WO2016092670A1

WO2016092670A1 - Composite material molding method and molding device

Info

Publication number: WO2016092670A1
Application number: PCT/JP2014/082848
Authority: WO
Inventors: 勝宏臼井; 荒井　直樹; 安藤　直人; 洸平川崎
Original assignee: 日産自動車株式会社
Priority date: 2014-12-11
Filing date: 2014-12-11
Publication date: 2016-06-16
Also published as: JPWO2016092670A1; JP6332470B2

Abstract

[Problem] The objective of the present invention is to provide a composite material molding method and molding device which make it possible to reduce the molding time while preventing molding failures. [Solution] A method of molding a composite material, in which a composite material is molded by disposing carbon fibers in a cavity in a molding die which can be opened and closed, injecting resin into the cavity in a state in which a mold clamping pressure has been applied to the molding die, and curing the resin. In this method of molding, the molding die is provided with a pressing portion which presses a reinforcing substrate against the molding die, and by pressing the reinforcing substrate against the molding die using the pressing portion before starting to inject the resin into the cavity, the state of the reinforcing substrate is such that said reinforcing substrate does not become displaced within the molding die (S3).

Description

Composite material molding method and molding apparatus

The present invention relates to a molding method and molding apparatus for a composite material.

In recent years, resin molded products have been used as automobile parts to reduce the weight of automobile bodies. The resin molded product is obtained by injecting resin into a cavity in a mold composed of a pair of lower mold (female mold) and upper mold (male mold) that can be opened and closed, and curing the resin in the cavity. In order to increase rigidity, the resin molded product may be formed as a composite material obtained by curing a resin together with a reinforced base material. In this case, the resin is injected and cured after the reinforced substrate is installed in the cavity.

JP 2002-59435 A

When the resin is injected into the cavity, the molding time can be shortened by increasing the resin injection pressure. However, when the resin is injected at a high pressure, the reinforced substrate disposed in the mold is displaced from a predetermined position. If the position of the reinforced base material is shifted, it may cause molding defects such as the strength of the molded product not being as designed. Therefore, there is a problem that the injection pressure of the resin cannot be increased and the molding time cannot be shortened.

Therefore, the present invention has been made to solve the above-described problems, and an object of the present invention is to provide a molding method and a molding apparatus for a composite material that can reduce molding time while preventing molding defects.

The method for molding a composite material according to the present invention that achieves the above object is to place a reinforced substrate in a cavity in a mold that can be opened and closed, and to inject resin into the cavity in a state where a mold clamping pressure is applied to the mold. This is a molding method for curing a resin to mold a composite material. In the molding method, a pressing portion that presses the reinforcing base against the mold is provided in the molding die, and the reinforcing base is pressed against the molding die by the pressing portion before the injection of the resin into the cavity is started. Then, the reinforced base material is not displaced in the mold.

In addition, the composite material molding apparatus according to the present invention that achieves the above object includes an openable / closable mold having a cavity in which a reinforcing substrate is disposed, a press section for applying a mold clamping pressure to the mold, and a cavity. And a resin injection portion for injecting the resin therein. The said shaping | molding apparatus is further provided in the shaping | molding die, and has a press part which presses a reinforcement base material with respect to a shaping | molding die. In the molding apparatus, the pressing unit presses the reinforcing base against the mold before the resin is injected into the cavity by the resin injection unit.

1 is a schematic view of a composite material molding apparatus according to Embodiment 1. FIG. It is the schematic which shows the structure of the resin injection | pouring part of the molding apparatus. It is the schematic which shows the press part of the shaping | molding apparatus, Comprising: It is an enlarged view corresponding to the part enclosed by the broken-line part A of FIG. It is explanatory drawing explaining the force acted on carbon fiber from the resin discharged from the direct gate of the shaping | molding apparatus, Comprising: It is an enlarged view corresponding to the part enclosed by the broken-line part C of FIG. 5 (A) and 5 (B) are explanatory views for explaining the operation of the pressing portion of the molding apparatus, corresponding to the portions surrounded by the broken line portion A in FIG. 1 before and during mold closing, respectively. It is an enlarged view which shows the mode of the part to perform. 6 (A) and 6 (B) are explanatory views for explaining the operation of the pressing portion of the molding apparatus, corresponding to the portions surrounded by the broken line portion B in FIG. 1 before and during mold closing, respectively. It is an enlarged view which shows the mode of the part to perform. 3 is a flowchart illustrating a method for forming a composite material according to Embodiment 1. FIG. 8A is a diagram showing an automobile part using a composite material, and FIG. 8B is a diagram showing a vehicle body in which the parts are joined. 5 is a flowchart showing a method for molding a composite material according to Embodiment 2. 10 (A) and 10 (B) are schematic views showing a pressing portion of a molding apparatus according to a modified example, and before and after attaching a pressing jig constituting the pressing portion, broken lines in FIG. FIG. 6 is an enlarged view showing a part corresponding to a part surrounded by part A. 11 (A) and 11 (B) are schematic views showing a pressing portion of the molding apparatus, and portions corresponding to portions surrounded by a broken line portion A in FIG. 1 before and during mold closing, respectively. It is an enlarged view shown. 12 (A) and 12 (B) are schematic views showing a pressing portion of a molding apparatus according to another modification, and are portions surrounded by a broken line portion A in FIG. 1 before and during mold closing, respectively. It is an enlarged view which shows the part corresponding to.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In addition, the following description does not limit the technical scope and terms used in the claims. In addition, the dimensional ratios in the drawings are exaggerated for convenience of explanation, and may differ from actual ratios.

