TWI744119B - 纖維強化樹脂成形品的製造方法及製造裝置 - Google Patents

纖維強化樹脂成形品的製造方法及製造裝置 Download PDF

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Publication number
TWI744119B
TWI744119B TW109142156A TW109142156A TWI744119B TW I744119 B TWI744119 B TW I744119B TW 109142156 A TW109142156 A TW 109142156A TW 109142156 A TW109142156 A TW 109142156A TW I744119 B TWI744119 B TW I744119B
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Taiwan
Prior art keywords
mold
preform
resin
gap
fiber
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TW109142156A
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English (en)
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TW202134027A (zh
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八田健
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日商豐田自動車股份有限公司
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/20—Opening, closing or clamping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/03—Injection moulding apparatus
    • B29C45/04—Injection moulding apparatus using movable moulds or mould halves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/02—Transfer moulding, i.e. transferring the required volume of moulding material by a plunger from a "shot" cavity into a mould cavity
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    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

為了提供一種纖維強化樹脂成形品的製造方法及製造裝置，能使集中在樹脂注入口附近的壓力分散而防止預製件的變形。 使設置於下模(第1模)(11)的可動模芯、即下模模芯(13)下降(從預製件(2)相對地離開)而使樹脂(3)朝向下模(第1模)(11)側流動，藉此使集中在樹脂注入口(14)附近的壓力分散而防止預製件(2)的變形。

Description

纖維強化樹脂成形品的製造方法及製造裝置
本發明是關於藉由纖維補強(強化)的高壓貯氣容器等之纖維強化樹脂成形品的製造方法及製造裝置。
在燃料電池車，是使用貯藏天然氣、氫氣等的燃料氣體之高壓貯氣容器(以下會有簡稱為貯氣容器的情況)。這樣的高壓貯氣容器，是以纖維強化樹脂成形品的形式來製造，該纖維強化樹脂成形品，係使用具有氣體阻隔性之中空的內襯(liner)作為芯材，並將內襯利用碳纖維強化塑膠、玻璃纖維強化塑膠(以下總稱為纖維強化樹脂層)被覆而構成。作為內襯，基於輕量化等的觀點，通常使用樹脂製的中空容器。
作為高壓貯氣容器的製造方法，以往，FW(纏繞成型(Filament Winding))法、RTM(樹脂轉注成型(Resin Transfer Molding))法是已知的。例如專利文獻1揭示一種利用RTM法之高壓貯氣容器的製造方法。在該製造方法，是在形成高壓貯氣容器的內部空間之內襯的外表面形成了纖維層而構成預製件，將該預製件配置於模具內，一邊朝向配置於前述模具內之前述預製件從進模口(gate)射出樹脂，一邊以前述預製件的中心軸線為旋轉中心而使前述預製件在前述模具內沿圓周方向旋轉。 [先前技術文獻] [專利文獻]
