WO2017110596A1

WO2017110596A1 - Method for manufacturing cutting body, and device for cutting composite material

Info

Publication number: WO2017110596A1
Application number: PCT/JP2016/087118
Authority: WO
Inventors: 勇登岡; 裕也秦
Original assignee: 帝人株式会社
Priority date: 2015-12-24
Filing date: 2016-12-13
Publication date: 2017-06-29
Also published as: JP2019058953A

Abstract

The present invention provides: a cutting device for cutting a composite material that contains reinforcing fibers and a plastic material, wherein the cutting device has a cutting blade and a pressurizing device, a securing layer for securing the cutting blade is provided between the cutting blade and the pressuring device, the yield stress and/or the 0.2% proof stress of the securing layer is 165 MPa or greater; and a method for manufacturing a cutting body in which the cutting device is used.

Description

Cutting body manufacturing method and composite material cutting apparatus

The present invention relates to a method for producing a cut body by cutting a composite material containing reinforcing fibers and a resin, and a cutting apparatus for cutting the composite material.

In recent years, so-called fiber-reinforced composite materials including matrix resin and reinforcing fibers such as carbon fibers have attracted attention in the mechanical field. Since these composite materials have fibers dispersed in a matrix resin, they are excellent in tensile modulus, tensile strength, impact resistance and the like, and are being studied for structural members such as automobiles. These fiber-reinforced composite materials can be formed into a desired shape using injection molding, compression molding, or the like.

Generally, since fiber reinforced resin is excellent in mechanical strength as compared with general-purpose resin, machining tends to be difficult. In particular, as compared with general-purpose resins, the durability of the machining blade is often greatly reduced, which has been one of the factors that hinder the mass production of products using fiber-reinforced resins. In addition, methods that do not use a processing blade include water jet and laser cutting, but considering mass production, there are difficulties in cost and processing time.

In Patent Document 1, in the punching process of a plastic plate reinforced with high-strength fibers, the fiber at the cutting edge is surely cut by a minute gap provided between the male convex blade and the female concave blade. The technology is proposed.
Patent Document 2 describes a technique in which carbon steel is used for a Thomson blade and is hardened to increase hardness as a method for efficiently cutting a fiber reinforced resin material.

Japanese Unexamined Patent Publication No. 2015-104797 Japanese Unexamined Patent Publication No. 2013-091128

However, in the methods described in Patent Documents 1 and 2, no examination has been made regarding the positioning accuracy of the cutting blade. Accordingly, an object of the present invention is to provide a method of manufacturing a cut body obtained by cutting a composite material into a desired shape and a manufacturing apparatus thereof without significantly increasing the cost.
Further, as a further problem, in the method described in Patent Document 1, since the cut pieces are discharged vertically downward, it is necessary to provide holes corresponding to the pattern shape of the cut pieces on the lower base, and the equipment cost is reduced. It will increase. In particular, from the viewpoint of improving productivity, when a cut body is continuously manufactured while conveying a composite material using a conveyor device such as a belt conveyor, a conveyor device such as a belt conveyor exists under the composite material. In addition, the cut piece cannot be discharged vertically downward. Furthermore, in the methods described in Patent Documents 1 and 2, although the blade has a closed cross section, it is structurally impossible to discharge the cut piece through the closed loop structure of the cutting blade.
Therefore, a further object of the present invention is to provide a method for manufacturing a cutting body efficiently and a manufacturing apparatus therefor even when the shape of the cutting blade is a closed loop structure.

In order to solve the above problems, the present invention provides the following means.

[1]
A cutting device for cutting a composite material including a reinforcing fiber and a resin,
The cutting device has a cutting blade and a pressure device, and a fixing layer for fixing the cutting blade is provided between the cutting blade and the pressure device,
At least one of the yield stress or the 0.2% proof stress of the fixed layer is 165 MPa or more.
Cutting device.
[2]
The cutting device according to [1], comprising at least one cutting blade having a closed loop structure.
[3]
The cutting device according to [2], wherein the cutting device includes at least one discharge passage for discharging a cut piece cut from the composite material.
[4]
The cutting device according to [3],
R _A is the minimum diameter of the circle including the projected figure in the thickness direction of the cut piece,
The maximum diameter of the circle that may be present in the interior of the cross section of the discharge passage when expressed as R _B, when the smallest of the R _B for all the cross-section was R _Bmin,
R _A <R _Bmin
Satisfying the cutting device.
[5]
The cutting apparatus according to [3] or [4], wherein, in one cutting operation, 1 to 7 cutting pieces are discharged through the discharge passage for each discharge passage.
[6]
The cutting device according to any one of [3] to [5], wherein a discharge passage is provided between the cutting blade and the pressurizing device.
[7]
The cutting device according to any one of [1] to [6], wherein the fixed layer is for fixing the cutting blade at a desired position in the vertical direction.
[8]
The cutting device has an elastic member,
The elastic member is for detaching the cut body, which is a cut composite material, from the cutting blade.
[1] The cutting device according to any one of [7].
[9]
The cutting device according to any one of [1] to [8], wherein the cutting device heats and cuts the composite material.
[10]
The cutting device according to any one of [1] to [9], wherein the fixed layer is iron or an alloy containing iron.
[11]
The reinforcing fiber contained in the composite material is carbon fiber, the resin is a thermoplastic resin, and the cutting device is a device for producing a molding material.
[1] The cutting apparatus according to any one of [10].
[12]
The cutting device according to any one of [1] to [11], wherein the cutting device includes two or more cutting blades.
[13]
A method of manufacturing a cut body by cutting a composite material containing reinforcing fibers and a resin using a cutting device equipped with a cutting blade and a pressure device,
The cutting device is provided with a fixing layer for fixing the cutting blade between the cutting blade and the pressurizing device,
At least one of the yield stress or the 0.2% proof stress of the fixed layer is 165 MPa or more.
Manufacturing method of cut body.
[14]
The cutting device according to [13], wherein the cutting device includes at least one cutting blade having a closed loop structure.
[15]
The cutting device according to [14], wherein the cutting device includes at least one discharge passage for discharging a cut piece cut from the composite material.
[16]
[15] A method for producing a cut body according to [15],
R _A is the minimum diameter of the circle including the projected figure in the thickness direction of the cut piece,
The maximum diameter of the circle that may be present in the interior of the cross section of the discharge passage when expressed as R _B, when the smallest of the R _B for all the cross-section was R _Bmin,
R _A <R _Bmin
The manufacturing method of the cutting body which satisfies.
[17]
The method for producing a cut body according to [15] or [16], wherein, in one cutting operation, 1 to 7 cutting pieces are discharged through the discharge passage per discharge passage.
[18]
The method for manufacturing a cut body according to any one of [15] to [17], wherein a discharge passage is provided between the cutting blade and the pressure device.
[19]
The method for manufacturing a cut body according to any one of [13] to [18], wherein the fixed layer is for fixing the cutting blade at a desired position in the vertical direction.
[20]
The cutting device has an elastic member,
The elastic member is for detaching the cut body, which is a cut composite material, from the cutting blade.
[13] The method for producing a cut body according to any one of [19] to [19].
[21]
The method for producing a cut body according to any one of [13] to [20], wherein the composite material is heated and cut.
[22]
The method for producing a cut body according to any one of [13] to [21], wherein the fixed layer is iron or an alloy containing iron.
[23]
The reinforcing fiber included in the composite material is carbon fiber, the resin is a thermoplastic resin, and the cut body is a molding material.
[13] The method for producing a cut body according to any one of [22].
[24]
The cutting device according to any one of [13] to [23], wherein the cutting device includes two or more cutting blades.