(Embodiment 1)
FIG. 1 is a schematic view of a molding apparatus 100 for a composite material 200. FIG. 2 is a schematic diagram illustrating the configuration of the resin injection unit 30. FIG. 3 is a schematic diagram showing the pressing portion 90, and is an enlarged view corresponding to a portion surrounded by a broken line portion A in FIG. FIG. 4 is an explanatory diagram for explaining the force applied to the carbon fiber 210 from the resin 220 discharged from the direct gate 13, and is an enlarged view corresponding to a portion surrounded by a broken line portion C in FIG. 5 (A) and 5 (B) are explanatory views for explaining the operation of the pressing portion 90, and are portions corresponding to portions surrounded by a broken line portion A in FIG. 1 before and after mold closing, respectively. It is an enlarged view which shows a mode. 6 (A) and 6 (B) are explanatory views for explaining the operation of the pressing portion 90, and are portions corresponding to portions surrounded by the broken line portion B in FIG. 1 before and during mold closing, respectively. It is an enlarged view which shows a mode. FIG. 7 is a flowchart showing a method for forming the composite material 200. FIG. 8A is a view showing automobile parts 301 to 303 using the composite material 200, and FIG. 8B is a view showing a vehicle body 300 to which the parts 301 to 303 are joined.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

The composite material 200 obtained by the molding method and the molding apparatus 100 according to the present embodiment is composed of a reinforced base material 210 and a resin 220. By combining with the reinforced substrate 210, the composite material 200 having higher strength and rigidity than the resin 220 alone is obtained. Further, as shown in FIG. 8, it is combined with a frame part such as a front side member 301 and a pillar 302, which are parts used in an automobile body 300 (see FIG. 8B), and an outer plate part such as a roof 303. By using the material 200, it is possible to reduce the weight of the vehicle body as compared with the case where a steel material is used.

The reinforced substrate 210 is formed of a woven sheet of carbon fiber, glass fiber, organic fiber or the like, and is placed in the cavity 15 formed in the mold 10 in a laminated state and preformed. In this embodiment, a carbon fiber having a small thermal expansion coefficient, excellent dimensional stability, and little deterioration in mechanical properties even at high temperatures is used. The preform may be performed by another mold other than the mold 10.

Resin 220 is formed by mixing a main agent and a curing agent. Specifically, an epoxy resin, a phenol resin, or the like that is a thermosetting resin is used as the resin 220. In the present embodiment, an epoxy resin having excellent mechanical characteristics and dimensional stability is used. Epoxy resins are mainly two-pack type, bisphenol A type epoxy resin is mainly used as the main agent, and amine-based one is used as the curing agent. They can be selected as appropriate. The viscosity of the resin 220 increases with time from the mixing of the main agent and the curing agent.

With reference to FIG. 1, the molding apparatus 100 according to this embodiment can be outlined as follows: a mold 10 that can be opened and closed in which a cavity 15 in which a carbon fiber 210 (corresponding to a reinforced base material) is disposed, and a mold 10. And a press part 20 for applying a mold clamping pressure Pm, and a resin injection part 30 for injecting a resin 220 into the cavity 15. The molding apparatus 100 includes a pressure gauge 50 that measures the pressure Pr in the cavity 15, a suction unit 60 that evacuates the mold 10, a mold temperature adjustment unit 70 that adjusts the temperature of the mold 10, and a molding apparatus. It further includes a control unit 80 that controls the operation of the entire 100 and a pressing unit 90 that is provided in the mold 10 and presses the carbon fibers 210 against the mold 10. Hereinafter, the molding apparatus 100 will be described in detail.

The mold 10 has a pair of upper mold 11 (male mold) and a lower mold 12 (female mold) that can be opened and closed. A sealable cavity 15 is formed between the upper mold 11 and the lower mold 12. The carbon fiber 210 is placed in the cavity 15 in advance in a state of being laminated and preformed. A direct gate 13 is provided above the upper mold 11. The direct gate 13 is connected to the resin injection part 30 and the resin 220 is injected into the cavity 15 from above. The resin 220 is impregnated into the inside from the upper surface of the carbon fiber 210. A suction port 14 is provided at the end of the lower mold 12. The suction port 14 is connected to the suction part 60, and the inside of the cavity 15 is evacuated to suck and remove air. Further, a groove 16 is provided in the periphery of the surface of the upper mold 11 where the cavity 15 is formed. The groove 16 is provided with a pressing portion 90 described later. In order to seal the inside of the cavity 15, a sealing member or the like may be provided on the mating surface of the upper mold 11 and the lower mold 12.

The pressing unit 20 applies a clamping pressure Pm to the upper mold 11 of the mold 10. The press unit 20 includes a cylinder 21 that uses fluid pressure such as hydraulic pressure, and adjusts the mold clamping pressure Pm by controlling the hydraulic pressure or the like.

