KR20190028487A - Molded product and compression molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molded article having protrusions excellent in parting and strength by using a thermoplastic resin fiber composite material and a molding method with good productivity.
A molded article comprising a substrate portion (420) and a protruding portion (403), wherein the protruded portion (403) and the substrate portion (403) are made of a continuous fiber reinforced thermoplastic resin composite material comprising a continuous reinforcing fiber and a thermoplastic resin. The average value of the height h _f of the continuous reinforcing fibers 170 in the protrusions 403 is 5% or more of the height h of the protrusions 403.

Description

Molded product and compression molding method

The present invention relates to a molded article made of a thermoplastic resin fiber composite material and a compression molding method for obtaining the molded article.

BACKGROUND ART [0002] Recently, as a material of a molded article used for structural parts such as various machines and automobiles, pressure vessels, tubular structures, and the like, a fabric made of a composite yarn or a composite yarn in which reinforcing fibers and thermoplastic resin fibers are continuously and uniformly mixed with each other ), A sheet having a continuous reinforcing fiber impregnated with a thermoplastic resin has been proposed. As a molding method of a molded article using a fabric, for example, a method in which a fabric is placed in a mold heated to 280 DEG C, a thermoplastic resin portion of a fabric is melted and then the mold is cooled to 50 DEG C Has been proposed. It is also possible to use a method in which the sheet material is preheated at a temperature not lower than the melting point or the glass transition temperature of the thermoplastic resin and inserted into a mold having a temperature adjusted to a predetermined temperature to perform compression molding.

BACKGROUND OF THE INVENTION [0002] Molded articles used for various machines and automobiles have protrusions such as ribs and bosses. Such a molded article is preferably high in strength from the viewpoint of reliability. The higher the height of the rib is, the higher the strength reinforcing effect is. However, when a composite material in the form of a foam or a plate is used as the base material, there is a problem in forming by compression molding alone. Also, the protruding portion on the boss or column has a limitation on the height that can be molded, as in the case of ribs. Conventionally, there has been proposed a method of molding a molded product having a small undulation of shape by compression molding or hybrid molding of compression molding and injection molding, using a continuous fiber reinforced thermoplastic resin composite material of a foamed or plate shape.

As a material of a molded article requiring mechanical strength, a continuous fiber-reinforced thermoplastic resin composite material called a prepreg impregnated with a matrix resin into a reinforcing material composed of long fibers such as continuous reinforcing fibers is widely used. When the prepreg is used as a material, the prepreg is preheated and softened, and then the prepreg is inserted into a mold maintained at a constant temperature of, for example, 30 DEG C to 150 DEG C, and solidified to manufacture a molded article.

However, in the case of a molded article having a complicated shape, if the prepreg is manufactured using only the compression molding method, the continuous reinforcing fiber is broken around the root of the rib by the stress at the time of molding, There is a problem that it can not be used, and there is a problem that the mechanical strength due to the molding failure is not sufficient.

As a method of manufacturing a molded article having a complicated shape, for example, Patent Document 1 discloses a method of producing a molded article having a complicated shape by using a member A consisting of continuous reinforcing fibers and a thermoplastic resin and a member B made of a discontinuous reinforcing fiber and a thermoplastic resin, There is proposed a method of heating until the temperature becomes 260 占 폚 and cold pressing at 150 占 폚. According to this method, a molded article having a rib having a high height or a boss and having a complicated shape with excellent strength can be obtained.

Japanese Laid-Open Patent Publication No. 2015-226986 Japanese Laid-Open Patent Publication No. 2015-101794

However, there is no report on a method of molding a molded article having a projection such as a rib or a boss by compression molding only. Further, there is also no report on a molded article having excellent strength, in which continuous reinforcing fibers penetrate deeply into the projections, and a compression molding method of the molded article.

On the other hand, in the method of using a plurality of kinds of base materials as in Patent Document 1, it is difficult to obtain a molded article having higher strength, in which the continuous reinforcing fiber penetrates deeply into the protruding portion, in addition to time and cost.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and it is an object of the present invention to provide a molded article having a complicated shape having protrusions with excellent formability and strength and a compression molding method for obtaining the molded article.

Another object of the present invention is to provide a method for obtaining a molded article having a complicated shape excellent in parting and strength by a single molding method using a prepreg.

That is, the present invention is as follows.

The molded article of the present invention is a molded article comprising a continuous fiber-reinforced thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin,

Wherein the molded article has a base portion and a protruding portion,

Continuous reinforcing fibers are present in the protrusions and the substrate portion,

The average value of the height of the continuous reinforcing fibers in the projections is 5% or more of the height of the projections.

Here, the term " protruding portion " refers to a portion protruding from a substrate portion into a rib, a boss, or a columnar shape (including a cylinder, a truncated cone, a quadrangular column, and a quadrangular pyramid).

With respect to the " height of protrusion ", ribs will be described with reference to the drawings by way of example. 1 is a schematic top view of an embodiment of the molded article of the present invention. 3 is a cross-sectional view of the rib 403 in the direction of the short side of FIG. 4 is a perspective view of the rib 403. Fig.

The height of the protruding portion means the distance (sign h) from the surface 420a having the ribs 403 of the base plate portion 420 to the top of the ribs 403 in the vertical direction as shown in Fig. 3 .

3, the "height of the continuous reinforcing fiber in the protruding portion" refers to a height of the vertical reinforcing fiber 170 from the side 420a on the side of the rib portion 403 on the base plate portion 420 to the top of the continuous reinforcing fiber 170 Direction (sign h _f ). The "upper end of the continuous reinforcing fiber" is a region in which the continuous reinforcing fiber 170 is not present in the inside of the rib 403 as shown in FIG. 4, for example, Quot; means the end of the continuous reinforcing fiber at the highest position of the continuous reinforcing fiber.

In addition, with respect to the "height of the continuous reinforcing fiber in the projection portion" of the columnar projection, the quadrangular pyramidal projection will be described with reference to the drawings, for example. 6 is a perspective view of a quadrangular pyramid. 7 is a sectional view of the quadrangular pyramid. 8 is a side projection view of the quadrangular pyramid.

The height of the continuous reinforcing fiber in the protruding portion when the protruding portion is in a columnar shape is the height of the continuous reinforcing fiber 170 from the side 420a having the quadrangular pyramid 413 of the base plate portion 420, (H _f ) in the vertical direction to the top. Further, in the case of the columnar phase, the "upper end of the continuous reinforcing fiber" may have, for example, a region (A or B) in which the continuous reinforcing fiber is not present in the projecting portion as shown in FIG. 8, Of the continuous reinforcing fiber at the highest position of the continuous reinforcing fiber.

The average value of the height of the continuous reinforcing fibers in the protrusions means the average value of the total height of the protrusions in the " height of the continuous reinforcing fibers in the protrusions "

The height and the average value of the continuous reinforcing fibers in the projections are obtained by using MATLAB software manufactured by MathWorks from side projected images obtained by a digital camera when reinforcing fibers are visually observed. If the reinforcing fibers can not be visually confirmed, photograph the reinforcing fibers with a soft X-ray machine. Using the MATLAB software from MathWorks, obtain the height and the average value as in the case of naked eye.

With respect to the ribs, the height of the continuous reinforcing fibers in the short side direction is small and the height of the continuous reinforcing fibers on the two sides in the long side direction are all equal, so the average value of the height of the continuous reinforcing fibers in the projections is The value obtained from one side in the long-side direction.

It is preferable that a region where the height of the continuous reinforcing fibers in the projections is 5% or more of the height of the projections is 20% or more of the base of the projections.

5 " in the case where the protruding portion is a rib, " a region of 5% or more of the height of the continuous reinforcing fiber is 20% or more of the base of the protruding portion " Fig. 5 is a side projection view of the rib 403 in the long-side direction. 5, the length in the long-side direction of the region where the height h _f of the continuous reinforcing fiber is 5% or more is represented by L _a . Means that the area of 5% or more of the height of the continuous reinforcing fiber is 20% or more of the bottom side of the protruding portion means that the length L _a is 20% or more of the length L _r of the bottom side. When the protruding portion is a rib, the influence in the short side direction is small and negligible. Therefore, it is expressed as a ratio to the length Lr of the bottom side of one side in the long side direction.

In the case where the protrusions other than the ribs are quadrangular pillars, for example, as shown in Fig. 6, the values are obtained for the lengths of the bottom sides (L (2 · a ₁ + 2 · b ₁ )).

It is preferable that the continuous reinforcing fibers in the projections are continuous with the continuous reinforcing fibers in the substrate portion. Here, "continuous" means that continuous reinforcing fibers are present continuously from the substrate portion. As a determination method, it can be confirmed that the continuous reinforcing fiber continuously remains from the substrate portion when the molded article is incinerated. It is also possible to confirm the continuous portion of the reinforcing fibers by observing with X-ray CT.

The area occupied by the continuous reinforcing fibers in the protruding portions continuous with the continuous reinforcing fibers in the substrate portion at the bottom of the protruding portion is preferably 20% or more of the bottom side, and most preferably 90% or more.

The area occupied by the continuous reinforcing fibers in the protruding portions continuous with the substrate portion is 20% or more of the bottom side in the case where the protruding portion is ribs will be described with reference to Fig. As shown in Fig. 4, for example, in the region A, when the continuous reinforcing fibers are not continuous from the inside of the substrate portion 420 and the continuous reinforcing fibers continue in the region other than the region A, Of the region occupied by the continuous reinforcing fibers is at least 20% of the bottom of the ribs in the protruding portion at the long side L of the rib (see Fig. 5) Means that the length L _b of the direction is 20% or more of the length L _r of the bottom side. The average value of the height of the continuous reinforcing fibers of the ribs is preferably not less than the thickness (T ₂ ) of the substrate portion, more preferably not less than twice, and more preferably not less than three times. Further, the height (h / T ₁ ) of ribs to the root thickness (T ₁ ) is preferably 2 or more, more preferably 4 or more, and most preferably 6 or more. In addition, the thickness of the rib portion sources (T ₁₎ is the substrate thickness portion (T ₂₎ or less is preferred, more preferably the thickness of the rib portion sources (T ₁₎ the thickness of the substrate (T ₂₎ of 3/4 or less, Most preferably not more than 1/2. If the thickness (T ₁ ) of the root of the rib portion is large, the linearity of the continuous reinforcing fiber of the substrate portion is lost, the linearity of the substrate portion is lost, and the tensile strength of the substrate portion may be lowered. Further, it is preferable that the density Vf of the continuous fibers having the height of the upper 10% when the height of the rib portion is 100% is 10% or less (see Fig. 3).

On the other hand, the case of the columnar protrusion will be described with reference to Fig. 8, for example. Means that the area occupied by the continuous reinforcing fibers in the protruding portions continuous with the substrate portion is 20% or more of the bottom side "means that the length L _b at the bottom of the area occupied by the continuous reinforcing fibers in the protruding portion is the length L of the bottom side, ≪ / RTI >

It is preferable that the thermoplastic resin in the projection and the thermoplastic resin in the substrate portion are the same. When the protrusions are made of a resin or a composite material different from the substrate portion, there is a case where an interface is formed between different materials, and the strength of the joint portion is inferior to that of the continuous reinforcing fiber composite material portion.