If the cutting apparatus in this invention is used, even if it cut | disconnects a composite material continuously, the positional accuracy of a cutting blade can be maintained with high.
Moreover, if the preferable aspect in this invention is employ | adopted, even if it uses the cutting blade of a closed loop structure, a cutting piece can be discharged | emitted smoothly, a composite material can be cut | disconnected continuously and a cut body can be manufactured.

An example of the cutting device in the present invention. An example of a cutting device using a closed-loop structured cutting blade. Conventional cutting device. (A) (b) (c) An example of a cutting device in which the shape of the cutting blade is a closed loop structure, and a discharge passage for discharging a cut piece cut from the composite material is provided. FIG. 4B is a schematic view seen from the A-A ′ cross section of FIG. (C) A schematic view of the B-B ′ cross section of FIG. (A) (b) An example of the cutting device provided with the elastic member. FIG. 5B is a schematic view seen from the A-A ′ cross section of FIG. (A) (b) (c) (d) An example of a cutting blade having a closed loop structure. (A) (b) (c) An example of a cutting blade having an open structure. (A) (b) (c) Cutting pattern of composite material (left of (a) (b) (c)) and corresponding blade shape ((a) (b) (c) Right). (D) The cutting pattern (left of (d)) and the corresponding blade shape (right of (d)) of the composite material in which no cut pieces are generated. (A) An example of a cutting device having one discharge passage for eight cutting blades having a closed loop structure. FIG. 9B is a schematic view seen from the B-B ′ cross section of FIG. (A) An example of a cutting device provided with eight discharge passages with respect to eight cutting blades having a closed loop structure. FIG. 10B is a schematic diagram viewed from the B-B ′ cross section in FIG.

[Reinforcing fiber]
The type of reinforcing fiber used in the present invention can be appropriately selected according to the type of resin, the use of the composite material, and the like, and is not particularly limited. For this reason, as the reinforcing fiber used in the present invention, any of inorganic fibers and organic fibers can be preferably used. Examples of the inorganic fibers include carbon fibers, activated carbon fibers, graphite fibers, glass fibers, tungsten carbide fibers, silicon carbide fibers (silicon carbide fibers), ceramic fibers, alumina fibers, natural fibers, mineral fibers such as basalt, and boron fibers. , Boron nitride fiber, boron carbide fiber, and metal fiber.

Examples of the metal fiber include aluminum fiber, copper fiber, brass fiber, stainless steel fiber, and steel fiber.
As said glass fiber, what consists of E glass, C glass, S glass, D glass, T glass, quartz glass fiber, borosilicate glass fiber, etc. can be mentioned.
Examples of the organic fibers include fibers made of resin materials such as polyaramid, PBO (polyparaphenylene benzoxazole), polyphenylene sulfide, polyester, acrylic, polyamide, polyolefin, polyvinyl alcohol, and polyarylate.

In the present invention, two or more kinds of reinforcing fibers may be used in combination. In this case, a plurality of types of inorganic fibers may be used in combination, a plurality of types of organic fibers may be used in combination, or inorganic fibers and organic fibers may be used in combination. As an aspect which uses multiple types of inorganic fiber together, the aspect which uses together a carbon fiber and a metal fiber, the aspect which uses a carbon fiber and glass fiber together, etc. can be mentioned, for example. On the other hand, examples of the mode in which a plurality of types of organic fibers are used in combination include a mode in which polyaramid fibers and fibers made of other organic materials are used in combination. Furthermore, as an aspect which uses an inorganic fiber and an organic fiber together, the aspect which uses a carbon fiber and a polyaramid fiber together can be mentioned, for example.

Favorable reinforcing fibers in the present invention include carbon fibers, aramid fibers, high-strength polyethylene fibers, polyarylate fibers, glass fibers, and steel fibers. Among these, carbon fibers can be preferably used. Carbon fibers are generally polyacrylonitrile (PAN) carbon fiber, petroleum / coal pitch carbon fiber, rayon carbon fiber, cellulosic carbon fiber, lignin carbon fiber, phenolic carbon fiber, vapor growth carbon. Although fiber etc. are known, in the present invention, any of these carbon fibers can be suitably used.

(Carbon fiber)
It is preferable to use inorganic fibers as the reinforcing fibers. This is because the elongation is relatively lower than that of the organic fiber, so that less shear stress is required when cutting.
Among these, in the present invention, it is preferable to use polyacrylonitrile (PAN) -based carbon fibers in terms of excellent tensile strength. When a PAN-based carbon fiber is used as the reinforcing fiber, the tensile elastic modulus is preferably in the range of 100 to 600 GPa, more preferably in the range of 200 to 500 GPa, and in the range of 230 to 450 GPa. Is more preferable. The tensile strength is preferably in the range of 2000 to 6000 MPa, more preferably in the range of 3000 to 6000 MPa.

