JP6971098B2 - Resin molded product manufacturing equipment and light irradiation equipment - Google Patents

Description

The present invention relates to a resin molded product manufacturing apparatus and a light irradiation apparatus. In particular, the present invention relates to a resin molded product manufacturing apparatus for filament winding molding using a photocurable resin, and a light irradiation device used in such a resin molded product manufacturing apparatus.

Fiber reinforced plastic (hereinafter referred to as FRP) is a composite material in which fibers such as glass fibers are contained in a resin. FRP is used as a lightweight, high-strength, high-rigidity material in various fields such as aircraft, ships, automobiles, and daily necessities. Further, as an example of a specific use of FRP, a container such as a high-pressure tank can be mentioned.

Examples of the form of FRP include those in which finely cut fibers are dispersed in a resin and those in which fibers are aligned in a specific direction and impregnated in the resin. In particular, the latter can obtain very high tensile strength in the direction in which the fibers are aligned. Further, by laminating a plurality of layers having different fiber directions, FRP having high tensile strength in various directions can be obtained. Such FRP is suitable for use as a container that requires high strength as described above.

Filament winding molding is one of the methods for producing FRP in which fibers are aligned in a specific direction. Filament winding molding involves impregnating a matrix resin with one or more glass fibers, carbon fibers, etc., winding the rotating mandrel while applying tension, curing it on the mandrel, and then removing the mold. This is a molding method for obtaining a molded product.

As a method for curing the resin, thermosetting in which the resin is cured while rotating the mandrel in a heating furnace is generally used. However, in the case of thermosetting, in order to suppress the progress of the curing reaction, there is a usable period (potential time) in the resin containing the curing agent. Therefore, it is necessary to frequently add the resin according to such a period.

In order to solve such a problem, a photocuring technique has been developed in which the resin on the mandrel is irradiated with light to cure the resin. In the case of photo-curing, the resin containing the photo-curing initiator may be shielded from light having a wavelength at which the curing reaction occurs. As a result, the resin can be kept in a usable state for a long period of time. Further, it is not necessary to frequently add the resin as in the case of the above-mentioned thermosetting.

Examples of filament winding molding by photocuring include the following Patent Documents 1 and 2. Specifically, Patent Document 1 is equipped with two or more lamps of at least one type selected from metal halide lamps and mercury lamps while winding a glass roving impregnated with a visible light curable resin around a mandrel and rotating the mandrel. It is described that the visible light is irradiated by using the light irradiation device.

Further, in Patent Document 2, a tow prepreg in which a fiber bundle is impregnated with a photocurable resin composition is wound around the outer peripheral surface of the liner while rotating a liner which is a hollow cylindrical member, and is wound around the outer peripheral surface of the liner. A method for manufacturing a composite container for irradiating the tow prepreg with light is described.

Japanese Unexamined Patent Publication No. 2010-12794 Japanese Unexamined Patent Publication No. 2011-206933

However, the light irradiation device described in Patent Document 1 is a device in which lamps are arranged in a straight line in one direction. Therefore, in the case of manufacturing a resin molded product having a shape in which the direction of the surface changes, such as the high-pressure tank described above, it is difficult to ensure quality and productivity.

Similarly, the manufacturing method described in Patent Document 2 can irradiate light only in a direction perpendicular to the rotation axis of the liner. Therefore, in a container such as a high-pressure tank in which both ends are closed, it is not possible to efficiently irradiate both end surfaces with light. Therefore, in the manufacturing method described in Patent Document 2, it takes a long time to cure the resin on both end faces. Further, in the production of a resin molded product such as the above-mentioned container, the productivity is lowered.

Therefore, the present invention comprises a resin molded product manufacturing apparatus capable of manufacturing a resin molded product such as a container having an upper surface and / or a lower surface, which is made of FRP using a photocurable resin, with high productivity. It is an object of the present invention to provide a light irradiation device capable of efficiently irradiating an object to be irradiated such as a liner wound with fibers impregnated with a photocurable resin with light.

In order to achieve the above object, the present invention provides the following means.
[1] A resin molded product manufacturing apparatus that cures the photocurable resin by irradiating the photocurable resin with light while rotating a liner wound with fibers impregnated with the photocurable resin. The first irradiation unit, which is arranged to face the outer surface of the liner and irradiates the liner on which the fiber impregnated with the photocurable resin is wound with light from the first direction, and the above. A liner in which fibers impregnated with the photocurable resin are wound so as to face the outer surface of the liner at a position different from the first irradiation unit in a direction parallel to the rotation axis of the liner. On the other hand, the second irradiation unit includes a second irradiation unit that irradiates light from a second direction whose angle with respect to the rotation axis of the liner is different from that of the first direction, and the second irradiation unit irradiates light in a planar manner. The surface light source is formed by arranging a plurality of light sources, and is formed of a resin that can rotate about an axis perpendicular to the rotation axis of the liner and the second direction. Product manufacturing equipment.
[2] The apparatus for manufacturing a resin molded product according to the above [1], wherein the first direction is perpendicular to the rotation axis of the liner .
[3] The surface light source is the resin molded product according to the above [1] or [2] , wherein the plurality of light sources are arranged side by side in a row direction and a column direction in a rectangular surface. Manufacturing equipment .
[ 4 ] The apparatus for manufacturing a resin molded product according to any one of [1] to [3 ], wherein the second irradiation unit is movable in a direction approaching and a direction away from the rotation axis of the liner.
[ 5 ] The apparatus for manufacturing a resin molded product according to any one of [1] to [4 ], wherein the second irradiation unit includes an LED as a light source.
[ 6 ] A light irradiation device that irradiates the irradiated object with light while rotating the irradiated object, which is arranged so as to face the outer surface of the irradiated object and is first with respect to the irradiated object. The first irradiation unit that irradiates light from the direction of the above is arranged at a position different from the first irradiation unit in a direction parallel to the rotation axis of the object to be irradiated, facing the outer surface of the object to be irradiated. The second irradiation unit comprises a second irradiation unit that irradiates the irradiated object with light from a second direction whose angle with respect to the rotation axis of the irradiated object is different from that of the first direction. Is a surface light source that irradiates light in a planar manner, and the surface light source is configured by arranging a plurality of light sources, and is an axis perpendicular to the rotation axis of the liner and the second direction. A light source that can rotate around.

