WO2018088135A1

WO2018088135A1 - Molded article, and compression molding method

Info

Publication number: WO2018088135A1
Application number: PCT/JP2017/037346
Authority: WO
Inventors: 安田　和治; 普菅野; 英明市来; 大賀齋藤
Original assignee: 旭化成株式会社
Priority date: 2016-11-11
Filing date: 2017-10-16
Publication date: 2018-05-17
Also published as: KR20190028487A; TW201819159A

Abstract

[Problem] To provide: a molded article that includes a projection having excellent formability and strength as a result of using a thermoplastic resin fiber composite material; and a molding method with favorable productivity. [Solution] A molded article containing a continuous fiber-reinforced thermoplastic resin composite material which comprises continuous reinforcing fibers and a thermoplastic resin. The molded article has a substrate (420) and a projection (403), with continuous reinforcing fibers (170) being present within the projection (403) and the substrate (420), and the average value of a height h_f of the continuous reinforcing fibers (170) within the projection (403) is 5% or more of a height h of the projection (403).

Description

Molded products and compression molding methods

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

In recent years, composite yarns and composite yarns in which reinforcing fibers and thermoplastic resin fibers are continuously and uniformly mixed as materials for molded products used in various machines and structural parts such as automobiles, pressure vessels, and tubular structures, etc. Fabrics made of (hereinafter also referred to as composite materials), and plate materials in which continuous reinforcing fibers are impregnated with a thermoplastic resin in advance have been proposed. As a method for forming a molded article using a fabric, for example, in Patent Document 1, the fabric is placed in a mold heated to 280 ° C., and after the thermoplastic resin portion of the fabric is melted, the mold is cooled to 50 ° C. A method of solidifying the material has been proposed. Further, there is a method in which the plate material is preliminarily heated to the melting point or glass transition temperature of the thermoplastic resin and inserted into a mold whose temperature has been adjusted to a constant temperature, and compression molding is performed.

Some molded products used in various machines and automobiles have protrusions such as ribs and bosses. Such a molded article is desired to have high strength from the viewpoint of reliability. The higher the height of the rib, the higher the strength reinforcing effect. However, when a cloth-like or plate-like composite material is used as the base material, there is a problem in formability only by compression molding. Further, the height of the boss or the columnar protrusion is also limited as in the case of the rib. Conventionally, a method has been proposed in which a molded product having a small undulation shape is formed by compression molding or a hybrid molding of compression molding and injection molding using a fabric-like or plate-like continuous fiber reinforced thermoplastic resin composite material. Yes.

In addition, as a material for molded products that require mechanical strength, a continuous fiber reinforced thermoplastic resin composite material called a prepreg in which a matrix resin is impregnated with a reinforcing material composed of continuous fibers such as continuous reinforcing fibers is widely used. Yes. When a prepreg is used as a material, the prepreg is preheated and softened, and then inserted into a mold kept at a constant temperature of, for example, 30 ° C. to 150 ° C. and solidified to produce a molded product.
However, in the case of a molded product having a complex shape, if the prepreg is used only for compression molding, the continuous reinforcing fiber is cut around the rib root due to the stress during molding, or the end of the protrusion cannot be molded well. Furthermore, there is a problem that the mechanical strength due to the molding failure is not sufficient.

Therefore, as a method for producing a molded product having a complicated shape, for example, Patent Document 1 discloses that a member A made of continuous reinforcing fibers and a thermoplastic resin and a member B made of discontinuous reinforcing fibers and a thermoplastic resin are stacked, There has been proposed a method in which the material temperature is heated to 260 ° C. with an infrared heater and cooled and pressed at 150 ° C. According to this method, it is described that a molded product having a complicated shape with a high rib and boss and excellent strength can be obtained.

Japanese Patent Laying-Open No. 2015-226986 Japanese Patent Laying-Open No. 2015-101794

However, there has been no report on a method of molding a molded product having a projection such as a complicated rib or boss only by compression molding. Furthermore, there is no report on a molded article having excellent strength, in which continuous reinforcing fibers have penetrated deep into the protrusions, and a compression molding method for the molded article.
On the other hand, the method using a plurality of types of base materials as in Patent Document 1 requires time and cost, and it is difficult to obtain a molded product having excellent strength in which continuous reinforcing fibers have penetrated deeply into the protrusions.
The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a molded product having a complicated shape having a protrusion having excellent shapeability and strength, and a compression molding method for obtaining the molded product. It is.
Furthermore, an object of the present invention is to provide a method for obtaining a molded product having a complicated shape excellent in formability and strength by a single molding method using a kind of prepreg.

