JPH0349916A - Molding method for composite material and composite simultaneous molding die therefor - Google Patents

Abstract

PURPOSE:To carry out curving process easily by applying press processing such as cutting or belt-shaped punching to one of a couple of sheets to be molded, dividing the sheets to be molded, and then injection filling molten resin into a space between a couple of sheets to be molded and forming a resin layer. CONSTITUTION:A punch 11 provided in a first or second mold (1 or 2) punches and divides a part of a sheet 4 to be molded together with the action of a die 31 provided in a third mold 3. Then, simultaneous mold clamping is released and the third mold 3 is removed, and then the first and second molds 1 and 2 retaining the sheets 4 and 5 to be molded are mold clamped to form a cavity section 6 between a couple of sheets to be molded. Then, molten resin is filled in said cavity section through an injection path 7 to form a resin layer, and a composite material with a curving processed section 8 with the sheet to be molded on one side only is manufactured by releasing mold clamping after solidifying the resin. The composite material thus manufactured can be curving processed easily by stretching and opening the curving processed section 8.

Description

Detailed Description of the Invention [Field of Industrial Application] The present invention relates to a method for molding a composite material and a composite simultaneous molding mold used therein. The present invention relates to a molding method for filling a resin layer and thereby molding a sandwich-like composite material into a desired shape, and a mold used therefor.

[Conventional technology] Conventional 1. Composite materials with a synthetic resin layer formed between two metal plates, so-called sandwich steel plates, are generally manufactured by, for example, extruding a synthetic resin into a plate shape and joining both sides of the synthetic resin to a metal plate using an adhesive. It is. However, the structure of the composite material manufactured by such a method is simply a flat plate material in which a resin layer is formed between metal plates, and it is not possible to realize various shapes such as punching or drawing. Therefore, in order to form such a composite material into a shape that matches the intended purpose, it is necessary to perform secondary processing such as punching and bending the flat sandwich steel plate, which is an extremely complicated process. It had become a thing.

In addition, as another method for manufacturing sand-inch steel sheets, there is a method proposed by the inventors of the present invention, in which composite materials of various shapes are manufactured by combining sheet metal press working and resin injection processing. (Japanese Patent Application No. 61-224223, Japanese Patent Application No. 62-211322). Specifically, two metal plates to be formed are placed in a stacked state between a pair of movable molds with uneven parts such as punches and dies for press processing, and a fixed mold, and the movable molds are moved. The molds are clamped by , and press working is performed first. Then, with one metal plate held in each mold, the movable mold is moved in the mold clamping release direction to create a cavity of a predetermined width between both metal plates. Alternatively, a cavity is formed on the outside of the metal plate through a hole formed by press working, and molten resin is injected into the cavity to form a resin layer. After the resin layer has solidified, the composite molded product is taken out.

In addition, the present inventors further improved the above manufacturing method by performing different pressing processes on each of the two molded plates between three mold bodies that can be simultaneously clamped, and removing the intermediate mold. A manufacturing method has also been proposed in which a cavity is then formed between the two corrugated molded plates and a synthetic resin is injected into the cavity (Japanese Patent Application No. 11873/1983).

According to these proposals by the inventors of the present invention, it is possible to obtain a composite material that has been subjected to punching, drawing, etc. according to the pressing of the sheet metal and the unevenness of the mold, thereby minimizing secondary processing. It became possible.

[Problem to be solved by the invention] By the way, in such a sandwich steel plate, J3 has
It can be said that the rigidity is ensured by the tensile strength or compressive strength of the resin layer and the adhesively suspended metal plate.

Therefore, when bending a sand-inch steel plate, it is necessary to perform the bending process against the tensile strength of the metal plate located on the opposite side of the bending direction. It is almost impossible to perform the bending process by manual bending work. Therefore, in carrying out the above-mentioned bending process, tools such as punches and dies, and machine tools such as a press machine are required, making the process very troublesome.

In addition, even when bending is performed using the above-mentioned tools or machine tools, processing defects such as breakage of the sheet metal outside the bent part or bending near the bent part are likely to occur in sand inch steel plates, and composite This makes bending the material even more troublesome.

The present invention was made in view of these problems,
The object of the present invention is to provide a method for forming a composite material and a mold for use in the method for providing the composite material with a bending receiving portion that can be easily bent.