The resin injecting unit 30 includes a main agent tank 31 filled with the main agent, a curing agent tank 32 filled with the curing agent, a tube 33 forming a conveyance path for the main agent and the curing agent, and injection of the resin 220 into the cavity 15. It has a pressure gauge 34 for measuring the pressure Pi, and a mixing head 40 (corresponding to a mixing unit) for mixing the main agent and the curing agent. The pressure gauge 34 is connected to the direct gate 13 in order to measure the injection pressure Pi of the resin 220.

Referring to FIG. 2, the resin injecting unit 30 further includes

pumps

35a and 35b disposed in

tubes

33a and 33b connected to the main agent tank 31 and the curing agent tank 32, respectively. The

pumps

35a and 35b discharge the main agent and the curing agent toward the mixing head 40 at a constant pressure.

The mixing head 40 forms a resin 220 by mixing a main agent and a curing agent. In the present embodiment, the mixing head 40 is disposed in the upper mold 11. The mixing head 40 is connected to the direct gate 13 and discharges the resin 220 to the cavity 15 through the direct gate 13.

More specifically, the mixing head 40 has a cylinder 41 and a piston 42. The cylinder 41 has two

chambers

41 u and 41 d defined by a base end portion 42 a of the piston 42. By adjusting the fluid pressure such as pneumatic pressure or hydraulic pressure supplied to the two

chambers

41u and 41d, the piston 42 moves in the vertical direction in the figure.

The cylinder 41 has

upper suction ports

44a and 44b and

lower discharge ports

45a and 45b. When the piston 42 moves upward in the figure, the

lower discharge ports

45a and 45b are opened, and the main agent and the curing agent are discharged. The main agent and the curing agent discharged from each of the

lower discharge ports

45a and 45b are mixed to form the resin 220. The formed resin 220 is discharged to the direct gate 13. When the piston 42 moves downward in the figure, the

upper suction ports

44a and 44b and the

lower discharge ports

45a and 45b communicate with each other through the

recesses

43a and 43b formed in the piston 42. The main agent and the curing agent pass through the

recesses

43a and 43b from the

lower discharge ports

45a and 45b, and are returned again to the main agent tank 31 and the curing agent tank 32 from the

upper suction ports

44a and 44b. By this operation, the main agent and the curing agent circulate in the

tubes

33a and 33b at a constant pressure.

By adjusting the amount of movement of the piston 42 in the vertical direction in FIG. 2, the opening degree of the flow path of the main agent and the curing agent is adjusted. The injection amount Qi of the resin 220 into the cavity 15 is adjusted according to the opening of the flow path, and the injection pressure Pi of the resin 220 conveyed to the mold 10 is adjusted. When the viscosity is 200 [mPa · s] or less in the state before the resin 220 is cured, the injection amount Qi and the injection pressure Pi of the resin 220 into the cavity 15 are Qi ² = A × Pi (A is It is known that there is a correlation expressed by an equation of a value determined by an outflow coefficient, a flow path area, and a fluid density.

As described above, the mixing head 40 is disposed in the mold 10. Thereby, the injection pressure Pi of the resin 220 can be further increased without causing the carbon fiber 210 to be displaced in the mold 10.

Specifically, as shown in FIG. 4, the resin 220 discharged from the direct gate 13 is brought into contact with the carbon fiber 210, thereby causing the carbon fiber 210 to act on the carbon fiber 210. . The force for shifting the position of the carbon fiber 210 is, for example, a force in a direction indicated by arrows F1 to F3 in FIG. The force in the direction indicated by arrow F1 or F3 can cause carbon fiber 210 to shift to the left or right in FIG. 4, respectively. Further, the force in the direction indicated by the arrow F2 can cause the carbon fibers 210 to flutter in the vertical direction in FIG. As the carbon fibers 210 flutter in the vertical direction, the carbon fibers 210 can be displaced.

The force to shift the position of the carbon fiber 210 applied from the resin 220 is weaker when the viscosity of the resin 220 is lower than when the viscosity is higher. The viscosity of the resin 220 increases as time passes after the main agent and the curing agent are mixed. In this embodiment, since the mixing head 40 is disposed in the mold 10, the time from when the main agent and the curing agent are mixed to form the resin 220 to when the resin 220 is injected into the cavity 15 is short. . That is, the resin 220 is injected into the cavity 15 with a low viscosity. Thereby, compared with a state with a high viscosity, the force which tries to position-shift the carbon fiber 210 which acts on the carbon fiber 210 when the resin 220 contacts at the time of injection | pouring is weak. Therefore, the injection pressure Pi of the resin 220 can be increased without causing the carbon fiber 210 to be displaced in the mold 10.

Also, the impregnation property of the carbon fiber 210 is higher when the viscosity is lower than when the viscosity is high. Therefore, the injection amount Qi of the resin 220 can be increased by reducing the viscosity of the resin 220 even at the same injection pressure Pi.

Referring to FIG. 1 again, the pressure gauge 50 includes a strain gauge and the like, and is disposed in the mold 10 for measuring the pressure Pr in the cavity 15.

The suction unit 60 has a vacuum pump (not shown). The suction part 60 sucks (evacuates) the air in the cavity 15 from the suction port 14 after the mold 10 is closed and before the injection of the resin 220 is started, and the inside of the cavity 15 is evacuated.

The mold temperature adjusting unit 70 has a heating member, heats the mold 10 to the curing temperature of the resin 220, and cures the resin 220 injected into the cavity 15. The heating member is an electric heater and heats the mold 10 directly. The heating member is not limited to this. For example, the temperature of the mold 10 may be adjusted by heating a heat medium such as oil with an electric heater and circulating the heat medium in the mold 10.