It is preferable that the density Vf of the continuous fibers having the height of the lower 10% when the height of the projections is 100% is 30% or more, more preferably 50% or more. The reason for this is that the strength of the projections is preferably such that the continuous reinforcing fibers are disposed in this portion because the stress is likely to be concentrated on the joining portion with the substrate portion with respect to the load from the upper portion.

In the case of producing a molded article having a protruding portion in injection molding, when a composite material is filled in a deep portion (concave portion) engraved on a mold cavity surface such as a rib, a so-called gas annulus is generated, It is known that the thermoplastic resin does not enter and the protrusions of the molded article are not formed to the end portions.

As a method for solving this phenomenon, the inventors of the present invention desirably have a method of efficiently removing gas components in a mold at a timing at which a gas is generated and a phenomenon of gas sticking occurs, and also in the compression molding method of the present invention, It was found that a compression molded product having a protruding portion was produced by performing subtraction.

That is, in one compression molding method according to the present invention,

A compression molding method for compression molding a continuous fiber-reinforced thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin to obtain a molded article having a base portion and a projection portion,

The continuous fiber-reinforced thermoplastic resin composite material is inserted into a mold and heated while being heated to a temperature not lower than the glass transition temperature or higher than the melting point of the thermoplastic resin while being compressed and then the mold is heated to a glass transition temperature of- A compression molding process for cooling the thermoplastic resin by cooling to -10 占 폚 or lower, preferably a glass transition temperature of -30 占 폚 or lower or a melting point of -50 占 폚 or lower, more preferably a glass transition temperature of -50 占 폚 or lower or a melting point of -100 占 폚 or lower and,

And a step of discharging the gas component in the mold generated from the continuous fiber-reinforced thermoplastic resin composite material to the outside of the mold during the compression molding process.

Here, the temperature at which the mold is heated means a set temperature for setting the cavity surface of the mold to a desired temperature. Since the cavity surface is a molding surface, it is difficult to provide a temperature measuring device such as a thermocouple, and it is difficult to measure the temperature of the actual cavity surface. For this reason, the temperature of the cavity surface is obtained by obtaining a correlation between the set temperature in the temperature measuring device provided in the vicinity of the cavity surface and the temperature adjusting means in a state in which the cavity surface is not formed in advance, do.

The temperature at which the mold is heated is based on the melting point or the glass transition temperature. When the thermoplastic resin is a crystalline thermoplastic resin, the melting point is used as a reference. When the thermoplastic resin is an amorphous resin, use.

As a specific method of discharging the gas, that is, the step of discharging the gas component in the mold out of the mold, the mold is closed after inserting the continuous fiber-reinforced thermoplastic resin composite material into the mold. When the mold temperature reaches a certain temperature, The mold clamping force is relaxed and the gas is released from the mold abutting surface (parting line) is used as a simple method. In another mode, a method of sucking air in the mold cavity or the continuous fiber-reinforced thermoplastic resin composite material or a gas component generated by heating is used. As the air or gas suction means, a gas vent line may be provided from the mold cavity and a vacuum pump may be used.

Another compression molding method of the present invention is a compression molding method for producing a molded article having a substrate portion and a projection portion by compression molding a thermoplastic resin composite material comprising a continuous reinforcing fiber and a thermoplastic resin,

The continuous fiber-reinforced thermoplastic resin composite material is inserted into the concave portion corresponding to the protruding portion of the metal mold and the metal mold is heated to a temperature not lower than the glass transition temperature of the thermoplastic resin or at a temperature higher than the melting point And the mold is then heated to a glass transition temperature of -10 占 폚 or lower or a melting point -10 占 폚 or lower, preferably a glass transition temperature -30 占 폚 or lower or a melting point -50 占 폚 or lower of the thermoplastic resin, The temperature is lowered to -50 占 폚 or lower or -100 占 폚 or lower to solidify the thermoplastic resin.

Further, as a result of intensive studies, the inventors of the present invention have found that a molded article having a complex shape can be produced only by a compression molding method using a kind of prepreg, and reached the present invention.

That is, another compression molding method according to the present invention is as follows.

A compression molding method for producing a molded article having a base portion and a projection portion by compression molding a prepreg made of a continuous reinforcing fiber and a thermoplastic resin,

The prepreg is preliminarily heated to a temperature not lower than the glass transition temperature of the thermoplastic resin or above the melting point to soften the prepreg,

The softened prepreg was inserted into the mold,

The mold is heated to a glass transition temperature of -80 占 폚 or higher or a melting point -80 占 폚 or higher of the thermoplastic resin to form a prepreg and then the mold is cooled to a glass transition temperature of -10 占 폚 or lower or a melting point of -10 占 폚 or lower of the thermoplastic resin The thermoplastic resin is solidified.

Here, the temperature at which the mold is heated is the set temperature of the mold.

The temperature at which the mold is heated is based on the melting point or the glass transition temperature. When the thermoplastic resin is a crystalline thermoplastic resin, the melting point is used as a reference. When the thermoplastic resin is an amorphous resin, the glass transition temperature Used as a reference.

According to the molded article of the present invention, protrusions having excellent shape and strength can be obtained.

Further, according to one compression molding method or another compression molding method according to the present invention, a molded article having a protruding portion excellent in negative formability and strength can be produced with good productivity.

According to another compression molding method of the present invention, a molded product having a complicated shape and excellent adherability and strength can be obtained by a compression molding method without using any other molding method as a kind of prepreg.

1 is a schematic top view of a molded article of the present invention.
Fig. 2 is a cross-sectional view taken along the line AA 'in Fig.
3 is a cross-sectional view of the rib.
4 is a perspective view of the rib.
Fig. 5 is a side view of the rib in the long-side direction, showing that the area where the height of the continuous reinforcing fiber is 5% or more of the height of the projection is 20% or more of the bottom side.
6 is a perspective view of a quadrangular pyramid.
7 is a sectional view of a quadrangular pyramid.
8 is a side projection view of four sides of a quadrangular pyramid.
9 is a schematic perspective view showing the compression molding method of the present invention.
10 is a schematic perspective view showing a hybrid molding method in which an injection molding method is combined with the compression molding method of the present invention.
11 is a schematic sectional view of one embodiment of a mold used in the compression molding method of the present invention.
12 is a schematic cross-sectional view for explaining details of one embodiment of a mold used in the compression molding method of the present invention.
Fig. 13 is a sectional view of a mold for molding a molded article shown in Fig. 1. Fig.
14 is a schematic perspective view of a quadrangular prism.
15 is a schematic perspective view of a truncated cone.
16 is a schematic view for explaining a tensile test method performed on the molded article of the present invention.
17 is a schematic view for explaining a bending test method performed on the molded article of the present invention.

Hereinafter, the present invention will be described.

[Molded article]

One embodiment of the molded article of the present invention will be described with reference to the drawings. 1 is a schematic top view showing an embodiment of a molded article. 2 is a cross-sectional view taken along line A-A 'in Fig.

1, the molded product 400 includes a substrate portion 420, holes 401 and 402, ribs 403, 405 and 407, bosses 409 and 410, frustums 411 and 412, A quadrangular pyramid 413, and quadrangular pillars 414 and 415, as shown in Fig.

In the molded article of the present embodiment, as shown in Fig. 2, the continuous reinforcing fibers 170 are present inside the ribs 403, 405, and 407 and the truncated cones 411 and 412. The continuous reinforcing fibers 170 inside the ribs and the truncated cones are continuous with the continuous reinforcing fibers 170 of the base portion 420 without breaking.

As described above, the average value of the height h _f of the continuous reinforcing fibers in the rib is 5% or more, preferably 10% or more, of the height h of the protrusions, more preferably 20 %, More preferably at least 50%, and most preferably at least 90%. Since the average value of the height of the continuous reinforcing fibers is 5% or more, it is possible to provide appropriate strength to the protrusions.

The average value of the height h _f of the continuous reinforcing fibers with respect to at least one of the protruding portions should be 5% or more of the height h of the protruding portions and more preferably 5% or more with respect to the two or more protruding portions, Most preferably at least 5%.

In a case where a plurality of like protrusions are provided, it is sufficient that at least one of the same protrusions satisfies the above-described average value, more than two of them satisfy the average value, and the average value is satisfied in all the like protrusions .

The region where the height of the continuous reinforcing fibers in the projections is 5% or more of the height of the projections is preferably 20% or more, more preferably 50% or more, particularly preferably 80% or more, most preferably 100 % to be. With 20% or more of the base, it is possible to provide appropriate strength to the protrusions even if the other areas are not continuous.

If the region where the fiber is not present in a part of the root of the protruding portion is too wide, there is a possibility that it becomes a starting point of fracture from the region. Therefore, the portion of the root of the individual protruding portion where the fiber is not inserted is preferably 50% , More preferably not more than 20%, and most preferably not more than 5%.

The continuous reinforcing fibers in the protrusions may have a part that is partially broken from the inside or may be present partially separated from the substrate part. However, there is no breakage or breakage of the fibers, and continuous reinforcing fibers inside the substrate part and the inside of the protrusions are continuous Preferably in a state of being present.

The protruding portion is formed by inserting a molten or semi-molten composite material into a portion corresponding to the protruding portion of the mold by compression molding. At this time, the thermoplastic resin is more likely to be inserted into the tip end of the projection than the continuous reinforcing fiber. On the other hand, continuous reinforcing fibers are difficult to insert into protrusions because they are difficult to move. However, the longer the insertion distance, the stronger the protrusion strength. In the molded article of the present invention, a molded article in which the continuous reinforcing fibers are deeply inserted into the projections can be obtained by adjusting the specific compression conditions to be described later, and further, the mold temperature at the time of molding. The height of the protrusion is greater than the substrate thickness (T ₂₎ is negative, it is also preferred that the thickness (T ₂₎ over the height of the continuous reinforcing fibers, the substrate portion of the molded article of the projection. The height of the projection, and more preferably at least three times that of at least twice the thickness (T ₂₎ and more preferably the substrate portion of the thickness (T ₂₎ parts of the substrate.

Furthermore, the thickness height (h) of the protruding substrate portion (T ₂₎ And the thickness (T ₁ ) of the root of the protrusion is preferably not more than the thickness (T ₂ ) of the substrate portion.

It is preferable that the thermoplastic resin in the projection and the thermoplastic resin in the substrate portion are the same. Generally, in the case of producing a molded article having a rib or a boss shape by using a continuous reinforcing fiber composite material, a material different from the continuous reinforced composite material provided for forming the base portion, for example, a tape Or a hybrid molding in which a base portion is mainly formed by compression molding and a protrusion portion of a boss or a rib is formed by injection molding is generally used. Although these methods can be used in the present invention as well, the formation of protrusions using only a single continuous reinforcing fiber composite material forming the substrate portion is simple in terms of productivity and facility, and also has a high economic effect. In addition, since the protrusions are formed only from a single continuous reinforcing fiber composite material, basically, the thermoplastic resin of the substrate portion and the protrusions are formed of the same material, so that there is no clear interface between different materials, particularly, a thermoplastic resin interface. This is important in securing the strength of the projection.