[Means for Solving Problem N] In order to achieve the above object, the method for molding a composite material of the present invention is such that the molds are arranged opposite to each other so as to be able to approach and separate from each other, and when the molds are in contact with each other in the clamping state, the molds face the opposing surface. A first mold body and a second mold body are arranged so as to be movable back and forth between the first mold body and the second mold body, and the first mold body and the second mold body are When the molds are simultaneously clamped together with the second mold body, a third mold body is used which presses the pair of plates to be formed together with these two mold bodies, and the third mold body is used after the above pressing process. At the same time, the body is moved back from between the first and second mold bodies, and the first mold body and the second mold body holding the processed plate to be formed are clamped to form the above-mentioned space between the pair of mold plates. After forming a cavity and injecting and filling the cavity with molten resin, the press-formed plate is integrated with the solidified resin layer from between the first and second mold bodies, which are unclamped. This is a method of forming composite materials that takes out the composite material that has become formed.During the above-mentioned press processing, one of the plates to be formed is cut or treated in a band shape to divide the plate at that point, thereby removing the composite material after forming. This is characterized in that the material is provided with a bending receiving part that can expand the divided part.

Further, the mold of the present invention capable of carrying out the method for molding the composite material is comprised of the first, second, and third mold bodies, and the first and second mold bodies are press-formed covers. The press processing surface of the first or second mold body, which has a holding means for holding the molded plate and comes into contact with the third mold body when the mold is clamped, is provided with a method for punching the plate to be formed into strips and dividing it into strips. A punch that protrudes to a predetermined maximum inside the cavity when forming the cavity is provided, and a die corresponding to the punch is provided in the third die, and the first or second die is provided with a die that protrudes to the maximum within the cavity. It is characterized in that an injection path for injecting molten resin is formed in the molten resin.

In such technical means, as the first, second and third mold bodies, a pair of metal plates are sandwiched between the first and third mold bodies, and between the third and second mold bodies, respectively; If these three mold bodies can be clamped at the same time, and when the first and second mold bodies are clamped, a cavity part for injecting molten resin is formed between the two mold bodies. The shape of the uneven surface for pressing formed on each mold body may be appropriately changed in design depending on the desired shape of the composite material.

In addition, in order to easily perform bending at a predetermined location of the composite material after forming, one of the plates to be formed is divided by press processing at the predetermined location. Such division of the plate to be formed can be easily carried out by punching out strips with a punch, as shown in the technical means of the mold of the present invention. In the bending receiving part formed in this way,
It is possible to bend the composite material with some ease by performing the bending process with the divided plate to be formed as the outside, but in order to make it even easier, it is necessary to insert the tip of the punch into the cavity when forming the cavity. It is preferable to make the resin layer protrude and inhibit the formation of a resin layer in the bending receiving part.

[Function] Hereinafter, the function of the present invention will be explained based on the attached FIG. 1.

First, a molded plate 4.5 is placed between the first mold body 1 and the third mold body 3, and between the third mold body 3 and the second mold body 2, and the first mold body By simultaneously clamping the second and third mold bodies 1, 2.3, different press workings are performed on the pair of molded plates 4.5 (see Figures 1 (a) and (b)). ). At this time, the punch 11 provided in the first or second mold body (the first mold body in the figure) works together with the die 31 provided in the third mold body 3 to form the plate 4. Divide a part of the material into strips by beating them into strips.

Next, after canceling the simultaneous mold clamping and removing the third mold body 3, the first and second mold bodies 1 and 2 holding the molded plate 4.5 are clamped by the holding means. A cavity portion 6 is formed between the pair of molded plates.

Then, by filling the cavity with molten resin through the injection path 7 to form a resin layer, and releasing the mold clamp after the resin is assimilated, the bending receiving part 8 in which only the plate to be formed on the -5 side is cut is formed. A composite material having the following characteristics can be obtained (see FIG. 1(d)).

The thus obtained composite material can be easily bent by expanding the bending receiving portion 8 (see FIG. 1(e)).

Note that when the punch tip protrudes into the cavity as shown in FIG. 1(C), the resin layer formed on the bending receiving part becomes thinner depending on the amount of protrusion of the punch tip. In addition, the bending receiving portion can be expanded more easily.

[Example] Hereinafter, a method for molding a composite material of the present invention and a mold used therein will be described in detail based on the accompanying drawings.

This example shows a first example in which a bracket for supporting a rotating shaft is molded using a part of the method for molding a composite material according to the present invention.

As shown in the cross-sectional view of FIG. 1, the mold used in this example includes a first mold body 1 and a second mold body disposed opposite to the first mold body 1 so as to be able to come into contact with and separate from the first mold body 1. The second mold body 2 is arranged to be able to move forward and backward between the first and second mold bodies 1.2, and can be simultaneously clamped together with the first and second mold bodies 1 and 2. It is composed of a third mold body 3 that performs the following steps.