(Fiber length of reinforcing fiber)
The fiber length of the reinforcing fiber used in the present invention can be appropriately determined according to the type of reinforcing fiber, the type of resin, the orientation state of the reinforcing fiber in the composite material, and the like, and is not particularly limited. Absent. Therefore, in the present invention, continuous fibers may be used or discontinuous fibers may be used depending on the purpose.
When discontinuous fibers are used, the average fiber length is usually preferably in the range of 0.1 mm to 500 mm, and more preferably in the range of 1 mm to 100 mm. In the present invention, reinforcing fibers having different fiber lengths may be used in combination. In other words, the reinforcing fiber used in the present invention may have a single peak in average fiber length, or may have a plurality of peaks.

The average fiber length of the carbon fiber, when the carbon fiber is cut into a certain length with a rotary cutter or the like, the cut length corresponds to the average fiber length, which is also the number average fiber length and the weight average fiber length. . When the fiber length of each carbon fiber is Li and the number of measurement is j, the number average fiber length (Ln) and the weight average fiber length (Lw) are obtained by the following formulas (2) and (3) (constant) In the case of the cut length, the weight average fiber length (Lw) is calculated by the calculation formula (2) of the number average fiber length (Ln)).
Ln = ΣLi / j Expression (2)
Lw = (ΣLi ² ) / (ΣLi) (3)
The measurement of the average fiber length in the present invention may be a number average fiber length or a weight average fiber length.

(Fiber diameter of reinforcing fiber)
The fiber diameter of the reinforcing fiber used in the present invention may be appropriately determined according to the type of the reinforcing fiber, and is not particularly limited. For example, when carbon fiber is used as the reinforcing fiber, the average fiber diameter is usually preferably in the range of 3 μm to 50 μm, more preferably in the range of 4 μm to 12 μm, and in the range of 5 μm to 8 μm. More preferably. On the other hand, when glass fiber is used as the reinforcing fiber, the average fiber diameter is usually preferably in the range of 3 to 30 μm. Here, the said average fiber diameter shall point out the diameter of the single yarn of a reinforced fiber. Therefore, when the reinforcing fiber is in the form of a fiber bundle, it refers to the diameter of the reinforcing fiber (single yarn) constituting the fiber bundle, not the diameter of the fiber bundle. The average fiber diameter of the reinforcing fibers can be measured by, for example, a method described in JIS R7607: 2000.

(Fiber form of reinforcing fiber)
Regardless of the type, the reinforcing fiber used in the present invention may be in the form of a single yarn consisting of a single yarn, or in the form of a fiber bundle consisting of a plurality of single yarns.
The reinforcing fiber used in the present invention may be only a single yarn, may be a fiber bundle, or a mixture of both. The fiber bundle shown here indicates that two or more single yarns are close to each other by a sizing agent or electrostatic force. When a fiber bundle is used, the number of single yarns constituting each fiber bundle may be substantially uniform or different in each fiber bundle. When the reinforcing fibers used in the present invention are carbon fibers and the carbon fibers are in a fiber bundle shape, the number of single yarns constituting each fiber bundle is not particularly limited, but usually 2 to 10 It is considered to be within the range of 10,000.

Generally, carbon fibers are in the form of fiber bundles in which thousands to tens of thousands of filaments are gathered. When carbon fiber is used as the reinforcing fiber, if the carbon fiber is used as it is, the entangled portion of the fiber bundle may be locally thick and it may be difficult to obtain a thin composite material. For this reason, when carbon fiber is used as the reinforcing fiber, the fiber bundle is usually used after being widened or opened.
Examples of the orientation state of the reinforcing fibers in the composite material include, for example, a unidirectional orientation in which the major axis direction of the reinforcing fibers is oriented in one direction, and a two-dimensional orientation in which the major axis direction is randomly oriented in the in-plane thickness direction of the composite material. Random orientation can be mentioned.

The orientation state of the reinforcing fibers in the present invention may be either the unidirectional orientation or the two-dimensional random orientation. Further, it may be an irregular orientation intermediate between the unidirectional orientation and the two-dimensional random orientation (an orientation state in which the major axis direction of the reinforcing fiber is not completely oriented in one direction and is not completely random). Furthermore, depending on the fiber length of the reinforcing fiber, the long axis direction of the reinforcing fiber may be oriented so as to have an angle with respect to the in-plane direction of the composite material, and the fibers are oriented so as to be entangled in a cotton-like manner. Further, the fibers may be oriented such as bi-directional woven fabrics such as plain weave and twill weave, multi-axial woven fabrics, non-woven fabrics, mats, knits, braids, paper made of reinforced fibers, and the like.

[Volume content of reinforcing fiber (Vf)]
With respect to the reinforcing fiber and resin contained in the composite material of the present invention, the volume fraction of reinforcing fiber (Vf) contained in the composite material defined by the formula (1) is not particularly limited, but is preferably 5 to 80%. It is more preferably 10 to 80%, further preferably 10 to 70%, still more preferably 20 to 50%, and most preferably 30 to 40%.
Formula (1) 100 × reinforced fiber volume / (reinforced fiber volume + resin volume)
When the reinforcing fiber volume ratio (Vf) is 5% or more, the reinforcing effect is sufficiently exhibited. On the contrary, if Vf is 80% or less, voids are hardly generated in the obtained composite material, and the physical properties are easily improved.

[resin]
The resin used in the present invention is not particularly limited, and may be a thermoplastic resin or a thermosetting resin.

(Thermoplastic resin)
When the resin contained in the composite material in the present invention is a thermoplastic resin, it becomes a cut body after being cut into a desired shape, which is preferable because it is used as a molding material for compression molding.
The molding material for compression molding will be described later.
The said thermoplastic resin is not specifically limited, According to the use etc. of a composite material, what has a desired softening point or melting | fusing point can be selected suitably, and can be used. Usually, those having a softening point in the range of 180 ° C. to 350 ° C. are used, but are not limited thereto.