The control unit 80 controls the overall operation of the molding apparatus 100. The control unit 80 includes a storage unit 81, a calculation unit 82, and an input / output unit 83. The input / output unit 83 is connected to the pressure gauges 34 and 50, the press unit 20, the valve 40, the suction unit 60, and the mold temperature adjusting unit 70. The storage unit 81 includes a ROM and a RAM. The calculation unit 82 is mainly composed of a CPU, and via the input / output unit 83, the injection pressure Pi of the resin 220 from the pressure gauges 34 and 50, the pressure Pr in the cavity 15, and the mold 10 from the press unit 20. Receives open / closed data. The calculation unit 82 is based on the data read from the storage unit 81 and the data received from the input / output unit 83, the position of the piston 42 of the mixing head 40, the suction pressure of the suction unit 60, and the mold temperature adjustment unit 70. Calculate the heating temperature. A control signal based on the calculated data is transmitted to the mixing head 40, the suction unit 60, and the mold temperature adjusting unit 70 via the input / output unit 83. In this way, the control unit 80 controls the injection pressure Pi of the resin 220, the injection timing of the resin 220, the pressure Pr in the cavity 15 during evacuation, the mold temperature, and the like.

The pressing unit 90 is provided in the mold 10 and presses the carbon fiber 210 against the mold 10. Specifically, the pressing unit 90 presses the carbon fiber 210 against the mold 10 before the resin 220 is injected into the cavity 15 by the resin injection unit 30. More specifically, the pressing unit 90 presses the carbon fiber 210 against the mold 10 before the mold 10 is closed. More specifically, the pressing unit 90 presses the carbon fiber 210 against the mold 10 with an adjustable pressure different from the mold clamping pressure Pm of the mold 10. In the first embodiment, the pressing portion 90 is provided in the molding die 10 as a separate body from the molding die 10.

As shown in FIG. 3, the pressing portion 90 includes an elastic member 91 and a pressing element 92 that are formed separately from the mold 10 in the present embodiment. One end of the elastic member 91 is attached to the bottom of the groove 16 of the upper mold 11, and the other end is attached to the upper surface of the pressing element 92.

5A and 5B, the length of the elastic member 91 is in a natural length state before the mold 10 starts closing. When the mold 10 is closed, the pressing element 92 contacts the carbon fiber 210. Furthermore, as the mold 10 is closed, the length of the elastic member 91 contracts in the direction of the arrow in FIG. When the length of the elastic member 91 contracts, an elastic force is applied from the elastic member 91 to the pressing element 92. Accordingly, the pressing element 92 presses the carbon fiber 210 against the mold 10.

6 (A) and 6 (B), when the mold 10 is closed, the side S of the upper mold 11 contacts the carbon fiber 210. At this time, the carbon fiber 210 receives a force in the direction of the arrow in FIG. The carbon fiber 210 can be displaced by a force acting from the side portion S of the upper mold 11. In order to prevent this displacement, the upper mold 11 and the lower mold 12 are generally provided with a draft angle. In the present embodiment, the contraction of the length of the elastic member 91 starts before the mold 10 is closed. That is, the action of the elastic force from the elastic member 91 on the pressing element 92 starts before the mold closing of the mold 10 is completed. Therefore, the pressing element 92 presses the carbon fiber 210 against the mold 10 before the mold closing of the mold 10 is completed. Thereby, it is possible to prevent the carbon fiber 210 from being displaced due to the force in the arrow direction shown in FIG. Further, since the draft angle can be set small, the degree of freedom in designing the shapes of the upper mold 11 and the lower mold 12 is increased.

Further, the contraction of the length of the elastic member 91 starts before the mold 10 is closed as described above. Then, the control unit 80 starts injecting the resin 220 after the mold closing of the mold 10 is completed as described above. That is, the pressing element 92 presses the carbon fiber 210 against the mold 10 before the resin 220 is injected into the cavity 15 by the resin injection portion 30. Thereby, when the resin 220 to which the injection pressure Pi is applied is injected into the cavity 15, it is possible to prevent the carbon fiber 210 from being displaced in the cavity 15 due to the force received from the resin 220. That is, the injection pressure Pi of the resin 220 can be increased without causing the carbon fiber 210 to be displaced in the mold 10. Since the molding time can be shortened by increasing the injection pressure Pi, the molding time can be shortened while preventing molding defects.

Further, the pressing of the carbon fiber 210 by the pressing portion 90 is performed by the elastic force of the elastic element 91 unlike the mold clamping pressure Pm of the mold 10 as described above. That is, the pressing unit 90 presses the carbon fiber 210 against the mold 10 with an adjustable pressure different from the mold clamping pressure Pm of the mold 10. Thereby, since the pressure when pressing the carbon fiber 210 can be adjusted independently of the mold clamping pressure Pm, the carbon fiber 210 can be pressed stably. Specifically, since the mold clamping pressure Pm is a very large pressure, it is difficult to control the magnitude of the pressure so as to stably press the carbon fiber 210. Further, the contact between the upper mold 11 and the lower mold 12 is not necessarily made evenly due to the influence of molding errors between the upper mold 11 and the upper mold 12. Therefore, by pressing the carbon fiber 210 against the mold 10 with an adjustable pressure different from the mold clamping pressure Pm of the mold 10, it becomes easy to load the carbon fiber 210 evenly. That is, the carbon fiber 210 can be pressed stably.

