JP6037384B2 - Press molding system for fiber composite molded product and press molding method for fiber composite molded product - Google Patents

Description

The present invention relates to a press molding system for a fiber composite molded product and a press molding method for a fiber composite molded product, which form a fiber composite molded product impregnated with a thermoplastic resin by heating and pressing a thermoplastic resin and a fiber material. is there.

Conventionally, when a fiber composite molded product is obtained from a resin on a fiber material such as carbon fiber, a method of molding a prepreg using a thermosetting resin as described in Patent Document 1 is known. In the molding of Patent Document 1, a prepreg is pressure-molded by disposing a release film such as a resin vertically. However, when a prepreg using a thermosetting resin is used, there are problems that it is necessary to perform high-temperature heating and pressurization for a long time and that the price of the resin raw material is relatively expensive.

On the other hand, a carbon fiber composite molded article is also molded using a thermoplastic resin. When pressurizing a thermoplastic resin with a press device, it is generally performed until the molding is completed with one press device, but as shown in Patent Document 2, at a temperature equal to or higher than the softening point or melting point of the thermoplastic resin. A preform is obtained by making a thermoplastic resin in a molten state, and then cooled to a softening point or a temperature lower than the melting point while being conveyed and pressurized to a second press. Patent Document 2 describes that a glass fiber reinforced sheet or a metal foil is used in order to prevent the molten resin from flowing out during the molding.

In Patent Document 3, as a step (B), a prepreg sandwiched between resin films is melted in a heater furnace, and as a step (C), a prepreg obtained by removing a resin film from a prepreg sandwiched between resin films is a mold. As a step of transporting and arranging the inside, and a step (D), a step of pressurizing and cooling the prepreg in a mold to form a molded product is described.

JP 2012-218257 A (Claim 1, 0046, FIG. 1, etc.) JP-A-9-277387 (Claim 1, 0040, 0055, 0056, 0057, 0058, 0081) JP 2012-192645 A (Claims 1, 0030, 0031, 0036)

However, it is difficult to transfer the molten preform, and in Patent Document 2, the preform is transported together with the mold from the first press to the second press. Therefore, in Patent Document 2, the lower die cannot be exchanged between the first press and the second press, and only a molded product having a shape close to that of the preform can be formed even in the secondary press. In addition, since the mold is expensive and heavy, when a system for transporting the mold between the presses is constructed, the cost is increased.

Moreover, although patent document 3 is supposed to remove a resin film from a prepreg by a manual process or a conveying apparatus in the process (C) after primary shaping | molding, the specific method and apparatus are not described. With respect to Patent Document 3, there is a problem that if the resin film is removed near the melting point or more, the molten resin flows out or it is difficult to separate the resin film and the molten resin. Moreover, after the temperature of the primary molded product is completely solidified, the resin film may be peeled relatively easily, but the next pressurizing step cannot be performed unless the temperature is increased again in the next pressurizing step, There is a problem that energy loss and a molding cycle become long. Therefore, cited document 2 and cited document 3 do not describe a good method for transferring the primary molded product to the secondary molding process after the primary molding process.

Therefore, in the present invention, in a press molding system or press molding method for a fiber composite molded product that forms a fiber composite molded product impregnated with a thermoplastic resin by heating and pressurizing a thermoplastic resin and a fiber material, from the primary press device. It is an object of the present invention to provide a press molding system or a press molding system for a fiber composite molded product capable of successfully sending a primary molded product from a secondary press device or a primary pressurizing step to the secondary pressurizing step. .

A press molding system for a fiber composite molded product according to claim 1 of the present invention is a fiber composite molded product that forms a fiber composite molded product impregnated with a thermoplastic resin by heating and pressurizing a thermoplastic resin and a fiber material. In a press molding system, a primary molded article is obtained in which a thermoplastic resin and a fiber material placed on a placing plate or a film for placement are heated and pressed to impregnate the fiber material with the thermoplastic resin. Place the press plate and the mounting plate or mounting film on the fork, vacuum suction, hold with a chuck, insert a hook into the hole provided in the mounting plate, pull it, and press the mounting plate The primary molded product is taken out from the primary press device via the mounting plate or the mounting film-like material by any means of taking out, and the mounting plate or the mounting film-like material is used using the pusher plate. Excluded state A transfer step of sending to the secondary press unit, that the mounting plate or mounting film material is provided with a 2 and primary press unit for obtaining at least pressurizing secondary molded article a primary molded article is removed Features.

The press molding system for a fiber composite molded product according to claim 2 of the present invention is a fiber composite molded product that forms a fiber composite molded product impregnated with a thermoplastic resin by heating and pressing a thermoplastic resin and a fiber material. In a press molding system, a primary molded article is obtained in which a thermoplastic resin and a fiber material placed on a placing plate or a film for placement are heated and pressed to impregnate the fiber material with the thermoplastic resin. There is provided a press device and a secondary press device that obtains a secondary molded product by at least pressurizing the primary molded product, wherein the thermoplastic resin and the fiber material melt at the melting point temperature of the thermoplastic resin. The first pressurizing step is performed by placing on the mounting plate or the film for mounting through the release layer that is not performed. In the transfer step from the primary press device to the secondary press device, the primary press is performed. Immediately before the end of the pressure process Taking out the primary molded product whose heating temperature or surface temperature is the melting point temperature of the thermoplastic resin minus 100 ° C. or more through the mounting plate or the mounting film, the mounting plate or the mounting film Except for the above, the primary molded product including the release layer is sent to a secondary press apparatus, the mounting plate or the film for mounting is removed, and at least the primary molded product including the release layer is pressurized 2 It is characterized by obtaining a next molded product .