As described above, according to the present invention, a resin molded product made of FRP using a photocurable resin, such as a container having an upper surface and / or a lower surface, can be produced with high productivity. It is possible to provide a manufacturing apparatus and a light irradiation apparatus capable of efficiently irradiating an object to be irradiated such as a liner wound with fibers impregnated with a photocurable resin with light.

It is sectional drawing of the container as an example of the resin molded article which concerns on one Embodiment of this invention. It is a perspective view which shows the filament winding molding apparatus as an example of the manufacturing apparatus of the resin molded article which concerns on one Embodiment of this invention. It is a front view which shows the rotating apparatus which the filament winding molding apparatus which concerns on one Embodiment of this invention includes. It is a front view which shows the light irradiation apparatus provided in the filament winding molding apparatus which concerns on one Embodiment of this invention. It is a top view which looked at the 1st irradiation unit as an example from the irradiation direction of light. It is a top view which looked at the 2nd irradiation unit as an example from the irradiation direction of light. It is a perspective view which shows the 1st modification of the light irradiation apparatus which concerns on one Embodiment of this invention. It is a front view which shows the 2nd modification of the light irradiation apparatus which concerns on one Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described.
In the present embodiment, the container V shown in FIG. 1 as an example of the resin molded product manufactured by applying the present invention, and the light shown in FIG. 2 as an example of the manufacturing apparatus of the resin molded product to which the present invention is applied. A filament winding molding apparatus (hereinafter referred to as FW molding apparatus) 1 for filament winding molding using a curable resin will be described.

However, the scope of the present invention is not limited to the configuration of the following embodiments. Further, in the following description, the "rotating shaft" refers to the rotating shaft of the liner L or the container V attached to the FW molding apparatus 1 unless otherwise specified. Further, the "axial direction" is defined as a direction parallel to the rotation axis.

<1. Resin molded products>
First, the configuration of the container V shown in FIG. 1 will be specifically described. FIG. 1 is a cross-sectional view of a container V as an example of a resin molded product according to an embodiment of the present invention.
As shown in FIG. 1, the container V of the present embodiment includes a liner L, an insert member M, and a composite material layer C.

The liner L has an outer surface having a rotating surface and constitutes an inner wall of the container V. The liner L includes a cylindrical body portion L1 extending in the axial direction, mirror portions L2 and L3 (upper surface L2, lower surface L3) that close both ends of the body portion L1, and a neck portion L4 at the center of one mirror portion L2. It has a bottom L5 at the center of the other mirror portion L3.

In the present embodiment, the liner L is manufactured, for example, by blow molding or injection molding a thermoplastic resin. As the material of the liner L, the light emitted by the plurality of light sources 511, 521, and 513 included in the irradiation units 51, 52, and 53 of the light irradiation device 50 shown in FIG. 4, which will be described later, in consideration of the use of the container V. It is preferable that the material permeates the material, and examples thereof include high-density polyethylene.

The neck portion L4 has a cylindrical portion L41 extending axially from the mirror portion L2 toward the outside of the container V. Further, the neck portion L4 is formed from an end wall L42 formed from one end of the outer side of the container V of the cylindrical portion L41 toward the rotation axis and toward the outside of the cylindrical portion L41 from one end of the outer side of the container V of the cylindrical portion L41. It has a flange L43. A circular through hole L44 centered on a rotation axis is formed in the end wall L42.

The bottom portion L5 has a neck portion L51 extending axially from the mirror portion L3 toward the outside of the container V, a flange L52 formed from one end of the outside of the container V of the neck portion L51 toward the direction away from the rotation axis, and a flange L52. It has a cylindrical portion L53 extending axially from the container V toward the outside of the container V.

An insertion hole L54 is formed in the bottom portion L5 in the axial direction from the outer end surface of the container V of the cylindrical portion L53 toward the inside of the container V. In the manufacturing process of the container V, the auxiliary shaft 42 included in the rotating device 40 shown in FIG. 3, which will be described later, is inserted into the insertion hole L54.

Regarding the depth of the insertion hole L54, it is preferable that the distance between the bottom of the insertion hole L54 and the inner surface of the liner L is equal to or greater than the thickness of the liner L in the mirror portion L3 without penetrating the liner L. Further, the depth of the insertion hole L54 is more preferably equal to or less than the total of the thickness of the flange L52 and the length of the cylindrical portion L53. This makes it possible to prevent the bottom L5 from being damaged when stress is concentrated on the bottom L5.

The insert member M is arranged inside the neck portion L4 of the liner L in a state of being in contact with the inner surface of the cylindrical portion L41 and the inner surface of the end wall L42. In this embodiment, the insert member M is integrally molded with the liner L. For example, when the liner L is blow molded, the insert member M can be integrally molded with the liner L by fixing the insert member M at a predetermined position in the mold. As the material of the insert member M, metal is preferable, and aluminum alloy is particularly preferable.