Each of the first, second and third mold bodies 1, 2.3 is, respectively,
A mold body 12 having an uneven surface for press working, that is, a mold surface
(or 22 or 33.34) and the block 13 (or 23 or 35) that supports these mold bodies during press working.
When the mold bodies 1, 2.3 are simultaneously clamped, the mold body 12 and the mold body 33 work together to press the plate 4 to be formed, while the mold body 22 and the mold body The mold surfaces of each mold body correspond to each other so that the mold body 34 can press the molded plate 5 together with the mold body 34.

First, in the first and second mold bodies 1 and 2, a punch plate 14.24 and a hole punch 15.21 are respectively installed on a block 13.23 facing the third mold body 3 facing each other. Each of these hole punches 15.21 has stepped portions 15a, 21a whose center portions are raised on the distal end surface (see FIG. 3). Further, in the first mold body, a cutting punch 11 for punching out the plate to be formed into a strip shape is erected together with a hole handling punch 15 by the punch plate 14 described above.

On the other hand, mold bodies 33, 3 disposed on both sides of the third mold body 3
4 includes the hole punch 15.21 and the cutting punch 1.
1 are provided with dies 32, 31 corresponding to each of the dies 32, 31, and during press working, the punches 11, 15, 21 are fitted into these dies 32, 31 to punch out the plates 4, 5 to be formed.

Moreover, a mold body 122 constituting the first and second mold bodies 1 and 2
2 are provided with knockouts 16 and 26 for holding the press-formed plates 45, respectively. This knockout 16.26 can be moved by the gap 17.27 provided on the back side by the pressure applied during press processing, and the above-mentioned punches emerge and retract from the knockout to punch out the plate to be formed. At the same time, the molded plate 4.5 is held in the mold bodies 12, 22 after press working, and when the first and second mold bodies 1, 2 are clamped, a cavity portion is formed between the molded plate 45. 6 is formed.

In the mold of this embodiment, as shown in FIG. 4, the tip of the cutting punch 11 that protrudes from the knockout 16 during press working is held in the same state as it is when forming the cavity 6, while Similarly, knockout 1
Each hole punch 15.21 protruding from the hole punch 6.26 has a stepped portion 15a, 21a formed on the tip surface of the cavity portion 6.
A hole punch 15 (or 2
1) is configured to abut against the step portion 15a (or 21a).

Furthermore, the molded product is placed in the second mold body 2.
An ejection mechanism is provided for removal from 2. This discharge mechanism consists of a pressure chamber 2 provided on the back side of the second mold body 2.
8 and a piston 29 which has a rod 25 extending through the mold body 2 and moves back and forth within the pressure chamber 28. By increasing the pressure on the back side of the piston 29 and moving it forward, the O-rad 25 is knocked out. 26 protrudes from the surface to extrude the molded product from the mold body 22.

Furthermore, stripper plates 36 are provided around the mold bodies 33 and 34 constituting the third mold body 3, and a spring (not shown) is disposed between the stripper plates 36 and the block 35. It is set up.

As shown in FIG. 4, in the mold of this embodiment configured in this way, the first mold body 1 is fixed to an injection molding machine 14 such as a plunger or screw, while the second mold body 2 is the first mold body 1 so that the mold can be clamped and opened by the action of hydraulic pressure, etc.
are placed facing each other. Further, the third mold body 3 disposed between the first mold body 1 and the second mold body 2 is sequentially arranged in parallel in the movement direction of the second mold body 2 (horizontal direction in the drawing). A moving mechanism consisting of a roller conveyor 11 equipped with a roller 70 that is placed on the roller conveyor 71 and a roller conveyor 73 equipped with a roller 12 that is placed on this roller conveyor 71 and installed in a direction perpendicular to the roller conveyor 71 (direction perpendicular to the drawing). It is placed on. With this moving mechanism, when the second mold body 2 comes into contact with the third mold body 3 when clamping the second and third mold bodies 1, 2.3, the third mold body 3 and roller conveyor 7
3 move together on the roller conveyor 11, making it possible to simultaneously clamp the first mold body 1, the second mold body 2, and the third mold body 3. The roller conveyor 7
It becomes possible to evacuate the third mold body 3 from between the first mold body 1 and the second mold body 2 by moving the top of the mold body 3 .

Next, the procedure for molding a bracket using this mold will be explained with reference to FIG. 6.