According to a third aspect of the present invention, there is provided a method for press-molding a fiber composite molded product comprising: a fiber composite molded product for molding a fiber composite molded product impregnated with a thermoplastic resin by heating and pressurizing a thermoplastic resin and a fiber material. In the press molding method, a primary molded article obtained by heating and pressurizing a thermoplastic resin and a fiber material placed on a placing plate or a film for placing to impregnate the fiber material with the thermoplastic resin is obtained. A primary molded product in which a heating step or a surface temperature immediately before the end of the primary pressing step is performed and a melting point temperature of the thermoplastic resin minus 100 ° C. or more is placed on the mounting plate or the mounting film The transfer step of sending the primary molded product to the secondary pressurizing step is performed in a state in which the mounting plate or the mounting film-like material is removed through the shaped material , and then the mounting plate or the mounting material. When less film material is removed primary molded article Wherein the second pressing step of obtaining a pressurizing secondary molded article is performed.

According to a fourth aspect of the present invention, there is provided the method for press-molding a fiber composite molded article according to the third aspect, wherein the thermoplastic resin and the fiber material are not melted at the melting temperature of the thermoplastic resin in the primary pressurizing step. The primary molded product including the release layer is secondary except for the mounting plate or the mounting film-like material described above in the transfer step. It is sent to a pressurizing process.

A press molding system for a carbon fiber composite molded product according to claim 1 of the present invention is a press for a fiber composite molded product that forms a fiber composite molded product impregnated with a thermoplastic resin by heating and pressurizing a thermoplastic resin and a fiber material. In a molding system, a primary press that obtains a primary molded product obtained by impregnating a thermoplastic resin into a fiber material by heating and pressurizing a thermoplastic resin and a fiber material placed on a placing plate or a film for placement. Place the device and the mounting plate or mounting film on the fork, vacuum suction, hold with a chuck, insert the hook into the hole provided in the mounting plate, pull it, and push out the mounting plate The primary molded product is taken out from the primary press device via the mounting plate or the mounting film-like material by any of the means described above, and the mounting plate or the mounting film-like material is removed using the pusher plate. In the state A transfer step of sending to the next press apparatus is provided with the 2 and primary press unit to the mounting plate or mounting film material has been removed primary molded product to obtain at least pressurizing secondary molded article, The primary molded product can be sent well from the primary press device to the secondary press device.

It is a side view of the press molding system used for the press molding method of the fiber composite molded product of this embodiment. It is an enlarged plan view which shows the transfer method of the primary molded product of the press molding method of the fiber composite molded product of this embodiment. It is an enlarged front view which shows the transfer method of the primary molded product of the press molding method of the fiber composite molded product of this embodiment. It is explanatory drawing which shows the action | operation at the time of the transfer of the primary molded product of the press molding method of the fiber composite molded product of this embodiment. It is explanatory drawing explaining the temperature of the molded product of the press molding method of the fiber composite molded product of this embodiment, the stroke of a press apparatus, etc. FIG.

First, the outline of the press molding system 11 of the fiber composite molded product of this embodiment will be described with reference to FIG. The press molding system 11 is provided with a primary press device 12 that performs a primary pressurization step on one side (left side) in FIG. 1 and a secondary press device 13 that performs a secondary pressurization step on the other side (right side). ing. And between the primary press apparatus 12 and the secondary press apparatus 13, the transfer apparatus which performs the transfer process which sends the primary molded product W pressure-molded with the primary press 12 toward the secondary press apparatus 13 is carried out. 14 is provided.

The primary press device 12 is provided with a movable platen 18 that can be moved up and down by being guided by a tie bar 17 between an upper platen 15 and a lower platen 16. A pressure plate 19 is disposed on the upper surface of the movable platen 18, and a pressure plate 20 is disposed on the lower surface of the upper plate 15. Further, a plurality of pressure plates 21 are arranged between the lower pressure plate 19 and the upper pressure plate 20 via members (not shown). The pressure plates 19, 20, and 21 of the present embodiment are hot plates having a flat surface, and a passage (not shown) through which a heat medium is circulated is formed. As the heat medium used in the present embodiment, heat medium oil is used. The passages of the pressure plates 19, 20, and 21 are connected to a heating medium supply device (not shown) that controls the temperature of the heating medium through a pipeline (not shown) on both the supply side and the discharge side. The heating means for the pressure plates 19, 20, and 21 may be a heater, and the number of the pressure plates 19, 20, and 21 is not limited, and only the upper and lower pressure plates 19 and 20 may be used. Further, the pressure plates 19, 20, and 21 may be those that can be heated and cooled. Further, in the present embodiment, the pressure plates 19, 20, and 21 are plate-like bodies and the surface is a flat surface, but may be other than a flat surface, or may be the shape of the final molded product or a shape close thereto.