Examples of the thermoplastic resin include polyolefin resin, polystyrene resin, thermoplastic polyamide resin, polyester resin, polyacetal resin (polyoxymethylene resin), polycarbonate resin, (meth) acrylic resin, polyarylate resin, polyphenylene ether resin, polyimide resin, Examples thereof include polyether nitrile resins, phenoxy resins, polyphenylene sulfide resins, polysulfone resins, polyketone resins, polyether ketone resins, thermoplastic urethane resins, fluorine resins, thermoplastic polybenzimidazole resins, and vinyl resins.

Examples of the polyolefin resin include polyethylene resin, polypropylene resin, polybutadiene resin, and polymethylpentene resin.
Examples of the vinyl resin include vinyl chloride resin, vinylidene chloride resin, vinyl acetate resin, and polyvinyl alcohol resin.
Examples of the polystyrene resin include polystyrene resin, acrylonitrile-styrene resin (AS resin), acrylonitrile-butadiene-styrene resin (ABS resin), and the like.

Examples of the polyamide resin include polyamide 6 resin (nylon 6), polyamide 11 resin (nylon 11), polyamide 12 resin (nylon 12), polyamide 46 resin (nylon 46), polyamide 66 resin (nylon 66), and polyamide 610. Resin (nylon 610) etc. can be mentioned.
Examples of the polyester resin include polyethylene terephthalate resin, polyethylene naphthalate resin, boribylene terephthalate resin, polytrimethylene terephthalate resin, and liquid crystal polyester. Examples of the (meth) acrylic resin include polymethyl methacrylate.

Examples of the polyphenylene ether resin include modified polyphenylene ether. Examples of the thermoplastic polyimide resin include thermoplastic polyimide, polyamideimide resin, polyetherimide resin, and the like. Examples of the polysulfone resin include a modified polysulfone resin and a polyethersulfone resin.
Examples of the polyetherketone resin include polyetherketone resin, polyetheretherketone resin, and polyetherketoneketone resin. As said fluororesin, polytetrafluoroethylene etc. can be mentioned, for example.

The thermoplastic resin used in the present invention may be only one type or two or more types. Examples of modes in which two or more types of thermoplastic resins are used in combination include modes in which thermoplastic resins having different softening points or melting points are used in combination, modes in which thermoplastic resins having different average molecular weights are used in combination, and the like. However, this is not the case.

(Thermosetting resin)
Although there is no limitation in particular as a thermosetting resin used for this invention, the epoxy resin which is excellent in the balance of heat resistance, a mechanical characteristic, and adhesiveness with carbon fiber is used preferably, Especially, amines, phenols, carbon -It is preferable to use an epoxy resin whose precursor is a compound having a carbon double bond. In addition, these thermosetting resins may be self-curing by heating, or may be blended with a curing agent or a curing accelerator.

Examples of epoxy resins having amines as precursors include tetraglycidyldiaminodiphenylmethanes, glycidyl compounds of aminophenol, glycidylanilines, and glycidyl compounds of xylenediamine. Tetraglycidyldiaminodiphenylmethanes are preferred because of their excellent heat resistance.
Examples of epoxy resins having phenols as precursors include bisphenol A type epoxy resins, bisphenol F type epoxy resins, bisphenol S type epoxy resins, phenol novolac type epoxy resins, and resorcinol type epoxy resins.
Examples of the epoxy resin using a compound having a carbon / carbon double bond as a precursor include polycyclic epoxy resins.
These epoxy resins may be used singly or may be appropriately mixed and used. A combination of a glycidylamine type epoxy resin and a bifunctional glycidyl ether type epoxy resin is particularly preferable because it has both heat resistance, water resistance and workability.

As a curing agent for the thermosetting resin composition when an epoxy resin is used as the thermosetting resin, any compound having an active group capable of reacting with an epoxy group can be used. , Dicyandiamide, dibasic acid dihydrazide alone or in a mixed system. Examples of aromatic amines include metaphenylenediamine, diaminodiphenylmethane, diaminodiphenylsulfone, and metaxylenediamine. These curing agents may be used alone or may be appropriately blended and used. Aromatic amines are particularly preferred because they can impart heat resistance to the cured resin.
Examples of thermosetting resins other than epoxy resins include cyanate ester resins, bismaleimide resins, and benzoxazine resins.

[Other agents]
In the composite material used in the present invention, various fibrous or non-fibrous fillers of organic fibers or inorganic fibers, flame retardants, UV-resistant agents, stabilizers, release agents, Additives such as pigments, softeners, plasticizers, and surfactants may be included.

[Production method of composite material]
The composite material used in the present invention can be produced by a generally known method. For example, an isotropic substrate described in WO2012 / 105080 pamphlet and JP2013-49298A is preferably used. In the composite material using the isotropic substrate, the carbon fibers are not oriented in a specific direction and are dispersed in a random direction in the plane.

[Cutting device]
The cutting device in the present invention is for cutting a composite material, and is shown in FIG. 1, for example.
The positioning layer of the pressure device and the fixed layer is preferably fixed by a clamping mechanism (a sandwiching mechanism) (the fixed layer and the pressure device are in contact but preferably not directly fixed).
The positioning layer and the fixing layer of the fixing layer are preferably fastened by bolts.
The cutting blade is preferably fixed by press-fitting into a slit provided in the positioning layer of the cutting blade.
The positioning layer of the cutting blade and the positioning layer of the fixed layer are preferably fastened by bolts.

1. Pressurizing device There is no limitation on the pressurizing device, and a known device can be used. For example, an electric motor is used as a pressure source, and a hydraulic pump is used as a pressure source. Further, as the reciprocating mechanism, it is possible to include any of a screw mechanism, a crank mechanism, a link mechanism, a cylinder mechanism, or a combination of a plurality of them.
Further, a fixing layer (103 in FIG. 1) can be attached to the pressurizing device (102 in FIG. 1). A fixed layer can be attached to the bottom (pressure surface) of the pressure device.

2. Cutting table The method for producing a cut body in the present invention is preferably produced by cutting a composite material with a cutting table. A known cutting table can be used, and there is no particular limitation as long as it can support the composite material. The cutting table in the present invention is intended for continuous cutting, and a fiber reinforced resin material is placed in a mold and burrs are removed with a punching blade. It does not include molds such as those described in JP-084038 and Japanese Unexamined Patent Publication No. 2013-99817. That is, the present invention does not trim the end material at the same time as molding, but continuously cuts the composite material to obtain a cut body.