■First step First, the plate 4 to be formed is placed between the first mold body 1 and the third mold body 3, and the molded plate 4 is placed between the second mold body 2 and the third mold body 3. Place the molding plate 5 (see FIG. 6(a)). The plates 4 and 5 to be formed are, for example, laminated steel plates with adhesive films pasted on their surfaces, and are set with their respective film surfaces facing the third mold body 3. The setting is performed, for example, by the suction force of an electromagnet provided within the stripper plate 36.

■Third process After setting the plate to be formed 4.5, the second mold body 2 is moved toward the first mold body 1, and the first, second and third mold bodies 1, 2.
The molds 4 and 5 are simultaneously clamped, and each molded plate 4.5 is pressed (see FIG. 6(b)). Due to this mold clamping,
Each knockout 16.2 provided in the mold body 12.22
The hole punch 15.21 protrudes from the knockout 16.26 and punches out a predetermined part of the plate 4.5 in a circular shape, and the cutting punch 11 The punch plate 4 protrudes from the knockout 16 and punches out the plate 4 to be formed into strips (along the direction perpendicular to the plane of the drawing) and divides them. Further, each of the plates 4 and 5 to be formed is punched out into the shape of a knockout 16.26 by the mold surface of the third mold body 3 and pushed into the mold body 12.22, respectively.

■Third process After the pressing of the plates 4 and 5 to be formed is completed as described above, the clamping state is released and the second mold body 2 is moved in the direction away from the first mold body 1. Let the three molds 1, 2.3
With the mold opened to a position where they are separated from each other, the third mold body 3 is retracted in the direction perpendicular to the mold clamping direction (see Fig. 4 (C)).
)reference). At this time, each processed plate 4.5 is brought into close contact with the surface of each knockout 16.26 due to frictional resistance at the sheared portion with the mold body 12.22, cutting punch 11, hole punch 15.21, etc. The mold body in condition 12.
22. Also, the blank material 41.51 punched out from the plate 4.5 to be formed is a stripper plate 36.
while the cutting bunch 11 and hole punch 1
Dies 31 and 32 of the third mold body 3 corresponding to 5.21, respectively
There will be some residue left behind.

■Fourth step After retracting the third mold body 3 in this way, the first mold body 1 and the second mold body 2 are clamped (see Fig. 6 ((f)).
Reference. At this time, each knockout 16, 26 is in a state of retreating to the position where it contacts the punch plate 14.24, and when the peripheral portion of the opposing mold body 12.22 is brought into contact, the held plate to be formed 4.5 A cavity portion 6 is formed in between. Next, the molten M resin injected from the injection molding machine 14 is injected into the cavity 6 through a sprue (not shown) provided in the first mold body. However, in this embodiment, as described above with reference to FIG.
Since 5a and 21a are held in a protruding manner in the cavity portion, the resin is prevented from flowing into the portion. When the resin is filled into the cavity 6 in this way, the molded plate 4
．． The adhesive film covering the inner surface of the molded plate 4.
5 and the injected resin are in an adhesive state.

(fifth step) After the resin injection is completed as described above, the pressure holding and cooling steps are carried out, and then the second mold body 2 is moved and the mold is opened. Then, when high-pressure fluid is introduced into the back side of the piston 29 of the pressure chamber 28 and the rod 25 is made to protrude from the knockout 26, the composite material with the resin layer formed between the plates 4.5 to be molded becomes the second mold body. 2, and the molded product can be taken out from between the first and second mold bodies 1.2 (Fig. 6(e)
reference).

In the composite material obtained from the mold of this example as described above, through holes 9 for fixing bearings are formed at locations corresponding to the hole punches 15 and 21, while the cutting punches 11 are provided with through holes 9 for fixing bearings. Band-shaped grooves 81 for bending are formed at corresponding locations, and serve as bending receiving portions.

(6) Sixth step Finally, the bending receiving portion 8 is subjected to a bending process, thereby completing a bracket that supports the rotating shaft through the pair of through holes 9 (see FIG. 6(f)).

At this time, the bending process can be easily performed in the bending receiving part 8 by placing the plate 4 punched into a band shape on the outside and bending the plate 5 to be formed so as to widen the band groove 81. Depending on the thickness and bending strength of the plate to be formed, manual bending may also be possible. Furthermore, since the bending receiving portion 8 is formed in advance, accurate bending can be performed with less distortion.