A pressurizing hydraulic cylinder 22 is provided below the lower plate 16, and the ram 23 of the hydraulic cylinder 22 is fixed to the lower surface of the movable plate 18. The hydraulic cylinder 22 is driven and controlled by a hydraulic pump (not shown) and its hydraulic circuit. The movable plate 18, the pressure plate 19 fixed to the movable plate 18, and the intermediate pressure plate 21 are sequentially pushed up toward the pressure plate 20 fixed to the upper plate 15 by driving the hydraulic cylinder 22 for pressurization. . Then, between the pressure plate 19 and the pressure plate 21, between the pressure plate 21 and the pressure plate 21, and between the pressure plate 21 and the pressure plate 20, pressure / impregnation molding for obtaining the primary molded product W is performed. Is called.

Further, the molding space 24 in which the movable plate 18 between the upper plate 15 and the lower plate 16 of the primary press device 12 and the pressure plates 19, 20, 21 and the like are disposed can be isolated from the outside by a sealable chamber 25. It has become. The chamber 25 is communicated with a vacuum pump through a pipe line and a valve or a filter (not shown). In FIG. 1, an opening / closing door 26 is provided on the left side surface of the chamber 25 to carry in a unit U of the fiber material F and the resin material R. An opening / closing door 27 for carrying out the next molded product W or the like is provided. The open / close doors 26 and 27 may be a single open / close door that is used both for carrying out and for carrying in. The primary press device 12 is provided with a control device (not shown) for controlling the temperature of the pressure plates 19, 20, 21 from the start of molding to the completion of molding, the applied pressure, the degree of vacuum in the chamber 25, and the like. The primary press device 12 is not limited to the illustrated ones such as the number of primary molded products formed at one time, the pressurization method, the arrangement, and the presence or absence of a vacuum chamber. Further, the pressure plates 19, 20, and 21 can be replaced with, for example, an in-row mold capable of compression molding.

Next, the secondary press apparatus 13 provided on the other side will be described. In the secondary press device 13, four tie bars 32 are erected on a fixed plate 31 on the lower side, and an upper plate 33 is fixed on the upper side. The upper plate 33 is provided with a hydraulic cylinder 34 for pressurization, and the ram 35 of the hydraulic cylinder 34 is fixed to the back surface of the movable plate 36. The movable platen 36 is guided by the tie bar 32 between the fixed platen 31 and the upper platen 33 and can move in the vertical direction. A fixed mold 37 (lower mold) as one mold is attached to the upper surface of the fixed plate 31 of the secondary press apparatus 13. A movable mold 38 (upper mold) which is the other mold is attached to the lower surface of the movable platen 36. A mold composed of a fixed mold 37 and a movable mold 38 is formed by fitting a movable mold 38 having a convex portion to a fixed mold 37 having a concave portion in accordance with the shape of the secondary molded product. The mold has an in-row structure in which a cavity whose volume can be changed is formed.

Further, inside the fixed mold 37 and the movable mold 38, pipes (not shown) through which the refrigerant or the heat medium and the refrigerant are circulated are formed. In the present embodiment, heat medium oil is used as the heat medium or refrigerant, but water alone may be used. The fixed mold 37 and the movable mold 38 are connected to a delivery-side pipe and a discharge-side pipe (not shown) so that heat-controlled oil whose temperature is controlled is circulated and supplied from a heating medium oil supply device (not shown). Has been. One of the fixed mold 37 and the movable mold 38 is provided with an ejector device (not shown) that projects the secondary molded product.

Further, a molding space 39 in which the movable platen 36 between the upper plate 33 and the fixed platen 31 and the fixed die 37, the movable die 38, etc. are disposed can be isolated from the outside by a sealable chamber 40. . The chamber 40 is communicated with a vacuum pump through a conduit and a valve, a filter, etc. (not shown). In FIG. 1, an opening / closing door 41 for carrying the primary molded product W is provided on the left side surface of the chamber 40. On the right side surface of the chamber 40, the secondary molded product after pressurization is carried out. Open / close door 42 is provided. The open / close doors 41 and 42 may be a single open / close door that is used for both unloading and loading. The secondary press device 13 is provided with a control device (not shown) for controlling the temperature and pressure of the fixed mold 37 and the movable mold 38 from the start of molding to the completion of molding, the degree of vacuum in the chamber 40 and the like. In addition, about the secondary press apparatus 13, a pressurization system, arrangement | positioning, the number formed at once, the presence or absence of the chamber for vacuum, etc. are not limited to the thing of this illustration.