That is, the present invention is as follows.
The molded product of the present invention is a molded product containing a continuous fiber reinforced thermoplastic resin composite material composed of continuous reinforced fibers and a thermoplastic resin,
The molded product has a substrate portion and a protrusion,
There are continuous reinforcing fibers in the protrusion and the substrate,
The average value of the height of the continuous reinforcing fibers in the protrusion is 5% or more of the height of the protrusion.

Here, the “projection part” refers to a part projecting from the substrate part into a rib, a boss, or a column (including a cylinder, a truncated cone, a quadrangular column, a quadrangular pyramid, and the like).
The “height of the protruding portion” will be described with reference to the drawings by taking a rib as an example. FIG. 1 is a schematic top view of an embodiment of the molded article of the present invention. FIG. 3 is a cross-sectional view of the rib 403 in FIG. 1 in the short side direction. FIG. 4 is a perspective view of the rib 403.
As shown in FIG. 3, the “height of the protruding portion” means a distance (reference symbol h) from the surface 420 a of the substrate portion 420 having the rib 403 to the upper end of the rib 403 in the vertical direction.

Further, “the height of the continuous reinforcing fibers in the protrusions” means the vertical distance from the surface 420a on the side of the substrate portion 420 having the ribs 403 to the upper end of the continuous reinforcing fibers 170 as shown in FIG. (Symbol h _f ). Note that the “upper end of the continuous reinforcing fiber” is the highest at the measurement point in the region, even if there is a region A where the continuous reinforcing fiber 170 does not partially exist in the rib 403, as shown in FIG. Means the end of continuous reinforcing fiber in position.

Further, the “height of continuous reinforcing fibers in the protrusion” of the columnar protrusion will be described with reference to the drawings, taking a quadrangular pyramidal protrusion as an example. FIG. 6 is a perspective view of a quadrangular pyramid. FIG. 7 is a cross-sectional view of the quadrangular pyramid. FIG. 8 is a side projection of the quadrangular pyramid.
As shown in FIG. 7, “the height of the continuous reinforcing fiber in the protruding portion” when the protruding portion is columnar is the upper end of the continuous reinforcing fiber 170 from the surface 420 a of the substrate portion 420 having the quadrangular pyramid 413. it is a vertical direction of the distance h _f up. In the case of a columnar shape, the “upper end of the continuous reinforcing fiber” is, for example, as shown in FIG. 8, even if there is a region A or B in which no continuous reinforcing fiber exists in the protrusion, It means the end of continuous reinforcing fiber in the highest position.

“The average value of the heights of the continuous reinforcing fibers in the protrusions” means the average value for the entire protrusions of the “height of the continuous reinforcing fibers in the protrusions” obtained above.
The height of the continuous reinforcing fibers in the protrusions and the average value thereof are obtained by using MATLAB software of MathWorks from the side projection image obtained by a digital camera when the reinforcing fibers are visible. If the reinforcing fiber cannot be confirmed visually, the reinforcing fiber is photographed with a soft X-ray apparatus, and the height and average value thereof are calculated using MATLAB software of MathWorks, as in the case of visual observation.
As for the ribs, the height of the continuous reinforcing fibers in the short side direction has little influence on the average value, and the heights of the continuous reinforcing fibers on the two side surfaces in the long side direction are the same. The “average value of the height of the continuous reinforcing fibers in the part” is a value obtained on one side of the long side direction.

The region in which the height of the continuous reinforcing fiber in the protrusion is 5% or more of the height of the protrusion is preferably 20% or more of the bottom of the protrusion.
With reference to FIG. 5, a description will be given of “the region where the height of the continuous reinforcing fiber is 5% or more is 20% or more of the bottom of the projection” when the projection is a rib. FIG. 5 is a side projection view of the rib 403 in the long side direction. In FIG. 5, showing a height h _f of more than 5% area of the continuous reinforcing fibers, the long side direction length in L _a. Means "the height of more than 5% is a region of continuous reinforcing fibers is not less than 20% of the base of the protrusion" is a, the length L _a is greater than or equal to 20% of the length L _r of the bottom side To do. When the protrusion is a rib, the influence in the short side direction is small and can be ignored, and therefore, it is expressed as a ratio to the length Lr of the bottom side of one side surface in the long side direction.
In the case where the protrusions other than the ribs are square pillars, for example, as illustrated in FIG. 6, the value is obtained with respect to the length L (2 · a ₁ + 2 · b ₁ ) of the base.