When the substrate portion and the protrusion of the molded article are made of the same fiber-reinforced thermoplastic composite material as described above, the material provided on the substrate is basically formed by inserting the resin into the protrusion by compression molding. At this time, the continuous reinforcing fiber is also inserted into the protruding portion, but the strength of the bonding portion of the protruding portion with the base portion is important as the structural member, and the density Vf of the continuous reinforcing fiber is preferably higher than the front end of the protruding portion.

[Compression molding method]

One embodiment of the compression molding method of the present invention will be described. Fig. 9 shows a schematic perspective view of the compression molding method.

One embodiment of the compression molding method of the present invention is a compression molding method for compression molding a continuous fiber-reinforced thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin to obtain a molded article having a base portion and a projection portion,

The continuous fiber-reinforced thermoplastic resin composite material is inserted into a mold, and the mold is heated to a temperature not lower than the glass transition temperature of the thermoplastic resin or higher than the melting point of the thermoplastic resin to form the mold. The mold is then heated to a glass transition temperature of- A compression molding step of cooling the thermoplastic resin by cooling to 10 占 폚 or lower, preferably a glass transition temperature of -30 占 폚 or lower or a melting point of -50 占 폚 or lower, more preferably a glass transition temperature of -50 占 폚 or lower or a melting point of -100 占 폚 or lower; ,

And a step of discharging the gas component in the mold generated from the continuous fiber-reinforced thermoplastic resin composite material to the outside of the mold during the compression molding process. Hereinafter, the present invention will be described in detail with reference to the drawings.

First, as shown in Fig. 9A, the mold 100 comprising the mold portions 10, 20 is opened.

Next, as shown in Fig. 9B, the fabric 70, which is a base material of the composite material, is cut into a desired shape and inserted into the cavity 30. Next, as shown in Fig.

<Compression Molding Step>

- Heating process -

Next, as shown in Fig. 9C, the mold 100 is closed (clamped) and the temperature of the cavity surface is raised while compressing. The temperature of the cavity surface of the mold is set to be not lower than the melting point of the thermoplastic resin constituting the composite material or higher than the glass transition temperature and is always kept at a constant temperature by the second temperature adjusting means (14, 24). By the heated cavity surface, the thermoplastic resin portion set in the cavity rapidly melts. The length of the fabric 70 to be inserted into the cavity 30 is adjusted according to a desired thickness of the obtained molded article.

Here, the composite material may be inserted at room temperature into the mold, but preheating may be performed before insertion into the mold. In particular, in the case of using a plate-like prepreg as a composite material, it is preferable to preheat the composite material to a glass transition temperature of -30 ° C or higher or a melting point -30 ° C or higher of the thermoplastic resin, Or preheated to a melting point or higher. In the case of using a warp sheet as a composite material, preheating may be performed before insertion into a metal mold as in the case of a plate material, and preheating may not be required. By performing the preliminary heating, it is possible to remove the gas component in the fabric, and it is possible to improve the adhesion.

The temperature of the mold cavity surface when molded by the compression molding is not lower than the glass transition temperature of the thermoplastic resin of -100 DEG C or higher, the glass transition temperature +100 DEG C or lower, the melting point of 100 DEG C or higher and the melting point +100 DEG C or lower, 50 占 폚 or higher glass transition temperature +50 占 폚 or lower melting point -50 占 폚 or higher melting point + 50 占 폚 or lower glass transition temperature -30 占 폚 or higher glass transition temperature +30 占 폚 or lower melting point -30 占 폚 or higher melting point + to be.

- Temperature increase rate - Temperature decrease rate -

In the present invention, it is preferable to perform high cycle molding in which the cavity surface of the mold can be rapidly heated and quenched. The rate of temperature rise when heating the mold in the compression molding step is 30 DEG C / min or more, the rate of temperature decrease when cooling the mold is 30 DEG C / min or more, and the difference between the heating temperature and the cooling temperature is 80 DEG C or more . It is preferable that the temperature raising rate is 80 ° C / min or more, the temperature decreasing rate is 100 ° C / min or more, the difference between the heating temperature and the cooling temperature is 100 ° C or more, / Min or more, and the difference between the heating temperature and the cooling temperature is more preferably 120 ° C or more.

The temperature raising rate and the temperature lowering rate can be increased to 30 占 폚 / min or more to increase the productivity. When the temperature difference is 80 占 폚 or higher, the impregnation of the resin into the reinforcing continuous fiber and the solidification and releasability at the time of drawing the molded article are improved. The higher the temperature, the better the impregnation property, and the lower the temperature, the better the solidification property and releasability.

Here, the heating temperature and the cooling temperature are the target set temperatures at the time of rapid heating or rapid cooling. The target temperature at the time of rapid heating is referred to as the target high temperature and the target temperature at the time of rapid cooling is referred to as the target low temperature. The cooling rate is a rate when the mold cavity surface is cooled from the target high temperature to the target low temperature. The temperature raising rate is a rate at which the temperature of the cavity is raised from the target low temperature to the target high temperature.

The thermoplastic resin is melted by rapidly heating the surface of the cavity with a temperature not lower than the melting point or the glass transition temperature of the thermoplastic resin constituting the continuous fiber-reinforced thermoplastic resin composite material, and then the cavity surface is thermally fused with the melting point of the thermoplastic resin or the glass transition The thermoplastic resin is rapidly cooled to a temperature lower than the temperature to cool and solidify the thermoplastic resin, whereby a thermoplastic resin fiber composite molded article having excellent economical efficiency in a high cycle can be obtained.

- Cooling solidification process -

Next, the cavity surfaces 31 and 32 of the mold 100 in the mold-clamped state are heated to a glass transition temperature of -10 占 폚 or lower or a melting point -10 占 폚 or lower, preferably a glass transition temperature -30 占 폚 Or a melting point of -50 占 폚 or lower, more preferably a glass transition temperature of -50 占 폚 or lower or a melting point of -100 占 폚 or lower to solidify the thermoplastic resin.

- Gas release process -

The gas component generated from the fabric 70 is discharged to the outside of the mold in the process from the step of inserting the fabric 70 to the step of solidifying the thermoplastic resin. In the compression molding method, unlike the injection molding, the multi-stage compression method in which the one-end clamping force is released at an arbitrary step in the mold clamping step is particularly effective. Particularly, in the compression molding method in which the temperature of the metal mold is variably changed, which is one form of the present invention, the composite material is heated to a predetermined temperature and the gas is taken out at the stage where the gas is generated. Valid.

The &quot; step of generating gas &quot; is a step in which the composite material inserted in the mold is heated to a predetermined temperature, and the preferable heating temperature is a melting point of -100 DEG C or higher or a glass transition temperature of 100 DEG C or higher, Quot; melting point -60 DEG C or higher or glass transition temperature -60 DEG C or higher &quot;.

Another method of releasing gas in the mold is a method of vacuum-treating the inside of the mold to remove gas generated from the composite material.

As a method of removing the gas generated in the mold, the following methods can be mentioned besides the above-mentioned method of adjusting the compression pressure at the time of mold compression. For example, a method of removing gas by forming a slit for gas venting communicating with the mold cavity can be mentioned. The slit may be formed on the parting surface of the mold or on the mold projecting pin. Further, the division surface of the mold constituting the mold cavity may be used.

Next, as shown in Figs. 9D and 9E, the mold 100 is opened and the molded article 71 is taken out. The drawing temperature of the molded article is preferably a glass transition temperature of -30 占 폚 or lower or a melting point of -80 占 폚 or lower, more preferably a glass transition temperature of -50 占 폚 or lower or a melting point of -100 占 폚 or lower.

After withdrawing the molded article, the fabric back, which is the base of the composite article, is again cut into a desired shape, inserted into the cavity, and closed. Thereafter, the compression molding process is repeated to produce a molded article.

It is also possible to increase the temperature of the mold cavity surface by circulating high-pressure heating steam or low-pressure superheated steam to the cooling medium passage of the mold, for example, simultaneously with the withdrawal of the molded article or withdrawing the molded article.

Further, superheated steam at 300 DEG C or more may be circulated on the cavity surface before insertion of the fabric to heat the cavity surface.

Further, it is also possible to directly heat the substrate by inserting the fabric into the cavity after inserting the superheated vapor at 300 DEG C or higher from the vacuum line into the cavity. The superheated steam inserted into the mold may be removed from the vacuum line after the desired time is inserted.

According to the compression molding method of the present embodiment, since the step of releasing the gas component is provided in the compression molding step, the composite material enters the deep portion of the projecting portion, so that a thermoplastic resin fiber composite molded product excellent in strength can be obtained.

Next, another embodiment of the compression molding method of the present invention will be described.

The present embodiment includes a step of inserting a composite material into a recess corresponding to a projection of a metal mold instead of the gas discharge step of the compression molding method of the above embodiment.

That is, the compression molding method of the present embodiment is a compression molding method for obtaining a molded article having a substrate portion and a projection portion by compression molding a thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin,

When the continuous fiber-reinforced thermoplastic resin composite material is inserted into a mold, at least a part of the continuous fiber-reinforced thermoplastic resin composite material is inserted into the concave portion corresponding to the projection of the metal mold and the metal mold is heated to a temperature not lower than the glass transition temperature of the thermoplastic resin, And then the mold is cooled to a glass transition temperature of -10 占 폚 or lower or a melting point of -10 占 폚 or lower of the thermoplastic resin to solidify the thermoplastic resin.

In order to insert the continuous reinforcing fibers into the protrusions, there is a method of flowing together the thermoplastic resin in the mold when the thermoplastic resin is melted and flowed, and a method of inserting at least a part of the composite material into the protrusions in advance.

As a method of inserting a part of the continuous fiber-reinforced thermoplastic resin composite material into the concave portion of the mold, for example, when a plurality of fabric bags are used in a stack, a number of fabric bags suitable for the desired thickness of the molded product are injected into the mold cavity. Is inserted into a mold and press-inserted into the concave portion by using a thin plate made of metal or the like.

The composite material may be inserted into at least one concave portion of the plurality of concave portions, and more preferably two or more.

It is also preferable that at least one of the same kind of recesses is inserted, more preferably two or more, and most preferably, all of the same kind of recesses are inserted.

The amount of insertion of the continuous fiber-reinforced thermoplastic resin composite material into the concave portion of the metal mold varies depending on the volume of the concave portion and the details of the manufacturing conditions, but is adjusted such that the average value of the height of the continuous reinforcing fibers is 5% . In addition, it is preferable that the composite material is adjusted so as to be continuous with the continuous reinforcing fibers in the substrate portion at 20% or more of the base of the protrusions.