The insert member M is formed with a through hole M1 centered on a rotation axis. The diameter of the through hole M1 is smaller than the diameter of the through hole L44 of the end wall L42. A female threaded portion M11 is formed on the inner peripheral surface of the through hole M1 over the entire length of the through hole M1 or a part of the outside of the container V. In the manufacturing process, the female threaded portion M11 is screwed with the threaded portion 411 of the drive shaft 41 included in the rotating device 40 shown in FIG. 3, which will be described later. Further, when the container V is used, for example, a male screw provided in a regulator or the like is screwed into the female screw portion M11.

The composite material layer C is formed on the outside of the liner L in the whole of the body portion L1, the mirror portions L2, and L3, and a part of the neck portion L4 and the bottom portion L5. The composite material layer C has a first hoop layer C1, a helical layer C2, and a second hoop layer C3. The composite material layer C is made of FRP in which the cured resin P is used as a matrix and the fibers F are contained in the matrix. The cured resin product P is produced by curing the photocurable resin P1 described later. Examples of the fiber F include glass fiber, carbon fiber, metal fiber and the like. Among them, it is preferable to use a glass fiber that easily transmits the light irradiated by the light irradiation device 50 described later.

The first hoop layer C1 is formed on the outside of the body portion L1. In the first hoop layer C1, the fiber F is wound by so-called hoop winding at an angle substantially perpendicular to the rotation axis. In the first hoop layer C1, the fiber F may be wound in one layer or may be wound so as to form two or more layers.

Here, the reason why the winding direction of the fiber F is substantially perpendicular to the rotation axis is that when the fiber F makes one round of the body portion L1 when the fiber F is strictly perpendicular to the rotation axis, it is the starting point of the fiber F. This is because the fibers F overlap and the fibers F do not advance in the axial direction. Therefore, in the present embodiment, the fiber F that has made one round of the body portion L1 advances in the axial direction by at least the diameter of the fiber F or more with respect to the fiber F that has made one round. When the fibers F are N fibers arranged in the axial direction, the fiber F that has made one round of the body portion L1 is at least N times the diameter of the fiber F or more in the axial direction with respect to the fiber F one round before. It is preferable to proceed to.

The first hoop layer C1 can suppress the deformation of the body L1 when a large force acts outward on the body L1 due to the pressure inside the container V or the like. This configuration is particularly effective in cylindrical containers such as this embodiment.

The helical layer C2 is formed on the outer side of the first hoop layer C1 in the body portion L1. Further, the helical layer C2 is formed on the outside of the liner L in the entire mirror portion L2 and L3, and a part of the neck portion L4 and the bottom portion L5.

In the helical layer C2, the fiber F is wound by so-called helical winding at an angle between the direction of the rotation axis and the direction of hoop winding. In the helical layer C2, the fibers F are wound so as to form a plurality of layers. Further, when the winding direction of the fiber F in one of the adjacent layers is the direction of the right-handed screw, the winding direction of the fiber F in the other layer is preferably the direction of the left-handed screw.

The helical layer C2 can suppress the deformation of the liner L with respect to the stress acting on the mirror portions L2, L3, the neck portion L4, and the bottom portion L5. Further, the fibers F of the helical layer C2 squeeze the first hoop layer C1 from the outside, so that the fibers F of the first hoop layer C1 are suppressed from moving in the axial direction, and the first hoop layer C1 is reinforced. ..

The second hoop layer C3 is formed on the outer side of the helical layer C2 in the body portion L1. In the second hoop layer C3, the fibers F are wound around the body portion L1 by hoop winding in the same manner as in the first hoop layer C1. In the second hoop layer C3, the fiber F may be wound in one layer or may be wound so as to form two or more layers.

The reason and effect of providing the second hoop layer C3 are described in the first hoop layer C1, and the fibers F of the second hoop layer C3 squeeze the helical layer C2 from the outside to form the helical layer C2. The effect is that the fiber F is more firmly fixed and the helical layer C2 is reinforced.

<2. Resin molded product manufacturing equipment>
Next, the configuration of the FW molding apparatus 1 shown in FIG. 2 will be specifically described. Note that FIG. 2 is a perspective view showing a FW molding apparatus 1 as an example of an apparatus for manufacturing a resin molded product according to an embodiment of the present invention.

As shown in FIG. 2, the FW molding apparatus 1 winds the fiber F impregnated with the photocurable resin P1 on the liner L while rotating the liner L, and illuminates the photocurable resin P1 on the liner L. This is a device for producing a resin molded product that cures the photocurable resin P1 by irradiating with the above to form a composite material layer C. Specifically, the FW molding apparatus 1 includes a fiber supply unit 10, a resin supply unit 20, a fiber guide unit 30, a rotation device 40, and a light irradiation device 50.

The fiber supply unit 10 includes a roving 11 having fibers F wound in a cylindrical shape, and a supply roller 12 for transporting the fibers F. In the fiber supply unit 10, one end of the fiber F is pulled out from the roving 11, the fiber F is brought into contact with the supply roller 12, and the supply roller 12 is rotated to supply the fiber F to the resin supply unit 20.

In the present embodiment, the roving 11 has a plurality of installed configurations, and the fiber F is drawn out from each roving 11. Depending on the application, the fiber supply unit 10 may supply pre-woven cloth-like fibers or the like. Further, in the present embodiment, one supply roller 12 is provided, but a plurality of supply rollers 12 may be provided if necessary.