The continuous reinforcing fiber in the protrusion is preferably continuous with the continuous reinforcing fiber in the substrate portion. Here, “continuous” means that continuous reinforcing fibers are continuously present from the substrate portion. As a determination method, it can be confirmed that the continuous reinforcing fibers remain continuously from the substrate portion when the molded product is incinerated. Moreover, the continuous part of a reinforced fiber can also be confirmed by observing by X-ray CT.

The area occupied by the continuous reinforcing fibers in the protrusions that are continuous with the continuous reinforcing fibers inside the substrate part at the bottom of the protrusions is preferably 20% or more of the bottom, and most preferably 90% or more. .
With reference to FIG. 4, a description will be given of “the region occupied by the continuous reinforcing fibers in the protrusion continuous with the substrate portion is 20% or more of the bottom” when the protrusion is a rib. As shown in FIG. 4, for example, in the case where the continuous reinforcing fibers are not continuous from the inside of the substrate part 420 in the region A and the continuous reinforcing fibers are continuous in the region other than the region A, "The area occupied by the continuous reinforcing fibers in the protruding portion is 20% or more of the bottom" means that the continuous continuous reinforcing fibers occupy at the bottom L (see FIG. 5) on one side of the long side direction of the rib. the length L _b of the long side direction of the region means that at least 20% of the length L _r of the base. The height of the average value of the continuous reinforcing fibers in the ribs is preferably at a thickness T ₂ or more substrate portions, more preferably 2 times or more, further preferably 3 times or more. Further, the rib height h / T ₁ with respect to the base wall thickness T ₁ is preferably 2 or more, more preferably 4 or more, and most preferably 6 or more. Further, the thickness T _{1 at} the base of the rib portion is preferably equal to or less than the thickness T ₂ of the substrate portion, and more preferably, the thickness T _{1 at} the base of the rib portion is 3/4 or less of the thickness T ₂ of the substrate portion. Most preferably, it is 1/2 or less. If the base of the wall thickness T ₁ of the rib portion is large, the linearity of the continuous reinforcing fiber substrate portion is lost, the linearity of the substrate portion is lost, the tensile strength of the substrate portions may be decreased. Further, it is desirable that the density Vf of the continuous fiber having a height of 10% at the top when the height of the rib portion is 100% is 10% or less (see FIG. 3).

On the other hand, the case of a columnar projection will be described with reference to FIG. 8, for example. The "region occupied by continuous reinforcing fibers in the protrusions contiguous with the substrate section is greater than or equal to 20% of the bottom", a length L _b in the bottom of the area occupied by the continuous reinforcing fibers in the protrusions of the bottom side It means 20% or more of the length L.

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

It is desirable that the density Vf of the continuous fiber having a height of 10% at the bottom when the height of the protrusion is 100% is 30% or more, more preferably 50% or more. This is because the strength of the protrusions is preferably such that continuous reinforcing fibers are disposed in this portion because stress tends to concentrate on the joint portion with the substrate portion with respect to the load from above.

When producing a molded product having protrusions in injection molding, when the composite material is melt-filled in a deep part (concave) carved into the mold cavity surface such as a rib, what is called a gas pool is generated. It is known that the thermoplastic resin melted up to the tip of the recess does not enter and the projection of the molded product is not formed up to the end.
As a method for solving this phenomenon, the inventors preferred a method of efficiently removing gas components in the mold at the timing when gas is generated and a gas accumulation phenomenon occurs, and in the compression molding method of the present invention, It has been found that by performing degassing at an arbitrary timing, a compression molded product having a protrusion is produced.