[專利文獻1]日本特開2019-056415號公報
[發明所欲解決之問題]
在上述利用RTM法的製造方法，為了迄預製件之樹脂層(束)的內層部為止使樹脂含浸，可考慮將樹脂高壓射出(注入)。然而，若將樹脂高壓射出，因為壓力容易集中在進模口(以下會有稱為樹脂注入口的情況)，而使進模口(樹脂注入口)附近和樹脂流動末端部的壓力差變大，有在成為高壓的區域造成預製件變形的疑慮。
本發明是有鑑於上述事情而開發完成的，其目的是為了提供一種纖維強化樹脂成形品的製造方法及製造裝置，使集中在樹脂注入口附近的壓力分散而防止預製件的變形。 [解決問題之技術手段]
為了達成前述目的，本發明的一態樣，是一種纖維強化樹脂成形品的製造方法，其係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造方法，其特徵在於，包含以下工序：準備包含第1模及第2模之模具的工序；以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間的工序；朝向前述模具內之前述第2間隙將樹脂從樹脂注入口注入的工序；藉由使前述第1模當中之與前述預製件相對向的部分之至少一部分從前述預製件相對地離開，在前述第1模之前述至少一部分和前述預製件之間形成比前述第1間隙更大的第3間隙，將朝向前述模具內的前述第2間隙所注入的前述樹脂填充在前述第1模和前述預製件之間填充的工序；藉由使前述第2模及前述第1模之前述至少一部分一起朝向前述預製件相對地接近，而將前述模具內的前述樹脂進行壓縮填充的工序。
又本發明的其他態樣，是一種纖維強化樹脂成形品的製造方法，其係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造方法，其特徵在於，包含以下工序：準備包含第1模及第2模之模具的工序，該第1模具有可動模芯，該可動模芯是與前述預製件相對向地配置且相對於前述預製件是可動的，可將形成於前述可動模芯和前述預製件間的間隙進行增減；以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間的工序；朝向前述模具內之前述第2間隙從樹脂注入口將樹脂注入的工序；藉由使前述可動模芯從前述預製件相對地離開，在前述可動模芯和前述預製件之間形成比前述第1間隙更大的第3間隙，在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂的工序；藉由使前述第2模及前述可動模芯一起朝向前述預製件相對地接近，將前述模具內的前述樹脂進行壓縮填充的工序。
在較佳態樣，在藉由使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂的工序，是使前述第2模朝向前述預製件相對地接近。
在其他的較佳態樣，在藉由使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂的工序，是一邊偵知被注入前述第2模和前述預製件間之前述樹脂的壓力，一邊使前述可動模芯從前述預製件相對地離開。
在其他的較佳態樣，在藉由使前述第2模及前述可動模芯一起朝向前述預製件相對地接近而將前述模具內的前述樹脂進行壓縮填充的工序，是以使被注入前述可動模芯和前述預製件間之前述樹脂的壓力與被注入前述第2模和前述預製件間之前述樹脂的壓力一致的方式，使前述第2模及前述可動模芯一起朝向前述預製件相對地接近。
又本發明的其他態樣，是一種纖維強化樹脂成形品的製造裝置，其係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造裝置，其特徵在於，具備模具、驅動機構、樹脂注入機構以及控制裝置，前述模具包含第1模及第2模，前述驅動機構是用於將前述模具朝向開閉方向進行驅動，前述樹脂注入機構，是用於從樹脂注入口將樹脂注入前述模具內，前述控制裝置，是控制前述驅動機構及前述樹脂注入機構的運轉狀態，前述控制裝置是控制成：藉由前述驅動機構，以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間，藉由前述樹脂注入機構，從樹脂注入口將樹脂朝向前述模具內的前述第2間隙注入，藉由前述驅動機構，使前述第1模當中之與前述預製件相對向的部分之至少一部分從前述預製件相對地離開，藉此在前述第1模之前述至少一部分和前述預製件之間形成比前述第1間隙更大的第3間隙，在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後的前述樹脂，藉由前述驅動機構，使前述第2模及前述第1模之前述至少一部分一起朝向前述預製件相對地接近，藉此將前述模具內的前述樹脂進行壓縮填充。