The resin supply unit 20 includes a resin tank 21, a transfer roller 22, and a transfer roller 23. The liquid photocurable resin P1 is stored in the resin tank 21. The photocurable resin P1 is a raw material for the cured resin P, that is, the matrix of the composite material layer C. Examples of the photocurable resin P1 include, but are not limited to, lipoxy LC-720 and LC-760, which are visible light curable resins.

The transport roller 22 is provided in the resin tank 21. By bringing the fiber F into contact with the lower side of the transport roller 22, the fiber F is guided into the resin tank 21, and the fiber F can be impregnated with the photocurable resin P1.

The transport roller 23 is provided between the resin tank 21 and the fiber guide portion 30. By rotating the transport roller 23 with the fiber F in contact with the transport roller 23, the fiber F impregnated with the photocurable resin P1 is sent to the fiber guide portion 30.

The fiber guide portion 30 includes a rail 31 and a fiber guide 32. The rail 31 is a pair of rod-shaped members extending in the axial direction of the liner L. The fiber guide 32 bundles the fibers F sent from the resin supply unit 20 inside the fiber guide 32 and sends them to the liner L which is fixed to the rotating device 40 and rotates.

The fiber guide 32 is attached to the rail 31 and can reciprocate on the rail 31 in the axial direction. As the operating mechanism of the fiber guide 32, for example, a rack is provided on one side of the rail 31, an electric motor with a pinion attached is provided in the fiber guide 32, and a structure in which the rack and the pinion are engaged (rack and pinion). And so on. The configuration of the fiber guide portion 30 described here is an example, and for example, a resin tank may be mounted on the fiber guide portion 30, or roving may be mounted.

With this configuration, the fiber guide portion 30 can control the winding structure of the fiber F by controlling the moving speed of the fiber guide 32. Further, by controlling the moving range of the fiber guide 32, the range in which the fiber F is wound can be adjusted.

The movement control of the fiber guide 32 is controlled by, for example, a computer (not shown). For example, when the container V as shown in FIG. 1 is manufactured, the operation of the fiber guide portion is controlled as follows.

First, the fiber guide 32 is supplied at a slow speed in the range of the body L1 (for example, (for example, the diameter of the fiber F + the thickness of the photocurable resin P1 between the fibers F) × (while the liner L makes one rotation). The first hoop layer C1 is formed by reciprocating at a speed (speed advancing by the number of fibers F). Next, the fiber guide 32 is reciprocated at a high speed (for example, a speed higher than that at the time of forming the first hoop layer C1) within a range covering the body portion L1 and the mirror portions L2 and L3, so that the helical layer C2 is reciprocated. It is formed. After that, the fiber guide 32 is reciprocated within the range of the body portion L1 at a slow speed (for example, the same speed as when the first hoop layer C1 is formed) to form the second hoop layer C3. The thickness of each layer can be controlled by the number of round trips of the fiber guide portion 30.

<3. Rotating device>
Next, the configuration of the rotating device 40 included in the FW forming device 1 will be described with reference to FIG. Note that FIG. 3 is a front view showing a rotating device 40 included in the filament winding molding device 1 according to the embodiment of the present invention.

As shown in FIG. 3, the rotating device 40 rotates the liner L, and includes a drive shaft 41, an auxiliary shaft 42, an auxiliary support portion 43, and a main body portion 44. The drive shaft 41 is a rod-shaped member on the rotation shaft and penetrates the main body 44. The drive shaft 41 includes a screw portion 411 at one end on the liner L side, and a gear 412 at a portion inside the main body portion 44.

The male threaded portion 411 is screwed into the female threaded portion M11 of the through hole L44 of the insert member M in the neck portion L4. As a result, the liner L is fixed to the drive shaft 41 and rotates together with the drive shaft 41.

In the present embodiment, when the liner L is viewed from the drive shaft 41 side, the fiber F sent from the fiber guide portion 30 reaches the liner L from the upper left of the liner L. Further, as the liner L rotates to the right, the fiber F is wound around the liner L. When the liner L is rotated counterclockwise, the fiber F may reach from the lower right of the liner L.

Further, in the present embodiment, the male threaded portion 411 and the female threaded portion M11 are right-handed threads. That is, in the present embodiment, the direction in which the liner L is rotated is the same as the direction in which the screw connecting the drive shaft 41 and the liner L is connected. According to this configuration, loosening of the screw can be suppressed. Further, the liner L is more reliably fixed to the drive shaft 41. When the liner L is rotated in the reverse direction, it is preferable that the male thread portion 411 and the female thread portion M11 are left-hand threads (reverse threads).

The auxiliary shaft 42 rotatably supports the mirror portion L3 side of the liner L. The auxiliary shaft 42 is a rod-shaped member on the rotating shaft. One end of the auxiliary shaft 42 is inserted into the shaft support portion 431 of the auxiliary support portion 43, which will be described later. Further, the other end of the auxiliary shaft 42 is inserted into the insertion hole L54 of the bottom portion L5 of the liner L.

The auxiliary support portion 43 includes a shaft support portion 431 on the upper side of a member extending vertically and a piston 432 on the lower side. The shaft support portion 431 pivotally supports the auxiliary shaft 42. A typical configuration of the shaft branch 431 is a ball bearing, but the present invention is not limited to this. The piston 432 is located below the liner L and extends axially.