That is, one compression molding method according to the present invention is:
A compression molding method in which a continuous fiber reinforced thermoplastic resin composite material composed of continuous reinforcing fibers and a thermoplastic resin is compression molded to obtain a molded product having a substrate portion and a protrusion,
A continuous fiber reinforced thermoplastic resin composite material is inserted into a mold, and while being compressed, the mold is heated to a temperature higher than the glass transition temperature or the melting point of the thermoplastic resin to form, and then the mold is molded into a thermoplastic resin. Glass transition temperature of −10 ° C. or lower or melting point −10 ° C. or lower, preferably glass transition temperature −30 ° C. or lower or melting point −50 ° C. or lower, more preferably glass transition temperature −50 ° C. or lower or melting point −100 ° C. or lower. A compression molding process for solidifying the thermoplastic resin,
And a step of releasing a gas component in the mold generated from the continuous fiber reinforced thermoplastic resin composite material out of the mold during the compression molding process.

Here, the temperature at which the mold is heated indicates a set temperature for setting the cavity surface of the mold to a desired temperature. Since the cavity surface is a molding surface, it is difficult to install a temperature measuring device such as a thermocouple, and it is difficult to measure the actual temperature of the cavity surface. For this reason, the temperature of the cavity surface is set in advance so as to obtain a desired cavity surface temperature by keeping a correlation between the temperature measuring device installed in the vicinity of the cavity surface and the set temperature in the temperature adjusting means without molding. Adjust.

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

As a specific method of degassing, that is, releasing the gas component in the mold out of the mold, the mold is closed after the continuous fiber reinforced thermoplastic resin composite material is inserted into the mold. When the temperature reaches an arbitrary temperature, a method of relaxing the mold clamping force and releasing the gas from the die mating surface (parting line) is used as a simple method. As another form, there is used a method of sucking air in a mold cavity or a continuous fiber reinforced thermoplastic resin composite material or a gas component generated by heating. As a means for sucking air or gas, a vacuum pump may be used by providing a gas vent line from the mold cavity.

Another compression molding method of the present invention is a compression molding method in which a thermoplastic resin composite material composed of continuous reinforcing fibers and a thermoplastic resin is compression-molded to obtain a molded product having a substrate portion and a protrusion. And
When inserting at least part of the continuous fiber reinforced thermoplastic resin composite material into the mold, the continuous fiber reinforced thermoplastic resin composite material is inserted into the recess corresponding to the protrusion of the mold, and the mold is heated while being compressed. Molding is performed by heating above the glass transition temperature or melting point of the plastic resin, and then the mold is glass transition temperature −10 ° C. or lower or melting point −10 ° C. or lower, preferably glass transition temperature −30 ° C. or lower of the thermoplastic resin. Alternatively, the thermoplastic resin is solidified by cooling to a melting point of −50 ° C. or lower, more preferably a glass transition temperature of −50 ° C. or lower or a melting point of −100 ° C. or lower.

Furthermore, as a result of intensive studies, the present inventors have found that a molded product having a complicated shape having protrusions can be produced using only a compression molding method using a kind of prepreg by setting specific production conditions. The present invention has been reached.
That is, still another compression molding method according to the present invention is as follows.
A compression molding method in which a prepreg composed of continuous reinforcing fibers and a thermoplastic resin is compression molded to obtain a molded product having a substrate portion and a protrusion,
Pre-preg is softened by preheating above the glass transition temperature or melting point of the thermoplastic resin,
Insert the softened prepreg into the mold,
The mold is heated to a glass transition temperature of the thermoplastic resin of −80 ° C. or higher or a melting point of −80 ° C. or more to mold the prepreg, and then the mold is subjected to a glass transition temperature of the thermoplastic resin of −10 ° C. or lower or a melting point of Cool to 10 ° C. or lower to solidify the thermoplastic resin.

Here, the temperature at which the mold is heated is a set temperature of the mold.
The temperature at which the mold is heated is based on the melting point or glass transition temperature. However, when the thermoplastic resin is a crystalline thermoplastic resin, the melting point is used as a reference, and when the thermoplastic resin is an amorphous resin. Is based on the glass transition temperature.

According to the molded article of the present invention, it is possible to obtain a protrusion having excellent shapeability and strength.
In addition, according to one compression molding method according to the present invention or another compression molding method according to the present invention, a molded product having protrusions excellent in formability and strength can be produced with high productivity.
According to yet another compression molding method according to the present invention, it is possible to obtain a molded article having a complicated shape, which is excellent in formability and strength only by the compression molding method, without combining other molding methods with a kind of prepreg. Can do.

