JP6821539B2 - Molding method for composite reinforced fiber resin molded products - Google Patents

Description

In the present invention, between the first plate to which the first mold is attached and the second plate to which the second mold is attached, the intermediate mold is centered on the axis in the direction orthogonal to the mold opening / closing direction. The present invention relates to a method for molding a composite reinforcing fiber resin molded product using an injection molding machine that is rotatably arranged.

As a method with good production efficiency for molding a reinforced fiber resin molded product containing a fiber and a resin, there are press molding and injection molding (including injection compression molding). However, when a plate material such as a prepreg is subjected to only primary molding by press molding to form a reinforced fiber resin molded product, the material such as the prepreg is thin and does not have excellent fluidity, so that it is complicated with ribs and the like. It is difficult to mold a reinforced fiber resin molded product having a shape. Also, in the case of injection molding, the material containing the molten fiber and resin injected into the cavity is not so excellent in fluidity, so it is possible to mold a reinforced fiber resin molded product with a complicated shape only by primary molding. Often difficult. Further, in the injection molding, the reinforced fiber resin molded product containing the fiber and the resin obtained only by the primary molding may have a problem in terms of aesthetics because a part of the fiber appears on the surface of the molded product.

As a device for dealing with the above problem, an apparatus or a molding method for molding a reinforced fiber resin molded product containing a fiber and a resin by primary molding and secondary molding, such as Patent Documents 1 to 3, is known. .. As shown in FIGS. 3 to 11, the molding apparatus for a composite molded product containing the fiber material of Patent Document 1 compress-molds a molten resin or prepreg, and then forms an upper mold or a lower mold without completely opening the mold. A space is formed between the primary molded products, and the molten resin is injected into the space to perform injection compression molding. However, in Patent Document 1, since the same mold cavity surface is used for primary molding and secondary molding, the degree of freedom in molding a composite molded product is limited, and only a molded product having a relatively simple shape can be molded. Can not. Further, Patent Document 1 also describes that core back molding is performed as described in (0039), but there is a problem that the mold structure becomes complicated. Furthermore, Patent Document 1 is not so excellent in terms of productivity because the same mold is used for the primary molding and the secondary molding.

As shown in FIG. 1 and the like, Patent Document 2 uses a composite material molding apparatus provided with a rotary mold replacement mechanism, and replaces a combination of a fixed mold and a moving mold when the mold is opened. The primary molding and the secondary molding are performed by injection molding. Since the primary molding and the secondary molding are combinations of different molds by using the molding apparatus provided with this mechanism, some problems of the above-mentioned Patent Document 1 are solved. However, Patent Document 2 has a problem that since two molds are arranged on the same parting surface and mold clamping is performed at the same time, only a composite material molded product having a small projected area can be molded for the mold clamping force of the molding apparatus. was there. Further, Patent Document 2 describes that a high-strength molded product is molded by making the flow paths of the two layers of materials different, but it is aesthetically pleasing to mold a composite material molded product having a complicated shape. There was no description about molding the composite material molded product in consideration, and it was not possible to deal with it.

In Patent Document 3, two molds are arranged in series with respect to the direction in which the mold clamping force is applied, and a composite material molded product having a smaller projected area than the mold clamping force of the molding apparatus of Patent Document 2. The problem of not being able to mold from the ground is solved. However, in Patent Document 3, in the primary insert molding step, the woven sheet is attached along the shape of the dummy mold, and the molding for forming the shape of the final molded product is performed by injection molding only in the secondary molding. .. Therefore, as in Patent Document 2, Patent Document 3 does not describe anything about molding a composite material molded product having a complicated shape or molding a composite material molded product in consideration of aesthetics, and cannot be dealt with. It was.

Japanese Unexamined Patent Publication No. 2013-216078 (Claim 3,0039, FIGS. 3 to 12) JP-A-2017-30169 (Claim 1, 0002, FIG. 1) JP-A-2014-43086 (Claim 1, 0077, FIG. 2)

As described above, in the molding method of the prior art, when molding a composite reinforced fiber resin molded product, it is difficult to mold a molded product having a complicated shape or to mold a molded product in consideration of aesthetics. It was.

In view of the above problems, in the present invention, the intermediate mold is orthogonal to the mold opening / closing direction between the first plate to which the first mold is attached and the second plate to which the second mold is attached. Using an injection molding machine that is rotatably arranged around the axis of direction, molding a composite reinforced fiber resin molded product with a complicated shape or molding a composite reinforced fiber resin molded product in consideration of aesthetics. An object of the present invention is to provide a molding method for a composite reinforcing fiber resin molded product that can be formed.