The main body 44 includes a drive device 441, a power transmission section 442, and a cylinder 443. The drive device 441 is a power source, and examples thereof include an electric motor, an internal combustion engine, and an external combustion engine. Among them, it is preferable to use an electric motor because of ease of control. The power transmission unit 442 is a gear that meshes with the gear 412 of the drive device 441 and the drive shaft 41. In this embodiment, a gear is used as a means for transmitting power from the drive device 441 to the drive shaft 41. Further, the means for transmitting power is not limited to this, and for example, means using a belt and a pulley can be used.

The cylinder 443 is located below the liner L. The cylinder 443 is a shaft extending from the main body portion 44 toward the auxiliary support portion 43. A piston 432 is inserted into the cylinder 443. With this configuration, the auxiliary support portion 43 is supported so as to be reciprocally movable in the axial direction (directions of arrows AL1 and AR1 in FIG. 3). Therefore, the auxiliary support portion 43 is moved in the direction of the liner L while the neck portion L4 of the liner L is fixed to the drive shaft 41 first. As a result, the auxiliary shaft 42 is inserted into the bottom L5, and the liner L is rotatably fixed to the rotating device 40.

<4. Light irradiation device>
Next, the configuration of the light irradiation device 50 included in the FW molding device 1 will be described with reference to FIG. Note that FIG. 4 is a front view showing the light irradiation device 50 according to the embodiment of the present invention.

The light irradiation device 50 irradiates the photocurable resin P1 (irradiated object) on the liner L with light, and includes a first irradiation unit 51, a second irradiation unit 52, and a third irradiation unit 53. , A retainer 54 and a trolley 55.

In the following description, the directions of the irradiation units 51, 52, 53 and the directions in which the irradiation units 51, 52, 53 irradiate light (first direction D1, second direction D2, and the second direction described later). The direction D3) of 3 means the direction in which the light emitted by each irradiation unit 51, 52, 53 is the strongest.

The first irradiation unit 51 faces the outer surface of the body portion L1 of the liner L. The first irradiation unit 51 includes a plurality of light sources 511 (the arrangement of the light sources 511 will be described with reference to FIG. 5 described later), and a cover 512. In the present embodiment, the direction D1 in which the first irradiation unit 51 irradiates light (hereinafter referred to as the first direction) is a direction toward the rotation axis and a direction perpendicular to the rotation axis.

The plurality of light sources 511 irradiate light in the first direction D1. The wavelength of the light emitted by each light source 511 is preferably a region where the photocurable resin P1 is efficiently cured. Further, the light emitted by each light source 511 preferably passes through the liner L. This is because even if there is a portion where it is difficult to directly irradiate the light, the light transmitted through the liner L reaches the portion.

For example, when the liner L is made of high density polyethylene, the light source 511 preferably emits light having a wavelength of 380 to 450 nm. It is preferable to use an LED as the light source 511. Since the LED is a light emitting element having high luminous efficiency, it can irradiate a large amount of light with low power consumption. The LED is also a light emitting element having a long life. Therefore, the maintenance cost due to the replacement of the light source 511 can be reduced. However, depending on the conditions, a metal halide lamp, an organic EL, an inorganic EL, or the like may be used as the light source 511.

The cover 512 has a plate-like shape arranged in parallel to the plane on which the plurality of light sources 511 are arranged between the photocurable resin P1 on the liner L, which is the object to be irradiated (the object to be irradiated), and the light source 511. It is a member. The cover 512 can protect the plurality of light sources 511 from the droplets of the photocurable resin P1. Therefore, even during the winding of the fiber F, the photocurable resin P1 can be irradiated with light, and the productivity of the container V is improved.

In this case, the cover 512 needs to be able to transmit light having a wavelength required for curing the photocurable resin P1. Examples of the material of the cover 512 include glass, quartz, polycarbonate, polymethyl methacrylate and the like. Further, glass and quartz having excellent solvent resistance and corrosion resistance are preferable, and glass is particularly preferable in consideration of the cost of equipment.

FIG. 5 is a plan view of the first irradiation unit 51 as an example as viewed from the light irradiation direction. In the first irradiation unit 51, as shown in FIG. 5, a plurality of light sources 511 are axes within the range of a rectangle having the axial direction as the longitudinal direction (including the case of a square. The same shall apply hereinafter unless otherwise specified). They are arranged side by side in the row direction parallel to the direction and in the column direction orthogonal to the row direction. That is, in the first irradiation unit 51, a surface light source that irradiates light in a plane is configured by arranging a plurality of light sources 511 side by side in the row direction and the column direction in the rectangular plane.

Regarding the arrangement of the plurality of light sources 511 constituting this surface light source, the following points should be considered. That is, the narrower the distance between the light sources 511 in the axial direction (row direction), the higher the uniformity of the light emitted to the liner L. On the other hand, the number of required light sources 511 increases, and costs such as power consumption and maintenance increase.

On the other hand, as the distance between the light sources 511 in the axial direction becomes wider, the number of required light sources 511 is reduced, and the cost of power consumption and maintenance can be suppressed. On the other hand, the uniformity of the light irradiated to the liner L is lowered. Further, since the effect of the photocurable resin P1 takes time in the portion where the intensity of the irradiated light is low, the productivity of the container V is lowered.

By providing the plurality of light sources 511 in the rotation direction (row direction) of the liner L, the amount of light emitted to the liner L is increased. Further, since the photocurable resin P1 on the liner L is irradiated with light for a longer time during one rotation, the productivity of the container V is improved.