又本發明的其他態樣，是一種纖維強化樹脂成形品的製造裝置，其係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造裝置，其特徵在於，具備模具、驅動機構、樹脂注入機構以及控制裝置，前述模具包含第1模及第2模，該第1模具有可動模芯，該可動模芯是與前述預製件相對向地配置且相對於前述預製件是可動的，可將形成於前述可動模芯和前述預製件間的間隙進行增減；前述驅動機構是用於將前述模具朝向開閉方向進行驅動，前述樹脂注入機構，是用於朝向前述模具內從樹脂注入口將樹脂注入，前述控制裝置，是控制前述驅動機構及前述樹脂注入機構的運轉狀態，前述控制裝置是控制成：藉由前述驅動機構，以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間，藉由前述樹脂注入機構，朝向前述模具內的前述第2間隙從樹脂注入口將樹脂注入，藉由前述驅動機構，使前述可動模芯從前述預製件相對地離開，藉此在前述可動模芯和前述預製件之間形成比前述第1間隙更大的第3間隙，在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂，藉由前述驅動機構，使前述第2模及前述可動模芯一起朝向前述預製件相對地接近，藉此將前述模具內的前述樹脂進行壓縮填充。
在較佳態樣，前述控制裝置，在使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂時，是藉由前述驅動機構使前述第2模朝向前述預製件相對地接近。
在其他的較佳態樣，係設置有：偵知被注入前述第2模和前述預製件之間的前述樹脂的壓力之壓力感測器，前述控制裝置，在藉由使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂時，是一邊利用前述壓力感測器偵知前述樹脂的壓力，一邊藉由前述驅動機構使前述可動模芯從前述預製件相對地離開。
在其他的較佳態樣，係設置有：偵知被注入前述可動模芯和前述預製件之間的前述樹脂的壓力之第1壓力感測器、及偵知被注入前述第2模和前述預製件之間的前述樹脂的壓力之第2壓力感測器，前述控制裝置，在使前述第2模及前述可動模芯一起朝向前述預製件相對地接近而將前述模具內的前述樹脂進行壓縮填充時，是以使利用前述第1壓力感測器所偵知之前述樹脂的壓力與利用前述第2壓力感測器所偵知之前述樹脂的壓力一致的方式，藉由前述驅動機構使前述第2模及前述可動模芯一起朝向前述預製件相對地接近。 [發明之效果]
依據本發明的一態樣，藉由使第1模的至少一部分或設置於第1模之可動模芯從預製件離開而使樹脂朝向第1模側流動，能使集中在樹脂注入口附近的壓力分散而防止預製件的變形。
以下，參照圖式來說明本發明的實施形態。
以下，作為纖維強化樹脂成形品的一例，是舉燃料電池車用高壓貯氣容器為例來做說明。但本發明的運用對象之纖維強化樹脂成形品，並不限定於燃料電池車用高壓貯氣容器，構成纖維強化樹脂成形品之內襯乃至預製件的形狀、材料等也不限定於圖示例。
在RTM法，是藉由在內襯將碳纖維多重(多層)地纏繞(捲繞)而作成在內襯的外表面形成有纖維層之預製件，在預製件的纖維層使環氧樹脂含浸並硬化，藉此製造在內襯的外周形成有包含碳纖維和環氧樹脂的纖維強化樹脂層之燃料電池車用高壓貯氣容器。內襯是形成高壓貯氣容器的內部空間之樹脂製(例如尼龍樹脂製)的中空容器。
燃料電池車用高壓貯氣容器，因為碳纖維厚厚地積層，迄碳纖維的內層為止要使樹脂含浸是困難的。亦即，燃料電池車用高壓貯氣容器之碳纖維的積層厚度，為了確保強度而成為非常厚(通常之RTM成形車體零件的約10倍)，要進行樹脂含浸是困難的，依據專利文獻1那樣的貯氣容器旋轉，迄碳纖維的內層為止之樹脂含浸效果不佳。此外，若為了迄碳纖維的內層為止使樹脂含浸而將樹脂高壓注入，會使壓力分布變得不均一，在成為局部高壓的部位，會造成貯氣容器內側之樹脂製內襯的變形發生等，而導致品質、性能降低。例如，在進模口(樹脂注入口)附近壓力容易集中，而使進模口附近成為高壓，且使進模口附近和樹脂流動末端部(相對於進模口的相反側)的壓力差變大。
又因為模具和貯氣容器的間隙狹小且貯氣容器形狀呈圓筒形，在進模口的相反側，樹脂不容易流動，要將樹脂全體均一地填充是困難的，而使得樹脂含浸變得不均一。因此，為了在硬化之前使樹脂朝向全體流動，例如必須使貯氣容器在模具內高速旋轉，但空間狹小，還有造成碳纖維損傷的可能性。
