JP5929986B2 - 繊維強化プラスチックの成形方法 - Google Patents
繊維強化プラスチックの成形方法 Download PDFInfo
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Description
なお、図11では、図10に示すプリプレグ36の構成において、プリプレグ36の中央部に補強用のリブ39を設けた構成を示しているが、他の構成は図6と同様の構成になっている。
高剛性粒子としては、曲げ弾性率が50000MPa以上の高い剛性をもつ、アルミナ、ジルコニア等のセラミック、ガラス、硬質耐熱樹脂、金属、鋳物砂等を用いることができる。特に、ジルコニア、石英からなるセラミックを用いた場合には、これらの物質は、熱伝導率が低いので、中子4の粒子群4aを構成する粒子としては好適な材料となる。
1.1≦(Da/Db)≦2.0・・・(1)
ここで、Daは粒子(a)の粒子の直径、Dbは粒子(b)の粒子の直径である。
こうして成形用金型15を使って圧縮することで、所定の肉厚を有し、所望の外表面形状を備え内部に中子を収納したプリプレグ3の半成形品が加圧成形される。
図3(b)に示すように、凹部6に排出用の孔6aを開けると、この孔6aから可撓性袋体4bに収容されている粒子群4aの第1粒子(a)及び第2粒子(b)の間に空気が流入し、粒子群4aを構成する粒子間の結合状態が崩れる。そして、結合状態が崩れた粒子群4aを、凹部6に形成した排出用の孔6aから外部に排出して、図3(c)に示すように、中空部10bを有する成形品10を完成する。粒子群4aを収容していた可撓性袋体4bとして、成形品10に対して剥離性のよい材料を使い、或いは可撓性袋体4bを二重に構成しておけば、粒子群4aに接する可撓性袋体4bも半成形品10aから取外すことができる。
前記中子4の粒子群4aの流動性の評価は次の方法で測定した。
まず、粒子群4aの流動性は厚さ30mm、長さ300mm、幅100mmのキャビティを持ち成形板の(1)中央、(2)中央から長さ方向に65mm、及び(3)中央から長さ方向に130mm、の各位置の中子の外表面の圧力が測定可能な金型を用いて、金型温度140℃、成形圧力1.5MPaとし、所定量のサンプルを金型の中央にチャージし、素早く型を閉じて、続いて直径38mmのピストンロッドで、前記キャビティの中央の中子の外表面の一部を8.0MPaで10mm押圧し、続いて成形圧力5.0MPaまで加圧して、サンプルの圧力変化を記録し圧力ピークが観測されたら、測定を終了する。
○:3箇所の表面の圧力ピーク値の範囲が10%以下で均一に内圧が掛かっている。
×:3箇所の表面の圧力ピーク値の範囲が10%以上で均一に内圧が掛かっていない。
各例で得られた中空成形品の外観は目視により下記基準で評価した。
○:成形品の外面にシワなど欠陥がなく外観が良好。
×:成形品の外面にシワなど欠陥があり外観が悪い。
(実施例1)
図1に示すように粒径比が1.5のジルコニア粒子の混合物(粒子(a):直径3mm、粒子(b):直径2mm)で、ジルコニア粒子の混合物に含まれる粒子(b)の総量の割合(粒子(b)の混合割合)が20質量%の粒子群をナイロンフィルムからなる袋体に収容して中子を作製した。炭素繊維強化エポキシ樹脂プリプレグ3(三菱レイヨン社製、製品名:TR3110 391IMU)を5プライで前記中子を内包し、成形用金型15の内周面形状と略同形状に、室温にてプリフォームした。予め140℃に加熱した成形用金型15の下型1のキャビティ面に形成した凹部1a内にプリフォームを載置し、上型2と下型1とを完全に型締めし、続いてピストンロッド5aで中子4の外表面の一部を8.0MPaで押圧した。10分後、型開きを行い、半成形品を取り出した。ピストンロッドによる押圧により形成された凹部6(図3(a))に排出用の孔を開け、ジルコニア粒子(粒子群4a)を排出用孔から外部に排出し(図3(b))、中空成形品を得た(図3(c))。