The arrangement of the plurality of light sources 511 shown in FIG. 5 is only an example, and the intervals of the light sources 511 may be changed depending on the location instead of the equal intervals depending on the conditions such as the shape of the liner L. Further, the configuration shown in FIG. 5 is an example of the arrangement of a plurality of light sources 511, and the formed surface is not limited to a rectangle.

As shown in FIG. 4, the second irradiation unit 52 is arranged at a position different from that of the first irradiation unit 51 in the direction parallel to the rotation axis. In the present embodiment, the second irradiation unit 52 is arranged on the mirror unit L2 side with respect to the first irradiation unit 51.

The second irradiation unit 52 faces the outer surface of the mirror portion L2 of the liner L. The second irradiation unit 52 includes a plurality of light sources 521 (the arrangement of the light sources 521 will be described with reference to FIG. 6 described later) and a cover 522. In the present embodiment, the direction D2 in which the second irradiation unit 52 irradiates light (hereinafter referred to as the second direction) is the direction toward the rotation axis and the direction toward the first irradiation unit 51 side. The angle of the second direction D2 with respect to the rotation axis is different from that of the first direction D1. That is, the second direction D2 is a direction that forms an acute angle with respect to the rotation axis or is parallel to the rotation axis.

The plurality of light sources 521 irradiate light in the second direction D2. As each light source 521, the same light source 511 used in the first irradiation unit 51 can be used. The cover 522 has a plate-like shape arranged in parallel to the plane on which the plurality of light sources 521 are arranged between the photocurable resin P1 on the liner L, which is the object to be irradiated (the object to be irradiated), and the light source 521. It is a member. As the cover 522, the same material as the cover 512 used in the first irradiation unit 51 can be used.

It is preferable that the power supply to each light source 521 of the second irradiation unit 52 is performed independently of each light source 511 of the first irradiation unit 51. As a result, for example, in the process of forming the first hoop layer C1 and the second hoop layer C3 that are not formed on the mirror portion L2, light irradiation is performed unless power is supplied to each light source 521 of the second irradiation unit 52. The electric power used by the device 50 can be reduced.

FIG. 6 is a plan view of the second irradiation unit 52 as an example as viewed from the light irradiation direction.
In the second irradiation unit 52, as shown in FIG. 6, a plurality of light sources 521 are arranged side by side in the row direction perpendicular to the rotation axis and in the row direction orthogonal to the column direction. That is, in the second irradiation unit 52, a surface light source that irradiates light in a plane is configured by arranging a plurality of light sources 521 side by side in the row direction and the column direction in the rectangular plane.

Regarding the arrangement and spacing in the row direction of the plurality of light sources 521 constituting this surface light source, the same reason as the arrangement and spacing in the row direction of the plurality of light sources 521 of the first irradiation unit 51 should be considered.

Further, the advantage of providing the plurality of light sources 521 in the row direction is considered to be the following advantages in addition to those described in the first irradiation unit 51. That is, the fluid photocurable resin P1 tends to be formed thicker on the rotating liner L as the portion closer to the rotation axis. Therefore, the photocurable resin P1 in the portion close to the rotation axis needs to be irradiated with more light in order to be cured.

Here, when the second irradiation unit 52 constitutes a surface light source as in the present embodiment, the portion closer to the rotation axis is irradiated with light at a wider angle. That is, the closer to the axis of rotation, the longer the light is irradiated. From this, when the second irradiation unit 52 is used as a surface light source, the photocurable resin P1 on the mirror portion L2 can be cured more efficiently and uniformly.

The arrangement of the plurality of light sources 521 shown in FIG. 6 is only an example, and the intervals of the light sources 521 may be changed depending on the location instead of the equal intervals depending on the conditions such as the shape of the liner L. Further, the configuration shown in FIG. 6 is an example of the arrangement of a plurality of light sources 521, and the formed surface is not limited to a rectangle.

As shown in FIG. 4, the third irradiation unit 53 is arranged at a position different from that of the first irradiation unit 51 in a direction parallel to the rotation axis. In the present embodiment, the third irradiation unit 53 is arranged on the mirror unit L3 side with respect to the first irradiation unit 51.

The third irradiation unit 53 faces the outer surface of the mirror portion L3 of the liner L. The third irradiation unit 53 includes a plurality of light sources 531 and a cover 532. In the present embodiment, the direction (hereinafter referred to as the third direction) D3 in which the third irradiation unit 53 irradiates light is an axial direction, that is, a direction parallel to the rotation axis.

The plurality of light sources 531 and the cover 532 are the same as the plurality of light sources 521 and the cover 522 in the second irradiation unit 52. Further, the arrangement and spacing of the plurality of light sources 531 constituting the third irradiation unit 53 are the same as the arrangement and spacing of the plurality of light sources 521 constituting the second irradiation unit 52, and thus the description thereof will be omitted here.

It is preferable that the power supply to each light source 531 of the third irradiation unit 53 is performed independently of each light source 511 of the first irradiation unit 51. As a result, for example, in the process of forming the first hoop layer C1 and the second hoop layer C3 that are not formed on the mirror portion L3, light irradiation is performed unless power is supplied to each light source 531 of the third irradiation unit 53. The power used by the device 50 can be reduced.

The retainer 54 includes a main body member 541, a first elevating device 542, a second elevating device 543, a third elevating device 544, and a second rotating device 545. The main body member 541 is a member extending in the axial direction on the irradiation units 51, 52, and 53. The second elevating device 543 and the second rotating device 545 are attached to the drive shaft 41 side. The third elevating device 544 is attached to the auxiliary shaft 42 side. The first elevating device 542 is attached between the second elevating device 543 and the third elevating device 544.