The method for molding a composite reinforced fiber resin molded product according to claim 1 of the present invention is to: between a first plate to which a first mold is attached and a second plate to which a second mold is attached. In a method for molding a composite reinforced fiber resin molded product using an injection molding machine in which an intermediate mold is rotatably arranged around an axis in a direction orthogonal to the mold opening / closing direction.
In the primary cavity formed by closing the first mold and the intermediate mold, a material containing reinforcing fibers and resin is injected from the first injection device to primary mold the primary molded product.
While the primary molded product is held in the intermediate mold, the released intermediate mold is rotated.
The intermediate mold holding the primary molded product and the second mold having rib grooves fixedly formed on the cavity surface are closed to form a secondary cavity for forming ribs .
A material containing reinforcing fibers and a resin in the secondary cavity, the content of the reinforcing fibers is lower than that of the primary molded product, or the length of the reinforcing fibers is shorter than that of the primary molded product, or When a resin-only material that does not contain reinforcing fibers is injected from a second injection device and secondary molding is performed to form a composite reinforcing fiber resin molded product , at least one of the injection speed and injection pressure and the nozzle are used during the secondary molding. The set temperature of the including heating cylinder is set higher than that in the case of primary molding, and the primary molding is characterized in that the injection side control is changed.

The method for molding a composite reinforced fiber resin molded product according to claim 2 of the present invention is to: between a first plate to which a first mold is attached and a second plate to which a second mold is attached. In a method for molding a composite reinforced fiber resin molded product using an injection molding machine in which an intermediate mold is rotatably arranged around an axis in a direction orthogonal to the mold opening / closing direction, the first mold and the intermediate mold are used. In the primary cavity formed by closing the mold, a material containing reinforcing fibers and resin is injected from the first injection device to primary mold the primary molded product, and the primary molded product is held in the intermediate mold. The intermediate mold released from the mold is rotated, and the intermediate mold holding the primary molded product and the second mold having a rib groove fixedly formed on the cavity surface are closed and ribbed. A material containing reinforcing fibers and a resin in the secondary cavity, and the content of the reinforcing fibers is lower than that of the primary molded product, or the length of the reinforcing fibers is the above 1 A material shorter than the next molded product, or a resin-only material that does not contain reinforcing fibers, is injected from the second injection device by increasing at least one of the injection speed, injection pressure, and set temperature of the heating cylinder including the nozzle. When the composite reinforced resin molded product is molded by performing the secondary molding, the primary molding and the secondary molding are performed by injection molding, and at least the heating and cooling mold is used in the secondary molding during the primary molding. The temperature is higher than the temperature of the mold, and in the secondary molding, the injection side control and the mold clamping side control are changed to perform molding to form a composite reinforced fiber resin molded product.

The method for molding a composite reinforced fiber resin molded product according to claim 3 of the present invention is to: between the first plate to which the first mold is attached and the second plate to which the second mold is attached. In a method for molding a composite reinforced fiber resin molded product using an injection molding machine in which an intermediate mold is rotatably arranged around an axis in a direction orthogonal to the mold opening / closing direction, the first mold and the intermediate mold are used. A primary molded product containing reinforcing fibers and resin is first-molded in a primary cavity formed by closing the mold using a first injection device, and the primary molded product is released while being held in an intermediate mold. The molded intermediate mold is rotated to close the intermediate mold holding the primary molded product and the second mold having a cavity surface forming a rib or a thinner portion thinner than the primary molded product. When the secondary cavity is formed, the primary molded product is heated, and the secondary cavity is a material containing reinforcing fibers and a resin from a gate formed in a second mold and contains reinforcing fibers. A material whose amount is lower than that of the primary molded product or whose reinforcing fiber length is shorter than that of the primary molded product , or a resin-only material that does not contain reinforcing fibers is injected using a second injection device. A composite reinforced resin in which at least one of the speed, injection pressure, and set temperature of the heating cylinder including the nozzle is increased to inject and secondary molding is performed, and ribs or thin parts thinner than the primary molded product are formed on the back surface side. The molded product is molded, the back surface side of the composite reinforced resin molded product is held in a second mold which is a core mold, and the molded product is released. It is characterized in that the back surface side of the molded product is projected.

In the molding method of the composite reinforced fiber resin molded product of the present invention, the intermediate mold opens and closes between the first plate to which the first mold is attached and the second plate to which the second mold is attached. In a molding method for a composite reinforced fiber resin molded product using an injection molding machine that is rotatably arranged around an axis in a direction orthogonal to the direction, the first mold and the intermediate mold are closed and formed. A material containing reinforcing fibers and resin was injected from the first injection device in the primary cavity, and the primary molded product was primary molded, and the primary molded product was released while being held in an intermediate mold. the intermediate mold is rotated, the primary molded article second cavity to form a fixedly rib closed mold and a second mold rib groove is formed in the intermediate mold and the cavity face that holds the Is a material containing reinforcing fibers and resin in the secondary cavity, and the content of the reinforcing fibers is lower than that of the primary molded product, or the length of the reinforcing fibers is shorter than that of the primary molded product. At least the injection speed and injection pressure at the time of secondary molding when a material or a resin-only material containing no reinforcing fibers is injected from a second injection device to perform secondary molding to form a composite reinforcing fiber resin molded product. Since the set temperature of the heating cylinder including one and the nozzle is set higher than that in the primary molding and the injection side control is changed from the primary molding, it is possible to mold a molded product having a complicated shape.