According to the compression molding method of the present embodiment, since the continuous fiber-reinforced thermoplastic resin composite material can be present in a wide area within the projection, a molded article having excellent strength of the projection can be obtained.

[Hybrid molding]

The compression molding method of the present invention can be used as a hybrid molding method by combining injection molding steps. Fig. 10 shows a schematic view of the hybrid molding. Elements that are the same as those in Fig. 9 are denoted by the same reference numerals, and a description thereof will be omitted (the same applies hereinafter).

As shown in Figs. 10A and 10B, the fabric 70 is inserted in the same sequence as the compression molding method.

As shown in Fig. 10C, the mold part 201 of the mold 200 for performing the hybrid molding is provided with a runner part 90 for filling the thermoplastic resin from the injection molding machine 80 by a known method.

After filling the thermoplastic resin, the mold is released as shown in Fig. 10D, and the hybrid molded product 72 made of the fabric bag 70 and the thermoplastic resin 81 is taken out, as shown in Fig. 10E.

In this hybrid molding method, a step of discharging the gas generated in the mold, which is exemplified in the first embodiment, may be formed before filling the thermoplastic resin with the injection molding machine. As a specific method of releasing the gas, the method of the above embodiment can be similarly used.

[mold]

Next, one embodiment of a mold usable in the compression molding method of the present invention will be described with reference to the drawings. The molds usable in the compression molding method of the present invention are not limited to those described below. Fig. 11 shows a schematic cross-sectional view of an embodiment of an in-mold type mold.

As shown in Fig. 11, the mold 100 includes a mold portion 10 as an upper mold, a mold portion 20 as a lower mold, and insulating plates 15 and 25 , The mold part (10) and the mold part (20) form the cavity (30). A composite material or the like is provided in the cavity 30 to form a molded product.

The mold part 10 includes a first temperature adjusting means 13 comprising a plurality of cooling medium passages capable of cooling the cavity surface 31 at least in the vicinity of the cavity surface 31 and a first temperature adjusting means 13, And a second temperature regulating means 14 composed of a plurality of rod-shaped cartridge heaters capable of heating at least the cavity surface 31 at a side opposite to the cavity surface 31 of the cavity surface 31. [

The mold portion 20 also includes a first temperature adjusting means 23 including a plurality of cooling medium passages capable of cooling the cavity surface 32 at least in the vicinity of the cavity surface 32, (24) composed of a plurality of rod-shaped cartridge heaters capable of heating at least the cavity surface (32) on the side opposite to the cavity surface (32) of the cavity surface (23).

The mold portion 10 is a structure divided into a first portion 11 having a first temperature regulating means 13 and a second portion 12 having a second temperature regulating means 14, (11) and the second part (12) can be separated by a spring (40).

The mold portion 20 is also divided into a first portion 21 having a first temperature regulating means 23 and a second portion 22 having a second temperature regulating means 24, The first portion 21 and the second portion 22 are configured to be removable by the spring 40.

A depressurizing path 33 for depressurizing the cavity 30 is formed in the mold section 20 when the mold 30 is clamped. The decompression path 33 is connected to a decompression means (not shown) provided outside the molding die by a vacuum line 60. A seal packing (50) is provided between the mold part (10) and the mold part (20).

Next, the details of the mold portion will be described with reference to Fig. 12 is a schematic cross-sectional view for explaining the details of the mold, and a part of the components is omitted.

12, the mold portions 10 and 20 are arranged such that the distance L0 from the cavity surface 31 to the first temperature control means 13 and the distance L0 from the cavity surface 31 to the cavity surface 31 It is preferable that the distance L1 to the opposite surface 16 satisfies the following relationship.

(L1 / L0) &gt; 3

In the case where the molding die is constituted by a plurality of mold parts, it is preferable that at least one mold part satisfying the numerical value range is satisfied, and it is more preferable that all the mold parts satisfy the numerical value range.

Here, the distance L0 from the cavity surface to the first temperature regulating means means the distance from the cavity surface to the center of the first temperature regulating means in a cross section perpendicular to the cavity surface of the mold.

The distance (L2) from the first temperature regulating means to the second temperature regulating means means a distance from the center of the first temperature regulating means to the center of the second temperature regulating means in a cross section perpendicular to the cavity surface of the mold .

The distance L1 from the cavity surface to the surface opposite to the cavity surface means a distance in a section perpendicular to the cavity surface of the mold.

The distance L0 from the cavity surface to the center of the first temperature regulating means means the shortest distance among them if the cavity surface has a concavo-convex shape and the distance from the cavity surface to the first temperature regulating means differs depending on the place .

When the cavity surface has a concavo-convex shape and the first temperature control means is formed at the same distance from the cavity surface along the concavo-convex shape, the distance L2 from the first temperature control means to the second temperature control means is It differs depending on the place. In this case, the distance (L2) from the first temperature control means to the second temperature control means means the shortest distance among the different L2.

The distance L1 from the cavity surface to the surface opposite to the cavity surface in the case where the cavity surface is a concavo-convex shape means an average distance of L1 different from each other.

In the case where the first temperature adjusting means and the second temperature adjusting means are provided with a plurality of cooling medium passages or a plurality of heaters, when the distance from the cavity surface differs depending on the place, for one passage or heater , The average value of the shortest distance to all passages or heaters.

 When the first part and the second part are integrally formed of the same material, the boundary between the first part and the second part is formed so as to extend from the center of the first temperature adjusting means in the cross section perpendicular to the cavity surface to the second temperature And is positioned at the position L0 away from the adjustment means side.

The mold of the present embodiment has a structure in which a first temperature adjusting means for cooling at least the vicinity of the cavity surface is provided and a second temperature adjusting means for heating at least a portion farther from the cavity surface than the first temperature adjusting means It is installed. The second temperature adjusting means heats the entire cavity of the cavity by heating the entire mold.

It is preferable that the first temperature adjusting means is closer to the cavity surface, but it is necessary to provide the first temperature adjusting means at a certain distance from the strength of the mold and the restriction of the design. The distance L0 from the cavity surface to the first temperature control means may vary depending on the dimensions of the first temperature means, but is preferably 30 mm or less, more preferably 20 mm or less, and further preferably 10 mm or less . Although the lower limit value of L0 is not particularly limited, it may vary depending on the dimension of the first temperature means. However, from the limit of the strength of the mold, the distance from the end of the first temperature means to the mold cavity surface is preferably 3 mm or more , And more preferably 6 mm or more.

In the mold of the present embodiment, the relationship between the distance L0 from the cavity surface to the first temperature control means and the distance L1 from the cavity surface to the surface opposite to the cavity surface is (L1 / L0) &gt; 3 , More preferably (L1 / L0)> 5, and most preferably (L1 / L0)> 10.

(L1 / L0) &gt; 3, it is possible to efficiently perform rapid heating during mold heating by increasing the capacity of the heat storage portion having a higher temperature than the cooling portion. Further, the closer the first temperature controlling means for cooling is to the cavity surface, the faster the cooling of the molded article during cooling. In addition, the smaller the cooling portion, the faster the mold can be heated at the time of heating the mold.

 Here, the cooling portion is a portion cooled by the first temperature control means and represents at least a first portion. The heat storage portion is a portion heated by the second temperature control means and represents at least a second portion.

The distance L2 from the first temperature control means to the second temperature control means is L2 &gt; L0, preferably 2 &lt; L2 / L0 &lt;

By making L2 &gt; L0, it is possible to satisfactorily prevent the cooling to the second temperature control means at the time of cooling, and at the same time, the control power of the second temperature control means can be prevented from being disturbed.

In the temperature control of the cavity surface, when the vertical temperature of the cavity temperature is small, L0 and L2 should be as close as possible. However, when the composite material is molded, the difference between the upper limit value and the lower limit value of the mold cavity temperature is, for example, 50 DEG C or more, preferably 100 DEG C or more, more preferably 150 DEG C or more. desirable.

The mold portion may be constituted by a first portion having a first temperature adjusting means and a second portion having a second temperature adjusting means. In this case, the first and second portions may be made of the same material, but more preferably, the material of the first portion is made of a material having a higher thermal conductivity than the material of the second portion. By using a material having a good thermal conductivity in the first portion, the first portion can be rapidly cooled during cooling. Further, even when the cooling of the first temperature regulating means of the first portion is stopped and heated, it becomes possible to quickly conduct the heat stored in the second portion having the second temperature regulating means.

In the case of the structure including the first portion having the cooling medium passage as the first temperature adjusting means and the second portion having the second temperature adjusting means, as shown in Fig. 12, the volume V (I) of the first portion, (V0 / V (I)) &gt; 1.3 is preferable, and the volume V0 of the metal part which is heated substantially. It is also preferable that (V0 / V (I)) <3. In order to rapidly heat the first portion and cool it rapidly, it is better to make V (I) small. Since the volume V (II) of the second portion is preferably large in terms of collecting heat, I)) &gt; 1.3 is preferable. On the other hand, the capacity of V (I) is limited in terms of weight reduction due to problems such as the strength of the mold and restriction of the shape of the cavity surface. If the volume V (II) of the second portion is excessively large, there is a restriction from the problem that the initial heating takes time or the heat is released to the outside of the mold. Further, the reduction of V (I) is limited by the limitation by the strength and the cavity shape, and (V0 / V (I)) <3 is preferable.

That is, the heating of the cavity surface can rapidly heat the cavity surface by supplying heat from the second portion serving as a heat storage portion that accumulates a certain amount of heat, thereby heating and melting the thermoplastic resin of the material provided in the cavity. Here, the larger the capacity of the heat storage portion, the more effectively the cavity surface can be heated. However, the size of the capacity of the heat storage portion can be appropriately determined in accordance with the size of the mold or the molding equipment from the viewpoint of the amount of energy consumed by heating in equipment.

That is, the heating of the cavity surface can rapidly heat the cavity surface by supplying heat from the second portion, which serves as a heat storage portion in which a certain amount of heat is stored, thereby thermally fusing the thermoplastic resin of the material provided in the cavity.

On the other hand, in the case where the first temperature control means is a plurality of cooling medium passages, for example, the cavity surface is cooled by allowing the cooling medium to flow through the cooling medium passages in the vicinity of the cavity surface, The thermoplastic resin can be cooled and solidified. At this time, in order to cool only the vicinity of the cavity surface, the smaller the mold capacity of the portion having the coolant passage is, the better, and the coolant passage is preferably closer to the cavity surface.

The same material may be used for the first portion and the second portion, but a material having a different thermal conductivity may be used. (I) (J / s · m · K) of the volume of the first part and the thermal conductivity C (I) of the material of the first part and the volume V (II) of the second part and the thermal conductivity C (II) (J / s · m · K)

V (I) x (1 / C (I))) &gt; 3

More preferably, {V (II) x (1 / C (II)) / {V (I) x

Most preferably, {V (II) x (1 / C (II))} / {V (I) x

to be.

It is possible to quickly cool the cavity surface during cooling and to reduce the temperature of the cavity surface during heating so as to satisfy the condition of { , The temperature can be rapidly raised by the heat storage of the second portion.

