの磁性金属材料により加熱板３２，４２が形成され、ρが５．０μΩ・ｃｍ以下の非磁性金属材料により冷却回路３７，４７が形成されているため、冷却回路３７，４７を加熱せずに、加熱板から伝熱によりキャビティ型３１，４１を急速に加熱できる。また、前述の熱可塑性樹脂系繊維強化複合材料成形品の製造方法［第１実施形態］と同様に、高周波誘導により加熱されない絶縁物で取り付け板３４，４４や側板３５，４５を形成すれば、ハイサイクルな熱可塑性樹脂系繊維強化複合材料成形品の製造がさらに容易になる。 As in the case of the mold 1, the mold 2 is formed by heating plates 32 and 42 made of a magnetic metal material having ρ of 4.0 to 100 μΩ · cm, and cooled by a nonmagnetic metal material having ρ of 5.0 μΩ · cm or less. Since the circuits 37 and 47 are formed, the cavity molds 31 and 41 can be rapidly heated by heat transfer from the heating plate without heating the cooling circuits 37 and 47. Moreover, if the mounting plates 34 and 44 and the side plates 35 and 45 are formed of an insulator that is not heated by high-frequency induction, as in the above-described method of manufacturing a thermoplastic resin-based fiber reinforced composite material molded product [first embodiment], Production of a high-cycle thermoplastic resin-based fiber reinforced composite material molded product is further facilitated.
なお、本発明の熱可塑性樹脂系繊維強化複合材料成形品の製造方法は、前述の金型２を用いる方法には限定されない。例えば、用いる金型は、前述した加熱板、熱伝導性の高いキャビティ型、冷却回路及び誘導加熱コイルを有するものであれば、所望のキャビティ形状を有する金型が使用できる。 In addition, the manufacturing method of the thermoplastic resin fiber reinforced composite material molded article of the present invention is not limited to the method using the mold 2 described above. For example, a mold having a desired cavity shape can be used as long as the mold used includes the above-described heating plate, cavity mold having high thermal conductivity, cooling circuit, and induction heating coil.
以上説明したように、本発明の金型は、特定の金属材料により形成した加熱板、キャビティ型及び冷却回路を用い、キャビティ面を急速加熱と急速冷却することができ、熱可塑性樹脂系繊維強化複合材料成形品等の成形品がハイサイクルで製造できる。 As described above, the mold of the present invention uses a heating plate, a cavity mold and a cooling circuit formed of a specific metal material, and can rapidly and rapidly cool the cavity surface, and is reinforced with thermoplastic resin fiber. Molded products such as composite material molded products can be manufactured in a high cycle.
以下、実施例を示して本発明を詳細に説明する。ただし、本発明は以下の記載によっては限定されない。 Hereinafter, the present invention will be described in detail with reference to examples. However, the present invention is not limited by the following description.
［実施例１］
図１に例示した構造の金型を製作した。上型、下型とも全く同じ仕様とした。キャビティ型は、上型と下型を向き合わせて閉じたときに、直径５０ｍｍの円柱状のキャビティが形成されるようなキャビティ面を有し、上型と下型との接触面の幅が左右両側とも２５ｍｍ、長手方向の長さが３００ｍｍであり、アルミニウム１０００製（２０℃における熱伝導率２４０Ｗ／ｍ／Ｋ）のものを使用した。
冷却回路は、キャビティに直径６．０ｍｍの貫通孔を開け、金型外は直径６．０ｍｍの市販の銅管（非磁性体、ρ＝１．６９μΩ・ｃｍ、株式会社コベルコマテリアル製）を使用し、図１０に示すように連通し、片側につき６本、合計１３本をスネーク状に配置した。上型、下型それぞれまとめて冷却水を流せるようにした。
誘導加熱コイルは、直径１０ｍｍの市販の銅管（株式会社コベルコマテリアル製）の表面を絶縁コーティングしたものを用い、コイルケース内に、図１１に示すように、銅管の間隔が１０ｍｍとなるよう渦状に配置した。コイルケースは、厚さ８ｍｍ、幅５０ｍｍの石綿スレート板製により枠組した。加熱板は、鉄鋼（磁性体、ρ＝１０．０μΩ・ｃｍ、厚さ５ｍｍ）を使用した。
[Example 1]
A mold having the structure illustrated in FIG. 1 was manufactured. The upper and lower molds have exactly the same specifications. The cavity mold has a cavity surface that forms a cylindrical cavity with a diameter of 50 mm when the upper mold and the lower mold are closed facing each other, and the width of the contact surface between the upper mold and the lower mold is left and right. Both sides were 25 mm, the length in the longitudinal direction was 300 mm, and those made of aluminum 1000 (thermal conductivity at 20 ° C. of 240 W / m / K) were used.