Next, the transfer device 14 will be described. The transfer device 14 is for taking out the primary molded product W pressed and molded by the primary press device 12 from the primary press device 12 and sending it to the secondary press device 13. The transfer device 14 can be self-propelled by a wheel 53 rotated by driving of a motor 52 on a rail 51 provided on the floor. A turntable 55 is rotatably attached to the main body 54 on the upper part of the main body 54 to which the wheels 53 of the transfer device 14 are attached. The gears of the rotating disk rotating motor 56 fixed to the main body 54 are engaged with the gears on the outer periphery of the rotating disk 55, and the rotating disk 55 can be rotated 180 ° by driving the motor 56. An elevating guide frame portion 58 that can be moved to one side and the other side by a mechanism using a motor 57, a ball screw, and a ball screw nut is provided upright on the rotating plate 55. The lift guide frame 58 is provided with a lift 60 that can be lifted and lowered by a mechanism using a motor 59 , a ball screw, and a ball screw nut.

As shown in FIG. 2, two forks 61, 61 are fixed to the elevating unit 60 in the horizontal direction toward the front. The lengths of the two forks 61 and 61 enter the first press device 12 to take out the primary molded product W placed on the upper surface of the pressure plate 19 or the like, or enter the secondary press device 13. The length is sufficient to place the primary molded product W on the cavity surface 37 a of the fixed mold 37. In addition, the width of one of the forks 61 is substantially the same as the width of a holding portion 65 of a press plate 64 described later. Further, the interval between the forks 61 provided in parallel is also longer than the length of the pressing portion 66 of the press plate 64. The tip of the fork 61 is a locking portion 61a bent upward. The locking part 61 a of the fork 61 is a member for locking the tip of the holding part 65 of the press plate 64.

An air cylinder 62 for pressing the primary molded product W in the same direction as the fork 61 is fixed behind the portion of the lifting device 60 of the transfer device 14 where the fork 61 is provided. A pusher plate 63 is fixed to the tip of the rod 62 a of the air cylinder 62 in a direction orthogonal to the fork 61. The length of the pusher plate 63 in the horizontal direction is equal to or smaller than the width of the pressing portion 66 of the press plate 64. The pusher plate 63 can move forward and backward relative to the forks 61, 61 fixedly provided on the elevating part 60. The transfer device 14 is not limited as long as the forks 61 and 61 have functions of forward and backward advancement and elevation. Further, a suction cup or the like may be used instead of the forks 61, 61. The pusher plate 63 is not essential, but is useful when only the primary molded product W is transferred from the press plate 64 onto the lower mold of the secondary press device 13.

Next, a press molding method of a fiber composite molded product using the press molding system 11 of the present embodiment will be described. Carbon fiber is used as the fiber material used in this embodiment. The carbon fiber is used in the form of a carbon fiber mat F having a thickness of 1 to 5 mm as an example. The carbon fiber mat F may be woven with directionality or may be non-woven. Alternatively, a large number of layers may be arranged to form a layer. Further, the carbon fiber mat F may be one obtained by adding another fiber layer (for example, glass fiber, metal fiber, aramid fiber, etc.) in addition to the carbon fiber.

Moreover, the thermoplastic resin which is matrix resin used by this embodiment consists of a polyamide (PA6) resin as an example, and is a thermoplastic resin sheet R with a thickness of 0.5-5 mm which is only an example. Polyamide is excellent in fluidity when melted and excellent in impregnation into the carbon fiber mat F. The thermoplastic resin sheet R is preferable because it is easy to handle, but it may be a thinner resin film or a resin plate that is harder and thicker than the sheet. Furthermore, the form of the thermoplastic resin R may be powdery or granular. The number of the thermoplastic resin sheet R and the carbon fiber mat F differs depending on the thickness and type of the thermoplastic resin sheet R and the carbon fiber mat F, and is not particularly limited. It is desirable that the weight percent ratio of the carbon fiber to the total (total weight of the thermoplastic resin and the carbon fiber) is 25 to 70%, more preferably 35 to 60%. These thermoplastic resin sheet R and carbon fiber mat F are preferably dried in advance.

Copper foils C, which are release layers, are respectively disposed above and below the thermoplastic resin sheet R and the carbon fiber mat F, and units U that are pressed between pressure plates at the time of molding are formed. The area of the copper foil C as the release layer is preferably the same as or larger than the areas of the thermoplastic resin sheet R and the carbon fiber mat F and covers the thermoplastic resin sheet R and the carbon fiber mat F. The release layer may be a metal foil (copper foil or aluminum foil, both of which have a melting temperature higher than the melting temperature of the matrix resin) or a resin (Teflon (registered) that has a melting temperature higher than that of the matrix resin. Any of a film-like product made of a thermosetting resin such as a trademark or a thermoplastic resin such as polyethylene terephthalate is used. These metal foils and film-like materials which are release layers are used in both the primary pressurizing step and the secondary pressurizing step, and in the primary molding, the pressurizing surfaces (or the pressurizing plates 20 and 21 on the upper surface side in particular) (or It plays a role in improving mold release from the mold surface. Also, in the secondary pressurizing step, it plays a role of improving the release from the mold. And when a secondary pressurization process is a last forming process, it peels after completion | finish of a secondary pressurization process. Accordingly, when the primary molded product is bent or deformed in the secondary pressurizing step, it is often desirable that the release layer does not cause wrinkles or break the release layer. As for the release layer, it is desirable to have a release layer on the side where the mounting plate abuts when removing the mounting plate such as the press plate 64 described later, but it is not essential. Alternatively, the release layer may remain on the surface of the final molded product.