The heat conductivity C (I) (J / s · m · K) of the material of the first portion is the thermal conductivity C (II) of the material of the second portion having the second temperature controlling means ) Of 3.5 times or more. That is, the cooling can be performed quickly when the thermal conductivity is high at the time of cooling, and when the thermal conductivity is high at the time of heating, the heat can be quickly taken away from the heat storage portion. This is particularly effective when the first part is cooled when it is cooled. In the case of not separating during cooling, if the thermal conductivity of the first portion is good, the second portion having the function of the heat storage portion at the time of cooling may be cooled, so that it is necessary to optimize the material appropriately.

It is more preferable that the first portion and the second portion have a separable structure. After the cavity is heated to a desired temperature, the mold is slightly opened in the cavity closed state to form the first portion 11 and the second portion 12 and the first portion 21 and the second portion 22 ), And forming a heat insulating layer of air is also effective because it increases the molding cycle.

As a specific method, by inserting the spring 40 between the first portion and the second portion, the first portion and the second portion can be separated while the cavity is closed by slightly opening the mold. The separation may be carried out in at least one of the plurality of mold parts.

With the mold separated, the cooling water is press-fitted into the cooling medium passage or the like, and the first portion including the mold cavity is quenched. At this time, the mold cavity surface is kept closed by using a spring or a hydraulic cylinder so that the cavity is not opened. The cooling water is stopped after the surface of the mold cavity is heated to a temperature lower than the heat distortion temperature of the thermoplastic resin for a predetermined time and compressed air is introduced into the cooling medium passage as necessary to discharge water in the cooling medium passage.

The cooling of the first part is achieved by circulating the cooling medium in the case where the first temperature control means is constituted by a plurality of cooling medium passages. However, how fast the cooling medium is circulated in a large quantity enables the rapid cooling of the cavity surface Or not.

For this reason, it is preferable that a structure capable of independently flowing the cooling medium in each cooling medium passage is provided. As a specific example, a manifold capable of simultaneously flowing the cooling medium at the same temperature can be mentioned. The manifold may be provided on the inflow side of the cooling medium passage outside the mold and the cooling medium may be circulated from the manifold to each cooling medium passage at the same time and the manifold may be provided on the discharge side of the cooling medium for discharging.

The flow rate greatly affects the cooling efficiency, and if necessary, the refrigerant may be circulated by using a pressurizing pump or the like. It is also possible to use a commercially available pressure-on pre-heater.

Examples of the medium for circulating in the cooling medium passage include water, chiller liquid, carbon dioxide gas, and compressed gas. The medium may be of one type, but the medium of different temperature may be distributed in multiple stages. For example, when the cavity temperature is heated to 300 占 폚, hot water of 150 占 폚 is flowed for several seconds, then cooling water of 60 占 폚 and cooling water of 10 占 폚 are passed in multiple stages, and when the mold reaches a certain temperature The pressurized hot water at 150 캜 may be flowed again to adjust the cavity surface to a uniform temperature.

When a composite material is placed in a cavity and heated and compression-molded in a cavity to obtain a molded article by melting and solidifying the thermoplastic resin of the composite material, impregnation of the thermoplastic resin into the continuous reinforcing fiber greatly affects the properties of the molded article. When air is present in the mold, the air remains voids in the molded product when the thermoplastic resin is melted, which causes fine unimpregnated portions to be formed in the continuous reinforcing fibers. By removing these gasses from the air or the resin in the mold, a molded article impregnated with the thermoplastic resin can be obtained more quickly. As a method of releasing the gas component generated in the mold, a decompression path capable of decompressing the cavity at the time of mold clamping may be provided. Alternatively, after the mold is once closed and the composite material is heated at a high temperature, , And the gas component generated from the composite material may be discharged outside the mold.

The temperature of the mold cavity at the time of opening the mold pressure is preferably not lower than the glass transition temperature of the thermoplastic resin of -50 占 폚 or higher and the glass transition temperature +50 占 폚 or lower, the melting point of -100 占 폚 or higher and the melting point + More preferably not less than 30 占 폚 and not more than +30 占 폚, a melting point of not less than -80 占 폚 and a melting point of not more than +10 占 폚, a glass transition temperature of not less than -30 占 폚 and not more than a glass transition temperature, Do. The mold-type clamping pressure for releasing the gas may be performed a plurality of times while raising the mold temperature. However, at least the initial mold-pressure releasing is preferably performed at a temperature not higher than the glass transition temperature or lower than the melting point.

It is required that the composite material is heated in the mold to melt the thermoplastic resin as one use form of the mold used in the present invention. The second temperature regulating means is preferably set such that the average temperature of the second portion is higher than the glass transition temperature of the thermoplastic resin material provided in the cavity in the case of amorphous resin, Temperature + 30 deg. C or higher, and most preferably glass transition temperature + 50 deg. C or higher. In the case of a crystalline resin, it is set to be not lower than the melting point of the thermoplastic resin material provided in the cavity, preferably not lower than +30 DEG C, and most preferably not lower than +50 DEG C.

The average temperature of the second part means the average temperature of the second part of the mold. As an example of the measuring method, a method of measuring the temperature by inserting a thermometer into the mold at a position 10 mm to 30 mm away from the vicinity of the second temperature adjusting means . In the case of using the cartridge heater as the second temperature regulating means, the temperature control is performed by controlling the on / off control of the power by detecting the above-mentioned temperature or by adjusting the capacity of the power source by performing PID control (Proportional-Integral-Differential Controller) .

There is no particular limitation on the second temperature regulating means. In addition to the stick-shaped cartridge heater, there is a heater using electric resistance in a heating medium such as heating oil or water vapor. However, in order to maintain the mold at a high temperature of not less than the melting point of the thermoplastic resin, It is preferable that the heater is a heater in terms of performance. Ceramic heaters, sheath heaters, and the like are available as the types of heaters, but the rod-shaped cartridge heaters are preferably used for simplicity and performance.

In the present embodiment, the mold portion 10 and the mold portion 20 have been described in the case where the first portions 11 and 21 and the second portions 12 and 22 are configured to be capable of being separated from each other. However, 40 may not be provided, but may be formed integrally with an adhesive or the like.

Since the heat insulating plates 15 and 25 have a role of suppressing heat flow due to heat conduction to the molding machine, it is better to be provided at the connection portion between the mold 100 and the molding machine.

The above-described molding metal mold can be applied to compression molding, but it is also possible to use a molding machine capable of suitably performing injection molding, for example, a sprue forming section, a runner forming section, It is also applicable to hybrid molding.

[Continuous fiber reinforced thermoplastic resin composite material]

The continuous fiber-reinforced thermoplastic resin composite material composed of continuous reinforcing fiber and thermoplastic resin includes composite yarns in which continuous reinforcing fibers and thermoplastic resin fibers are continuously and uniformly mixed with each other, composite yarns in which thermoplastic resin is coated on continuous reinforcing fibers, Or a plate prepreg obtained by impregnating a continuous reinforcing fiber with a thermoplastic resin. The preparation of the prepreg is not particularly limited, but may be a method in which a continuous powder of a thermoplastic resin is added to the continuous reinforcing fiber to form a plate by heat pressing in advance, or a plate obtained by hot pressing a continuous reinforcing fiber and a thermoplastic resin film Can be used. Further, the continuous reinforcing fiber and the thermoplastic resin fiber are mixed to form a filament yarn, and the filament yarn is produced by heating the filament yarn to a temperature not lower than the glass transition temperature or melting point of the thermoplastic resin to impregnate the thermoplastic resin into the reinforcing fiber, Can be used.

<Continuous reinforcing fiber>

The continuous reinforcing fibers may be those used as ordinary fiber reinforced composite materials. Examples of the continuous reinforcing fibers include glass fibers, carbon fibers, aramid fibers, ultrahigh tensile polyethylene fibers, polybenzazole-based fibers, liquid crystal polyester fibers, Metal fibers, ceramic fibers, and the like. From the viewpoints of mechanical properties, thermal properties, and general versatility, glass fibers, carbon fibers, and aramid fibers are preferable.

As the continuous reinforcing fiber, when a glass fiber is selected, a bundling agent may be used, and the bundling agent preferably comprises a silane coupling agent, a lubricant and a binding agent.

With respect to the details of the glass fiber and the bundling agent, those described in Patent Document 1 can be suitably used.

- Form of continuous reinforcing fiber -

The number of single fibers of the continuous reinforcing fiber is preferably 30 to 15,000 from the viewpoint of openability in the hybridization process and handling property.

As the continuous reinforcing fiber, when the carbon fiber is selected, the bundling agent is preferably composed of a lubricant and a binding agent.

The kind of the binder, the lubricant, and the binding agent are not particularly limited and known ones can be used. As a specific material, those described in Patent Document 1 can be used.

When other continuous reinforcing fibers are used, the type and amount of the bundling agent to be used for the glass fiber and the carbon fiber may be appropriately selected depending on the characteristics of the continuous reinforcing fiber, and the concentration of the bundling agent used for the carbon fiber Type, and amount of application.

&Lt; Thermoplastic resin &

The thermoplastic resin in the present invention refers to all those generally referred to as thermoplastic resins. Styrene-acrylonitrile copolymer (SAN resin), acrylonitrile-butyl acrylate rubber-styrene copolymer (AAS resin), styrene-acrylonitrile copolymer Styrene copolymer (AES), acrylonitrile-chlorinated polyethylene-styrene copolymer (ACS), ABS resin (for example, acrylonitrile-butadiene-styrene copolymer, acrylonitrile -Butadiene-styrene-alpha methyl styrene copolymer, acrylonitrile-methyl methacrylate-butadiene-styrene copolymer); Acrylic resins such as polymethyl methacrylate (PMMA); Olefin resins such as low density polyethylene (LDPE), high density polyethylene (HDPE) and polypropylene (PP); Vinyl chloride resins such as polyvinyl chloride and polyvinylidene chloride; Vinyl chloride-based resins such as ethylene vinyl chloride-vinyl acetate copolymer and ethylene-vinyl chloride copolymer; Polyester resins such as polyethylene terephthalate (PETP, PET) and polybutylene terephthalate (PBTP, PBT); Polycarbonate resins such as polycarbonate (PC) and modified polycarbonate; Polyamide-based resins such as polyamide 66, polyamide 6 and polyamide 46; Polyacetal (POM) resins such as polyoxymethylene copolymer and polyoxymethylene homopolymer; (PEI), thermoplastic polyimide (TPI), polyetherketone (PEK), polyetheretherketone (PEEK), polyetheretherketone (PEEK), and polyetheretherketone Phenylene sulfide (PSU) and the like; Cellulose derivatives such as cellulose acetate (CA), cellulose acetate butyrate (CAB) and ethyl cellulose (EC); Liquid crystal polymers (LCP) such as liquid crystal polymers and liquid crystal aromatic polyesters; Thermoplastic elastomers such as thermoplastic polyurethane elastomer (TPU), thermoplastic styrene butadiene elastomer (SBC), thermoplastic polyolefin elastomer (TPO), thermoplastic polyester elastomer (TPEE), thermoplastic polyvinyl chloride elastomer (TPVC), thermoplastic polyamide elastomer . As the thermoplastic resin in the present invention, the thermoplastic resin as described above may be produced in the molding step of the present invention. Or may be formed by the method of the present invention using a blend of one or more thermoplastic resins. The thermoplastic resin may contain a filler and / or an additive.