The cooling circuit has a through hole with a diameter of 6.0 mm in the cavity, and a commercially available copper tube with a diameter of 6.0 mm (non-magnetic material, ρ = 1.69 μΩ · cm, manufactured by Kobelco Materials Co., Ltd.) outside the mold. Then, as shown in FIG. 10, communication was made, and a total of 13 wires were arranged in a snake shape on each side. The upper mold and the lower mold were allowed to flow together in the cooling mold.
As the induction heating coil, a commercially available copper tube (made by Kobelco Material Co., Ltd.) having a diameter of 10 mm is used as an insulating coating, and the spacing between the copper tubes is 10 mm in the coil case as shown in FIG. Arranged in a vortex. The coil case was framed by an asbestos slate plate having a thickness of 8 mm and a width of 50 mm. The heating plate was steel (magnetic material, ρ = 10.0 μΩ · cm, thickness 5 mm).
上型及び下型の誘導加熱コイルに、それぞれ２ｋＷの出力でジェネレーターから通電した。熱電対をキャビティ表面に設置し、キャビティの温度変化を測定したところ、キャビティ表面は約５０秒で室温から３００℃まで加熱されることが確認できた。また直径５０ｍｍ、長さ３００ｍｍのキャビティ内の最高と最低の温度差は７℃以内であった。ここで誘導加熱を中止し、冷却回路に冷却水を通水したところ、２０秒でキャビティ表面の最高温度が８０℃まで下がった。 The upper and lower induction heating coils were each energized from the generator with an output of 2 kW. When a thermocouple was installed on the cavity surface and the temperature change of the cavity was measured, it was confirmed that the cavity surface was heated from room temperature to 300 ° C. in about 50 seconds. The difference between the highest and lowest temperatures in the cavity having a diameter of 50 mm and a length of 300 mm was within 7 ° C. When induction heating was stopped here and cooling water was passed through the cooling circuit, the maximum temperature of the cavity surface decreased to 80 ° C. in 20 seconds.