Regarding the molding method of the composite reinforced fiber resin molded product of the first embodiment, the fixed mold and the intermediate mold, and the movable mold and the intermediate mold are opened respectively, and the composite reinforced fiber resin molding previously molded. It is a schematic explanatory view which shows the state after the product sticks out and the rotation of an intermediate mold is completed. FIG. 5 is a schematic explanatory view showing a state in which a fixed mold and an intermediate mold and a movable mold and an intermediate mold are respectively closed according to the molding method of the composite reinforced fiber resin molded product of the first embodiment. FIG. 5 is a schematic explanatory view showing a state in which primary molding and secondary molding of the composite reinforcing fiber resin molded product are performed with respect to the molding method of the composite reinforcing fiber resin molded product of the first embodiment. Regarding the molding method of the composite reinforced fiber resin molded product of the first embodiment, the fixed mold and the intermediate mold, the movable mold and the intermediate mold are opened, and the composite reinforced fiber resin molded product is projected. It is the schematic explanatory drawing which shows the state which is. Regarding the molding method of the composite reinforced fiber resin molded product of the second embodiment, the fixed mold and the intermediate mold and the movable mold and the intermediate mold are opened, respectively, and the composite reinforced fiber resin molded product is projected. It is a schematic explanatory drawing which shows the state.

The injection molding machine 11 according to the embodiment of the present invention will be described with reference to FIG. 1 and the like. The injection molding machine 11 for a composite molded product is composed of a mold clamping device 12, a first injection device 13 on the fixed side provided on both sides thereof, and a second injection device 14 on the movable side. .. Explaining the mold clamping device 12, the fixing plate 16 which is the first plate to which the fixed mold 15 which is the first mold is attached and the second plate to which the movable mold 17 which is the second mold is attached are attached. An intermediate member 19 is movably arranged between the movable platen 18 and the intermediate member 19 in the mold opening / closing direction, and the intermediate molds 20 and 21 are centered on the axis O in the direction orthogonal to the mold opening / closing direction. It is rotatably attached to.

A hole 16a into which the nozzle of the injection device 13 is inserted toward the fixing mold 15 is provided in the center of the fixing plate 16. Further, mold clamping cylinders 23 (only one mold clamping cylinder 23 has a cross section shown in the schematic explanatory view of FIG. 1 and the like) are provided in the vicinity of the four corners of the fixing plate 16, and the tie bar 24 is provided by the piston rod of the mold clamping cylinder 23. It is configured. The mold clamping cylinder 23 is a bidirectionally actuated hydraulic cylinder, and a large-area mold clamping oil chamber 25 is provided on the side of the tie bar 24 in the fixing plate 16 and is provided on the anti-tie bar side (first injection device 13 side). ) Is provided with a small-area strong-type opening oil chamber 26. Further, the mold clamping cylinder 23 is changed by the mold clamping of each cycle and the strong mold opening (release) by the mold clamping cylinder 23. The position correction of the tie bar 24 and the tie bar 24 when the thickness of the attached mold is changed. The adjusting means 27 for correcting the position of the cylinder is provided.

A plurality of concave grooves for locking the half nut 30 are formed in a portion of the four tie bars 24 provided in parallel from the fixed plate 16 toward the movable plate 18 on the side far from the mold clamping cylinder 23. A locking portion 31 is provided. The tie bar 24 is inserted into holes 18a near the four corners of the movable board 18, and the movable board 18 is moved in the mold opening / closing direction on a guide such as a linear motion guide (not shown) provided on the base while being guided by the tie bar 24. It has become so. A hole 18b is provided in the center of the movable platen 18 into which the nozzle of the second injection device 14 is inserted toward the movable mold 17. The movable platen 18 and the second injection device 14 are connected and can move in the mold opening / closing direction at the same time. The injection device 13 or 14 may be arranged on the side of the mold clamping device 12.

Next, the movable platen moving mechanism 32 that moves the movable platen 18 in the mold opening / closing direction will be described. The servomotor 33 of the movable panel moving mechanism 32 is fixed to the bracket provided on the base. A ball screw 34 that can be rotated by the servomotor 33 is shaft-held at a plurality of locations on the base. On the other hand, a ball screw nut 35 is attached to the bracket of the movable board 18, and the ball screw nut 35 is inserted through the ball screw 34.

Next, the intermediate member 19 and the intermediate molds 20 and 21 will be described. An intermediate member 19 is movably arranged in the mold opening / closing direction between the fixed plate 16 to which the fixed mold 15 is attached and the movable plate 18 to which the movable mold 17 is attached. In the present embodiment, the intermediate member 19 includes an upper beam member 28 having a constant thickness and a lower beam member (not shown). Holes 29 to which guide bushes are fixed are provided in the vicinity of both ends of the upper beam member 28, and upper tie bars 24 are inserted into the holes 29, respectively. A servomotor 39 for rotating the turntable is arranged above the central portion of the upper beam member 28.

The lower beam member is movably placed on a guide such as a linear motion guide provided on the base in the opening / closing direction of the mold. Further, holes to which guide bushes are fixed are provided in the vicinity of both ends of the lower beam member, and lower tie bars 24 are inserted into the holes. A rotation shaft 40 is provided in the vertical direction (direction orthogonal to the mold opening / closing direction) between the central portion of the upper beam member 28 of the intermediate member 19 in a plan view and the central portion of the lower beam member in a plan view. The rotating shaft 40 is rotatably held with respect to the upper beam member 28 and the lower beam member.