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

The present invention will be described below.
[Molding]
An embodiment of a molded article of the present invention will be described with reference to the drawings. FIG. 1 is a schematic top view showing an embodiment of a molded article. 2 is a cross-sectional view taken along the line AA ′ in FIG.
As shown in FIG. 1, the molded product 400 includes a substrate portion 420,

holes

401 and 402, ribs (403, 405, 407), bosses (409, 410), a truncated cone (411, 412), and a quadrangular pyramid 413. And a projecting portion made of a quadrangular column (414, 415).

In the molded product of this embodiment, continuous reinforcing fibers 170 are present inside the ribs (403, 405, 407) and the truncated cones (411, 412) as shown in FIG. The continuous reinforcing fibers 170 inside the ribs and inside the truncated cone are continuous with the continuous reinforcing fibers 170 of the substrate portion 420 without breaking.

As described above, the average value of the height h _f of the continuous reinforcing fiber in the rib is 5% or more of the height h of the protrusion, preferably 10% or more, and more preferably the height of the protrusion. It is 20% or more, more preferably 50% or more, and most preferably 90% or more. When the average value of the heights of the continuous reinforcing fibers is 5% or more, the protrusions can have appropriate strength.
For at least one of the protrusions, the average value of the height h _f of the continuous reinforcing fibers may be 5% or more of the height h of the protrusions, and more than 5% of the two or more protrusions. Preferably, it is most preferably 5% or more in all protrusions.
When there are a plurality of the same kind of protrusions, at least one of the same kind of protrusions may satisfy the average value, and two or more of the protrusions may satisfy the average value. It is most preferable that all of the above satisfy the average value.

The region in which the height of the continuous reinforcing fiber in the protrusion is 5% or more of the height of the protrusion is preferably 20% or more, more preferably 50% or more, particularly preferably 80% of the bottom of the protrusion. % Or more, most preferably 100%. By being 20% or more of the bottom side, it is possible to give the protrusions appropriate strength even if other regions are not continuous.

If a region where no fiber is present in a part of the root in the protrusion is too wide, there is a possibility that it may become a starting point of destruction. Therefore, a portion where no fiber is inserted in the root in each protrusion is 50% or less. Is preferable, more preferably 20% or less, and most preferably 5% or less.

The continuous reinforcing fibers in the protrusions may have a part that is partially broken inside, or may be partly separated from the substrate part. It is preferable that the continuous reinforcing fibers inside the protrusions exist in a continuous state.

The protrusion is formed by inserting a molten or semi-molten composite material into a portion corresponding to the protrusion of the mold by compression molding. At this time, the thermoplastic resin is easier to insert up to the tip of the protrusion than the continuous reinforcing fiber. On the other hand, continuous reinforcing fibers are difficult to move and therefore difficult to insert into the protrusions. However, the longer the insertion distance, the stronger the protrusions. In the molded article of the present invention, a molded article in which continuous reinforcing fibers are inserted deeply into the protrusions can be obtained by adjusting specific compression conditions described later and further by adjusting the mold temperature during molding. The height of the projection is greater than the thickness T ₂ of the substrate portion, and the height of the continuous reinforcing fibers in the projections, the thickness T ₂ or more substrate portions of the molded article is preferred. The height of the protrusions, more preferably 2 times or more the thickness T ₂ of the substrate portion, and further preferably not less than 3 times the thickness T ₂ of the substrate portion.

Furthermore, the height h of the protrusion is at least twice the thickness T ₂ of the substrate portion, and it is preferable the thickness T ₁ of the root of the protrusion is less than the thickness T ₂ of the substrate portion.

It is preferable that the thermoplastic resin in the protrusion and the thermoplastic resin in the substrate are the same. In general, when creating a molded article having a rib or boss shape using a continuous reinforcing fiber composite material, the boss or rib portion is made of a material different from the continuous reinforcing composite material installed for forming the substrate portion, for example, a tape shape. In general, hybrid molding is used in which the substrate is formed by compression molding, the substrate portion is mainly formed by compression molding, and the protrusions of the bosses and ribs are formed by injection molding. Although it is possible to use these methods in the present invention, it is easier and more economical in terms of productivity and equipment to form the protrusions with only a single continuous reinforcing fiber composite material that forms the substrate part. The effect is also high. Furthermore, by forming the protrusions with only a single continuous reinforcing fiber composite material, the thermoplastic resin of the substrate part and the protrusions is basically formed of the same material. There is no interface of the thermoplastic resin material. This is important in securing the strength of the protrusion.