When the continuous fiber-reinforced thermoplastic resin composite material comprising the continuous reinforcing fiber and the thermoplastic resin is a fabric, the thermoplastic resin may be a polyolefin resin, a polyamide resin, a polyester resin, a polyetherketone, a polyetheretherketone, , Polyphenylene sulfide, and a thermoplastic polyether imide.

- Polyester resin -

The polyester-based resin means a polymer compound having -CO-O- (ester) bond in the main chain. For example, polyethylene terephthalate, polybutylene terephthalate, polytetramethylene terephthalate, poly-1,4-cyclohexylene dimethylene terephthalate, and polyethylene-2,6-naphthalene dicarboxylate can be cited , But are not limited thereto.

Regarding the details of other polyester-based resins, those described in Patent Document 1 can be used suitably.

- polyamide based resin -

The polyamide-based resin means a polymer compound having -CO-NH- (amide) bond in the main chain. Examples thereof include polyamides obtained by ring-opening polymerization of lactams, polyamides obtained by the self-condensation of omega -aminocarboxylic acids, polyamides obtained by condensing diamines and dicarboxylic acids, and copolymers thereof. But are not limited thereto.

As the polyamide, one type may be used alone, or two or more types may be used as a mixture. With respect to the details of other lactam, diamine (monomer) and dicarboxylic acid (monomer), those described in Patent Document 1 can be suitably used.

Specific examples of the polyamide include polyamide 4 (poly-alpha-pyrrolidone), polyamide 6 (polycaproamide), polyamide 11 (polyundecanamide), polyamide 12 (polydodecanamide ), Polyamide 46 (polytetramethylene adipamide), polyamide 66 (polyhexamethylene adipamide), polyamide 610, polyamide 612, polyamide 6T (polyhexamethylene terephthalamide), polyamide 9T Nonane methylene terephthalamide), and polyamide 6I (polyhexamethylene isophthalamide), and copolymerized polyamides containing them as a component.

Examples of the copolymerized polyamide include copolymers of hexamethylene adipamide and hexamethylene terephthalamide, copolymers of hexamethylene adipamide and hexamethylene isophthalamide, and copolymers of hexamethylene terephthalamide and 2-methylpentanediamine And copolymers of terephthalamide.

The concrete production method of the mixed fiber used in the thermoplastic resin fiber composite material is not particularly limited, but a known method can be used as the method of hybridizing. For example, a carded joint method in which continuous reinforcing fibers and thermoplastic resin fibers are folded and aligned in a state of being opened after being opened by an external force by an electrostatic force, a pressure caused by a fluid spray, a pressure for pressing on a roller, Interlaced (interlaced) method. Among them, it is preferable to use a fluid intercalation method capable of suppressing the damage of the continuous reinforcing fiber and having excellent openability and uniform mixing. In the fluid interlacing method, a fluid such as air, nitrogen gas, A method of making two or more vortex turbulence zones parallel to a yarn axis by using a non-bulking yarn under a tension of not inducing a loop or crimp by inducing fibers in this band Or a method in which only continuous reinforcing fibers are opened or after the continuous reinforcing fibers and thermoplastic resin fibers are opened together and then the fluid is entangled (fluid intercalation after carding). Particularly, it is preferable that the thermoplastic resin fibers are subjected to a process of thermally processing alone, followed by a preliminary twisting process, followed by continuous mixing with the same apparatus by a fluid intercalation method.

In addition, the method described in Patent Document 2 can be suitably used for the details of the Horn Island method.

The thermoplastic resin constituting the thermoplastic resin fiber composite material may be coated on the continuous reinforcing fiber in the composite yarn or impregnated with the continuous reinforcing fiber. The coating or impregnation of the thermoplastic resin may be carried out at the time of producing the continuous reinforcing fiber, or may be carried out by a separate step after the continuous reinforcing fiber is produced.

The shape of the thermoplastic resin fiber composite material is not particularly limited and may be a sheet, a film, or a pellet. From the viewpoint of operability and shape flexibility, a fabric-like shape is preferable.

The method for obtaining the fabric is not particularly limited, and a known method for fabricating an appropriate fabric selected according to the application and purpose can be used. For example, the fabric may be a woven fabric such as a shuttle loom, a rapier loom, an air jet loom, a water jet loom, or the like, and may include at least a composite yarn. Preferably, it may be obtained by inserting weft yarns into warp yarns in which fibers including composite yarns are arranged. The knitted fabric is obtained by knitting a fiber including a composite yarn at least partially using a knitting machine such as a circular knitting machine, a flat knitting machine, a tricot knitting machine, and a rachel knitting machine. The nonwoven fabric may be obtained by forming a fibrous assembly comprising a composite fiber in at least a portion of the fibrous structure in a sheet form called a web and then subjecting it to a physical action such as a needle punching machine, a stitch bond machine, a columnar flow machine, Or by bonding the fibers together by thermal action or an adhesive.

As for the other form of the fabric, etc., the method described in Patent Document 1 can be suitably used.

As a method of cutting the fabric to a desired shape, there are a water jet cutter, a laser cutter, a plotter cutter, an ultrasonic cutter, a superhigh-cutter press cutter, and an open-end press cutter. In view of economy, productivity and performance, Do. The temperature of the blade of the open press cutter is appropriately set depending on the material, but it is preferably at least the melting point or the glass transition temperature of the thermoplastic resin, preferably at the melting point + 30 DEG C or higher or the glass transition temperature +30 DEG C or higher, more preferably at the melting point + Or a glass transition temperature + 70 DEG C or higher.

Incidentally, in the case of cutting a fabric or prepreg made of a continuous fiber-reinforced thermoplastic resin composite material by a water jet cutter or a laser cutter described above before inserting it into a mold, the following problems may arise. That is, in the case of using a water jet cutter, there is a case where the abrasive mixed with water adheres to the composite material or the abrasive material enters the inside, thereby deteriorating the quality of the composite material. In the case of using a laser cutter, the thermoplastic resin at the cutting end is burned, which may result in deterioration of the physical properties of the composite material after molding.

In order to prevent the above-described problem, it is preferable to cut the cutting surface of the continuous fiber-reinforced thermoplastic resin composite material while melting the thermoplastic resin by a blade having a temperature equal to or higher than the melting point of the thermoplastic resin, and solidify the melted thermoplastic resin.

The continuous fiber-reinforced thermoplastic resin composite material produced as described above is characterized in that at least a part of the thermoplastic resin on the cut surface of the composite material is melted and solidified, and the molecular weight of the thermoplastic resin melt- It is preferably 20% or more of the molecular weight. The "at least part of the thermoplastic resin" is preferably at least 50%, more preferably at least 80%, and most preferably 100% of the thermoplastic resin at the cut surface. The melt-solidification of the thermoplastic resin on the cut surface can be confirmed by visual observation, but it can preferably be confirmed by energy dispersive X-ray analysis (EDX).

 The molecular weight of the thermoplastic resin that has been solidified by melting is measured from a composite material (sample) taken from the cut surface. More specifically, a sample is cut out in a thickness region of 500 mu m from the surface of the cut surface at an arbitrary position of the central portion (the portion excluding the width of 1 mm from the peripheral edge of the cut surface). This sample was dissolved in 1,1,1,3,3,3-hexafluoro-2-propanol to remove insoluble continuous reinforcing fibers, and the 1,1,1,3,3,3-hexafluoro -2-propanol is measured by a gel permeation chromatography (GPC) apparatus is the molecular weight of the thermoplastic resin which has been solidified by melting. Similarly, the molecular weight of the thermoplastic resin itself constituting the composite material is also dissolved in 1,1,1,3,3,3-hexafluoro-2-propanol, and can be measured by a gel permeation chromatography (GPC) apparatus.

If the molecular weight of the thermoplastic resin melt-solidified at the cut surface is 20% or more of the molecular weight of the thermoplastic resin itself constituting the composite material, deterioration of the physical properties of the composite material can be suppressed, and machining of the cut surface becomes possible. It is preferably in the range of 20% or more, more preferably 40% or more, and further preferably 50% or more.

In the composite material formed as described above, the continuous reinforcing fiber and the thermoplastic resin are continuously and uniformly mixed with each other, so that the continuous reinforcing fiber can be uniformly fixed to the thermoplastic resin. Therefore, this composite material preferably includes a composite yarn of continuous reinforcing fibers and continuous thermoplastic resin. By using this composite yarn, the handling property in the step of knitting or the like which is made into a fabric is excellent, and the obtained fabric is able to be a composite material formed body exhibiting sufficient mechanical properties even in short-time molding.

In the cutting melting process, it is preferable to cut the composite material while melting the thermoplastic resin by applying a thermal history by a blade having a temperature equal to or higher than the melting point of the thermoplastic resin. The temperature of the blade is preferably not lower than the melting point of the thermoplastic resin and is preferably higher than the melting point by 50 캜 and more preferably by 75 캜. From the viewpoint of deterioration of the thermoplastic resin, it is preferable that the temperature of the blade is a melting point of +150 DEG C or less. The blade may be a Swedish blade, a Thomson blade, a super blade or the like, and preferably a blade made of a material having high hardness or high rigidity.

By cutting a composite material composed of a continuous reinforcing fiber and a thermoplastic resin by a blade heated to a temperature equal to or higher than the melting point of the thermoplastic resin, the composite material is cut while the thermoplastic resin is melted to produce a cut surface, The thermoplastic resin is solidified to form a cut surface, thereby making it possible to produce a composite material in which the end face is not loosened.

Example

[Example 1]

(mold)

As the mold, the molds shown in Figs. 11 and 13 were used. Fig. 13 is a first section of the mold of Fig. 11, and is a cross-sectional view of a portion corresponding to the cross-sectional view taken along the line A-A 'of Fig. 1; As shown in Fig. 13, the mold used in this embodiment has first temperature adjusting means 313 and 323 on the first portions 310 and 320 of the mold, and the ribs 403 and 405 , 407, and a truncated cone 412, respectively. Since the second portions 12 and 22 having the second temperature adjusting means 14 and 24 of the mold are the same as those in Fig. 11, the description is omitted.

A Korson alloy (Mold Max-V, manufactured by Materion Brush Co., Ltd.) having a thermal conductivity of 165 J / s · m · K was used for the first portions 310 and 320 having the cooling medium passages 313 and 323, The mold parts 10 and 20 having the cartridge heaters 14 and 24 were made of carbon steel (S55C) with a thermal conductivity of 40 J / s · m · K. The volume V0 (V0 / V (I)) of the substantially heated mold portion with respect to the volume V (I) of the first portion is 10.