A rotary disk 41 that rotates around the axis O (axis core) of the rotary shaft 40 is fixed to the rotary shaft 40. The rotating disk 41 included in the intermediate member 19 is a plate body having a constant thickness, and the intermediate mold 20 is attached to the plate surface on one side, and the intermediate mold 21 is attached to the plate surface on the other side. ing. Therefore, the intermediate molds 20 and 21 also rotate around the axis O of the rotating shaft 40. Further, each of the upper beam member 28 or the lower beam member is provided with a positioning pin (not shown) for positioning and fixing the turntable 41.

The upper beam member 28 and the lower beam member of the intermediate member 19 are not indispensable, and a turntable may be rotatably provided with respect to the intermediate member moving in the mold opening / closing direction on the base. Further, the turntable 41 is not essential, and one intermediate mold having at least two cavity forming surfaces may be rotatably attached to the intermediate member moving in the mold opening / closing direction.

An intermediate member moving mechanism 43 for moving the intermediate member 19 in the mold opening / closing direction by using a servo mechanism is provided between the intermediate member 19 and the movable platen 18. In the intermediate member moving mechanism 43, the servomotor 44 is fixed to a bracket provided on the movable platen 18. A ball screw 45 rotatable by the servomotor 44 is held on the movable platen 18 at a plurality of positions. On the other hand, a ball screw nut 46 is attached to the bracket of the upper beam member 28 or the like of the intermediate member 19, and the ball screw nut 46 is inserted through the ball screw 45. In the schematic plan view of FIG. 1 and the like, the intermediate member moving mechanism 43 is omitted and two units are described, but four units are arranged in the vicinity of each tie bar. The movable platen moving mechanism 32 and the intermediate member moving mechanism 43 may use a hydraulic cylinder.

In the present embodiment, among the molds attached to the injection molding machine 11, the cavity forming surface 17a of the movable mold 17 which is a core mold has a plurality of rib grooves 17b for forming ribs which are convex portions with respect to the molded product main body. It is formed. In the mold in which the rib groove 17b is fixedly formed on the cavity forming surface 17a in this way, the mold structure can be simplified as compared with the mold in which the rib groove 17b is formed by the retreat of the core. Maintenance is also easy. An ejector device 37 is attached to the movable mold 17. Here, due to the restrictions of the drawings, the ejector pin of the ejector device 37 is shown so as to project the portion of the primary molded product P1, but the portion where the ejector pin is formed at the bottom of the rib groove 17b and is secondary molded. It may be made to protrude, or both the portion of the primary molded product P1 and the portion formed by the secondary may be projected. Further, the rib groove 17b of the cavity forming surface 17a and the ejector device 37 may be provided in the intermediate molds 20 and 21 and the fixed mold 15.

In the present embodiment, the ejector device 37 is provided in the movable mold 17 which is the second mold, but may be provided in the intermediate molds 20 and 21. In particular, the composite reinforced resin molded product P2 is held on the core mold (convex mold) side of the movable mold 17 and the intermediate molds 20 and 21 and released, and the mold is released by the ejector device provided on the core mold. Things are often done.

Further, the intermediate dies 20 and 21 which are cavities (concave molds) have a structure capable of holding the primary molded product P1 when the primary molded product P1 is opened after molding. In the present invention, the first mold may be a movable mold, the first plate may be a movable plate, the second mold may be a fixed mold, and the second plate may be a fixed plate. Further, in the present embodiment, a rib is formed as an example of a complicated shape, but an additional portion of a complicated shape portion other than the rib or an additional portion of a thin wall may be formed.

Next, the control device 22 of the injection molding machine 11 will be described. In FIG. 1 and the like, the control device 22 is conceptually described as one structure, but in reality, it is often composed of a plurality of structures such as servo amplifiers of the servomotors 33 and 44. The control device 22 is connected to each servomotor 44 of the intermediate member moving mechanism 43, and a signal from the encoder 44a is taken in. The control device 22 is also connected to the servomotor 33 of the movable panel moving mechanism 32, and the signal from the rotary encoder 33a is taken in. Further, the control device 22 is connected to the hydraulic device 36 so that the servo valve 38 and the like can be controlled. Furthermore, the control device 22 is also connected to a first injection device 13, a second injection device 14, an ejector device 37, a setting display device (not shown), an external temperature control device of the injection molding machine 11, and the like.

Next, a method of molding the composite reinforced fiber resin molded product of the first embodiment using the injection molding machine 11 will be described with reference to FIGS. 1 to 4. In FIG. 1, the fixed mold 15 and the intermediate mold 20 and the movable mold 17 and the intermediate mold 21 are opened. After the composite reinforcing fiber resin molded product P2 molded last time is taken out by a take-out robot (not shown), the intermediate dies 20 and 21 and the turntable 41 are rotated 180 ° around the rotation axis O for primary molding. The product P1 faces the movable mold 17.