The unit U of the thermoplastic resin sheet R and the carbon fiber mat F in which the copper foil C as the release layer is arranged up and down is placed on the press plate 64 that is a placement plate, and is primary by a carry-in device (not shown). It is conveyed to the press device 12. As shown in FIGS. 2 and 3, the press plate 64 is made of a stainless steel plate having a smooth surface with a thickness of about 0.5 mm to 8 mm, and has a central square pressure member 66 and both sides of the pressure member 66. The holding portion 65 is provided at a higher position by being bent twice. And the unit U of the thermoplastic resin sheet R and the carbon fiber mat F in which the copper foil C is arranged up and down is placed on the portion of the pressure part 66. In addition, it may replace with a mounting board and you may use the film-like thing for mounting further thinner which consists of a metal or resin. The unit U of the thermoplastic resin sheet R and the carbon fiber mat F on which the copper foils C are arranged up and down may be carried in at room temperature or carried in after preheating.

The unit U of the thermoplastic resin sheet R and the carbon fiber mat F in which the copper foils C are arranged vertically is placed on the press plate 64, and the opening / closing door 26 is opened by a carrying device (not shown). It is mounted on each pressure plate 19 and 21 of the primary press apparatus 12 from the opened opening. The temperature of each of the pressure plates 19 and 21 at this time is equal to or higher than the melting point temperature of the thermoplastic resin sheet R (matrix resin) (for example, the melting point temperature plus 30 ° C.). In addition, you may use the transfer apparatus 14 in the case of carrying in. When the unit U of the thermoplastic resin sheet R and the carbon fiber mat F in which the copper foils C are all arranged up and down is placed on the pressure plates 19 and 21 together with the press plate 64, the carry-in device is retracted and opened and closed. The door 26 is closed, and a primary pressurizing step for impregnating the carbon fiber mat F with the thermoplastic resin R is started.

In the primary pressurizing step, first, the molding space 24 in the chamber 25 is vacuumed. Although the vacuum degree of the internal space 24 is not limited, it is evacuated to 10 hPa-100 hPa as an example. Then, the hydraulic cylinder 22 of the primary press device 12 is operated, and the pressurizing plate 21 is pushed up sequentially from the lower pressurizing plates 19, 21, and the copper foil C is arranged between the pressurizing plates 19, 20, 21 up and down. Pressurization of the unit U of the thermoplastic resin sheet R and the carbon fiber mat F is performed. At this time, between the pressure plate 19 and the pressure plate 20 and the like, in order from the bottom, a press plate 64 as a mounting plate, a copper foil C as a release layer, a thermoplastic resin sheet R and a carbon fiber mat F, a release plate. It arrange | positions in order of the copper foil C which is a mold layer, and pressurization is performed. A flat press plate may also be placed on the copper foil C. About the applied pressure, the surface pressure applied to the unit U is preferably 0.3 to 30 MPa. In addition, the pressure plate 19, 20, 21 and the unit U are brought into a contact state or a close state without applying pressure from the beginning by devising the primary press device 12 at the time of pressurization. The melting of the thermoplastic resin R may be advanced by the heat of 21.

As shown in FIG. 5, the temperature at which the unit U of the thermoplastic resin sheet R and the carbon fiber mat F is pressurized is not different from that at the time of placement, and as an example, is equal to or higher than the melting point temperature of the thermoplastic resin R (as an example). Pressurization is performed at a melting point temperature plus 30 ° C.). The temperature at the time of pressurization is, for example, preferably in the range of the melting point temperature of the molten thermoplastic resin R to the melting point temperature plus 100 ° C., more preferably the melting point temperature to the melting point + 60 ° C. In this embodiment, the melting point temperature of polyamide (PA6) is 225 ° C., so the temperature during pressurization is preferably 225 ° C. or more and 325 ° C. or less, more preferably 225 ° C. or more and 285 ° C. or less. Then, pressurization is continued at the above temperature for 20 to 600 seconds to impregnate the carbon fiber mat F with the thermoplastic resin R.

In the present embodiment, as described above, the temperature of the pressure plates 19, 20, and 21 is controlled to be constant, and the pressurization step is performed at that temperature until the end, but after the temperature is lowered in the second half of the pressurization step, The primary molded product W may be taken out. In that case, the temperature of the heat transfer oil supplied to the pressure plates 19, 20, 21 is lowered to lower the temperature of the pressure plates 19, 20, 21, and the carbon fiber mat F is impregnated with the thermoplastic resin R. The temperature of the molded product W is lowered to the melting point or less of the thermoplastic resin R. As a result, the primary molded product W can be transferred to the secondary press device 13 by the transfer device 14 while further maintaining the shape of the primary molded product W.