The cooling medium passages 313 and 323 are provided at an interval of 20 mm at a position having an inner diameter of 8 mm and a distance L0 from the central portion to the cavity surface of 15 mm.

(GLE4103, capacity 1000 W,? 10 mm x 400 mm, watt density 8.3 W / cm 2) manufactured by HAKKO Electric Co., Ltd. was used as the second temperature adjusting means 14 and 24.

The distance L2 from the center of the cooling medium passage to the center of the stick-shaped cartridge heater is 30 mm.

(materials)

A fineness of 685 dtex with 1.0 mass% of the following concentrator A and 400 glass fibers was used as the continuous reinforcing fiber.

Composition of Concentrate A (in terms of solid content):

Silane coupling agent: 0.6% by mass of? -Aminopropyltriethoxysilane (trade name: KBE-903, Shin-Etsu Chemical Co., Ltd.)

Lubricant: wax 0.1% by mass (trade name: Carnauba wax (manufactured by Kato Yoko))

Binders: 5% by mass of an acrylic acid / maleic acid copolymer salt (trade name: Aquaric TL (manufactured by Nippon Catalysts Co., Ltd.))

(Trade name: Leona (registered trademark) 470 / 144BAU (manufactured by Asahi Kasei Fibers Corporation), fineness of 470 dtex, mono number of 144), which is not entangled, was used as the thermoplastic resin fiber.

A fiber bundle was prepared by aligning a bundle of 400 glass fiber bundles and 2 bundles of PA (polyamide) fiber having a fineness of 470 dtex substantially perpendicularly to a fluid entangled nozzle, Composite yarn was obtained.

Fluid interlocking nozzle: Kyocera KC-AJI-L (1.5 mm diameter, propelling type)

· Air pressure: 2 kg / ㎠

· Processing speed: 30 m / min

The composite yarn was used as warp and weft yarns (warp yarns) having an oblique density of 6/5 mm and a weft density of 6/5 mm. No fluff or fibril-like water was generated at the time of weaving, no adhesion of seams or fluff was observed even at the loom, and the weaving property was good.

The warp yarns were cut so as to conform to the shape of the desired compression molded article by overlapping seven yarns. Six sheets of 7 sheets were superposed and cut using an open end heated to 330 캜. The cut surface was fused, and a substrate excellent in handling was obtained.

(Compression molding)

A molded article was produced by the compression molding method shown in Fig. 9 according to the following procedure.

The molding machine used Toshiba Machine Manufacturing (S100V-8A) with a maximum clamping force of 300 tons.

 Table 1 shows the details of the mold, substrate, and each process.

[Step 1] (Clamp Set and Mold Clamping) A mold is opened, and one of seven clogs cut in the desired shape is inserted into a mold, and a metal thin plate is attached to all of the concave portions corresponding to the ribs of the mold To the depth of the rib tip. Next, six overlapping fabric rolls were set at predetermined positions in the mold when the mold temperature was 150 DEG C, and were clamped at a mold clamping force of 240 MPa.

[Step 2] (Mold heating) In a mold-clamped state, the cavity surface was heated to 300 deg. C using a cartridge heater, and the polyamide resin constituting the fabric was melted in the mold and infiltrated into the glass fiber .

[Step 3] (Mold separation, cooling) The mold clamping force was lowered, and the cavity surface was cooled by passing cooling water of 25 DEG C through the cooling medium passage with the cavity closed.

The water flow was stopped 5 seconds after the temperature of the cavity surface reached 150 DEG C, the mold was opened 10 seconds after stopping the water flow, and at the same time, the water in the cooling medium passage was discharged as compressed air.

[Step 4] (Release) After the mold release, the molded article was taken out immediately and the process was returned to Step 1.

The outer dimensions of the obtained molded article 400 were 250 mm x 250 mm and the thickness was 2 mm.

[Example 2]

A molded article was prepared in the same manner as in Example 1 except that the same mold as in Example 1 was used.

Seven sheets were superimposed in the fabric bag, and the sheets were cut in a thermal blade. Seven sheets were stacked in the mold cavity without press-fitting into the ribs. As a molding method, when the cavity surface reached 240 占 폚 between [Step 1] and [Step 2] instead of press-fitting the fabric into the concave portion corresponding to the rib of the mold in [Step 1] of Example 1, Deg.] C for 0.5 seconds. Thereafter, a mold clamping force of 240 MPa was applied again to mold.

[Example 3]

A molded article was prepared in the same manner as in Example 1, except that the substrate was the same as that of Example 1, the protrusions other than the ribs and the substrate were formed from a substrate, and the rib portions were formed by injection molding.

[Step 1] (Fabric set and mold-type fastening) Seven sheets of a fabric cut into the above-described desired shape were cut and prepared by thermally cutting the same. Seven sheets were laminated without being pressed into the ribs, And set at a predetermined position in the mold at 150 DEG C, and was clamped with a mold clamping force of 240 MPa.

[Process 2] (Injection molding) A resin composition of a polyamide 66 resin (trade name: LEONA (registered trademark) 14G50) containing 50% of short fiber GF only in the rib portion was molded at a cylinder set temperature of 290 DEG C , An injection pressure of 20 MPa, an injection speed of 50 mm / sec, injection pressure of 20 MPa was applied.

[Step 3] (Mold Heating) In a mold clamped state, the cavity surface is heated to 300 deg. C by using a cartridge heater to melt the polyamide resin constituting the fabric into the mold to impregnate the glass fiber And the injection resin composition and the fabric were bonded together.

[Step 4] (Mold separation and cooling) The mold clamping force was lowered and the first part and the second part were separated by 5 mm each while the cavity was closed. Cooling water of 25 캜 was passed through the cooling medium passage, Lt; / RTI &gt; The quantity of cooling water during cooling was 15 L / min.

The water flow was stopped 5 seconds after the temperature of the cavity surface reached 150 DEG C, the mold was opened 10 seconds after stopping the water flow, and at the same time, the water in the cooling medium passage was discharged as compressed air.

[Step 5] (Release) After the mold was released, the molded article was taken out immediately, and the process was returned to Step 1.

[Example 4]

[Step 1] (Preparation of prepreg) A prepreg sheet was prepared in advance in the following procedure using the same fabric as in Example 1 as a substrate. Seven warp sheets were sandwiched between two steel plates with a mold having a thickness of 3.0 mm and then put in a compression molding machine heated at 300 DEG C and heated at a compression force of 5 MPa for 10 minutes and transferred to a cooling plate and cooled for 5 minutes A prepreg of a 3 mm plate was prepared.

The sheet material was heated using an infrared heater, and after 7 minutes, the sheet material was continuously heated for 3 minutes after the surface temperature of the sheet material reached 300 ° C, and immediately inserted into the same mold as in Example 1 in which the mold temperature was set at 250 ° C, Compression molding.

The obtained molded article was 250 mm x 250 mm and the thickness was 2 mm.

[Comparative Example 1]

A sheet material was prepared in the same manner as in Example 1, using the same fabric as that of Example 1.

Seven warp sheets were sandwiched between two steel plates fitted with a 2.2 mm thick mold, and then put into a compression molding machine heated to 300 DEG C, heated for 10 minutes under a compressive force of 5 MPa, transferred to a cooling plate, cooled for 5 minutes, Respectively.

The plate material was heated by using an infrared heater, and after 7 minutes, the surface temperature of the plate material reached 300 캜 and then continuously heated for 3 minutes. The plate material was immediately inserted into a mold set at a mold temperature of 150 캜 and compression molded.

The obtained molded article was a flat plate of 250 mm x 250 mm and a thickness of 2 mm.

[Comparative Example 2]

A plate material of a prepreg was prepared in advance in the following procedure using the same fabric as in Example 1 as a base material.

Seven warp sheets were sandwiched between two steel plates fitted with a 2.2 mm thick mold, followed by heating in a compression molding machine heated to 300 DEG C for 10 minutes under a compressive force of 5 MPa, then transferred to a cooling plate, cooled for 5 minutes, A prepreg plate of 2.2 mm was produced.

The sheet material was heated by using an infrared heater, and after 7 minutes, the sheet material was continuously heated for 3 minutes after the surface temperature of the sheet material reached 300 ° C, and immediately inserted into the same mold as in Example 1 in which the mold temperature was set at 150 ° C, Compression molding.

[Comparative Example 3]

[Step 1] (Preparation of rib portion)

A resin composition of a polyamide 66 resin (trade name: LEONA (registered trademark) 14G50) containing 50% of short fiber GF was extruded at a cylinder setting temperature of 290 DEG C, an injection pressure of 20 MPa, an injection speed of 50 mm / sec, and an injection maintaining pressure of 20 MPa was applied to cut only the rib portion of the obtained molded article.

[Step 2] (Fabrication of substrate portion)

A plate material of a prepreg having a size of 250 mm x 250 mm and a thickness of 2.2 mm was formed by the same process as in Comparative Example 1.

[Step 3] (Adhesion of base portion and rib portion)

Both the material of the rib portion obtained in Step 1 and Step 2 and the plate material of the prepreg were heated by using an infrared heater and heated continuously for 3 minutes after the surface temperature of the plate reached 300 캜 after 7 minutes, The rib portion was first placed in the same mold as in Example 1 in which the mold temperature was set to 150 占 폚, and then the plate material was inserted and compression molded to bond the rib portion and the base portion of the injection resin composition.

[Comparative Example 4]

As the substrate, the same fabric as in Example 2 was used. As the molding method, the same method as in Example 2 was used except that no gas was withdrawn.

The strengths of the protrusions in Examples and Comparative Examples were evaluated according to the following conditions. The results are shown in Table 1.

[Evaluation condition]

(The tensile strength)

The tensile strength was measured according to ISO 527-1 under the following conditions except for the shape of the test piece. The rib portion or flat plate portion from the molded article was cut into a rectangular shape with a length of 80 mm and a width of 20 mm, and the apparent strength was measured.

Here, the apparent strength refers to the strength obtained by assuming that the cross-sectional area of the test piece required for calculating the tensile strength is assumed to be a rectangular shape in which the rib portion is ignored, and the thickness and width of the test piece including the rib are measured, The tensile strength was calculated.

· Test environment: 23 ℃ 50 RH%

· Tensile speed: 5 mm / min

· Chuck: 50 mm

Apparatus used: Instron 50 kN (manufactured by Instron)

Fig. 16 shows the outline of this tensile strength test. In the figure, reference numeral 500 is the test piece described above. A tensile force is applied to the test piece 500 in a direction indicated by an arrow in the figure, and the tensile strength is measured.

(Bending stiffness)

The bending stiffness was measured in accordance with ISO 178 under the following conditions except for the shape of the test piece.

The rib portion or plate portion from the molded article was cut into a rectangular shape with a length of 80 mm and a width of 50 mm, and the apparent elastic modulus was measured.