From the state shown in FIG. 1, the servomotor 33 of the movable platen moving mechanism 32 and the servomotor 44 of the intermediate member moving mechanism 43 are operated, and the fixed mold 15 and the intermediate mold 20 are closed as shown in FIG. The primary cavity C1 is formed. At the same time, the intermediate mold 21 and the movable mold 17 holding the primary molded product P1 are closed to form the secondary cavity C2. Then, mold clamping is performed by the mold clamping cylinder 23 (here, mold clamping is also included in the concept of mold closing described in the claims). Next, as shown in FIG. 3, a molten material containing reinforcing fibers and resin from the first injection device 13 in the primary cavity C1 formed by molding (molding) the fixed mold 15 and the intermediate mold 20. Is injected to form the primary molded product P1.

In the present invention, the type of reinforcing fiber used for molding the primary molded product P1 is not limited, but carbon fiber or glass fiber is assumed as an example, and a mixture of a plurality of types of fibers may be used. The type of resin used for molding the primary molded product P1 is also not limited, but a thermoplastic resin such as polypropylene, polyethylene, or polyamide is assumed as an example. The reinforcing fibers and the resin supplied to the first injection device 13 may be separately supplied (directly molded), or the resin pellets may contain the reinforcing fibers. However, in any case, the material containing the reinforcing fibers and the resin does not have good fluidity at the time of injection, so even if a curved surface shape or a box-shaped main body can be formed, a complicated shape such as a rib can be formed. When molding, it is often not possible to fill the material deep into the rib groove. When the primary molded product P1 is thin and has a large area, it may be desirable to use injection compression molding or a heating / cooling mold together. In the present embodiment, as compared with the case of Patent Document 3, the main body can be attached to some extent even in the primary molding. Therefore, by adding the secondary molding described later, a composite reinforcing fiber resin molding having a more complicated shape can be formed. The product P2 can be molded.

Further, the intermediate mold 21 and the movable mold 17 holding the primary molded product P1 are formed by closing (molding) the intermediate mold 21 and the movable mold 17 at the same time as or before and after the injection for molding the primary molded product P1. A molten material composed of reinforcing fibers and resin is injected into the cavity C2 (the space formed by the primary molded product P1 and the rib groove 17b of the cavity forming surface 17a of the movable mold 17), and the back surface side of the primary molded product P1. Alternatively, secondary molding is performed on the back surface side including the side surface side. The type of reinforcing fiber used for the secondary molding and the method of supplying the reinforcing fiber and the resin into the heating cylinder are not limited as in the primary molding. In the present embodiment, a material (1 to 25% by weight as an example) which is the same type of reinforcing fiber and resin as the primary molding, has a short fiber length (1 to 10 mm at the time of supply) and a low fiber content is used. Used. However, the material for secondary molding may be either a combination of fibers and resin having a short fiber length or a combination of fibers and resin having a low content rate, and a molten material consisting only of resin without containing fibers is used. It may be something to do. Further, the type of the reinforcing fiber or the resin may be changed between the primary molding and the secondary molding. By using a resin material containing these short fibers, a resin material having a low fiber content, or a resin material containing no fibers, a resin material containing long fibers or a resin material having a high fiber content is used. Since it is excellent in fluidity as compared with

When the primary molding and the secondary molding are performed by injection molding (including injection compression molding), the injection side control (including injection speed, injection pressure, holding pressure, and set temperature of the heating cylinder including the nozzle) is naturally performed. It is often changed, but when molding a complicated shape such as a rib or a thin portion thinner than the primary molding, it may be changed as follows. That is, in the secondary molding, at least one of the injection speed, the injection pressure, and the set temperature of the heating cylinder including the nozzle is set higher than that in the primary molding. Among them, the set temperature of the heating cylinder is raised by 1 to 20 ° C. even when the same resin is used. By changing the injection side control in this way, it is possible to improve the injection filling in a narrow portion or the like.

Alternatively, when a complicated shape such as a rib or a thin portion thinner than the primary molding is additionally molded, the mold clamping side control may be changed as follows. That is, the temperature of the mold used for the secondary molding may be higher than the temperature of the mold used for the primary molding. The mold temperature is also raised by 1 to 20 ° C. even when the same resin is used. The control of the mold temperature includes the use of a heating / cooling mold. In general, the volume of the secondary molding portion is often smaller than that of the primary molding portion, so even if the mold temperature for secondary molding is raised, the cooling time is extended so much and the molding cycle is lengthened. There is no. Further, as the control of the mold clamping device 12, it is conceivable to increase the compression speed at the time of injection compression molding, or to increase the compression stroke at the time of injection compression molding.

Further, the injection molding machine of the present embodiment moves the primary molded product to another molding machine in order to rotate the primary molded product P1 together with the intermediate dies 20 and 21 and then close the mold to enter the secondary molding. The secondary molding can be performed before the temperature of the primary molded product P1 is lowered as compared with the above. Therefore, there is an advantage that the primary molded product P1 and the material containing the fiber and the resin of the secondary molding can be well bonded. However, in the present invention, the primary molded product P1 may be heated and then secondary molded. In that case, when the intermediate dies 20 and 21 holding the primary molded product P1 are rotated to the secondary molding position, the entire primary molded product P1 or the secondary molding is performed by irradiation with far infrared rays or the heat of an electric heater. The joint portion of the above may be heated. Further, the second mold (movable mold 17) for secondary molding or the intermediate molds 20 and 21 are used as heating and cooling molds, and the primary molded product P1 is heated when the mold is closed, and then the material for secondary molding. May be injected.