この金型を使用して成形確認を実施した。熱可塑性樹脂系繊維強化複合材料としては、東洋紡績株式会社製の、ガラス繊維（連続繊維）にポリプロピレンを含浸させたテープ（Quick Form（登録商標）、巾１５ｍｍ、厚み１５０μｍ、Ｖｆ＝５０％）からなる平織物（クロス材料）を使用した。成形した時に均等に１０層になるように、３００ｍｍ×１５７０ｍｍのクロス材料を加圧用チューブに緩く巻きつけた。熱可塑性樹脂系繊維強化複合材料を巻きつけたチューブを図５に例示したように金型のキャビティ内に挿入し、チューブ内に８気圧の圧縮空気を充填して膨張させ、熱可塑性樹脂系繊維強化複合材料を内側からキャビティ型に押し付けると共に、高周波誘導加熱を開始した。熱電対により、キャビティ型のキャビティ表面温度が４０秒で２００℃に達したことを確認した後、３分経ってから誘導加熱を止め、冷却回路に冷却水を流した。キャビティ表面温度が１００℃以下になったことを確認した後、冷却を止め、チューブから圧縮空気を抜いて、成形品を金型から取り出した。外径が５０ｍｍ、厚みが約１．５ｍｍの状態の良いチューブ状の熱可塑性樹脂系繊維強化複合材料成形品が得られた。該成形品は、内部にもボイドは少なく充分にコンソリデーションされていることが観察された。 Mold confirmation was performed using this mold. As a thermoplastic resin fiber reinforced composite material, a tape made by impregnating polypropylene into glass fiber (continuous fiber) manufactured by Toyobo Co., Ltd. (Quick Form (registered trademark), width 15 mm, thickness 150 μm, Vf = 50%) A plain woven fabric (cloth material) was used. A cloth material of 300 mm × 1570 mm was loosely wrapped around a pressure tube so that there were 10 layers evenly when molded. A tube around which a thermoplastic resin fiber reinforced composite material is wound is inserted into a mold cavity as illustrated in FIG. 5, and the tube is filled with 8 atmospheres of compressed air to expand the thermoplastic resin fiber. The reinforced composite material was pressed from the inside against the cavity mold, and high frequency induction heating was started. After confirming that the cavity surface temperature of the cavity mold reached 200 ° C. in 40 seconds with a thermocouple, induction heating was stopped after 3 minutes, and cooling water was allowed to flow through the cooling circuit. After confirming that the cavity surface temperature was 100 ° C. or lower, cooling was stopped, compressed air was removed from the tube, and the molded product was taken out of the mold. A tube-shaped thermoplastic resin-based fiber reinforced composite material molded article having an outer diameter of 50 mm and a thickness of about 1.5 mm was obtained. It was observed that the molded product was sufficiently consolidated with few voids inside.
［実施例２］
キャビティ型として、アルミニウム板の代わりに同じ寸法のジュラルミンＡ２０１７（アルミニウム−銅合金、２０℃における熱伝導率２３０Ｗ／ｍ／Ｋ）を使用した以外は、実施例１と全く同じ仕様、構成で金型を作製し、実施例１と同じ条件で誘導加熱を行った。その結果、約５５秒でキャビティ型の温度が３００℃に達した。誘導加熱を中止し、冷却回路に冷却水を通水したところ、キャビティ表面温度が２０秒で８０℃まで下がった。
[Example 2]
Mold with exactly the same specifications and configuration as Example 1 except that duralumin A2017 (aluminum-copper alloy, thermal conductivity at 20 ° C. at 230 ° C./K) was used as the cavity mold instead of the aluminum plate. And induction heating was performed under the same conditions as in Example 1. As a result, the temperature of the cavity mold reached 300 ° C. in about 55 seconds. When induction heating was stopped and cooling water was passed through the cooling circuit, the cavity surface temperature dropped to 80 ° C. in 20 seconds.
［比較例１］
キャビティ型として、アルミニウム板の代わりに同じ寸法の炭素鋼（２０℃の熱伝導率５３Ｗ／ｍ／Ｋ）を使用した以外は、実施例１と全く同じ仕様、構成で金型を作製し、実施例１と同じ条件で誘導加熱を行った。その結果、キャビティ型の温度が平均２５０℃に達するのに３４０秒かかった。キャビティの最高温度と最低温度の差は７２℃であった。誘導加熱を中止し、冷却回路に冷却水を通水したところ、キャビティ表面温度が４５秒で８０℃まで下がった。
以上のように、本発明の金型は、キャビティ型の加熱及び冷却が急速に行え、またキャビティ面の温度分布が均一であるため、熱可塑性樹脂系繊維強化複合材料成形品をハイサイクルで表面外観ムラのない成形ができる。
[Comparative Example 1]
A mold was prepared and implemented with exactly the same specifications and configuration as Example 1 except that carbon steel of the same dimensions (thermal conductivity of 20 ° C. 53 W / m / K) was used as the cavity mold instead of the aluminum plate. Induction heating was performed under the same conditions as in Example 1. As a result, it took 340 seconds for the cavity mold temperature to reach an average of 250 ° C. The difference between the maximum temperature and the minimum temperature of the cavity was 72 ° C. When induction heating was stopped and cooling water was passed through the cooling circuit, the cavity surface temperature dropped to 80 ° C. in 45 seconds.