於是，本實施形態是採用以下的構成。
[高壓貯氣容器的製造裝置] 圖1係顯示實施形態的作為纖維強化樹脂成形品的一例之高壓貯氣容器的製造裝置之縱剖面圖。
在本實施形態所製造之作為高壓貯氣容器的中間體之預製件2，係包含：內襯、及形成在內襯的外表面且與內襯成為一體之纖維層。內襯是形成高壓貯氣容器的內部空間且具有氣體阻隔性之樹脂製的中空容器。纖維層例如具有10mm~30mm左右的厚度。纖維層，是藉由纏繞成型法，在內襯的外表面將纖維重重地纏繞而形成的。
作為在內襯上捲繞的纖維，可使用例如碳纖維、玻璃纖維、聚芳醯胺纖維等。纖維可由連續纖維所構成，亦可由長纖維、短纖維所構成。如後述般，藉由在內襯上捲繞的纖維(層)使樹脂含浸並硬化，來形成被覆內襯的周圍之纖維強化樹脂層。作為樹脂可使用：環氧樹脂、不飽和聚酯樹脂、聚醯胺樹脂等的熱固性樹脂，聚乙烯樹脂、聚酯樹脂等的熱塑性樹脂。
製造裝置1，是使用RTM(Resin Transfer Molding)法，在構成預製件2之纖維層使樹脂3(符號是在圖4等圖示)含浸，進而使含浸後的樹脂3硬化，而藉此製造高壓貯氣容器。
製造裝置1具備模具10，模具10是由複數個模、例如作為固定模之下模11、及作為可動模之上模12所構成。藉由將下模11和上模12閉合(也稱為合模)，來形成纖維強化樹脂層用的模穴(cavity)。為了將積層有纖維之預製件2配置於模具10內，例如模具10的模穴被製作成比預製件2大上公差量。
又在此，是將下模11設為固定模並將上模12設為可動模(相對於固定模為可動的模)，但例如將上模12設為固定模並將下模11設為可動模亦可，將下模11及上模12雙方皆設為可動模亦可。又在此，模具10是由下模11及上模12共2個模所構成，但亦可由3個以上的模所構成。
又在本例，在下模11之與預製件2相對向的位置具備有下模模芯13，下模模芯13形成前述模穴的一部分，且是相對於配置在模具10內的預製件2(在上下方向)可動的可動模芯。亦即，下模模芯13，是與配置在模具10內的預製件2相對向地配置，下模模芯13之與預製件2相對向的面(上表面)，是連同下模11(的模穴面)一起成為形成前述模穴的模穴面。藉由使該下模模芯13相對於預製件2(在上下方向)可動，使形成在下模模芯13和預製件2之間的間隙增減。在圖示例，下模模芯13雖設置成與預製件2之下表面的中央部分相對向，當然下模模芯13的設置位置並不限定於此，較佳為設置成與預製件2的下表面全體相對向。
預製件2，是藉由沿著內襯的軸配置之主軸25而在模具10內被軸支。亦即，主軸25是構成將預製件2在模具10內(模穴內)支承之支承機構。
在模具10(圖示例為下模11)埋設有真空脫氣配管15。在真空脫氣配管15連接真空泵50。藉由將真空泵50驅動，可透過真空脫氣配管15將模具10內(模穴內)實施真空脫氣(排氣)。亦即，真空泵50和真空脫氣配管15是構成將模具10內(模穴內)實施真空脫氣之真空脫氣機構。
又在模具10(圖示例為上模12)埋設有樹脂注入配管16，樹脂注入配管16是形成朝模穴開口的進模口(樹脂注入口)14。進模口14，在本例是配置在與預製件2之(軸方向的)中央部相對向的位置。在樹脂注入配管16連接樹脂注入機60。可從樹脂注入機60透過樹脂注入配管16而從進模口14朝向模具10內(模穴內)將樹脂3注入(供給)。亦即，樹脂注入機60和樹脂注入配管16是構成朝向模具10內(模穴內)將樹脂3注入的樹脂注入機構。樹脂3是例如由主劑和硬化劑所構成的2液系熱固性的環氧樹脂。因此，樹脂注入機60係具備：主劑用的樹脂貯藏器61、樹脂集聚部62、加壓裝置63、硬化劑用的樹脂貯藏器66、樹脂集聚部67、加壓裝置68、以及將主劑和硬化劑所混合而成的樹脂3朝向樹脂注入配管16供給之開閉閥65。
在本例，是在下模11(的下模模芯13)埋設有壓力感測器(第1壓力感測器)17。壓力感測器17是偵知預製件2之下表面側、亦即預製件2的下表面和下模11(的下模模芯13)之間的樹脂3之壓力。又在上模12埋設有壓力感測器(第2壓力感測器)18。壓力感測器18是偵知預製件2之上表面側、亦即預製件2的上表面和上模12之間的樹脂3之壓力。壓力感測器17、18所獲得的壓力資訊(樹脂壓力)是朝後述的控制裝置90輸入。
又製造裝置1係具備：用於將預製件2搬送到既定位置之搬送機構20、用於將模具10(詳而言之，下模11的下模模芯13、上模12)朝開閉方向(上下方向)驅動之驅動機構30、控制模具10(下模11、上模12)的溫度之溫度控制裝置40、作為控制製造裝置1全體的運轉狀態(詳而言之，搬送機構20、驅動機構30、溫度控制裝置40、作為真空脫氣機構之真空泵50、作為樹脂注入機構之樹脂注入機60的加壓裝置63、68和開閉閥65的運轉狀態等)之控制器的控制裝置90。