When the cooling of the material containing the secondary molded fiber and resin is completed, the mold release (strong mold opening) is performed using the mold clamping cylinder 23, and the movable platen is moved by the movable platen moving mechanism 32 and the intermediate member moving mechanism 43. The molds of 18 and the intermediate member 19 are opened. In the present embodiment, at the time of mold release, the composite reinforcing fiber resin molded product P2 for which the secondary molding has been completed is released while being held by the movable mold 17. When the movable platen 18 and the movable mold 17 reach the mold opening completion position, the ejector device 37 operates as shown in FIG. 4, and the composite reinforcing fiber resin molded product P2 protrudes from the movable mold 17, which is not shown. It is taken out of the injection molding machine 11 by a robot.

Next, the molding method of the composite reinforced fiber resin molded product of the second embodiment of the present invention will be described with reference to FIG. 5, focusing on the differences from the first embodiment. The molding method of the composite reinforced fiber resin molded product of the second embodiment is to additionally mold a thin portion by secondary molding on the surface side of the primary molded product P3. The ejector devices 56 and 56 are attached to the turntable 53 or the intermediate molds 54 and 55 of the intermediate member 52 of the injection molding machine 51 of the second embodiment. FIG. 5 shows a process corresponding to FIG. 4 of the first embodiment, and shows a situation in which the ejector device 56 is activated and the composite reinforced fiber resin molded product P4 is projected from the intermediate mold 54. .. In FIG. 5, the intermediate dies 54 and 55 are convex core dies, and the fixed dies 57 and the movable dies 58 are concave cavities.

The primary molded product P3 of the molding method of the composite reinforced fiber resin molded product of the second embodiment is molded by injection molding (including injection compression molding) of the same material as that of the first embodiment. Then, the primary molded product P3 after molding is held by the intermediate mold 54 (or 55) which is a core mold, and moves to a position facing the movable mold 58 as the intermediate mold 54 (or 55) rotates. Then, injection molding (including injection compression molding) is performed in the cavity formed between the primary molded product P3 and the movable mold 58 which are closed and held in the intermediate mold 54 (or 55) to perform secondary molding. Perform molding. In the second embodiment, the secondary molding is mainly performed to improve the aesthetic appearance of the composite reinforced resin molded product P4. That is, in the primary molded product P3 molded from a material containing reinforcing fibers and resin, the reinforcing fibers may be exposed on the surface, which may cause an aesthetic problem. In such a case, by injection molding only the resin containing no reinforcing fiber by secondary molding and coating the surface of the primary molded product P3, the composite reinforcing fiber resin molded product P4 having a beautiful surface can be molded. it can. Regarding the second embodiment, in addition to only the surface side of the primary molded product, a thin portion may be additionally molded on the front surface side and the side surface side of the primary molded product, or on each surface. The material for secondary molding may be a resin containing reinforcing fibers, and the length or content of the reinforcing fibers in that case is preferably in the same range as that of the first embodiment.

In the second embodiment, the ejector device 56 is installed on the back surface side of the primary molded product P3 so that the dents do not affect the aesthetic appearance. Therefore, when there is a gate on the movable mold 58 side, it is preferable to provide an ejector device 56 on the intermediate mold 56. However, depending on the arrangement position of the second injection device and the arrangement of the gate in the mold, the ejector device 56 may be provided in the movable mold 58 (or the fixed mold 57).

Next, the molding method of the composite reinforced fiber resin molded product of the third embodiment will be described only by sentences, focusing on the differences from the first embodiment and the like. In the third embodiment, the primary molded product is molded from the prepreg. That is, the prepreg is set (inserted) on the cavity surface of the fixed mold or the intermediate mold, which is the first mold, by using a robot or the like. At this time, the prepreg may be one in which several sheets are laminated at a position different from that of the injection molding machine, or one in which the prepreg is preliminarily attached. Further, although the prepreg is not essential, it is desirable that the prepreg is preheated at a position different from that of the injection molding machine, or is preheated after being set in the injection molding machine and before press molding.

After the prepreg is set, the mold is closed, and the primary molding by pressing the prepreg is performed between the fixed mold and the intermediate mold. At that time, secondary molding is performed between the movable mold and the intermediate mold at the same time or slightly before and after. Then, as in the steps of FIGS. 2 to 4 of the first embodiment, after the primary molded product is molded, the primary molded product is held in the intermediate mold to open the mold (remove) and the primary molding is performed. Rotation of product and intermediate mold, re-mold closing, secondary molding (additional molding) to primary molded product, mold opening and holding of composite reinforced resin molded product in movable mold, etc., protrusion from movable mold, etc. Is done.

Also in the third embodiment, it is possible to add a complicated shape such as a rib by secondary molding by injection molding, and in that case, a material containing fibers having a short length (1 to 10 mm as an example) or , A material having a low fiber content (1 to 25% by weight as an example), or a resin material containing no fiber is used. The secondary molding by these injection moldings is mainly additionally molded on the back surface side, but may be performed on the back surface side and the side surface side, or each surface. The molding method of the composite reinforced fiber resin molded product of the third embodiment is suitable for a thin plate of the main body, a strength of the main body, a clean surface of the main body, and the like. There are many. However, the method for molding the composite reinforced fiber resin molded product of the third embodiment is often not suitable for those having a thick plate thickness of the main body portion and those having a significantly different plate thickness. Further, when the injection molding machine used in the third embodiment is a dedicated machine for molding a composite reinforcing fiber resin molded product that performs primary molding using a prepreg, only one injection device may be used.