As described above, the mold of the present invention can rapidly heat and cool the cavity mold, and the temperature distribution on the cavity surface is uniform. Molding without uneven appearance is possible.
本発明の金型は、金型の急速な加熱、冷却が可能であるため、自動車部品等の用途の熱可塑性樹脂系繊維強化複合材料成形品をハイサイクルに製造できる。 Since the mold of the present invention can rapidly heat and cool the mold, a thermoplastic resin-based fiber-reinforced composite material molded product for use in automobile parts and the like can be manufactured in a high cycle.
＜金型１＞
１０：上型、２０：下型、１１：上キャビティ型、２１:下キャビティ型、１２：上型発熱磁性体、２２：下型発熱磁性体、１３：上型誘導加熱コイルケース、２３：下型誘導加熱コイルケース、１４：上型冷却回路（冷却管）、２４：下型冷却回路（冷却管）、１５：上型加熱コイル、２５：下型加熱コイル、１６：上型キャビティ、２６:下型キャビティ
＜金型２＞
３０：上型、４０：下型、３１：上キャビティ型、４１:下キャビティ型、３２：上型発熱磁性体、４２：下型発熱磁性体、３３：上型誘導加熱コイルケース、４３：下型誘導加熱コイルケース、３４：上型取り付け板、４４：下型取り付け板、３５：上型側板、４５：下型側板、３６：上型キャビティ、４６：下型キャビティ、３７：上型冷却回路（冷却管）、４７：下型冷却回路（冷却管）、３８：上型加熱コイル、４８：下型加熱コイル、
５０：熱可塑性樹脂系繊維強化複合材料成形品、 ５１：加圧チューブ、
Ｘ：熱可塑性樹脂系繊維強化複合材料、
Ｙ：成形前熱可塑性樹脂系繊維強化複合材料
Ｚ：成形後熱可塑性樹脂系繊維強化複合材料
<Mold 1>
10: Upper mold, 20: Lower mold, 11: Upper cavity mold, 21: Lower cavity mold, 12: Upper mold heat generating magnetic body, 22: Lower mold heat generating magnetic body, 13: Upper mold induction heating coil case, 23: Lower Mold induction heating coil case, 14: upper mold cooling circuit (cooling pipe), 24: lower mold cooling circuit (cooling pipe), 15: upper mold heating coil, 25: lower mold heating coil, 16: upper mold cavity, 26: Lower mold cavity <Mold 2>
30: Upper mold, 40: Lower mold, 31: Upper cavity mold, 41: Lower cavity mold, 32: Upper mold heat generating magnetic body, 42: Lower mold heat generating magnetic body, 33: Upper mold induction heating coil case, 43: Lower Mold induction heating coil case, 34: upper mold mounting plate, 44: lower mold mounting plate, 35: upper mold side plate, 45: lower mold side plate, 36: upper mold cavity, 46: lower mold cavity, 37: upper mold cooling circuit (Cooling pipe), 47: lower mold cooling circuit (cooling pipe), 38: upper mold heating coil, 48: lower mold heating coil,
50: Thermoplastic resin fiber reinforced composite material molded product, 51: Pressurized tube,
X: Thermoplastic resin fiber reinforced composite material,
Y: Thermoplastic resin fiber reinforced composite material before molding Z: Thermoplastic resin fiber reinforced composite material after molding
Claims (6)
加圧チューブの周囲に巻き付けた熱可塑性樹脂系繊維強化複合材料を、該加圧チューブがキャビティの長手方向に沿うように、前記金型のキャビティ内に配置して該金型を閉じる配置工程と、
前記誘導加熱コイルに電流を通じて磁性体を高周波誘導加熱し、熱伝導によりキャビティ型を熱可塑性樹脂系繊維強化複合材料の成形温度に調節した後、前記加圧チューブを加圧して膨張させ、熱可塑性樹脂系繊維強化複合材料をキャビティ面に内側から密着させ、熱可塑性樹脂系繊維強化複合材料に内部から圧力をかけて内圧成形する成形工程と、
前記成形工程の後に、前記高周波誘導加熱を停止し、前記冷却回路に冷媒を流通させてキャビティ面を冷却し、前記熱可塑性樹脂系繊維強化複合材料を固化する冷却工程と、
前記冷却工程の後に、金型から熱可塑性樹脂系繊維強化複合材料成形品を取り出す取り出し工程と、
を有する熱可塑性樹脂系繊維強化複合材料成形品の製造方法。 A method for producing a thermoplastic resin-based fiber reinforced composite material molded article using the mold according to any one of claims 1 to 4,