Furthermore, in this embodiment, the tip of the hole punch 15.degree. 21 protrudes into the cavity 6 as shown in FIG. The diameter of the through hole formed in the resin layer is small. Therefore, the outer diameter of the hole punch 15.21 is set slightly larger than the outer diameter of the bearing to be fitted, and
By setting the outer diameter of the stepped portions 15a, 21a to be slightly smaller than the outer diameter of the bearing, the resin layer can completely fix the bearing and prevent the bearing from rattling.

In addition, the materials used when molding the above composite material,
For example, the molding conditions are as shown below.

Sheet to be formed: Electrogalvanized steel sheet (Nippon Steel Corporation)
Bonde steel plate, Zin coated steel plate, etc.), stainless steel plate, aluminum plate adhesive film...Atomer film (QE305) or (NEO50) (manufactured by Takushiro Kagaku Co., Ltd.), Nisdyne HM film F-78 (Building Chemical Co., Ltd.) Co., Ltd.), Chemit K F-2000 (manufactured by Toshi Co., Ltd.) Synthetic resin: polypropylene, polyethylene, polyamide, ABS Press pressure: approximately 20 tOn Injection pressure: approximately 240 to 97 cd; In the embodiment, a first mold body 1 and a second mold body 2
We adopted a configuration in which a cavity is formed in both the
It may be formed only on one of the molds.

[Effects of the Invention] As explained above, according to the present invention, after dividing one of a pair of plates to be formed by cutting or punching out a band, the plate to be formed is divided. By injecting and filling molten resin between the molded plates to form a resin layer, it is possible to form a bending receiving part on the composite material at the same time as molding the composite material, which allows easy bending. Secondary processing after molding is simplified, making it possible to improve work efficiency.

Furthermore, as secondary processing is simplified, processing defects that tend to occur during secondary processing can be prevented, and composite molded products with high precision can be produced.

[Brief explanation of drawings]

FIG. 1 is a diagram showing a schematic configuration of a method for molding a composite material according to the present invention, FIG. 2 is a sectional view showing a first embodiment of a mold according to the present invention, and FIG. 3 is a mold according to the first embodiment. FIG. 4 is a sectional view showing the protruding state of the punches when forming the cavity, FIG. 5 is a schematic diagram showing the movement mechanism of the third mold body, and FIG. FIG. 2 is an explanatory diagram showing a procedure for molding a composite material using a mold according to an example. [Description of symbols] 1: First mold body 3: Third mold body 4.5: Formed plate 6: Cavity portion 7: Injection path 8: Bending processing receiving portion 11: Cutting punch 15.21: Hole punch Bunch 31.32: Dai

Claims (2)

[Claims] (1) A first mold body 1 and a second mold body 2 which are arranged facing each other so as to be able to approach and separate from each other, and which form a cavity portion together with the opposing surfaces when the mold is in a clamped state; It is arranged so that it can move forward and backward between the first mold body 1 and the second mold body 2, and when the molds are simultaneously clamped together with the first mold body 1 and the second mold body 2, these two mold bodies In conjunction with this, a third mold body 3 is used to press the pair of plates 4 and 5 to be formed, and after the press process, the third mold body 3 is applied to the first and second mold bodies 1 and 2. At the same time, the first mold body 1 and the second mold body 2 holding the processed molded plates 4 and 5 are clamped to form the cavity part 6 between the pair of molded plates. After injecting and filling the molten resin into this cavity, the press-formed plates 4 and 5 are inserted between the unclamped first and second mold bodies 1 and 2 into the resin layer 7 after solidification. This is a method of forming a composite material in which the integrated composite material is taken out, and during the above-mentioned press processing, one of the plates 4 to be formed is cut or punched into strips, and the plate 4 to be formed 4 is divided at that point. A method for forming a composite material, which comprises providing the composite material after molding with a bending receiving portion 8 that can expand the divided portion. (2) A first mold body and a second mold body that are arranged facing each other so as to be able to come into contact with and separate from each other, and that form a cavity portion together with the opposing surfaces when the mold is in a clamped state; It is arranged so that it can move forward and backward between the mold body and the second mold body, and when the molds are simultaneously clamped together with the first mold body and the second mold body, a pair of covers and a third mold body for press-working the molded plate, and the first and second mold bodies have holding means for holding the pressed plate to be formed, and when the mold is clamped, the third mold body A punch is provided on the press processing surface of the first or second mold body that comes into contact with the body, and is provided with a punch that punches out the plate to be formed into strips and divides it, and that protrudes a predetermined amount into the cavity when forming the cavity. The third die is provided with a die corresponding to the punch, and the first or second die is formed with an injection path for injecting molten resin into the cavity. Composite simultaneous molding mold.