Next, the molding method of the composite reinforced fiber resin molded product of the fourth embodiment will be described only by sentences, focusing on the differences from the third embodiment. In the fourth embodiment, the primary molded product is molded by impregnating the fiber mat with a molten resin. That is, the fiber mat is set (inserted) on the cavity surface of the fixed mold or the intermediate mold, which is the first mold, by using a robot or the like. The fiber mat at this time may be preliminarily attached at a position different from that of the injection molding machine. The fiber mat may be preheated at a position different from that of the injection molding machine, or may be preheated after setting. Further, the fiber mat may be one to which a binder or a resin for bonding is also attached.

After setting the fiber mat, the mold is closed, injection is performed from the first injection device into the cavity between the fixed mold and the intermediate mold, and the fiber mat is impregnated with the molten resin to form a primary molded product. Is molded. At this time, the inside of the cavity may be evacuated before injection. The resin to be impregnated by the injection may be a thermoplastic resin or a thermosetting resin as long as it is a resin having excellent fluidity, and examples thereof include polyamide and epoxy.

At that time, secondary molding is performed between the movable mold and the intermediate mold at the same time or slightly before and after. Then, as in FIGS. 2 to 4 of the first embodiment, after the primary molded product is molded, the primary molded product is held in the intermediate mold to open the mold (remove), and the primary molded product is formed. The intermediate mold is rotated, remolded closed, secondary molded into a primary molded product, opened and held in a movable mold or the like of a composite reinforced resin molded product, and protruded from the movable mold or the like. Also in the fourth embodiment, it is possible to add a complicated shape such as a rib by secondary molding using a resin by injection molding or a resin containing fibers as in the third embodiment.

When a resin containing fibers is used, a material containing short fibers (1 to 10 mm as an example), a material having a low fiber content (1 to 25% by weight as an example), or a resin material containing no fibers is used. Is used. The method for molding the composite reinforced fiber resin molded product of the third embodiment is also suitable for a product having a relatively thick main body portion. Further, in the fourth embodiment, when the fiber remains on the surface of the primary molded product in which the fiber mat is impregnated with the resin, which affects the aesthetic appearance expected as the molded product, the secondary molding is performed. The surface layer may be additionally molded by injection molding (including injection compression molding).

Although the present invention is not listed one by one, it is not limited to the above-described embodiment, and any combination of the above descriptions or ones skilled in the art added or modified based on the gist of the present invention. Needless to say, it applies.

The intermediate mold is rotatably arranged around the axis in the direction orthogonal to the mold opening / closing direction between the first plate to which the first mold is attached and the second plate to which the second mold is attached. Regarding the injection molding machine to be installed, a rotatable plate with an intermediate mold attached is provided in the center in a fixed or slightly movable direction in the mold opening / closing direction, and a first movable plate (first movable plate) is provided on both sides thereof. The first movable mold attached to the plate) and the second movable mold attached to the second movable plate (second plate) may be arranged so that the mold can be opened and closed.

Alternatively, the injection molding machine may be provided with a vertical mold clamping device that opens and closes the mold in the vertical direction. In that case, the rotating disk to which the intermediate mold is attached is rotated around the rotating shaft provided in the horizontal direction. Regarding the vertical mold clamping device, when inserting an insert such as a prepreg in the third embodiment or a fiber sheet in the fourth embodiment, the upward cavity forming surface of the intermediate mold and the mold of the lower plate are used. There is an advantage that the insert can be easily set on the upward cavity forming surface. Further, when the molten material containing fibers and resin is supplied on the cavity forming surface of the mold opened by stamping molding from the material supply device provided with the heating cylinder, the material is similarly applied to the cavity forming surface of the upward mold. It is advantageous to supply.

In the above embodiment, the injection device includes an example in which two injection devices 13 and 14 are provided, but three or more injection devices may be used. In that case, the primary molding may be sequentially or simultaneously molded using two or more injection devices, and the secondary molding after the rotation of the intermediate mold is sequentially or simultaneously molded using two or more injection devices. May be good. Alternatively, molding may be performed at 3 o'clock in a separate process.

Further, a primary molded product containing reinforcing fibers and resin is injection-molded in the primary cavity, and the content of the reinforcing fibers, which is a material containing reinforcing fibers and resin, is on the back surface side of the primary molded product. A material having a lower length or a shorter reinforcing fiber length than the primary molded product, or a resin-only material containing no reinforcing fiber is injected to add a complicated shape such as a rib by secondary molding. The molding method for molding the composite reinforced fiber resin molded product is effective even in an injection molding machine as in Patent Document 2, regardless of whether it is a vertical mold or a horizontal mold. That is, it is an injection molding machine in which a rotary table is provided on one of a fixed plate or a movable plate, a rotary mold is attached to the rotary table, and the mold is clamped to the other mold of the fixed plate or the movable plate. This injection molding machine is equipped with two or more injection devices, and after primary molding in the primary cavity, the mold is opened, and then the rotary mold holds the primary molded product and is rotationally moved together with the rotary table. A composite reinforcing fiber resin molded product is formed by secondary molding in a closed secondary cavity. Even in that case, in the secondary molding as described in the first embodiment and the second embodiment described above, the material is changed from the primary molding, or the injection side control or the mold clamping side control is changed. Is performed to mold the composite reinforcing fiber resin molded product.