The first elevating device 542 is a device that supports the first irradiation unit 51 and moves the first irradiation unit 51 in the vertical direction. As a specific configuration of the first elevating device 542, in FIG. 4, an electric motor is used as a power source, and power is transmitted to the first irradiation unit 51 by a rack and a pinion, but this is only an example. Not limited to this.

The first irradiation unit 51 can be moved in the direction toward and away from the rotation axis by the first elevating device 542, and can irradiate the container V having various diameters with light from an appropriate position. ..

Further, the second elevating device 543 and the third elevating device 544 are devices that support the second irradiation unit 52 and the third irradiation unit 53, respectively, and move the second irradiation unit 52 and the third irradiation unit 53 in the vertical direction. be. The second elevating device 543 and the third elevating device 544 can have the same configuration as the first elevating device 542. With this configuration, in the case of the container V having a large diameter, that is, even if the mirror portions L2 and L3 are large, it is possible to irradiate the entire mirror portions L2 and L3 with light. In particular, since the third irradiation unit 53 can be raised and lowered, it is possible to efficiently irradiate the photocurable resin P1 around the bottom L5 with light.

The second rotation device 545 is a device that rotates the second irradiation unit 52 around an axis perpendicular to the rotation axis and the second direction D2. That is, the second irradiation unit 52 can rotate in the directions of the arrows AL2 and AR2 shown in the figure.

Examples of the second rotating device 545 include, but are not limited to, an electric motor and the like. With this configuration, the mirror portion L2 can be efficiently irradiated with light by bringing the second direction D2, which is the direction of the second irradiation unit 52, closer to the axial direction. Further, by increasing the angle formed by the axial direction and the second direction D2, the photocurable resin P1 on the neck portion L4 can be efficiently irradiated with light.

The bogie 55 includes a support column 551, a main body portion 552, and wheels 553. The column 551 is a column member extending in the vertical direction. A main body member 541 of the retainer 54 is attached to the upper part of the support column 551. Further, the lower portion of the support column 551 is attached to the main body portion 552. As these mounting structures, screw fastening, integration by welding, etc. can be appropriately selected.

Weights and the like can be appropriately provided on the main body portion 552. As a result, the center of gravity of the carriage 55 can be lowered and the posture of the light irradiation device 50 can be stabilized. The wheel 553 is attached to the lower side of the main body portion 552 to movably support the light irradiation device 50 on the floor surface (or the ground). It is preferable that the wheel 553 is provided with a stopper in order to fix the light irradiation device 50 when the light irradiation device 50 is used.

<5. First modification of the light irradiation device>
Next, a first modification of the light irradiation device 50 according to the embodiment of the present invention will be described with reference to FIG. 7. Note that FIG. 7 is a perspective view showing a first modification of the light irradiation device 50 according to the embodiment of the present invention.

In the light irradiation device 50 in the first modification, as shown in FIG. 7, three sets of irradiation units 50A, 50B, and 50C are provided around the rotation axis.

The set 50A includes a first A irradiation unit 51A, a second A irradiation hand knit 52A, and a third A irradiation unit 53A. The set 50B includes a first B irradiation unit 51B, a second B irradiation hand knit 52B, and a third B irradiation unit 53B. The set 50C includes a first C irradiation unit 51C, a second C irradiation hand knit 52C, and a third C irradiation unit 53C.

Although the configuration of the light irradiation device 50 other than the irradiation units 51A to 53A, 51B to 53B, and 51C to 53C is not shown in FIG. 7, the irradiation units 51A included in each set 50A, 50B, and 50C are not shown. ~ 53A, 51B to 53B, 51C to 53C are supported by the same configuration as the configuration of the irradiation units 51, 52, 53 shown in FIG.

In this example, the second A irradiation unit 52A, the second B irradiation unit 52B, and the second C irradiation unit 52C all have vertices in the direction of the rotation axis and have a triangular shape that widens as the distance from the rotation axis increases. It is a light source. With this configuration, the gap between the irradiation units can be arranged in a small size without interfering with the irradiation units 52A, 52B, and 52C, and the photocurable resin P1 on the mirror unit L2 can be efficiently irradiated with light. can.

Similarly, the third A irradiation unit 53A, the third B irradiation unit 53B, and the third C irradiation unit 53C all have vertices in the direction of the rotation axis and have a triangular shape whose width increases as the distance from the rotation axis increases. It is a light source.

When a plurality of point light sources such as LEDs are arranged in the second A to 2C irradiation units 52A, 52B, 52C and the third A to 3C irradiation units 53A, 53B, 53C, the arrangement method is particularly limited. Instead, for example, they may be arranged in a grid pattern or arranged so as to form rows parallel to each side of the triangle.

According to this configuration, the photocurable resin P1 on the liner L is irradiated with more light while the liner L makes one rotation. Therefore, the photocurable resin P1 cures faster, so that the time required for manufacturing the container V is shortened and the productivity is improved.

In the example shown in FIG. 7, the sets 50A, 50B, and 50C have the same configuration, but may have different configurations as appropriate in consideration of manufacturing conditions, equipment size, and the like.

<6. Second modification of the light irradiation device>
Next, a second modification of the light irradiation device 50 according to the embodiment of the present invention will be described with reference to FIG. Note that FIG. 8 is a front view showing a second modification of the light irradiation device 50 according to the embodiment of the present invention. Further, in FIG. 8, the rotation axis A of the liner L is illustrated by a alternate long and short dash line.