[高壓貯氣容器的製造方法] 圖2係說明實施形態的作為纖維強化樹脂成形品的一例之高壓貯氣容器的製造方法之流程圖。又圖3~圖7係分別顯示預製件配置工序及真空脫氣工序、臨時合模狀態下的樹脂注入工序、上模下降及下模模芯下降狀態下的樹脂注入工序、上模下降及下模模芯上升狀態下的樹脂注入工序、正式合模及樹脂注入停止工序以及樹脂硬化工序的狀態之縱剖面圖。
(模具準備工序:S201) 首先，準備前述構成的模具10，其是由具有下模模芯13的下模11及上模12所構成。
(預製件準備工序:S202) 又如前述般事先準備預製件2，其是藉由在內襯的外表面將纖維纏繞(捲繞)而形成了纖維層。
(模具保溫工序:S203) 接著，由控制裝置90控制溫度控制裝置40，將模具10(下模11、上模12)在既定溫度進行保溫。當樹脂3為熱固性樹脂的情況，該既定溫度是樹脂3之硬化溫度以上的溫度。
又在此，最初就將模具10在樹脂3之硬化溫度以上進行保溫，但例如最初將模具10在低於樹脂3的硬化溫度進行保溫，在後述工序的適宜時點(例如將模具10完全合模後等)再將模具10在樹脂3的硬化溫度以上進行保溫亦可。
(預製件配置工序:S204) 接著，由控制裝置90控制搬送機構20及驅動機構30，將預製件2配置在模具10內(亦即，下模11和上模12之間)(圖1、圖3)。具體而言，在將上模12開啟的狀態下，搬送機構20按照控制裝置90的控制而在下模11載置預製件2。這時，預製件2是藉由主軸25軸支。之後，驅動機構30按照控制裝置90的控制，開始進行合模，而將上模12臨時合模。臨時合模是指將上模12開啟的狀態和正式合模的狀態之中間狀態，是使下模11和上模12空出間隙的狀態，如圖3所示般，移動到在上模12和預製件2之間空出數mm的間隙(第2間隙)的位置。形成在上模12和預製件2之間的間隙(第2間隙)是比形成在下模11和預製件2之間的間隙(第1間隙)更大。
(真空脫氣工序:S205) 接著，在上述臨時合模的狀態下(換言之，合模完畢前)，由控制裝置90控制真空泵50，藉此將模具10內實施真空脫氣(圖3)。
(臨時合模狀態下的樹脂注入工序:S206) 在上述真空脫氣停止(完畢)後，將樹脂3朝向模具10內進行射出注入(圖4)。具體而言，控制裝置90將開閉閥65開啟，將貯留在樹脂集聚部62的主劑藉由加壓裝置63加壓，將貯留在樹脂集聚部67的硬化劑藉由加壓裝置68加壓，將主劑和硬化劑混合而成為(未硬化的)樹脂3。藉此，在設置於上模12之樹脂注入配管16內使(未硬化的)樹脂3流過，而從進模口(在圖示例，設置於預製件2的中央部之進模口)14朝向預製件2將樹脂3進行射出注入。因為上模12處於臨時合模狀態，是朝向形成在上模12和預製件2(的上表面)之間的間隙(第2間隙)將樹脂3進行射出注入。
(在上模下降及下模模芯下降狀態下的樹脂注入工序:S207) 接著，由控制裝置90控制驅動機構30，一邊將上模12閉合(射出壓縮)一邊使設置於下模11之下模模芯13下降(亦即，從預製件2相對地離開)(圖5)。藉此，使下模模芯13和預製件2的間隙(第3間隙)增大(換言之，在下模模芯13和預製件2之間形成比第1間隙更大之數mm左右的第3間隙)，從預製件2的上表面進行樹脂含浸，且甚至在下模11(特別是下模模芯13)和預製件2(的下表面)之間隙也將樹脂3均一地填充。這時，為了使預製件2的上表面側之樹脂3的壓力緩和且甚至在預製件2的下表面側也使樹脂3均一地流動，是一邊藉由壓力感測器18偵知預製件2之上表面側的(亦即，被注入上模12和預製件2之間)樹脂3的壓力，一邊使下模模芯13下降。例如，控制裝置90可根據壓力感測器18的偵知壓力(樹脂壓力)來控制上模12、下模模芯13的下降速度等。
(在上模下降及下模模芯上升狀態下的樹脂注入工序:S208) 接著，由控制裝置90控制驅動機構30，使上模12下降到下降端而將模閉合，同時使設置在下模11之下模模芯13(迄與下模11的模穴面成為同一面之原來位置為止)上升(亦即，朝向預製件2相對地接近) (圖6)。這時，藉由壓力感測器18偵知預製件2之上表面側的樹脂3之壓力，並藉由壓力感測器17偵知預製件2之下表面側的樹脂3之壓力。而且，以使壓力感測器18、17所偵知之樹脂3的壓力一致的方式使上模12下降及使下模模芯13上升(亦即，使上模12及下模模芯13一起朝向預製件2相對地接近)。藉此，模具10內的樹脂3被均一地壓縮填充，而含浸在預製件2的纖維層內。例如，控制裝置90在使上模12及下側模芯13一起(同時)閉合而朝向預製件2接近時，可根據壓力感測器18、17的偵知壓力(樹脂壓力)來控制上模12的下降速度、下模模芯13的上升速度等。