When the primary molded product W in which the fiber material is impregnated with the thermoplastic resin is formed by the primary pressurizing step, the ram 23 of the hydraulic cylinder 22 is retracted, and the pressurizing plates 19, 20, 21 are spaced apart from each other. Is done. After the vacuum break in the chamber 25 is performed, the open / close door 27 is opened. Then, the process proceeds to the transfer process. In the transfer process, the forks 61 and 61 are caused to enter the opening in which the open / close door 27 is opened together with the horizontal movement of the lifting guide frame portion 58 of the transfer device 14. As shown in FIGS. 2 to 4, the forks 61, 61 are entered below the holding portion 65 of the press plate 64 placed on the pressure plate 19 or the pressure plate 21, and then the fork 61 is slightly raised. As a result, the holding portion 65 is lifted. Then, the elevating guide frame portion 58 is moved horizontally to retract the forks 61, 61. Thereby, the primary molded product W is taken out from the primary press apparatus 12 through the press plate 64 which is a mounting plate. Note that the method of taking out the primary molded product W from the primary press device 12 via the mounting plate or the mounting film-like material is not limited to the above. A hook may be inserted into a hole provided in the mounting plate to pull it, or the mounting plate may be pushed out and taken out, or the mounting plate or the film for mounting may be vacuum-sucked or held out with a chuck. .

As shown in FIG. 5, in this embodiment, the surface temperature of the primary molded product W at the time of taking out is the same as the temperature at the time of pressurization. The surface temperature of the primary molded product W at the time of taking out is preferably in the range of the melting point temperature minus 100 ° C. or higher of the thermoplastic resin R plus the melting point temperature plus 100 ° C. Is even more desirable. Further, in terms of increasing the thermal efficiency of the press molding system 11, the surface temperature of the primary molded product W at the time of taking out is more preferably equal to or higher than the melting point temperature, and in that case, the range up to + 60 ° C. is even more desirable. In addition, although the surface temperature at the time of taking out is described about the temperature of the primary molded product W desirable at the time of transfer in the above, the heating temperature immediately before the end of the primary pressurizing step may be used instead of the surface temperature. . That is, even if the temperature of the pressure plates 19, 20, and 21 of the primary press device 12 immediately before the end of the primary press process is measured by the temperature sensor, a heating temperature substantially equal to the surface temperature of the primary molded product W can be obtained. Alternatively, when the pressure plates 19, 20, and 21 are not cooled and the temperature hardly changes, even if the temperature of the heat medium immediately before the end of the primary press process is measured by a temperature sensor, a substantially equal heating temperature can be obtained.

Next, the transfer device 14 in which the primary molded product W (including the molded product W1 and the release layer C) is placed on the fork 61 of the transfer device via the press plate 64 is driven by the motor 52. The whole is moved backward (moved to the right in FIG. 1), and the rotating plate 55 is rotated by driving the motor 56, so that the direction of the forks 61, 61 is changed toward the secondary press device 13. Further, the heights of the elevating part 60 and the forks 61, 61 are also adjusted in accordance with the height of the fixed die 37 of the secondary press device 13. Then, the entire transfer device 14 is moved forward (moved to the right in FIG. 1), and the fork 61 and the press plate 64 are placed on the fixed die 37 from the opening where the open / close door 41 of the secondary press device 13 is opened. The placed primary molded product W is moved. At this time, as particularly referred to in the drawing on the left side of FIG. 4, first, the forks 61, 61 are advanced so as to be positioned above the other side (the back side) of the cavity surface 37 a of the fixed mold 37. Then, as shown in the right side of FIG. 4, the motor 57 is driven and the forks 61 and 61 are moved backward together with the lifting guide frame 58 (moved to the left in FIG. 1). At the same time, the rod 62a and the pusher plate 63 of the air cylinder 62 are extended so that the relative position of the pusher plate 63 with respect to the fixed mold 37 is not changed. That is, as shown in the right side of FIG. 4, when the transfer device 14 is retracted, the press plate 64 is retracted together with the fork 61 by being caught by the engaging portion 61 a at the tip of the fork 61, but the position of the pusher plate 63 is changed. Therefore, the primary molded product W cannot be moved backward, and the position is changed so as to slide on the pressing portion 66 of the press plate 64. When the press plate 64 moves together with the fork 61 from the cavity surface 37a of the fixed mold 37 by a certain amount or more, the primary molded product W falls on the cavity surface 37a and is placed thereon.

In this embodiment, since the friction coefficient is very small between the smooth press plate 64 made of stainless steel and the copper foil C on the surface of the primary molded product W, the primary molded product W can be easily slid. . And in the secondary press apparatus 13, only the primary molded product W from which the press plate 64 which is a mounting plate is removed is pressed and molded. Further, the press plate 64 remaining on the forks 61, 61 is lowered to a position different from that of the secondary press device 13. By performing the transfer process in this way, the primary molded product W can be sent to the secondary press device 13 (secondary pressurizing process) while maintaining a relatively high temperature state, leading to energy saving. The time of the secondary pressurization process can be shortened, which contributes to shortening of the molding cycle.