3. Fixed layer In the present invention, at least one of the yield stress and the 0.2% yield strength of the fixed layer (for example, 103 in FIG. 1) is 165 MPa or more. This is because there is a problem that the fixed layer is plastically deformed when the composite material is continuously cut. Therefore, at least one of yield stress and 0.2% proof stress must be 165 MPa or more. . When the fixed layer is plastically deformed, for example, as shown by 301 in FIG. 3, the positioning accuracy of the cutting blade is lowered (that is, the vertical displacement of the cutting blade occurs). The fixing layer in the present invention is for fixing the cutting blade at a specific position in the vertical direction, and can fix the cutting blade at a fixed position in the vertical direction.

At least one of the yield stress and the 0.2% yield strength of the fixed layer is preferably 200 MPa or more. Specifically, from the viewpoint of availability, the fixed layer is more preferably iron or an alloy containing iron, and even more preferably an iron-containing alloy.
On the other hand, the upper limit of at least one of yield stress or 0.2% yield strength is preferably 1500 MPa or less, more preferably 1000 MPa or less, and even more preferably 700 MPa or less.
Yield stress or 0.2% proof stress is measured based on JIS Z 2241: 2011.

The thickness of the fixed layer depends on the size of the discharge passage described later, but is preferably 1 mm or more, more preferably 5 mm or more, and even more preferably 10 mm or more. The upper limit of the thickness of the fixed layer is preferably 100 mm or less, more preferably 80 mm or less.
The width of the fixed layer is not particularly limited as long as it can support the cutting blade, but is preferably 0.5 mm or more, and more preferably 3 mm or more. The upper limit of the width of the fixed layer is preferably 100 mm or less, more preferably 70 mm or less.
Although the shape of a fixed layer is not specifically limited, A rectangular parallelepiped is mentioned as an example.
Moreover, the fixed layer in the present invention can suppress an uneven load on the cutting blade, and can apply a uniform load over the entire cutting blade. By utilizing this characteristic, the composite material can be continuously cut even when a plurality of cutting blades are provided in the cutting device or when a plurality of cutting blade shapes are provided.

4). Cutting blade The cutting blade in this invention is shown by 104 of FIG. 1, FIG. 2, for example.

4.1 Types The blade material, hardness, blade edge shape, etc. to be used can be appropriately selected according to the material properties, thickness, etc., but the blade hardness is preferably HRC28-70, and more preferably the hardness HRC45-63. preferable. The hardness of HRC28 or higher is preferable because the durability of the cutting blade is improved. HRC70 or less is preferable because the toughness of the blade is improved.
The angle of the cutting edge of the cutting blade is preferably 25 to 60 degrees, and the R dimension of the blade tip is preferably 0.2 mm or less. When the angle of the cutting blade is 25 degrees or more, durability is improved, and when the angle is 60 degrees or less, cutting with a low linear pressure is preferable. It is preferable that the R dimension of the blade tip is 0.2 mm or less because cutting can be performed with a low linear pressure.
The root thickness of the blade is preferably 0.5 to 2.0 mm. If it is 2.0 mm or less, it is preferable because it can be cut with a low linear pressure, and if it is 0.5 mm or more, durability is improved, which is preferable.

4.2 Shape The shape of the cutting blade is not particularly limited, and may be a closed loop structure or an open structure.
Here, the open structure means that the cutting blade is open, and the drawings viewed from the cutting edge side of the cutting blade are cutting blades as shown in FIGS. 7A to 7C, for example. That is, the open structure means that the line connecting the cutting edge of the cutting blade is not closed. When the cutting blade has an open structure, a cut piece cut from the composite material may or may not be generated. For example, when the cutting blade shown on the right in FIG. 8D is used, no cut piece is generated (left in FIG. 8D). On the other hand, when a corner of the composite material is cut using a cutting blade as shown on the right in FIG. 8C, a cut piece 801 shown on the left in FIG. 8C is generated.
On the other hand, the closed loop structure refers to a shape as seen from the cutting edge side of the cutting blade, for example, as shown in FIGS. 6 (a) to 6 (d). Not only a circle but also an ellipse, a triangle, a square, various polygons, Those having an indefinite shape are also included. That is, the closed loop structure means that the line connecting the cutting edge of the cutting blade is closed.
When it is cut with a cutting blade having a closed loop structure, a cut piece is generated in many cases (for example, (a) and (b) in FIG. 8). That is, when the shape of the cutting blade is a closed loop structure, a new problem arises that the cutting piece cut from the composite material is easily caught by the cutting blade, and it becomes difficult to discharge the cutting piece.
In addition, the cut piece cut | disconnected from the composite material in this invention is the remaining part byproduced from the cut body obtained by cut | disconnecting a composite material to a desired shape.

5). Discharge passage In order to avoid the clogging of the cut piece from the closed-loop structure cutting blade, the cut piece passes through the inside of the closed-loop structure of the cut blade, and then the discharge passage (401 in FIG. 4) provided in the fixed layer. ) And is preferably discharged out of the cutting device. That is, it is preferable that the cutting device according to the present invention includes at least one discharge passage for discharging a cut piece cut from the composite material. If the cut pieces do not clog the closed-loop structured cutting blade, it is easy to continuously cut the composite material.
When the cutting blade has a closed-loop structure, when the cutting pieces are discharged continuously vertically rather than dropping vertically, the cutting pieces continue to be inserted inside the closed-loop cutting blade one after another. Therefore, it is advantageous in terms of equipment.
The cutting device preferably includes a discharge passage between the cutting blade and the pressure device.

For example, in the discharge passage shown in FIG. 4, two fixing layers for fixing the cutting blade are provided (103 in FIG. 4), and the space between the fixed layers is the discharge passage (401 in FIG. 4). The discharge passage provided in the fixed layer is connected to the discharge passage provided in the positioning layer (105 in FIG. 4) of the fixed layer, and the cut pieces are cut using air (402 in FIG. 4B) or the like. It is good to discharge outside the device. As long as the cut piece can be discharged out of the cutting apparatus, the shape and structure of the discharge passage are not limited to those shown in FIG.
The material for the positioning layer of the fixed layer for providing the discharge passage is not particularly limited as long as it is inexpensive and easy to process. For example, it is preferable to use a veneer plate.
In addition, if a cheap and easy-to-process material (for example, a veneer plate) is used up to the fixed layer, the position of the cutting blade tends to become unstable due to the load during cutting, as shown in FIG.