Furthermore, the pressing portion 90 is provided in the mold 10 as a separate body from the mold 10. Thereby, manufacture of the shaping | molding apparatus 100 becomes easy and the manufacturing cost of the shaping | molding apparatus 100 can be held down. For example, the molding apparatus 100 can be manufactured by a simple method of attaching a pressing portion 90 manufactured separately from the molding die to an existing molding die that does not include the pressing portion 90. Thereby, manufacture of the shaping | molding apparatus 100 becomes easy and manufacturing cost can be held down.

Also, the design of only the pressing part 90 can be changed without changing the mold 10. Thereby, it becomes easy to design the shaping | molding apparatus 100 optimally so that the carbon fiber 210 may not position-shift within the shaping | molding die 10. FIG. For example, it becomes easy to optimally design the elastic force of the elastic member 91, the shape of the pressing element 92, and the like according to the shape and material of the reinforcing base 210, the pressing position of the reinforcing base 210, and the like.

Furthermore, the mold 10 and the pressing part 90 can be exchanged independently. Thereby, the maintainability of the molding apparatus 100 is improved. For example, when the pressing part 90 is damaged, the composite material can be continuously molded without exchanging the molding die 10 by exchanging only the pressing part 90.

Hereinafter, the procedure of the molding method of the composite material 200 will be described with reference to FIG.

As shown in FIG. 7, the molding method of the composite material 200 includes a step of arranging the carbon fibers 210 (step S1), a step of starting the mold closing of the molding die 10 (step S2), and the carbon fibers 210 as the molding die. 10 (step S3), a process of completing mold closing of the mold 10 (step S4), a process of performing vacuum suction (step S5), and a process of injecting resin 220 (step S3). Step S6 and Step S7), a step of curing the resin 220 (Step S8), and a step of demolding (Step S9). Hereinafter, each process is explained in full detail. Note that, except for the operations of steps S1, S8, and S9, the control unit 80 executes the processing of each step.

First, carbon fibers 210 are laminated, placed in the cavity 15 of the mold 10 and preformed (step S1). At this time, the inner surface of the mold facing the cavity 15 is degreased using a predetermined organic solvent, and is subjected to a mold release process using a mold release agent.

Next, closing of the mold 10 is started (step S2). In this embodiment, by applying a clamping pressure Pm to the mold 10 by the press unit 20, the upper mold 11 and the lower mold 12 approach the mold 10 and the mold closing proceeds.

Next, the carbon fiber 210 is not displaced in the mold 10 (step S3). This prevents the carbon fiber 210 from being displaced in the cavity 15 by the force in the direction of the arrow shown in FIG. 6B when the mold 10 is closed. Therefore, the carbon fiber 210 is prevented from being displaced by contacting the mold 10 when the mold 10 is closed. In the present embodiment, the carbon fiber 210 is pressed against the mold 10 by the pressing portion 90 provided in the mold 10, so that the carbon fiber 210 is not displaced in the mold 10. As described above, in the first embodiment, the pressing portion 90 is provided in the mold 10 as a separate body from the mold 10.

Next, the mold closing of the mold 10 is completed (step S4). When the upper mold 11 of the mold 10 contacts the lower mold 12, the mold closing of the mold 10 is completed. At this time, an airtight cavity 15 is formed between the upper die 11 and the lower die 12.

Next, air is sucked from the suction port 14 by the suction part 60, vacuuming is performed, and the inside of the cavity 15 is evacuated (step S5). At this time, the control unit 80 adjusts the pressure so that the pressure becomes negative. After completion of evacuation, the suction port 14 is completely closed and kept closed until the end of molding. By performing evacuation, bubbles generated on the surface can be prevented, voids and pits of the composite material 200 which is a molded product can be reduced, and mechanical properties and design properties of the composite material 200 can be improved.

Next, the resin 220 is injected into the cavity 15 (step S6). At this time, the carbon fiber 210 is not displaced in the mold 10 by step S2. Therefore, displacement of the carbon fiber 210 in the cavity 15 due to the force applied from the resin 220 is prevented. Therefore, the injection pressure Pi of the resin 220 can be increased without the carbon fiber 210 being displaced in the mold 10. The resin 220 is formed by mixing the main agent and the curing agent in the mixing head 40 disposed in the mold 10. The time from when the main agent and the curing agent are mixed to form the resin 220 to when the resin 220 is injected into the cavity 15 is short. That is, the resin 220 is injected into the cavity 15 with a low viscosity. Thereby, compared with a state with a high viscosity, the force which tries to position-shift the carbon fiber 210 which acts on the carbon fiber 210 when the resin 220 contacts at the time of injection | pouring is weak. Therefore, the injection pressure Pi of the resin 220 can be increased without causing the carbon fiber 210 to be displaced in the mold 10. Moreover, since the impregnation property to the carbon fiber 210 is higher when the viscosity is lower than when the viscosity is high, the injection amount Qi of the resin 220 can be increased even at the same injection pressure Pi. The injection of the resin 220 into the cavity 15 is continued until the resin 220 is completely filled in the cavity 15 (Step S7: “No”, Step S6).