When the substrate part and protrusions of the molded body are made of the same fiber-reinforced thermoplastic composite material as described above, basically the material placed on the substrate part is inserted into the protrusions by compression molding. Formed. At this time, continuous reinforcing fibers are also inserted into the protrusions, but the strength of the joints between the protrusions and the substrate part is important as a structural member, and the density Vf of the continuous reinforcing fibers is closer to the substrate part than the tip of the protrusion part. Higher is preferable. *

[Compression molding method]
An embodiment of the compression molding method of the present invention will be described. FIG. 9 shows a schematic perspective view of the compression molding method.
One embodiment of the compression molding method of the present invention is a compression method in which a continuous fiber-reinforced thermoplastic resin composite material comprising continuous reinforcing fibers and a thermoplastic resin is compression-molded to obtain a molded product having a substrate portion and a protruding portion. A molding method,
The continuous fiber reinforced thermoplastic resin composite material is inserted into a mold, and while the mold is compressed, the mold is heated to a temperature higher than the glass transition temperature or the melting point of the thermoplastic resin, and then molded. Glass transition temperature −10 ° C. or lower or melting point −10 ° C. or lower, preferably glass transition temperature −30 ° C. or lower or melting point −50 ° C. or lower, more preferably glass transition temperature −50 ° C. or lower or melting point −100 ° C. or lower A compression molding process for solidifying the thermoplastic resin;
And a step of releasing a gas component in the mold generated from the continuous fiber reinforced thermoplastic resin composite material out of the mold during the compression molding process. Hereinafter, specific description will be given with reference to the drawings.

First, as shown in FIG. 9a, the mold 100 including the

mold parts

10 and 20 is opened.
Next, as shown in FIG. 9 b, the cloth 70, which is a cloth-like base material that is a composite material, is cut into a desired shape and inserted into the cavity 30.

<Compression molding process>
-Heating process-
Next, as shown in FIG. 9c, the mold 100 is closed (clamped), and the temperature of the cavity surface is raised while being compressed. The temperature of the cavity surface of the mold is set to be equal to or higher than the melting point of the thermoplastic resin constituting the composite material or the glass transition temperature, and is always adjusted to a constant temperature by the second temperature adjusting means 14 and 24 described later. . The thermoplastic cavity portion of the fabric set in the cavity is quickly melted by the heated cavity surface. The number of fabrics 70 to be inserted into the cavity 30 is adjusted according to the desired thickness of the obtained molded product.

Here, the composite material may be inserted at room temperature into the mold, but may be preheated before being inserted into the mold. In particular, when a plate-like prepreg is used as the composite material, it is preferable to preheat the composite material to a glass transition temperature of the thermoplastic resin of −30 ° C. or higher or a melting point of −30 ° C. or higher. It is more preferable to preheat to above or above the melting point. When a fabric-like material is used for the composite material, it may be preheated or not preheated before being inserted into the mold, as is the case with the plate material. By preheating, it is possible to remove the gas component in the fabric and improve the shapeability.

The temperature of the mold cavity surface when molding by compression molding is a glass transition temperature of the thermoplastic resin of −100 ° C. or higher and a glass transition temperature of + 100 ° C. or lower, or a melting point of −100 ° C. or higher and a melting point of + 100 ° C. or lower, preferably Glass transition temperature −50 ° C. or higher and glass transition temperature + 50 ° C. or lower, melting point −50 ° C. or higher and melting point + 50 ° C. or lower, more preferably glass transition temperature −30 ° C. or higher and glass transition temperature + 30 ° C. or lower, melting point −30 ° C. or higher and Melting point + 30 ° C. or lower.