(正式合模及樹脂注入停止工序:S209) 當樹脂3的填充完畢之後，由控制裝置90控制驅動機構30，將上模12及設置在下模11的下模模芯13完全合模(正式合模)。而且，在樹脂3朝纖維層內的含浸完畢後，將樹脂3的注入停止(圖7)。
(樹脂硬化工序:S210) 在前述的樹脂3之注入停止後，使樹脂3硬化(圖7)。
(脫模工序:S211) 當樹脂3硬化之後，由控制裝置90控制驅動機構30，將上模12開啟。藉由使樹脂3硬化完畢，獲得在內襯的外周形成有纖維強化樹脂層之高壓貯氣容器4。
如以上所說明般，在燃料電池車用高壓貯氣容器，當基於RTM含浸技術進行貯氣容器製造時，對於將碳纖維(纖維層)厚厚地積層(捲繞)之大型貯氣容器全體，要均一地施加樹脂壓力而將環氧樹脂填充並使其含浸硬化是困難的。另外，貯氣容器因為是將碳纖維厚厚地積層，必須將樹脂高壓填充才能使其含浸到最內層為止，因此進模口(樹脂注入口)正下方等的壓力變得過高，而造成貯氣容器內部的樹脂製內襯變形、纖維偏移等之導致生產性降低、貯氣容器性能降低的重要品質問題發生。
本實施形態，為了避免進模口14的壓力集中並朝向碳纖維厚積層部使樹脂3均一地含浸，換言之，為了使樹脂注入時施加於進模口14等的壓力分散並使施加於貯氣容器全體的樹脂壓力均一化、低壓化，是在模具10的下模11設置上下可動的可動模芯、即下模模芯13，且在上模12及下模11設置用於偵知樹脂壓力的壓力感測器18、17。在將貯氣容器(預製件2)設置於模具10而進行合模時，藉由將上模12和下模11空出間隙，而在上模12和貯氣容器(預製件2)之間形成間隙，藉此將環氧樹脂注入時的樹脂流動阻力降低，而將壓力急劇上升予以緩和。此外，為了使貯氣容器全體的壓力均一化、低壓化而朝積層內使樹脂3含浸，一邊將上模12閉合(射出壓縮)一邊朝貯氣容器上表面使樹脂3含浸，又為了使貯氣容器上表面的壓力緩和，一邊偵知貯氣容器上表面的壓力，一邊以甚至在貯氣容器下表面也能使樹脂3均一流動的方式形成在下模11和貯氣容器之間的間隙(成為樹脂流路的間隙)，藉由使作為嵌件(insert)之下模模芯13下降，而謀求低壓化及樹脂的均一含浸。
藉此，使樹脂注入時施加於進模口14的壓力分散，且謀求施加於貯氣容器全體的壓力之均一化。又能謀求模具10內的流動舉動之最佳化，並謀求積層方向的樹脂含浸性提高。還能一邊將模具10內的壓力舉動進行回饋控制一邊使樹脂3含浸。又藉由在積層方向均一地加壓，可謀求樹脂含浸性提高及貯氣容器表面品質提高。
又本實施形態，在樹脂3填充於上下模內之後，為了使貯氣容器上表面和下表面的注入壓力均一且使壓力低壓化(分散)，是一邊藉由壓力感測器18、17偵知貯氣容器的上表面和下表面的壓力，一邊以使其等成為相同的方式將上模12和下模模芯13同時合模而進行壓縮填充，藉此謀求低壓化及樹脂的均一含浸化，可獲得樹脂含浸性提高、及貯氣容器性能提高以及良好的表面品質。
藉此，可謀求施加於貯氣容器全體之壓力的均一化。又能一邊謀求模具10內的流動動作之最佳化，一邊謀求積層方向之樹脂含浸性的提高。還能一邊將模具10內的壓力動作進行回饋控制一邊使樹脂3含浸。又藉由在積層方向均一地加壓，可謀求樹脂含浸性提高及貯氣容器表面品質提高。
因此，在本實施形態，在基於RTM含浸技術使環氧樹脂含浸時，對於貯氣容器全體可均一地且低壓地在積層方向(板厚方向)使環氧樹脂含浸，因此可謀求高壓貯氣容器的性能提高及品質穩定化，還能高速填充，還能謀求大幅縮短成形周期。
如此般，依據本實施形態，使設置於下模(第1模)11之可動模芯、即下模模芯13下降(從預製件2相對地離開)而使樹脂3朝向下模(第1模)11側流動，能使集中在樹脂注入口14附近的壓力分散而防止預製件2的變形。
又根據上模(第2模)12和預製件2之間的樹脂3之壓力，使設置於下模(第1模)11之可動模芯、即下模模芯13下降(從預製件2相對地離開)，藉此能在預製件2全體均一地使樹脂3含浸。
又以使下模(第1模)11和預製件2之間的樹脂3之壓力和上模(第2模)12和預製件2之間的樹脂3之壓力一致的方式，使設置於下模(第1模)11之可動模芯、即下模模芯13上升(朝向預製件2相對地接近)，藉此能使施加於預製件2全體的壓力變得均一，因此可在預製件2全體均一地使樹脂3含浸。
以上，是將本發明的實施形態利用圖式詳細說明，但具體的構成並不限定於該實施形態，縱使是不脫離本發明之要旨的範圍內之設計變更等，仍包含於本發明中。