When the specified amount of the resin 220 is injected into the cavity 15 (step S7: “Yes”), the resin 220 in the cavity 15 is left until it is sufficiently cured (step S8). The entire mold 10 is temperature-adjusted in advance to the curing temperature of the resin 220 by the mold temperature adjusting unit 70.

When the mold 10 is opened and the molded composite material 200 is demolded, the molding is completed (step S9).

As described above, in the molding apparatus 100 and the molding method according to the present embodiment, the carbon fiber 210 is not displaced in the molding die 10 before the injection of the resin 220 into the cavity 15 is started.

According to the molding apparatus 100 configured as described above and the molding method using the molding apparatus 100, the injection pressure Pi of the resin 220 can be increased without causing the carbon fiber 210 to be displaced in the molding die 10. Accordingly, the molding time can be shortened while preventing molding defects.

In the molding apparatus 100 and the molding method using the molding apparatus 100 according to the present embodiment, the pressing portion 90 is provided in the molding die 10 as a separate body from the molding die 10.

According to the molding device 100 configured as described above and the molding method using the molding device 100, the molding device 100 can be manufactured by attaching the pressing portion 90 manufactured separately from the molding die 10 to the molding die 10. Thereby, manufacture of the shaping | molding apparatus 100 becomes easy and the manufacturing cost of the shaping | molding apparatus 100 can be held down. Further, the design of only the pressing portion 90 can be changed without changing the mold 10. Thereby, it becomes easy to design the shaping | molding apparatus 100 optimally so that the carbon fiber 210 may not position-shift within the shaping | molding die 10. FIG. Furthermore, the mold 10 and the pressing part 90 can be exchanged independently. Thereby, the maintainability of the molding apparatus 100 is improved. Therefore, it is possible to manufacture a molding apparatus that can reduce molding time while preventing molding defects optimally and at low cost, and the maintainability of the molding apparatus is improved.

In the molding apparatus 100 and the molding method using the molding apparatus 100 according to the present embodiment, the resin 220 is formed by mixing the main agent and the curing agent in the mixing head 40 disposed in the molding die 10. The

According to the molding apparatus 100 configured as described above and a molding method using the molding apparatus 100, the time from when the main agent and the curing agent are mixed to form the resin 220 to when the resin 220 is injected into the cavity 15. Can be shortened. The viscosity of the resin 220 increases with time from the mixing of the main agent and the curing agent. That is, the resin 220 can be injected into the cavity 15 with a low viscosity by shortening the time from when the main agent and the curing agent are mixed until the resin 220 is injected into the cavity 15. Thereby, compared with a state with a high viscosity, the force which tries to position-shift the carbon fiber 210 which acts on the carbon fiber 210 when the resin 220 contacts at the time of injection | pouring can be weakened. Therefore, the injection pressure Pi of the resin 220 can be further increased without causing the carbon fiber 210 to be displaced in the mold 10. Moreover, since the impregnation property to the carbon fiber 210 is higher when the viscosity is lower than when the viscosity is high, the injection amount Qi of the resin 220 can be increased even at the same injection pressure Pi. Therefore, the molding time can be further shortened while preventing molding defects.

In the molding apparatus 100 and the molding method using the molding apparatus 100 according to the present embodiment, the carbon fiber 210 is not displaced before the mold 10 is closed.

According to the molding device 100 configured as described above and the molding method using the molding device 100, the carbon fiber 210 can be prevented from being displaced by contacting the molding die 10 when the die is closed. Therefore, the molding time can be shortened while preventing molding defects more reliably.

In the molding apparatus 100 and the molding method using the molding apparatus 100 according to the present embodiment, the mold 10 is evacuated after the mold 10 is closed and before the resin 220 is injected.

According to the molding apparatus 100 configured as described above and a molding method using the molding apparatus 100, the inside of the cavity 220 is in a vacuum state before the resin 220 is injected. It is possible to prevent bubbles from forming, and to reduce voids and pits of the composite material 200 that is a molded product. Thereby, the mechanical characteristics and designability of the composite material 200 can be improved.

In the molding apparatus 100 and the molding method using the molding apparatus 100 according to the present embodiment, the carbon fiber 210 is pressed against the molding die 10 with an adjustable pressure different from the clamping pressure of the molding die 10.

According to the molding apparatus 100 configured as described above and the molding method using the molding apparatus 100, the pressure when pressing the carbon fiber 210 can be adjusted independently of the pressure of clamping, so that the carbon fiber 210 is stabilized. Can be pressed. Therefore, the molding time can be shortened while preventing molding defects more reliably.

In the molding apparatus 100 and the molding method using the molding apparatus 100 according to the present embodiment, the reinforcing base 210 is formed from carbon fiber.

According to the molding apparatus 100 configured as described above and the molding method using the molding apparatus 100, the use of carbon fiber for the reinforced base material results in a small coefficient of thermal expansion, excellent dimensional stability, and mechanical properties even at high temperatures. The composite material 200 with little deterioration in characteristics can be formed.

In the molding apparatus 100 and the molding method using the molding apparatus 100 according to the present embodiment, the composite material 200 is used for an automobile part.

According to the molding apparatus 100 configured as described above and the molding method using the molding apparatus 100, the automobile part of the composite material 200 suitable for mass production can be molded, and the weight of the vehicle body can be reduced.