Here, the apparent modulus of elasticity is a strength obtained by assuming that the cross-sectional area of the test piece required for calculating the modulus of elasticity is assumed to be a rectangular shape in which the rib portion is neglected, and the thickness and width of the test piece including the rib are measured and used as the cross- And the elastic modulus was calculated.

· Test environment: 23 ℃ 50 RH%

Test speed: 1 mm / min

· Span: 32 mm

Apparatus used: Instron 50 kN (manufactured by Instron)

· Elastic modulus calculation section: strain 0.05% - 0.25%

Fig. 17 shows the outline of this tensile strength test. The reference numeral 600 in the figure is the test piece described above. A load is applied to the test piece 600 in the direction of the arrow through the jig 601, and the bending rigidity is measured.

(A ₁ × b ₁ ) and the size of the front end face (a ₂ × b ₂ ) of the quadrangular column at the outside of the column. 15, the diameter (d _base ) of the bottom surface of the frusto-conical _base and the diameter (d _top ) of the _top surface of the truncated cone, to be. The &quot; bottom dimension &quot; of the rib means the thickness (T ₁ ) of the root of the rib, Is the thickness (T ₃ ) of the front end face of the rib, to be.

&Lt; Ratio of the area of the continuous reinforcing fiber having a height of 5% or more to the bottom side &gt;

The length in the long side direction of the region where the height of the continuous reinforcing fiber is 5% or more is obtained from the side projected image obtained by the digital camera, and then the ratio of the rib to the length of the bottom side in the long side direction is calculated. , And the length of the base (total circumference).

<Appearance>

The appearance was evaluated by the following evaluation criteria.

A: There was no shot part at all, and a molded article according to the design was obtained.

B: Shot part occurred.

As shown in Table 1, in Examples 1, 2, 3 and 4, the average value of the height of the continuous reinforcing fibers was 5% or more in any protruding portion, and there was no shot portion and appearance was good. The area where the height of the continuous reinforcing fibers in the projections was 5% or more of the height of the projections was 20% or more of the base of the projections. Also, the area of the continuous reinforcing fibers in the projections with respect to the base of the region where the continuous portion of the substrate portion was continuous with the continuous reinforcing fibers was 20% or more.

On the other hand, in Comparative Example 2 in which the prepreg was used and neither the gas drawing nor the press-fitting was performed, and in Comparative Example 4 in which the fabric was used and neither the gas drawing nor the press fitting was performed, a shot portion occurred.

Industrial availability

According to the present invention, it is possible to provide a thermoplastic resin fiber composite molded article requiring mechanical properties at high levels, such as structural parts of various machines and automobiles.

According to another compression molding method of the present invention, a molded article having a complicated shape and having mechanical properties at a high level can be obtained. Therefore, these molded articles can be used for structural parts such as various machines and automobiles, It can also be used in casings and the like.

Examples of automobile parts which can be used include the following parts and parts thereof.

Specifically, the steering shaft, the mount, the sunroof, the step, the roof trim, the door trim, the trunk, the boot reed, the bonnet, the seat frame, the seat back, the retractor, the retractor support bracket, , An elastic panel, an instrument panel, a rear gate, a ceiling beam, a seat, a seat frame, an elastic beam, a buffering lamp, a reflector, a grinding, a front end module, a back door inner, a brake pedal, , Wiper holder, EPS (Electric Power Steering), small motor, heat sink, ECU (Engine Control Unit) box, ECU housing, steering gearbox housing, plastic housing, casing for EV motor, wire harness, , Combination switch, small motor, spring, damper, wheel, wheel cover, frame, subframe, side frame, two-wheel frame, fuel tank, oil pan, intake manifold, propeller shaft A cylinder, a driving motor, a monocoque, a hydrogen tank, an electrode of a fuel cell, a panel, a floor panel, a shell panel, a door, a cabin, a roof, a hood, a valve, an exhaust gas recirculation Boa, members (Engine mounting, Front floor cross, Footwell cross, Seat cross, Inner side, Rear cross, Suspension, Filler Rainforth, Front side, Front panel, Upper, Dash panel cross, Steering) Bumper, body filler, front body filler, bumpers, crash bar, crash rail, corrugate, roof rail, upper body, side rail, blading, door surround assembly, airbag member, body filler, , Rain reinforcements (instrument panels, rails, loops, front body fillers, roof rails, roof side rails, rockers, door belt lines, Front filler upper, Front body filler lower, Center filler, Center filler hinge, Door out side panel), Side outer panel, Front door window frame, MICS (Minimum Intrusion Cabin System) Bulk, Talk box, Radiator support, Radiator Bumper Beam, Door Beam, Bulkhead, Fans, Water Pump, Fuel Pump, Electronic Control Throttle Body, Engine Control ECU, Starter, Alternator, Manifold, Transmission, Clutch, Dash Panel, Dash Panel Insulator Pad, Door Side Impact Protection Beam (Bumpers, shock absorbers), shock absorbers, shock absorbers, filler gauges, roofside inner garbage, crash boxes, door panels, door panels, door panels, door pads, Resin ribs, side rail front spacer, side rail spacer, seat belt pretensioner , Airbag sensor, arm (suspension, lower, hood), suspension link, shock absorber bracket, fender bracket, inverter bracket, inverter module, hood inner panel, hood panel, cowl louver, cowl top outer front panel, cowl top outer panel , Floor silencer, dump sheet, hood insulator, fender side panel protector, cow insulator, cowl top ventilator looper, cylinder head cover, tire deflector, fender support, strut tower bar, mission center tunnel, floor tunnel, radiator core support, Luggage panels, and rugby floors.

100, 200: mold
10, 20, 201: mold part
11, 21, 310, 320: first part
12, 22: second part
13, 23, 313, 323: first temperature control means (cooling medium passage)
14, 24: second temperature regulating means (stick-shaped cartridge heater)
15, 25:
16, 26: a face opposite to the cavity face
30: cavity
31, 32: Cavity face
33: Path
40: spring
50: Seal packing
60: vacuum line
70: fabric
71, 78, 400, 440: molded article
72: Hybrid molded article
77: prepreg
80: Injection molding machine
90: Runner part
L0: distance from the cavity surface to the first temperature control means
L1: Distance from the cavity surface to the surface opposite to the cavity surface
L2: distance from the first temperature control means to the second temperature control means
V0: Volume of mold part
V (I): Volume of the first part
V (II): Volume of the second part
170: Continuous reinforcing fiber
401, 402: hole
403, 405, 407: ribs
409, 410: Boss
411, 412:
413:
414, 415: Square pillar
420:
420a: surface of the substrate portion
h: Height of protrusion
h _f : height of continuous reinforcing fiber
L _r : length of the bottom side of the rib in the long side direction
L: Length of bottom side
L _a : the length of the region where the height of the continuous reinforcing fiber is 5% or more of the height of the projection
L _b : length of the region where the continuous reinforcing fibers in the projections are continuous with the continuous reinforcing fibers of the substrate portion
T ₁ : Thickness of the root of the projection
T ₂ : thickness of the substrate portion
T ₃ : Thickness of the front end face of the projection

Claims (16)

A molded article comprising a continuous fiber-reinforced thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin,
Wherein the molded article has a substrate portion and a projection portion,
Wherein the continuous reinforcing fibers are present in the projecting portion and the substrate portion,
And the average value of the height of the continuous reinforcing fibers in the protrusions is 5% or more of the height of the protrusions. The method according to claim 1,
Wherein the area of the protruding portion where the height of the continuous reinforcing fiber is 5% or more of the height of the protruding portion is 20% or more of the base of the protruding portion. 3. The method according to claim 1 or 2,
And the continuous reinforcing fibers in the protrusions are continuous with the continuous reinforcing fibers in the substrate portion. The method of claim 3,
Wherein the area occupied by the continuous reinforcing fibers in the protrusions continuing to the substrate portion at the base of the protrusions is 20% or more of the base of the protrusions. 5. The method according to any one of claims 1 to 4,
Wherein the height of the protrusions is greater than the thickness of the substrate portion, and the average value of the heights of the continuous reinforcing fibers is greater than or equal to the thickness of the substrate portion. 6. The method of claim 5,
And the height of the protruding portion is three times or more the thickness of the substrate portion. 7. The method according to any one of claims 1 to 6,
Wherein the resin in the protrusions and the resin in the substrate portion are the same. 8. The method according to any one of claims 1 to 7,
Wherein the density Vf of the continuous fibers at the height of the upper 10% when the height of the projections is 100% is 10% or less. 9. The method according to any one of claims 1 to 8,
And the density Vf of the continuous fibers having a height of the lower 10% when the height of the projections is 100% is 30% or more. 10. The method according to any one of claims 1 to 9,
Wherein a height of the protrusion is at least twice the thickness of the substrate portion, and a thickness of a root of the protrusion is equal to or less than a thickness of the substrate portion. 11. The method of claim 10,
And the height of the protruding portion is three times or more the thickness of the substrate portion. A compression molding method for compression molding a continuous fiber-reinforced thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin to obtain a molded article having a base portion and a projection portion,
Inserting the continuous fiber-reinforced thermoplastic resin composite material into a mold and heating the mold to a temperature not lower than or equal to the glass transition temperature of the thermoplastic resin while compressing the thermoplastic resin, compressing the mold to a glass transition temperature of -10 Lt; 0 &gt; C or less or a melting point -10 &lt; 0 &gt; C or lower to solidify the thermoplastic resin,
And a step of releasing the gas component in the mold generated from the continuous fiber-reinforced thermoplastic resin composite material out of the mold during the compression molding process. A compression molding method for compression molding a thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin to obtain a molded article having a base portion and a projection portion,
At least a part of the continuous fiber-reinforced thermoplastic resin composite material is inserted into the recessed portion corresponding to the protruding portion of the metal mold and the metal mold is pressed into the recessed portion of the thermoplastic resin And the mold is cooled to a glass transition temperature of -10 占 폚 or lower or a melting point -10 占 폚 or lower of the thermoplastic resin to solidify the thermoplastic resin. A compression molding method for producing a molded article having a base portion and a projection portion by compression molding a prepreg made of a continuous reinforcing fiber and a thermoplastic resin,
The prepreg is preliminarily heated to a temperature not lower than the glass transition temperature of the thermoplastic resin or above the melting point to soften the prepreg,
The soft prepreg is inserted into the mold,
The mold is heated to a glass transition temperature of -80 占 폚 or higher or a melting point -80 占 폚 or higher of the thermoplastic resin to form the prepreg and then the mold is heated to a glass transition temperature of -10 占 폚 or lower or a melting point- C or lower to solidify the thermoplastic resin. 11. The method of claim 10,
Wherein a height of the protrusion of the molded article is at least twice the thickness of the substrate portion of the molded article and a thickness of a root of the protrusion is not more than a thickness of the substrate portion. The method according to claim 12 or 13,
Wherein at least a part of the thermoplastic resin on the cut surface of at least a part of the composite material is melted and solidified, and the molecular weight of the thermoplastic resin which is solidified by melting is 20 %, &Lt; / RTI &gt;

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