JPS61205114A - Method of molding composite material - Google Patents

Abstract

PURPOSE:To enable to perform continuous bending molding easily at high speed without having disorder in fiber orientation, even in case of material whose fiber content being high, by a method wherein the bending molding is performed step by step by passing a molding material through a space between multi-stage molding rolls whose curvature radii have been reduced gradually while the same is being softened through heating up to the temperature directly below the thermal deformation temperature beforehand. CONSTITUTION:A strip material 10, which is a resin series composite material, is fed on a conveyor roller 1a, sent to a heating part 2 by a nipple roll 1b and heated up to the temperature in the vicinity of the deformation temperatures of respective molding materials by an infrared heater 2a. As for the strip material 10 softened by heating, bending molding is applied to the same gradually by multi-stage molding rolls 3a-3d while the same is being heated by an infrared heater 3e of a molding part 3, which is sent to a cooling part 4. As for the molding rolls 3a-3d, their curvature radii are being reduced gradually from the roll 3a to the roll 3d, which possess 90 deg. V-shaped angular shape processing surfaces possessing R1=R101mm, R2=R50mm, R3=R24mm and R4=R12mm.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application> The present invention relates to a composite material molding method for continuously molding a resin-based composite material made of carbon fiber/thermoplastic resin having a thin and elongated structure.

<Prior art and problems to be solved by the invention> In recent years, there has been a plan to continuously form open cross-sectional structural elements of resin composite materials, and therefore it has become necessary to provide a continuous bending method. is the latest technology and there are almost no similar examples.

As a conventional method for forming thin-walled long structural products, a general method involves continuous drawing or extrusion from a mold having a predetermined cross-sectional shape. However, when trying to mold a thin-walled long structure of a composite material made of carbon fiber/thermoplastic resin using this method, there are the following problems: ■ It is difficult to make the molded product thin, ■ Fiber orientation tends to be disturbed, ■ It is not practical due to problems such as the inability to increase the fiber content and the inability to increase the molding speed.

In view of the above-mentioned problems, the present invention uses a thin and long resin-based composite material made of carbon fiber/thermoplastic resin as a raw material to easily produce materials with high fiber content without disturbance of fiber orientation and at high speed. The purpose of this invention is to provide a method for forming composite materials that can be continuously bent.

Means for Solving the Problems> The present invention achieves the above object in a method of continuously bending and forming a resin-based composite material having an open cross-section thin-walled elongated structure made of carbon fiber/thermoplastic resin. , is characterized in that the forming material is bent in stages between multiple forming rolls whose radius of curvature is gradually reduced while the forming material is heated and softened in advance to just below the heat deformation temperature.

Embodiment Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

FIG. 1 is an explanatory diagram showing the basic configuration of an embodiment of a stepwise continuous bending apparatus for carrying out the method of the present invention. As shown in the figure, this molding device includes a conveyor roller 1a
and a material inlet section 1 consisting of a nipple roller 1b, a heating section 2 consisting of an infrared heater 2a, a forming section 3 consisting of multistage forming rolls 3a to 3d and an infrared heater 3e, and a cooling roll 4a.

4b, and a control section 5 that controls the heating/cooling temperature of each section, the feeding speed of each roll, and the pressing force of each roll. Here, the curvature radius of the forming rolls 3a to 3d of the forming section 3 gradually decreases in the order of 3a, 3b, 3c, and 3d. Moreover, this forming roll 3d and the cooling roll 4a of the cooling part 4.

4b has the same shape.

An example of a flat material made of carbon fiber/thermoplastic resin used in the method of the present invention carried out in such an apparatus is shown in FIGS. 2(a) and 2(bl). (One direction)/Boriethersulfone (hereinafter abbreviated as PES). Figure 2(b) is a plan view of the flat material of high modulus carbon fiber (±45° plain weave)/Nylon 6. FIG.

The strip material 10, which is a resin-based composite material as shown in FIGS. The strip material 10 softened by heating is heated by the infrared heater 3e in the molding section 3 and gradually rolled by the multistage molding rolls 3a to 3d. The molded product is bent into a shape and sent to the cooling section 4. In the cooling section 4, the molded product in a high temperature state is cooled by cooling rolls 4a and 4b and solidified into a desired shape.