(Embodiment 2)
The molding apparatus according to the second embodiment is different from the molding apparatus 100 according to the first embodiment in the following points. That is, the resin injection unit 30 of the molding apparatus 100 according to the first embodiment starts injecting the resin 220 into the cavity 15 after the mold 10 is closed. On the other hand, the resin injection part of the molding apparatus according to the second embodiment has the resin 220 into the cavity 15 after the carbon fiber 210 is not displaced in the mold 10 and before the mold 10 is closed. The molding apparatus 100 is different from the molding apparatus 100 according to the first embodiment in that the injection is started.

The configuration related to the above differences will be described below. The same components as those of the molding apparatus 100 according to the first embodiment are denoted by the same reference numerals and description thereof is omitted.

The resin injection unit according to the present embodiment starts injection of the resin 220 into the cavity 15 after the pressing unit 90 presses the carbon fiber 210 against the mold 10 and before the mold 10 is closed. To do. Thereby, the injection of the resin 220 can be started before the mold 10 is closed without the carbon fiber 210 being displaced in the mold 10.

Next, a method for forming the composite material 200 according to this embodiment will be described. The molding method according to the second embodiment is different from the molding method according to the first embodiment in the following points. That is, the resin injection (step S6) of the molding method according to the first embodiment was started after the mold closing of the mold 10 was completed (step S4). On the other hand, in the molding method according to the second embodiment, the resin injection (step S31) is started after the carbon fiber 210 is not displaced in the mold 10 and before the mold 10 is closed. However, it is different from the molding method according to the first embodiment.

The configuration related to the above differences will be described below.

FIG. 9 is a flowchart showing a molding method of the composite material 200 according to Embodiment 2 of the present invention. The same steps as those in the molding method according to Embodiment 1 are denoted by the same reference numerals, and description thereof is omitted.

In step S31, resin 220 is injected. Step S31 is performed after the carbon fiber 210 is not displaced in the mold 10 (step S3) and before the mold 10 is closed (step S4). That is, in the molding method according to the present embodiment, the injection of the resin 220 into the cavity 15 is started after the carbon fiber 210 is not displaced in the mold 10 and before the mold 10 is closed. The Specifically, injection of the resin 220 into the cavity 15 is started after the pressing unit 90 presses the carbon fiber 210 against the mold 10 and before the mold 10 is closed. Thereby, the injection of the resin 220 can be started before the mold closing of the mold 10 is completed without the carbon fiber 210 being displaced in the mold 10.

In step S32, the resin 220 is continuously injected. The injection of the resin 220 into the cavity 15 is continued until the resin 220 is completely filled in the cavity 15 after the mold closing of the mold 10 is completed (step S4) (step S7: “No”, step S32). ).

As described above, in the molding apparatus and the molding method according to the present embodiment, the resin 220 is injected after the carbon fiber 210 is not displaced in the mold 10 and before the mold 10 is closed. To start.

According to the molding apparatus configured as described above and a molding method using the molding apparatus, the injection of the resin 220 can be started before the mold 10 is closed without the carbon fiber 210 being displaced in the mold 10. . Therefore, the molding time can be further shortened while preventing molding defects.

(Other modifications)
In the first embodiment and the second embodiment, the pressing unit 90 presses the carbon fiber 210 against the molding die 10 with an adjustable pressure different from the clamping pressure Pm of the molding die 10. Not only the configuration but also the configuration of the pressing portion can be changed as long as the carbon fiber 210 is pressed against the mold 10 before the resin 220 is injected into the cavity 15 by the resin injection portion.

10 (A) and 10 (B) are schematic views showing a pressing portion 490 of a forming apparatus according to a modified example, and before and after attaching

pressing jigs

491 and 492 described later, respectively. 4 is an enlarged view showing a portion corresponding to a portion surrounded by a broken line portion A. FIG. 11 (A) and 11 (B) are schematic views showing the pressing portion 490 of the molding apparatus, corresponding to portions surrounded by a broken line portion A in FIG. 1 before and during mold closing, respectively. FIG.

10A and 10B, the forming die 410 has an upper die 411 provided with a groove 416 and a lower die 412 provided with a groove 417. The upper mold 411 and the lower mold 412 are configured in the same manner as the upper mold 11 and the lower mold 12 except that the

grooves

416 and 417 are provided.

The pressing part 490 has pressing

jigs

491 and 492. The pushing

jigs

491 and 492 are detachably attached to the

grooves

416 and 417, respectively. The pushing jig 491 has a convex part 493, and the pushing jig 492 has a concave part 494.

11A and 11B, as the mold 410 is closed, the convex portion 493 of the pushing jig 491 pushes the carbon fiber 210 into the concave portion 494 of the pushing jig 492. As a result, the carbon fiber 210 is not displaced in the mold 10. According to the said structure, the press part 490 can be comprised by the simple structure which attaches the pushing jig | tool 491,492 to the shaping | molding die 410 so that attachment or detachment is possible. The shapes and materials of the pushing jig 491 and the pushing jig 492 can be selected according to the shape of the composite material 200 to be molded and the types of materials constituting the carbon fiber 210 and the resin 220.

12 (A) and 12 (B) are schematic views showing a pressing portion 590 of a molding apparatus according to another modified example, and are respectively shown by a broken line portion A in FIG. 1 before mold closing and during mold closing. It is an enlarged view which shows the part corresponding to the part enclosed.