11,51 Injection molding machine 12 Mold clamping device 13 First injection device 14 Second injection device 15,57 Fixed mold 16 Fixed plate 17,58 Movable mold 18 Movable plate 19, 52 Intermediate members 20, 21, 54 , 55 Intermediate mold 40 Rotating shaft 41,53 Rotating machine C1 Primary cavity C2 Secondary cavity P1, P3 Primary molded product P2. P4 Composite Reinforced Fiber Resin Molded Product

Claims (3)

The intermediate mold is rotatably arranged around the axis in the direction orthogonal to the mold opening / closing direction between the first plate to which the first mold is attached and the second plate to which the second mold is attached. In the molding method of the composite reinforcing fiber resin molded product using the injection molding machine provided,
In the primary cavity formed by closing the first mold and the intermediate mold, a material containing reinforcing fibers and resin is injected from the first injection device to primary mold the primary molded product.
While the primary molded product is held in the intermediate mold, the released intermediate mold is rotated.
The intermediate mold holding the primary molded product and the second mold having rib grooves fixedly formed on the cavity surface are closed to form a secondary cavity for forming ribs .
A material containing reinforcing fibers and a resin in the secondary cavity, the content of the reinforcing fibers is lower than that of the primary molded product, or the length of the reinforcing fibers is shorter than that of the primary molded product, or When a resin-only material that does not contain reinforcing fibers is injected from a second injection device and secondary molding is performed to form a composite reinforcing fiber resin molded product , at least one of the injection speed and injection pressure and the nozzle are used during the secondary molding. A molding method for a composite reinforced fiber resin molded product, characterized in that the set temperature of the including heating cylinder is set higher than that at the time of primary molding, and the primary molding is to change the injection side control. The intermediate mold is rotatably arranged around the axis in the direction orthogonal to the mold opening / closing direction between the first plate to which the first mold is attached and the second plate to which the second mold is attached. In the molding method of the composite reinforcing fiber resin molded product using the injection molding machine provided,
In the primary cavity formed by closing the first mold and the intermediate mold, a material containing reinforcing fibers and resin is injected from the first injection device to primary mold the primary molded product.
While the primary molded product is held in the intermediate mold, the released intermediate mold is rotated.
The intermediate mold holding the primary molded product and the second mold having rib grooves fixedly formed on the cavity surface are closed to form a secondary cavity for forming ribs .
A material containing reinforcing fibers and a resin in the secondary cavity, the content of the reinforcing fibers is lower than that of the primary molded product, or the length of the reinforcing fibers is shorter than that of the primary molded product, or Composite reinforced resin molding is performed by injecting a resin-only material that does not contain reinforcing fibers from a second injection device by increasing at least one of the injection speed, injection pressure, and set temperature of the heating cylinder including the nozzle to perform secondary molding. When molding a product
Both the primary molding and the secondary molding are performed by injection molding, and at least the heating and cooling mold is used in the secondary molding to make the temperature higher than the temperature of the mold in the primary molding, and injection in the secondary molding. A molding method for a composite reinforced fiber resin molded product, which comprises molding a composite reinforced fiber resin molded product by changing the side control and the mold clamping side control. The intermediate mold is rotatably arranged around the axis in the direction orthogonal to the mold opening / closing direction between the first plate to which the first mold is attached and the second plate to which the second mold is attached. In the molding method of the composite reinforcing fiber resin molded product using the injection molding machine provided,
A primary molded product containing reinforcing fibers and resin is first-molded using a first injection device in a primary cavity formed by closing the first mold and an intermediate mold.
While the primary molded product is held in the intermediate mold, the released intermediate mold is rotated.
When forming a secondary cavity by closing the intermediate mold holding the primary molded product and the second mold having a rib or a cavity surface forming a thin portion thinner than the primary molded product. Then, the primary molded product is heated,
A material containing reinforcing fibers and a resin from a gate formed in a second mold in the secondary cavity, and the content of the reinforcing fibers is lower than that of the primary molded product, or the length of the reinforcing fibers is the above. Use a second injection device to increase at least one of the injection speed, injection pressure, and set temperature of the heating cylinder including the nozzle for a material shorter than the primary molded product or a resin-only material that does not contain reinforcing fibers. injection and molding the back side ribs or primary thin thin portion than the molded product is formed a composite reinforced resin molded product subjected to secondary molding Te,
The back surface side of the composite reinforced resin molded product was released while being held in the second mold which is the core mold.
A method for molding a composite reinforced fiber resin molded product, which comprises projecting the back surface side of the composite reinforced resin molded product by an ejector arranged in the second mold.

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