Then, when the transfer device 14 is moved backward, the opening / closing door 41 of the secondary press device 13 is closed, and the secondary pressurizing process is started. In the secondary pressurizing step, first, the molding space 39 in the chamber 40 is vacuumed. Although the degree of vacuum of the internal space 39 is not limited, it is evacuated to the same extent as the primary press device 12. Then, the hydraulic cylinder 34 of the secondary press device 13 is operated, the movable platen 36 and the movable mold 38 are lowered, and the primary molded product W is pressurized between the fixed mold 37 and the movable mold 38. As for the pressing force in the secondary pressurizing step, the surface pressure applied to the molded product is desirably 0.3 to 30 MPa. In the secondary pressurizing step, since the press plate 64 having a certain thickness is removed from the primary molded product W, the shape changes such as curved surface formation, trimming, drilling, etc. from the flat primary molded product W 2. The next processing can be performed.

Further, as shown in FIG. 5, the temperature of the fixed mold 37 and the movable mold 38 at the start of the secondary pressurization process is equal to or higher than the melting point. The temperature of the mold at the start of the pressurizing process of the secondary press apparatus 13 is in the range of the melting point temperature −50 ° C. to the melting point + 100 ° C. of the thermoplastic resin used as an example, and more preferably the melting point temperature to the melting point + 60 ° C. A range is desirable. And a secondary pressurization process is performed over 10 second-300 second. In the second half of the secondary pressurization step, a refrigerant is circulated through the passages of the fixed mold 37 and the movable mold 38, so that the temperature is equal to or lower than the heat deformation temperature of the thermoplastic resin of the secondary molded product (final molded product). The temperature is lowered to a temperature at which deformation remains to the extent that there is no problem even if the molded product is released. Since the temperatures of the fixed mold 37 and the movable mold 38 are lowered at the time of mold release, when the molding cycle is important, the temperature is not sufficiently increased when the next primary molded product is placed. However, in that case, the temperature is raised even during pressurization after placement. In the secondary pressurizing step, the pressurization while cooling the primary molded product W at the melting point or lower from the beginning is not excluded.

When the secondary pressurizing step is completed, the movable mold 38 is then raised to open the mold. At this time, since the secondary molded product has a release layer on the surface, it can be easily released. When the mold is opened, the secondary molded product is ejected from the fixed mold 37 or the movable mold 38 by an ejector device (not shown). The extruded secondary molded product is carried out of the secondary press device 13 by a transfer device (not shown), and the copper foil C as a release layer is peeled off. In the press molding system 11 of the fiber composite molded product, the relationship between the primary press device 12 and the secondary press device 13 is that when the primary press device 12 simultaneously pressurizes and impregnates a plurality of primary molded products W. The molding time of the secondary press device 13 may be (primary molding time / number of sheets simultaneously pressed by the primary press device), or the secondary press device 13 capable of simultaneously pressing a plurality of sheets, A secondary press device 13 may be arranged. Further, the press molding system 11 is not limited to the one that is finished in the secondary pressurizing step, and may be one in which a 3:00 pressurizing step is provided after the secondary pressurizing step.

In the above-described embodiment, the unit U of the thermoplastic resin sheet R and the carbon fiber mat F is sandwiched between release layers such as a metal foil and a resin fill, and the primary molded product W also has a release layer. It is carried into the secondary pressurization process. However, the unit U of only the thermoplastic resin sheet R and the carbon fiber mat F is placed on the mounting plate such as the press plate 64 and the primary molding without the release layer except for the mounting plate in the transfer process. The product W may be sent to the secondary pressurizing step. In that case, it is desirable to place a press plate used only in the primary pressurizing step on the unit U of the thermoplastic resin sheet R and the carbon fiber mat F.

Next, a press molding method for a fiber composite molded product and a press molding system for a fiber composite molded product according to a second embodiment will be described. The primary molding press apparatus is provided with a mold having irregularities, and the mold is provided with a push-up ejector apparatus having a certain area or more. When the primary pressurizing process is completed in the primary press device, the mounting plate or the film-like material for mounting and the primary molded product are lifted by the ejector device. Then, the placed mounting plate or the mounting film-like product and the primary molded product are held and moved by the transfer device, and only the mounting plate or the mounting film-like product is removed to obtain the primary molded product. Supply to secondary press machine. Then, the final molded product is formed with a secondary press.

Next, a fiber composite molded product press molding method and a fiber composite molded product press molding system according to a third embodiment will be described. The primary molding press apparatus is provided with a mold having projections and depressions, and a part of the mold that forms a recess is partially opened, and a mounting plate or a film-like object for mounting and 1 are formed from the opened part. The next molded product is taken out. In the fourth embodiment, in the mold of the primary molding press apparatus, the upper mold is concave and the lower mold is protruding. The primary molded product that has undergone the primary pressurization process is opened in a form that remains on the protruding cavity forming surface of the lower mold. Accordingly, regardless of the presence or absence of the ejector device, the removal is facilitated when the transfer device or the film-form material for mounting and the primary molded product are subsequently taken out. Further, in the fifth embodiment, the shape of the cavity forming surface may be flat or the upper die and the lower die may be uneven, but the placing plate or the placing film-like product and the primary molded product once The mold is opened while being held by the upper mold. Then, a transfer device such as a fork enters the lower part of the upper die and the primary molded product, and drops the primary molded product etc. onto the fork by the protrusion by the ejector or the like. Furthermore, the upper die or the lower die may move out of the pressure position of the primary press apparatus.