表1に示す、中子4の粒子群4aに含まれるジルコニア粒子(b)の混合割合とした以外は、実施例1と同様に中空成形品を得た(図3(c))。
表1に示す、中子4の粒子群4aに含まれるジルコニア粒子(b)の混合割合が10質量%とした以外は、実施例1と同様に中空成形品を得た(図3(c))。
表1に示す、粒子径が均一なジルコニア粒子を中子4の粒子群4aに用いるとした以外は、実施例1と同様に中空成形品を得た(図3(c))。
一方、中子4の粒子群4aを構成する粒子にジルコニア粒子を用い、その第1粒子群(a)の直径Daと第2粒子群(b)の直径Dbとの比(Da/Db)が1.5であり、粒子群4aの総量に対する第2粒子群(b)の総量の割合が10質量%の粒子群を使用した比較例1、及び、粒子径が均一な径のジルコニア粒子を使用した比較例2の製造方法では、粒子群4aを構成する粒子は最も高い密度で充填されることになり、粒子群を構成する粒子の流動性が阻害され、圧力の伝達性が損なわれ、得られた成形品は寸法精度が低下し、外面にシワなど欠陥があり良好な外観を得ることが出来なかった。
上型2と下型1との間を型締め状態にしたとき、あるいは上型2と下型1とによってプリプレグ3を所定の圧力で加圧している加圧状態にしたとき、上型2と下型1との間隔がそれ以上拡がらないようにする。そのため、図示例によれば上型2に上下型2,1の間隔を一定に保持する金型間隔保持手段20が設けられている。図4に示すように、金型間隔保持手段20には、ピストンロッド5aで中子4を押圧変形させたときに、上型2に対してプリプレグ3の変形による押圧力の増大で上型2が持ち上がらない構成が採用される。
例えば、図4に示す上型2でプリプレグ3を押圧する押圧面が長方形形状であって、押圧面の横幅Wが100mmの長さで、奥行きが300mmの長さであると仮定する。このとき、押圧面の面積としては、10cm×30cm=300cm2 になる。また、ピストンロッド5aの直径をφ38mmと仮定し、シリンダ5のシリンダ径をφ130mmと仮定する。そして、上型2を押圧するプレス装置における油圧シリンダのシリンダ径をφ252mmとする。
金型間隔保持手段20の左右一対の押え部材21a,21aを上型2の左右側面の上端部に形成された下傾斜面2a,2aに向けて接近するように水平に移動させると、上型2の左右側面の上端部に形成した下傾斜面2a,2aとくさび面21b,21bとによるくさび作用が働く。ここで、前記押え部材21aの左右方向への移動停止位置により、上下型2,1の上下成形面間の離間距離が決まり、上型2の上方への、それ以上の移動が阻止される。すなわち、押え部材21a, 21aの接近移動を停止させると、たとえ上型2に対して下方から如何に強大な力が作用しても、上型2はそれ以上上方へと移動せず不動状態を維持し、寸法精度の高い成形品を得ることができる。
図5及び図7(B)を用いて、本発明に係わる変形例2を説明する。上記変形例1では、金型間隔保持手段20の押え部材として、単純に傾斜したくさび面21b,21bを有する一対の押え部材21a, 21aを用いた例について説明したが、変形例2では、金型間隔保持手段20に、鋸歯状のくさび面22b,22bをそれぞれに有する一対の押え部材22a,22aを用いている。また、各押え部材22a,22aに形成した鋸歯状のくさび面22b,22bに摺接するため、上型2の両端部には、鋸歯状の面がそれぞれ形成されている。
他の構成は、実施例1と同様の構成を備えており、同様の構成部材については、実施例1で用いた部材符号と同じ部材符号を用いることにより、その部材についての説明は省略する。
図6及び図7(C)を用いて、本発明に係わる変形例3の構成について説明する。変形例1では、金型間隔保持手段20として、単純に傾斜したくさび面21b,21bを有する一対の押え部材21a, 21aを用いた構成について説明したが、変形例3では、金型間隔保持手段20として、水平方向に延びる下面に上傾斜面を形成したくさび部23b,23bと、その外側端部から垂直下方に延びる垂直部23f,23fとを有する一対の押え部材23a,23aを用いており、一方の上型2の左右両端部を、前記一対の押え部材23a,23aを前記両端部に当接させたとき、各押え部材23a,23aの対向面が密接する面形状に形成している。