In the cutting device of the present invention, at least one of the yield stress or the 0.2% proof stress of the fixed layer is 165 MPa or more, and the positioning layer of the fixed layer is made of a material that is inexpensive and easy to process (for example, a veneer plate). Even when a cutting blade having a closed loop structure is used, it is easy to discharge the cut pieces, and the positional accuracy (with time) of the cutting blade can be kept high.

(Area size of discharge passage)
When at least one cutting blade having a closed loop structure is provided and at least one discharge passage for discharging a cutting piece cut from the composite material,
In the cutting device according to the present invention, the maximum cross-sectional area in the plate thickness direction of the cut piece is S _k1 , and the minimum cross-sectional area of the discharge passage is S _k2 .
One or more cutting pieces are discharged through the discharge passage in one cutting of the composite material, and the total value of S _k1 of each cutting piece is ΣS _k1 , and the cutting device has one or more cutting pieces. a discharge passage, when the total value of _{S k2} of each discharge passage of a [sigma] s _k2, it is preferable that ΣS _k1 <ΣS _k2.

Here, the minimum cross-sectional area of the discharge passage refers to the minimum area in the plane direction perpendicular to the traveling direction of the passage. By satisfying ΣS _k1 <ΣS _k2 , there is an excellent effect that the cut pieces are not clogged in the discharge passage.
Moreover, it is preferable that S _k1 of the cut piece is smaller than S _{k2 of the} discharge passage through which the cut piece passes.

In the cutting device of the present invention and the method for producing a cut body,
R _A is the minimum diameter of the circle including the projected figure in the thickness direction of the cut piece (the diameter of the smallest circle among the circles including the projected figure in the thickness direction of the cut piece so that the projected figure does not protrude).
Maximum diameter of the circle that may be present in the interior of the cross section of the discharge passage (diameter of the largest circle of the circle that may be present in without protruding from the interior of the cross-section of the discharge passage) when expressed as R _B, for all of the cross-section the smallest of the _{R B} when the _{R Bmin} of
R _A <R _Bmin
It is preferable to satisfy.

Further, it is preferable that 1 to 7 cutting pieces are discharged through the discharging passage per discharging passage at one cutting, and 1 to 4 cutting pieces are discharged through the discharging passage. Preferably, 1 to 2 cutting pieces discharged through the discharge passage are more preferable. Most preferably, the number of cut pieces discharged per time and the number of discharge passages are the same.
FIG. 9 shows an example of a cutting device having one discharge passage for eight cutting blades having a closed loop structure, and FIG. 9 shows a cutting device having eight discharge passages for eight cutting blades having a closed loop structure. An example is shown in FIG.

6). Elastic member It is preferable that the cutting device in this invention has an elastic member. The elastic member is for detaching the cut body, which is a cut composite material, from the cutting blade, for example, as indicated by reference numeral 501 in FIG. The elastic member does not hinder cutting by elastic deformation when cutting the composite material (when the composite material is pushed and cut by the cutting blade, the elastic member is compressed in the upward direction in FIG. 5). On the other hand, after cutting the composite material, the cut body (composite material after cutting) is easily detached from the cutting blade by the stored elastic energy. Moreover, it is preferable that the vertically downward position of the elastic member protrudes below the cutting edge of the cutting blade (for example, 501 in FIG. 5).
In order to continuously cut the composite material when no elastic member is used, a method of manually detaching the cut body from the cutting blade or mechanically detaching may be provided separately.

7). Fixed layer positioning layer (105 in FIG. 1)
In order to increase the horizontal positioning accuracy of the fixed layer, it is preferable to provide a fixed layer positioning layer. As described above, the positioning layer of the fixed layer is preferably made of a material that can be easily processed for providing the discharge passage, and examples thereof include a wood board (may be a single board or a plywood board). A plywood board is preferred.
In the present invention, the fixed layer and the pressurizing device are not directly fastened by bolts or the like so that it can correspond to various cut patterns of the composite material, and the fixed layer is not easily displaced in the horizontal direction. It is preferable to provide a positioning layer.
The positioning layer of the fixed layer is preferably fixed to the pressure device by a clamping mechanism (a sandwiching mechanism) (the fixed layer and the pressure device are in contact but preferably not fixed by a bolt or the like).
The positioning layer and the fixing layer of the fixing layer are preferably fastened by bolts.

8). Cutting blade positioning layer (106 in FIG. 1)
In order to increase the horizontal positioning accuracy of the cutting blade, it is preferable to provide a cutting blade positioning layer.
In the present invention, the cutting blade is directly fastened to the fixed layer so that cutting blades of various shapes can be selected and used easily and can be easily replaced when the blade is worn. It is preferable to provide a positioning layer for the cutting blade so that the cutting blade is not easily displaced in the horizontal direction.
The cutting blade is preferably fixed by press-fitting into a slit provided in the positioning layer of the cutting blade.
The positioning layer of the cutting blade and the positioning layer of the fixed layer are preferably fastened by bolts.

[Method of manufacturing cut body]
The method for producing a cut body in the present invention is a method for producing a cut body by cutting a composite material containing reinforcing fibers and a resin using a cutting device provided with a cutting blade and a pressure device. Is provided with a fixing layer for fixing the cutting blade between the cutting blade and the pressure device, and at least one of the yield stress or the 0.2% proof stress of the fixing layer is 165 MPa or more.
The cutting is preferably performed by placing the composite material on a cutting table and lowering the cutting blade once with respect to one composite material with the cutting blade. What is necessary is just to make a cutting blade reciprocate up and down whenever a body is manufactured.

For the cutting of the composite material in the present invention, it is preferable to heat the composite material in advance. This is because the composite material is softened and the linear pressure required for cutting is reduced. When the composite material is heated, the heating method is not particularly limited, and any method can be used. Specifically, a method using a hot air dryer or an electric heating type dryer, a method of sandwiching between a hot plate in a mold, a belt conveyor, a hot roller, etc., dielectric heating or induction heating (IH) by infrared, microwave, high frequency, etc. Is illustrated.