1:高壓貯氣容器(纖維強化樹脂成形品)的製造裝置 2:預製件 3:樹脂 4:高壓貯氣容器(纖維強化樹脂成形品) 10:模具 11:下模(第1模) 12:上模(第2模) 13:下模模芯(可動模芯) 14:進模口(樹脂注入口) 15:真空脫氣配管(真空脫氣機構) 16:樹脂注入配管(樹脂注入機構) 17:壓力感測器(第1壓力感測器) 18:壓力感測器(第2壓力感測器) 20:搬送機構 25:主軸 30:驅動機構 40:溫度控制裝置 50:真空泵(真空脫氣機構) 60:樹脂注入機(樹脂注入機構) 61,66:樹脂貯藏器 62,67:樹脂集聚部 63,68:加壓裝置 65:開閉閥 90:控制裝置
[圖1]係顯示實施形態的高壓貯氣容器(纖維強化樹脂成形品)的製造裝置之縱剖面圖。 [圖2]係說明實施形態的高壓貯氣容器(纖維強化樹脂成形品)的製造方法之流程圖。 [圖3]係顯示實施形態的高壓貯氣容器之製造裝置的預製件配置工序及真空脫氣工序的狀態之縱剖面圖。 [圖4]係顯示實施形態的高壓貯氣容器之製造裝置的臨時合模狀態下的樹脂注入工序的狀態之縱剖面圖。 [圖5]係顯示實施形態的高壓貯氣容器之製造裝置的上模下降及下模模芯下降狀態下的樹脂注入工序的狀態之縱剖面圖。 [圖6]係顯示實施形態的高壓貯氣容器之製造裝置的上模下降及下模模芯上升狀態下之樹脂注入工序的狀態之縱剖面圖。 [圖7]係顯示實施形態的高壓貯氣容器之製造裝置的正式合模及樹脂注入停止工序以及樹脂硬化工序的狀態之縱剖面圖。
1:高壓貯氣容器(纖維強化樹脂成形品)的製造裝置 2:預製件 10:模具 11:下模(第1模) 12:上模(第2模) 13:下模模芯(可動模芯) 14:進模口(樹脂注入口) 15:真空脫氣配管(真空脫氣機構) 16:樹脂注入配管(樹脂注入機構) 17:壓力感測器(第1壓力感測器) 18:壓力感測器(第2壓力感測器) 20:搬送機構 25:主軸 30:驅動機構 40:溫度控制裝置 50:真空泵(真空脫氣機構) 60:樹脂注入機(樹脂注入機構) 61,66:樹脂貯藏器 62,67:樹脂集聚部 63,68:加壓裝置 65:開閉閥 90:控制裝置

Claims (10)

  1. 一種纖維強化樹脂成形品的製造方法，係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造方法，其特徵在於，包含以下工序： 準備包含第1模及第2模之模具的工序； 以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間的工序； 朝向前述模具內之前述第2間隙將樹脂從樹脂注入口注入的工序； 藉由使前述第1模當中之與前述預製件相對向的部分之至少一部分從前述預製件相對地離開，在前述第1模之前述至少一部分和前述預製件之間形成比前述第1間隙更大的第3間隙，將朝向前述模具內的前述第2間隙所注入的前述樹脂填充在前述第1模和前述預製件之間的工序； 藉由使前述第2模及前述第1模之前述至少一部分一起朝向前述預製件相對地接近，而將前述模具內的前述樹脂進行壓縮填充的工序。
  2. 一種纖維強化樹脂成形品的製造方法，係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造方法，其特徵在於，包含以下工序： 準備包含第1模及第2模之模具的工序，該第1模具有可動模芯，該可動模芯是與前述預製件相對向地配置且相對於前述預製件是可動的，可將形成於前述可動模芯和前述預製件間的間隙進行增減； 以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間的工序； 朝向前述模具內之前述第2間隙從樹脂注入口將樹脂注入的工序； 藉由使前述可動模芯從前述預製件相對地離開，在前述可動模芯和前述預製件之間形成比前述第1間隙更大的第3間隙，在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂的工序； 藉由使前述第2模及前述可動模芯一起朝向前述預製件相對地接近，將前述模具內的前述樹脂進行壓縮填充的工序。
  3. 如請求項2所述之纖維強化樹脂成形品的製造方法，其中， 在藉由使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂的工序，是使前述第2模朝向前述預製件相對地接近。
  4. 如請求項2所述之纖維強化樹脂成形品的製造方法，其中， 在藉由使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂的工序，是一邊偵知被注入前述第2模和前述預製件間之前述樹脂的壓力，一邊使前述可動模芯從前述預製件相對地離開。