他の構成は、変形例1と同様の構成になっており、同様の構成部材については、実施例1で用いた部材符号と同じ部材符号を用いることにより、その部材についての説明を省略する。
かかる構成によって、金型間隔保持手段20を作動させると、一対の押え部材24a,24aにおけるくさび面24b,24bと上型2の両端部に形成したくさび面とが係合し、上型2の上下両方向への移動を完全に阻止することになる。
1a・・・・・・・下型に形成された凹部
2・・・・・・・・上型
2a・・・・・・・下傾斜面
3・・・・・・・・プリプレグ
4・・・・・・・・中子
4a・・・・・・・粒子群(粒子)
4b・・・・・・・可撓性袋体
5・・・・・・・・シリンダ
5a・・・・・・・ピストンロッド
6・・・・・・・・凹部
6a・・・・・・・排出用の孔
8・・・・・・・・突出部
10・・・・・・・成形品
10a・・・・・・半成形品
10b・・・・・・中空部
15・・・・・・・成形用金型
20・・・・・・・金型間隔保持手段
21a・・・・・・押え部材
21b・・・・・・くさび面
22a・・・・・・押え部材
22b・・・・・・くさび面
22c・・・・・・水平面
22d・・・・・・下傾斜面
23a・・・・・・押え部材
23b・・・・・・くさび部
23c・・・・・・上傾斜面
23d,23e・・垂直面
23f・・・・・・垂直部
24a・・・・・・押え部材
24b・・・・・・くさび面
30・・・・・・・成形用金型
31・・・・・・・下型
31a・・・・・・凹部
32・・・・・・・上型
33・・・・・・・中子
33a・・・・・・粉粒子群
33b・・・・・・包装材
34,35・・・・繊維強化熱可塑性樹脂材(FRTP)
36・・・・・・・プリプレグ
37・・・・・・・縦の部位
39・・・・・・・リブ
41a,41b・・成形用金型
42a,42b・・合せ面
43・・・・・・・中子
44・・・・・・・押出し機
45・・・・・・・溶融樹脂
46・・・・・・・加圧ユニット
51,52・・・・第1及び第2圧力チャンバ
55・・・・・・・チャンバ壁
57・・・・・・・型組立体
57a,57b・・型部分
Claims (3)
- 高剛性で流動性を有する複数の粒子を含む粒子群を可撓性袋体に収容して所望形状の中子を形成すること、
樹脂と繊維とを含むプリプレグを前記中子の周囲に配置すること、
前記中子とその周囲に配置された前記プリプレグとを成形用金型の上型と下型との間に配置すること、
前記成形用金型を型締めし圧縮成形すること、及び
型締め終了時に前記中子の外表面の一部部位を押圧して中子の内圧を高め、前記粒子群の流動性を向上させて中子の外周表面積を広げること、を含んでなり、
前記粒子群が互いに粒子径の異なる第1粒子群(a)及び第2粒子群(b)とを含み、 前記第1粒子群(a)の直径Daと前記第2粒子群(b)の直径Dbとの比Da/Dbが1.1以上2.0以下であり、
前記可撓性袋体に収容された粒子群の総量に対する第2粒子群(b)の総量の割合が20〜60質量%の範囲である、
ことを含んでなることを特徴とする繊維強化プラスチックの成形方法。 - 前記高剛性で流動性を有する粒子の曲げ弾性率が50000MPa以上である、請求項1に記載の繊維強化プラスチックの成形方法。
- 前記高剛性で流動性を有する粒子がセラミック粒子である、請求項2に記載の繊維強化プラスチックの成形方法。
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US10022898B2 (en) | 2018-07-17 |
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US20150183139A1 (en) | 2015-07-02 |
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