[Molding materials]
When the resin contained in the composite material in the present invention is a thermoplastic resin, the cut body is preferably used as a molding material for compression molding. When producing a molded product having a complex shape by compression molding a composite material containing reinforcing fibers and a thermoplastic resin, the resulting molded product has a poor appearance with wrinkles and the like in the complex shape portion. There is. With respect to such a problem, by forming the molding material in a desired shape in advance, it is possible to produce a molded article having a good appearance without generating wrinkles during compression molding. In particular, when a composite material containing carbon fibers having a fiber length of 1 to 100 mm is used as a molding material for compression molding, it is difficult to flow at the time of molding, and the above-mentioned problem appears prominently.

By using a cutting body cut into a desired shape as a molding material by using the cutting device according to the present invention, a fiber-reinforced molded body having a complicated three-dimensional shape can be manufactured by compression molding, and molding that does not reduce the appearance and strength. You can get a body. By using a cut body that has been cut into a desired shape in advance as a molding material, a molded body with good quality and yield can be obtained.
From the above viewpoint, the composite material and the cut body obtained by cutting the composite material preferably include a thermoplastic resin.

Examples are shown below, but the present invention is not limited thereto. In addition, each value in a present Example was calculated | required according to the following method.

(1) The average fiber length of the reinforcing fibers is measured by measuring the fiber length of 300 fibers randomly extracted from the sample left after removing the resin by heating the composite material to 500 ° C. in the air, in units of 1 mm. Until the average was obtained.
In all examples, the weight average fiber length of the carbon fiber was 20 mm.

(2) Number of continuous possible cuttings The composite materials described in each example were cut until a cutting failure occurred, and the number of cuttings until a cutting failure appeared was counted and evaluated.

(3) Position accuracy of the cutting blade after cutting the composite material (exceeded) Excellent: There was no change in the position of the cutting blade in the vertical direction.
Bad: The vertical position of the cutting blade changed by 1 mm or more.

(4) Clogging of discharge passage of cut pieces Excellent: The cut pieces were not clogged in the discharge passage and could be discharged out of the cutting apparatus.
Better: When the cut piece flows through the discharge passage, it can be discharged if it can be discharged without rotating, but when the cut piece rotates, the discharge passage is clogged.
Bad: The cutting piece was clogged in the discharge passage, and could not be discharged out of the cutting device.

[Production Example 1 of Composite Material]
As a reinforcing fiber, a carbon fiber “Tenax” (registered trademark) STS40-24KS (average fiber diameter 7 μm) manufactured by Toho Tenax Co., Ltd., treated with a nylon sizing agent is used. As a thermoplastic resin, nylon 6 manufactured by Unitika Co., Ltd. is used. Based on the method described in the pamphlet of WO2012 / 105080 using resin A1030, an isotropic material is prepared, preheated at 240 ° C for 90 s, and then heated at 240 ° C for 180 s while applying a pressure of 2.0 MPa. Pressed. Subsequently, it cooled to 50 degreeC in the pressurization state, the flat fiber of volume fiber content rate Vf = 35% of thickness 2.7mm was obtained, and this was made into the composite material 1.

[Example 1]
1. Preparation of the cutting device 1.1 Cutting blade For a circular shape (closed loop structure) using 440160 manufactured by Osaka Die Seisakusho, with a root thickness of 1.0 mm, a cutting edge R of 0.05 mm or less, a cutting edge angle of 45 degrees, an HRC of 54, and an inner diameter of 16 mm. It was.
When the minimum diameter of the circle including the projected figure in the thickness direction of the cut piece is R _A , R _A is 16 mm.
1.2 Fixed Layer An iron alloy (SS400, yield stress or 0.2% proof stress is 215 MPa) having a rectangular parallelepiped with a thickness of 20 mm, a width of 16 mm, and a length of 20 mm is provided at the base of the cutting blade (see FIG. 5 (a)). The fixed layers were placed 20 mm apart. In addition, when mounting a cutting blade on a fixed layer, the flange part was provided in the cutting blade and the contact area with the fixed layer was increased. SS400 is a general structural rolled steel specified in JIS G 3101: 2010.
1.3 Discharge passage When providing the above-mentioned two fixed layers, a discharge passage larger than R _A (16 mm) of the cut piece was provided by being separated by 20 mm.
The maximum diameter of the circle that may be present in the interior of the cross section of the discharge passage when expressed as _{R B,} when the smallest of the _{R B} for all the cross-section was _{R _Bmin,} _{R Bmin} is 20 mm.
1.4 Pressurizer DAE YANG HYDRAULIC TECHNOLOGY MACHINERY DYMSP-50 was used.
1.5 Elastic member Styrene butadiene foam rubber is used, and it has a donut shape with a thickness of 8 mm and a width of 20 mm, and surrounds a cutting blade having a closed loop structure (thickness is the vertical direction of the paper in FIG. 5, width is the horizontal direction of FIG. 5) .
1.6 Plywood was used for the positioning layer of the fixed layer and the positioning layer of the cutting blade. The positioning layer of the fixed layer was provided with a discharge passage so as to be continuous with the discharge passage provided in the fixed layer so that the cut pieces can be discharged out of the cutting device.
The prepared cutting blade, fixed layer, discharge passage, pressurizing device, elastic member, and positioning layer were installed as shown in FIGS.

2. Cutting the composite material Using the above-described cutting apparatus, the composite material 1 heated to 150 ° C. was continuously cut at a linear pressure of 14 ton / m to produce a cut body. The results are shown in Table 1.

[Example 2]
Except not using an elastic member, the composite material 1 was cut | disconnected using the cutting device similar to Example 1, and the cut body was manufactured. The results are shown in Table 1. Since the cut body does not use an elastic member, it was manually detached from the cutting blade and continued to be cut.

[Example 3]
The composite material 1 was cut using the same cutting device as in Example 1 except that the number of cutting blades was set to 8 and the number of discharge passages was kept at 1 to produce a cut body. The cutting device used is shown by the schematic diagram shown in FIG. The results are shown in Table 1. Since the cut pieces were clogged in the discharge passage, the continuous cutting was interrupted.