In this way, in order to bend and form a molding material made of carbon fiber/thermoplastic resin, unlike the cold roll forming process that involves plastic deformation of a metal material, it is preferable to use a molding material that exhibits elastic deformation at room temperature by thermal deformation. It is necessary to soften the material by heating it to just below the temperature and gradually cause plastic deformation. Therefore, in the above-mentioned method, the shape of the forming rolls 3a to 3d having a multistage structure that gradually disperses the change in shape during forming is important.

An example of the specific shape of the forming rolls 3a to 3d is shown in FIG. 3 (al to dl).
Then, the radius of curvature gradually decreases from 3a to 3d, and R,=R101ffi', R2=R, respectively.
50″″″, R3=R24″″, R4=R12″
It has a machined surface with a 90°■ type angle shape.

The width of the processed surface is such that the lower roll W' of the forming roll 3a is 90 mm, and the width W of the other rolls is 80 mm. Further, the gap between the upper and lower forming rolls 3a to 3d varies from 1.2 to 0.7 mm. Of course, the thickness may be constant, for example, 1 mm, depending on the plate thickness. Further, as shown in FIG. 5, the guideline angle is determined from -θ=T, and is -0=0.05.

An example of other specific conditions when such forming rolls 3a to 3d are used is shown below.

■ Size of molding material: plate thickness 1 mm, plate width 80 mm, length 0.4 to 1.1 mm (basically endless is fine) ■ Heat molding temperature: Carbon fiber/nylon 6...200
℃ Carbon fiber / PES...230 ℃ ■ Material temperature during roll forming: Carbon fiber / Nylon 6.
...160 ~ 190℃ ■ Forming (feeding) speed: 0.1 m/win ■ Forming roll pressure crab 250 kgf/80 mm width ■ Carrier sheet: stainless steel sheet (0.1 mm thick) Also, Fig. 5 shows the above-mentioned The forming flower is shown in which the strip material 10 is bent in stages by the forming rolls 3a to 3d. Here 10 a, 10 b, 10
c, 10 d are molded o-ru 3 a, 3 b, respectively
, 3 c and 3 d show cross sections of the strip material 10 bent into respective angle shapes.

The molded product molded according to this example has no disorder of fibers, and the tensile modulus of elasticity of the flat plate part near the bending process is 127.
It was a high-performance composite material molded product with an angular open cross-section, thin wall, and a long structure that fulfilled approximately 80% of the composite law at 0.00 kgf/m.

In addition, in the above-mentioned example, the carbon fiber content of the strip material IO is V=0.547, and the tensile modulus of carbon fiber is 290 Q Okgf/*:, so the calculated tensile strength of the molded product is The elastic modulus is 15860 kgf/m.

Molded products produced by the method of the present invention are, for example, structural parts for aerospace equipment, automobiles and transportation equipment, general industrial machinery, and sports and leisure goods.

It can be applied to electrical/electronic parts, etc.

<Effects of the Invention> As specifically explained above in conjunction with the examples, if a resin composite material with an open cross-section thin elongated structure made of carbon fiber/thermoplastic resin is molded by the molding method according to the present invention,
There is no disturbance in fiber orientation, and high-performance bent products can be easily and continuously formed. Further, according to the method of the present invention, materials with a high carbon fiber content can also be used, and even in this case, the molding speed can be increased, which is economical.

[Brief explanation of drawings]

FIG. 1 is a basic configuration diagram of an example of a molding apparatus for carrying out the method of the present invention, FIGS. 2 (al) and (b) are plan views of an example of carbon fiber/thermoplastic resin used in the method of the present invention, Figure 3 (a
l , (bl , (8) , (cil is an explanatory diagram showing an example of the forming roll of the above-mentioned forming apparatus, FIG. 4 is an explanatory diagram of the guideline angle, and FIG. 5 is an explanatory diagram of the forming roll of the above-mentioned forming roll. It is a sectional view showing a flower. In the drawing, 2 is a heating section, 3a to 3d are forming rolls, 3e is an infrared heater, 4a and 4b are cooling rolls, and 10 is a strip-like material. (b) - ■Yo = Blasphemy ※※Katakei Shigeru Figure 3 (a) (b) (c)
(d) No. 411 Mushi J1 Guidelines

Claims (1)

[Claims] In a method of continuously bending and forming a resin-based composite material with a thin open cross-section and long structure made of carbon fiber/thermoplastic resin, the radius of curvature is gradually reduced while the forming material is heated and softened in advance to just below the heat distortion temperature. A method for forming composite materials that is characterized by stepwise bending and forming between multiple forming rolls.