  5. 如請求項2所述之纖維強化樹脂成形品的製造方法，其中， 在藉由使前述第2模及前述可動模芯一起朝向前述預製件相對地接近而將前述模具內的前述樹脂進行壓縮填充的工序，是以使被注入前述可動模芯和前述預製件間之前述樹脂的壓力與被注入前述第2模和前述預製件間之前述樹脂的壓力一致的方式，使前述第2模及前述可動模芯一起朝向前述預製件相對地接近。
  6. 一種纖維強化樹脂成形品的製造裝置，係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造裝置，其特徵在於， 具備模具、驅動機構、樹脂注入機構以及控制裝置， 前述模具包含第1模及第2模， 前述驅動機構是用於將前述模具朝向開閉方向進行驅動， 前述樹脂注入機構，是用於從樹脂注入口將樹脂注入前述模具內， 前述控制裝置，是控制前述驅動機構及前述樹脂注入機構的運轉狀態， 前述控制裝置是控制成： 藉由前述驅動機構，以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間， 藉由前述樹脂注入機構，從樹脂注入口將樹脂朝向前述模具內的前述第2間隙注入， 藉由前述驅動機構，使前述第1模當中之與前述預製件相對向的部分之至少一部分從前述預製件相對地離開，藉此在前述第1模之前述至少一部分和前述預製件之間形成比前述第1間隙更大的第3間隙，在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後的前述樹脂， 藉由前述驅動機構，使前述第2模及前述第1模之前述至少一部分一起朝向前述預製件相對地接近，藉此將前述模具內的前述樹脂進行壓縮填充。
  7. 一種纖維強化樹脂成形品的製造裝置，係將在內襯的外表面形成有纖維層之預製件予以形成，使樹脂含浸在前述預製件的前述纖維層並使之硬化來製造纖維強化樹脂成形品的製造裝置，其特徵在於， 具備模具、驅動機構、樹脂注入機構以及控制裝置， 前述模具包含第1模及第2模，該第1模具有可動模芯，該可動模芯是與前述預製件相對向地配置且相對於前述預製件是可動的，可將形成於前述可動模芯和前述預製件間的間隙進行增減； 前述驅動機構是用於將前述模具朝向開閉方向進行驅動， 前述樹脂注入機構，是用於朝向前述模具內從樹脂注入口將樹脂注入， 前述控制裝置，是控制前述驅動機構及前述樹脂注入機構的運轉狀態， 前述控制裝置是控制成： 藉由前述驅動機構，以將比前述第1模和前述預製件間的第1間隙更大之第2間隙形成在前述第2模和前述預製件間的方式，將前述預製件配置在前述第1模和前述第2模之間， 藉由前述樹脂注入機構，朝向前述模具內的前述第2間隙從樹脂注入口將樹脂注入， 藉由前述驅動機構，使前述可動模芯從前述預製件相對地離開，藉此在前述可動模芯和前述預製件之間形成比前述第1間隙更大的第3間隙，在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂， 藉由前述驅動機構，使前述第2模及前述可動模芯一起朝向前述預製件相對地接近，藉此將前述模具內的前述樹脂進行壓縮填充。
  8. 如請求項7所述之纖維強化樹脂成形品的製造裝置，其中， 前述控制裝置，在使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂時，是藉由前述驅動機構使前述第2模朝向前述預製件相對地接近。
  9. 如請求項7所述之纖維強化樹脂成形品的製造裝置， 其係設置有：偵知被注入前述第2模和前述預製件之間的前述樹脂的壓力之壓力感測器， 前述控制裝置，在藉由使前述可動模芯從前述預製件相對地離開而在前述第1模和前述預製件之間填充朝向前述模具內的前述第2間隙注入後之前述樹脂時，是一邊利用前述壓力感測器偵知前述樹脂的壓力，一邊藉由前述驅動機構使前述可動模芯從前述預製件相對地離開。
  10. 如請求項7所述之纖維強化樹脂成形品的製造裝置， 其係設置有：偵知被注入前述可動模芯和前述預製件之間的前述樹脂的壓力之第1壓力感測器、及偵知被注入前述第2模和前述預製件之間的前述樹脂的壓力之第2壓力感測器， 前述控制裝置，在使前述第2模及前述可動模芯一起朝向前述預製件相對地接近而將前述模具內的前述樹脂進行壓縮填充時，是以使利用前述第1壓力感測器所偵知之前述樹脂的壓力與利用前述第2壓力感測器所偵知之前述樹脂的壓力一致的方式，藉由前述驅動機構使前述第2模及前述可動模芯一起朝向前述預製件相對地接近。
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