[Example 4]
The composite material 1 was cut using the same cutting device as in Example 3 except that one discharge passage was provided for each cutting blade, and a cut body was manufactured. The used cutting apparatus is shown by the schematic diagram shown in FIG. The results are shown in Table 1.

[Example 5]
The composite material 1 was cut using the same cutting device as in Example 1 except that the cutting blade had an open structure and the shape shown in FIG. The results are shown in Table 1.

[Example 6]
A cut body was manufactured in the same manner as in Example 1 except that the thickness of the iron alloy used as the fixed layer was 5 mm. Since the thickness of the fixed layer was 5 mm, _RBmin of the cross section of the discharge passage was 5 mm. As a result, when the cut piece flows through the discharge passage, it can be discharged if it can be discharged without rotating. However, when the cut piece rotates, the discharge passage is clogged.

[Comparative Example 1]
The composite material 1 was cut in the same manner as in Example 5 except that a cutting device using a plywood was used for the fixed layer. The results are shown in Table 1.

The composite material (cut body) cut using the cutting device of the present invention can be molded by compression molding. The molded body can be used for various components such as an inner plate, an outer plate, a structural member of an automobile, various electric products, a frame of a machine, a casing, and the like. Preferably, it can be used as an automobile part.

Although the present invention has been described in detail and with reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention.
This application is based on a Japanese patent application filed on December 24, 2015 (Japanese Patent Application No. 2015-251704), the contents of which are incorporated herein by reference.

DESCRIPTION OF SYMBOLS 101 Cutting device 102 Pressurizing device 103 Fixed layer 104 for fixing a cutting blade Cutting blade 105 Positioning layer of fixed layer (for example, plywood)
106 Cutting blade positioning layer 201 Cutting device 301 using a cutting blade having a closed loop structure The positioning accuracy of the cutting blade is reduced, and the difference 401 generated in the heights of the two cutting blades 401 Discharge passage 402 Air flow 501 Elasticity Member 801 Cutting piece

Claims

A cutting device for cutting a composite material including a reinforcing fiber and a resin,
The cutting device has a cutting blade and a pressure device, and a fixing layer for fixing the cutting blade is provided between the cutting blade and the pressure device,
At least one of the yield stress or the 0.2% proof stress of the fixed layer is 165 MPa or more.
Cutting device.
The cutting device according to claim 1, comprising at least one cutting blade having a closed loop structure.
The cutting apparatus according to claim 2, wherein the cutting apparatus includes at least one discharge passage for discharging a cut piece cut from the composite material.
The cutting device according to claim 3,
R A is the minimum diameter of the circle including the projected figure in the thickness direction of the cut piece,
The maximum diameter of the circle that may be present in the interior of the cross section of the discharge passage when expressed as R B, when the smallest of the R B for all the cross-section was R Bmin,
R A <R Bmin
Satisfying the cutting device.
The cutting apparatus according to claim 3 or 4, wherein 1 to 7 cutting pieces are discharged through the discharge passage for each discharge passage at one time of cutting.
The cutting apparatus according to any one of claims 3 to 5, wherein a discharge passage is provided between the cutting blade and the pressurizing apparatus.
The cutting apparatus according to any one of claims 1 to 6, wherein the fixing layer is for fixing the cutting blade at a desired position in the vertical direction.
The cutting device has an elastic member,
The elastic member is for detaching the cut body, which is a cut composite material, from the cutting blade.
The cutting device according to any one of claims 1 to 7.
The cutting device according to any one of claims 1 to 8, wherein the cutting device heats and cuts the composite material.
The cutting device according to any one of claims 1 to 9, wherein the fixed layer is iron or an alloy containing iron.
The reinforcing fiber contained in the composite material is carbon fiber, the resin is a thermoplastic resin, and the cutting device is a device for producing a molding material.
The cutting device according to any one of claims 1 to 10.
The cutting device according to any one of claims 1 to 11, wherein the cutting device comprises two or more cutting blades.
A method of manufacturing a cut body by cutting a composite material containing reinforcing fibers and a resin using a cutting device equipped with a cutting blade and a pressure device,
The cutting device is provided with a fixing layer for fixing the cutting blade between the cutting blade and the pressurizing device,
At least one of the yield stress or the 0.2% proof stress of the fixed layer is 165 MPa or more.
Manufacturing method of cut body.
The cutting device according to claim 13, wherein the cutting device includes at least one cutting blade having a closed loop structure.
The cutting apparatus according to claim 14, wherein the cutting device includes at least one discharge passage for discharging a cut piece cut from the composite material.
It is a manufacturing method of the cutting object according to claim 15,
R A is the minimum diameter of the circle including the projected figure in the thickness direction of the cut piece,
The maximum diameter of the circle that may be present in the interior of the cross section of the discharge passage when expressed as R B, when the smallest of the R B for all the cross-section was R Bmin,
R A <R Bmin
The manufacturing method of the cutting body which satisfies.
The method for producing a cut body according to claim 15 or 16, wherein 1 to 7 pieces of cut pieces are discharged through the discharge passage for each discharge passage at one time of cutting.
The method for manufacturing a cut body according to any one of claims 15 to 17, wherein a discharge passage is provided between the cutting blade and the pressure device.
The method for manufacturing a cut body according to any one of claims 13 to 18, wherein the fixing layer is for fixing the cutting blade at a desired position in the vertical direction.
The cutting device has an elastic member,
The elastic member is for detaching the cut body, which is a cut composite material, from the cutting blade.
The method for producing a cut body according to any one of claims 13 to 19.
The method for producing a cut body according to any one of claims 13 to 20, wherein the composite material is heated and cut.
The method for producing a cut body according to any one of claims 13 to 21, wherein the fixed layer is iron or an alloy containing iron.
The reinforcing fiber included in the composite material is carbon fiber, the resin is a thermoplastic resin, and the cut body is a molding material.
The method for producing a cut body according to any one of claims 13 to 22.
The cutting body manufacturing method according to any one of claims 13 to 23, wherein the cutting device comprises two or more cutting blades.