A disposing step of disposing the thermoplastic resin fiber-reinforced composite material wound around the pressurizing tube in the cavity of the mold so that the pressurizing tube is along the longitudinal direction of the cavity and closing the mold; ,
The magnetic material is induction-heated by high-frequency induction through the induction heating coil, the cavity mold is adjusted to the molding temperature of the thermoplastic resin-based fiber reinforced composite material by heat conduction, and then the pressure tube is pressurized and expanded to provide thermoplasticity. A molding process in which a resin-based fiber reinforced composite material is closely adhered to the cavity surface from the inside, and an internal pressure molding is performed by applying pressure from the inside to the thermoplastic resin-based fiber reinforced composite material;
After the molding step, the high-frequency induction heating is stopped, the coolant is circulated through the cooling circuit to cool the cavity surface, and the thermoplastic resin-based fiber reinforced composite material is solidified;
After the cooling step, taking out the thermoplastic resin fiber reinforced composite material molded product from the mold,
A method for producing a thermoplastic resin-based fiber reinforced composite material molded article having
前記金型のキャビティ内に熱可塑性樹脂系繊維強化複合材料を配置する配置工程と、
前記誘導加熱コイルに電流を通じて磁性体を高周波誘導加熱し、熱伝導によりキャビティ型を熱可塑性樹脂系繊維強化複合材料の成形温度に調節した後、金型で熱可塑性樹脂系繊維強化複合材料を圧縮成形する成形工程と、
前記成形工程の後に、前記高周波誘導加熱を停止し、前記冷却回路に冷媒を流通させてキャビティ面を冷却し、前記熱可塑性樹脂系繊維強化複合材料を固化する冷却工程と、
前記冷却工程の後に、金型から熱可塑性樹脂系繊維強化複合材料成形品を取り出す取り出し工程と、
を有する熱可塑性樹脂系繊維強化複合材料成形品の製造方法。 A method for producing a thermoplastic resin-based fiber reinforced composite material molded article using the mold according to any one of claims 1 to 4,
An arranging step of arranging a thermoplastic resin-based fiber reinforced composite material in the cavity of the mold;
After the magnetic material is induction-heated by high-frequency induction through the induction heating coil, the cavity mold is adjusted to the molding temperature of the thermoplastic resin fiber reinforced composite material by heat conduction, and then the thermoplastic resin fiber reinforced composite material is compressed by the mold. Molding process to mold;
After the molding step, the high-frequency induction heating is stopped, the coolant is circulated through the cooling circuit to cool the cavity surface, and the thermoplastic resin-based fiber reinforced composite material is solidified;
After the cooling step, taking out the thermoplastic resin fiber reinforced composite material molded product from the mold,
A method for producing a thermoplastic resin-based fiber reinforced composite material molded article having
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