The present invention is not enumerated one by one, but is not limited to that of the above-described embodiment, and it goes without saying that those skilled in the art also apply modifications made in accordance with the spirit of the present invention. is there. The fiber material used may be carbon fiber, glass fiber, Kepler fiber, metal fiber such as aluminum, and other types of fiber material such as natural fiber. Further, the thermoplastic resin R is not limited and may be a mixed material with a thermosetting resin. The matrix resin used in the present invention is a thermoplastic resin, typically polypropylene, polyethylene, polystyrene, ABS resin, AS resin, polycarbonate, polyethylene terephthalate, polyamide, polyacetal, polyphenylene sulfide, polyphenylene ether, thermoplastic polyurethane, and the like. Other types of thermoplastic resins may be used.

DESCRIPTION OF SYMBOLS 11 Press molding system 12 Primary press apparatus 13 Secondary press apparatus 14 Transfer apparatus 19,20,21 Pressure plate 37 Fixed mold 38 Movable mold 61 Fork 64 Press plate (mounting plate)
C Copper foil (release layer)
F Carbon fiber mat R Thermoplastic resin sheet W Primary molded product

Claims (4)

In a fiber composite molded product press molding system for molding a fiber composite molded product impregnated with a thermoplastic resin by heating and pressing a thermoplastic resin and a fiber material,
A primary press device for obtaining a primary molded product obtained by impregnating a thermoplastic resin into a fiber material by heating and pressurizing the thermoplastic resin and the fiber material placed on the placing plate or the film for placement;
Place the mounting plate or mounting film on the fork, vacuum suction, hold with a chuck, insert a hook into the hole provided in the mounting plate, pull, and push the mounting plate to remove The primary molded product is taken out from the primary press device via the mounting plate or the mounting film-like material by the means described above, and the mounting plate or the mounting film-like material is removed using the pusher plate. A transfer process to be sent to the secondary press machine;
A press molding system for a fiber composite molded product, comprising: a secondary press device that obtains a secondary molded product by pressing at least a primary molded product from which a mounting plate or a film for mounting is removed. . In a fiber composite molded product press molding system for molding a fiber composite molded product impregnated with a thermoplastic resin by heating and pressing a thermoplastic resin and a fiber material,
A primary press device for obtaining a primary molded product obtained by impregnating a thermoplastic resin into a fiber material by heating and pressurizing the thermoplastic resin and the fiber material placed on the placing plate or the film for placement;
A secondary press device that at least pressurizes the primary molded product to obtain a secondary molded product, wherein the thermoplastic resin and the fiber material do not melt at the melting temperature of the thermoplastic resin in the primary press device Is placed on the mounting plate or the mounting film-like material through the first pressurizing step,
In the transfer process from the primary press apparatus to the secondary press apparatus, a primary molded product whose heating temperature or surface temperature immediately before the end of the primary pressurizing process is equal to or higher than the melting point temperature of the thermoplastic resin minus 100 ° C. is described above. The primary molded product including the release layer is sent to a secondary press device, except for the mounting plate or the mounting film-like material before taking out through the mounting plate or the mounting film-like material ,
A press molding system for a fiber composite molded product, wherein a secondary molded product is obtained by pressing at least a primary molded product including the release layer from which a mounting plate or a film for mounting is removed . In a method for press-molding a fiber composite molded article in which a thermoplastic resin and a fiber material are heated and pressurized to form a fiber composite molded article impregnated with the thermoplastic resin.
A primary pressurizing step is performed in which a thermoplastic resin and a fiber material placed on a placing plate or a placing film-like material are heated and pressed to obtain a primary molded product in which the fiber material is impregnated with the thermoplastic resin. I,
Next , before taking out the primary molded product whose heating temperature or surface temperature just before the end of the primary pressurizing step is equal to or higher than the melting point temperature of the thermoplastic resin minus 100 ° C. through the mounting plate or the film for mounting. A transfer process is performed in which the primary molded product is sent to the secondary pressurizing process in a state where the mounting plate or the film for mounting is removed .
Next , a press of a fiber composite molded product is performed, wherein a secondary pressurizing step is performed to obtain a secondary molded product by pressing at least the primary molded product from which the mounting plate or the film for mounting is removed. Molding method. In the primary pressurizing step, the thermoplastic resin and the fiber material are placed on a placing plate or a placing film-like material through a release layer that does not melt at the melting point temperature of the thermoplastic resin,
4. The fiber according to claim 3, wherein, in the transfer step, a primary molded product including the release layer is sent to a secondary pressurization step, except for the mounting plate or the film for mounting described above. Press molding method for composite molded products.