12A and 12B, the pressing portion 590 may be configured as a part of the mold 510. Specifically, the molding die 510 is configured to include an upper die 511 provided with a convex portion 591 and a lower die 512 provided with a concave portion 592. At this time, the upper mold 511 and the lower mold 512 are configured in the same manner as the upper mold 11 and the lower mold 12 except that the convex portions 591 and the concave portions 592 are provided. The pressing portion 590 may be constituted by a convex portion 591 provided on the upper mold 511 and a concave portion 592 provided on the lower mold 512. The convex portion 591 pushes the carbon fiber 210 into the concave portion 592, so that the carbon fiber 210 is not displaced in the mold 510. According to the said structure, the press part 590 can be comprised by the simple structure which changes the shape of the shaping | molding die 510. FIG.

As mentioned above, although the shaping | molding method and shaping | molding apparatus of the composite material 200 were demonstrated through embodiment and the modification, this invention is not limited only to the structure demonstrated in embodiment, Based on description of a claim suitably It is possible to change.

10, 410, 510 Mold,
11, 411, 511 Upper mold,
12, 412, 512 Lower mold,
13 Direct gate,
14 Suction port,
15 cavities,
16, 416, 417 groove,
20 Press department,
30 resin injection part,
31 Main agent tank,
32 Hardener tank,
33 tubes,
34, 50 pressure gauge,
35 pump,
40 mixing head (mixing part),
41 cylinders,
42 piston,
60 suction part,
70 Mold temperature controller,
80 control unit,
90, 490, 590 pressing part,
91 elastic member,
92 pressing elements,
100 molding equipment,
200 composite materials,
210 carbon fiber (reinforced substrate),
220 resin,
300 body,
301, 302, 303 Auto parts,
491, 492 pushing jig,
493, 591 convex part,
416, 417, 494, 592 recess,
Pm mold clamping pressure,
The pressure in the Pr cavity,
Pi injection pressure,
Qi injection amount,
S side.

Claims

A molding method in which a reinforced base material is disposed in a cavity in a mold that can be opened and closed, a resin is injected into the cavity in a state where a clamping pressure is applied to the mold, and the resin is cured to mold a composite material. Because
A pressing part for pressing the reinforced substrate against the mold is provided in the mold.
Before starting the injection of the resin into the cavity, the reinforced base material is pressed against the mold by the pressing portion, so that the reinforced base material is not displaced in the mold. Material forming method.
The molding method according to claim 1, wherein the pressing portion is provided in the molding die as a separate body from the molding die.
A mixing part for mixing at least two different liquids is disposed in the mold,
The shaping | molding method of Claim 1 or Claim 2 which forms the said resin by mixing a main ingredient and a hardening | curing agent in the said mixing part.
Before closing the mold, the reinforced base material is not displaced in the mold,
The molding method according to any one of claims 1 to 3, wherein injection of the resin into the cavity is started after the mold is closed.
Before closing the mold, the reinforced base material is not displaced in the mold,
The injection of the resin into the cavity is started after the reinforced base material is not displaced in the mold and before the mold of the mold is closed. The forming method according to item.
The molding method according to any one of claims 1 to 4, wherein the inside of the mold is evacuated after the mold is closed and before the injection of the resin is started.
The press according to any one of claims 1 to 6, wherein when the reinforcing base is pressed against the molding die by the pressing portion, the pressing is performed by an adjustable pressure different from the clamping pressure of the molding die. The forming method as described.
The molding method according to any one of claims 1 to 7, wherein the reinforcing base is formed of carbon fiber.
The molding method according to any one of claims 1 to 8, wherein the composite material is used for automobile parts.
A mold that can be opened and closed in which a cavity for placing a reinforced substrate is formed,
A press part for applying a clamping pressure to the mold,
A resin injection portion for injecting resin into the cavity;
A pressing portion that is provided on the mold and presses the reinforcing base against the mold;
The pressing unit is a composite material molding apparatus that presses the reinforcing base against the mold before the resin is injected into the cavity by the resin injection unit.
The molding apparatus according to claim 10, wherein the pressing portion is provided in the molding die as a separate body from the molding die.
A mixing unit for mixing at least two different liquids is provided in the mold,
The molding apparatus according to claim 10 or 11, wherein the resin is formed by mixing a main agent and a curing agent in the mixing unit.
The pressing portion presses the reinforced substrate against the mold before closing the mold.
The molding apparatus according to any one of claims 10 to 12, wherein the resin injection unit starts injection of the resin into the cavity after the mold is closed.
The pressing portion presses the reinforced substrate against the mold before closing the mold.
The resin injection portion starts injection of the resin into the cavity after the pressing portion presses the reinforcing base against the mold and before closing the mold. The molding apparatus according to any one of 10 to 12.
A suction part for evacuating the inside of the mold;
The molding apparatus according to any one of claims 10 to 13, wherein the suction section evacuates the mold after the mold is closed and before the injection of the resin is started.
The molding apparatus according to any one of claims 10 to 15, wherein the pressing portion presses the reinforcing base against the molding die with an adjustable pressure different from a clamping pressure of the molding die. .
The molding apparatus according to any one of claims 10 to 16, wherein the reinforcing base is formed of carbon fiber.
The molding apparatus according to any one of claims 10 to 17, wherein the composite material is a material for automobile parts.