As shown in FIG. 8, the light irradiation device 50 in the second modification includes a first L irradiation unit 51L and a first R irradiation unit 51R in place of the first irradiation unit 51. Although the configuration of the light irradiation device 50 other than the irradiation units 51L and 51R is not shown in FIG. 8, the first L irradiation unit 51L and the first R irradiation unit 51R are the first irradiation shown in FIG. It is supported by the same configuration as that supporting the unit 51.

In FIG. 8, the irradiation directions D1L, D1R, and D2 of the light of the first L irradiation unit 51L, the first R irradiation unit 51R, and the second irradiation unit 52 are shown by a alternate long and short dash line. The angle θ1L formed by the direction D1L in which the first L irradiation unit 51L irradiates light and the rotation axis A is an acute angle. Further, the angle θ1L is larger than the angle θ2 formed by the direction D2 in which the second irradiation unit 52 irradiates light and the rotation axis A (θ2 <θ1L <90 °).

The first R irradiation unit 51R is arranged between the first L irradiation unit 51L and the third irradiation unit 53. The first R irradiation unit 51R is directed to the rotation axis A and is directed to the first L irradiation unit 51L side. That is, the angle θ1R formed by the direction D1R on which the first R irradiation unit 51R irradiates light and the rotation axis A is an acute angle (0 ° <θ1R <90 °).

According to the configuration of the second modification, even a container V2 having a bulge in the body as shown in FIG. 8 can be efficiently irradiated with light and productivity can be improved. can.

<7. Effect of this embodiment>
As described above, the FW molding apparatus 1 according to the present embodiment is arranged on the outer surface of the liner L so as to face the outer surface of the liner L. In a direction parallel to the first irradiation unit 51, the liner L is arranged at a position different from the first irradiation unit 51 so as to face the outer surface of the liner L, and the angle of the liner L with respect to the rotation axis is different from the first direction D1 in the second direction D2. A second irradiation unit 52 that irradiates light is provided.

According to this configuration, a resin molded product having a shape having a cross section in which the angle with respect to the rotation axis changes in a cross section including the rotation axis, for example, mirror portions L2 and L3 such as a container V, that is, an upper surface and / or a lower surface is manufactured. Even in this case, the photocurable resin P1 can be efficiently irradiated with light. Therefore, according to the present embodiment, it is possible to provide a FW molding apparatus 1 capable of manufacturing a container V made of FRP using a photocurable resin and having an upper surface and / or a lower surface with high productivity.

It should be noted that the configuration of the present embodiment is particularly effective when a light source having high directivity such as an LED is used.

1 ... Filament winding (FW) molding device (device for manufacturing resin molded products) 10 ... Fiber supply section 20 ... Resin supply section 30 ... Fiber guide section 40 ... Rotating device 50 ... Light irradiation device 51 ... First irradiation unit 511 ... Light source 52 ... 2nd irradiation unit 521 ... light source 53 ... 3rd irradiation unit 531 ... light source 54 ... retainer 542 ... 1st elevating device 543 ... 2nd elevating device 544 ... 3rd elevating device 55 ... trolley V ... container L ... liner M ... Insert member C ... Composite material layer P1 ... Photocurable resin (irradiated object)

Claims (6)

A resin molded product manufacturing apparatus that cures the photocurable resin by irradiating the photocurable resin with light while rotating a liner wound with fibers impregnated with the photocurable resin.
A first irradiation unit arranged so as to face the outer surface of the liner and irradiating the liner on which the fiber impregnated with the photocurable resin is wound with light from a first direction.
A fiber impregnated with the photocurable resin was wound so as to face the outer surface of the liner at a position different from the first irradiation unit in a direction parallel to the rotation axis of the liner. A second irradiation unit that irradiates light from a second direction whose angle with respect to the rotation axis of the liner is different from that of the first direction with respect to the liner.
Equipped with
The second irradiation unit is a surface light source that irradiates light in a planar manner.
The surface light source is a resin molded product manufacturing apparatus that is configured by arranging a plurality of light sources and is rotatable about an axis of rotation of the liner and an axis perpendicular to the second direction. The apparatus for manufacturing a resin molded product according to claim 1, wherein the first direction is perpendicular to the rotation axis of the liner. The apparatus for manufacturing a resin molded product according to claim 1 or 2 , wherein the surface light source is configured by arranging the plurality of light sources side by side in a row direction and a column direction in a rectangular surface. The apparatus for manufacturing a resin molded product according to any one of claims 1 to 3 , wherein the second irradiation unit is movable in a direction approaching and a direction away from the rotation axis of the liner. The apparatus for manufacturing a resin molded product according to any one of claims 1 to 4 , wherein the second irradiation unit includes an LED as a light source. A light irradiation device that irradiates the irradiated object with light while rotating the irradiated object.
A first irradiation unit arranged to face the outer surface of the irradiated object and irradiating the irradiated object with light from a first direction, and a first irradiation unit.
The first irradiation unit is arranged at a position different from the first irradiation unit in a direction parallel to the rotation axis of the irradiated object and facing the outer surface of the irradiated object. The direction is a second irradiation unit that irradiates light from a second direction having a different angle with respect to the rotation axis of the object to be irradiated.
Equipped with
The second irradiation unit is a surface light source that irradiates light in a planar manner.
The surface light source is a light irradiation device that is configured by arranging a plurality of light sources and is rotatable about an axis perpendicular to the rotation axis of the liner and the second direction.

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