-Temperature increase / decrease rate-
In the present invention, high cycle molding is preferred in which the cavity surface of the mold can be rapidly heated and cooled rapidly. The heating rate when heating the mold in the compression molding process is 30 ° C./min or more, the cooling rate when cooling the mold is 30 ° C./min or more, and the difference between the heating temperature and the cooling temperature Is 80 ° C. or higher. The heating rate is 80 ° C./min or more, the cooling rate is 100 ° C./min or more, and the difference between the heating temperature and the cooling temperature is preferably 100 ° C. or more, and the heating rate is 150 ° C./min. More preferably, the cooling rate is 200 ° C./min or more, and the difference between the heating temperature and the cooling temperature is 120 ° C. or more.
Productivity can be increased by setting the temperature raising rate and the temperature lowering rate to 30 ° C./min or more. Further, by setting the temperature difference to 80 ° C. or more, the impregnation property of the reinforced continuous fiber of the resin, the solidification property when the molded product is taken out, and the release property are improved. The higher the temperature, the better the impregnation, and the lower the temperature, the better the solidification and release properties.

Here, the heating temperature and the cooling temperature are temperatures set as targets when rapid heating or rapid cooling is performed. The target temperature for rapid heating is called the target high temperature, and the target temperature for rapid cooling is called the target low temperature. The temperature decreasing rate is a rate at which the mold cavity surface is cooled from the target high temperature to the target low temperature. The temperature increase rate is a rate at which the temperature of the cavity is increased from the target low temperature to the target high temperature.

The cavity surface is melted by rapidly heating the cavity surface above the melting point or glass transition temperature of the thermoplastic resin constituting the continuous fiber reinforced thermoplastic resin composite material, and then the cavity surface is heated while the mold is clamped. By rapidly cooling below the melting point or glass transition temperature of the plastic resin to cool and solidify the thermoplastic resin, it is possible to obtain a thermoplastic resin fiber composite molded article excellent in economic efficiency at a high cycle.

-Cooling and solidification process-
Next, with the mold clamped, the cavity surfaces 31 and 32 of the mold 100 may have a glass transition temperature of −10 ° C. or lower or a melting point of −10 ° C. or lower, preferably a glass transition temperature of −30 ° C. or lower. The thermoplastic resin is solidified by cooling to a melting point of −50 ° C. or lower, more preferably a glass transition temperature of −50 ° C. or lower or a melting point of −100 ° C. or lower.

-Gas release process-
The gas component generated from the fabric 70 is discharged out of the mold in the steps from inserting the fabric 70 to solidifying the thermoplastic resin. In the compression molding method, unlike the injection molding, a multistage compression method in which the mold clamping force is once released at any stage is particularly effective in the stage of mold clamping. In particular, in the compression molding method that variably changes the temperature of the mold, which is an embodiment of the present invention, the protrusion of the composite material is heated to a constant temperature and the gas is released when the gas is generated. It is effective for producing a complex shape product having

The “stage where gas is generated” is a stage where the composite material inserted into the mold is heated to a certain temperature. The preferable heating temperature is “melting point−100 ° C. or higher or glass transition temperature−100 ° C. More preferably, “melting point −60 ° C. or higher or glass transition temperature −60 ° C. or higher”.

As another form of releasing the gas in the mold, there is a method of evacuating the mold and removing the gas generated from the composite material.
As a method for removing the gas generated in the mold, the following method can be cited in addition to the method for adjusting the compression pressure at the time of mold compression as described above. For example, there may be mentioned a method of removing gas by providing a gas vent slit communicating with the mold cavity. The slit may be provided on the parting surface of the mold, or may be provided on the mold protruding pin. Furthermore, a dividing surface of a mold constituting the mold cavity may be used.

Next, as shown in FIGS. 9d and 9e, the mold 100 is opened and the molded product 71 is taken out. The temperature for taking out the molded product is preferably a glass transition temperature of −30 ° C. or lower or a melting point of −80 ° C. or lower, more preferably a glass transition temperature of −50 ° C. or lower or a melting point of −100 ° C. or lower.

After taking out the molded product, the cloth, which is a composite material, is cut into a desired shape, inserted into the cavity, and the mold is closed. Thereafter, the compression molding process is repeated to produce a molded product.

It is also possible to raise the temperature of the mold cavity surface by flowing high-pressure heating steam or low-pressure superheated steam through the cooling medium passage of the mold at the same time as or after taking out the molded article.
Furthermore, the cavity surface may be heated by circulating superheated steam at 300 ° C. or higher through the cavity surface before insertion of the fabric.

It is also possible to directly heat the substrate by inserting superheated steam at 300 ° C. or higher from the vacuum line into the cavity after inserting the fabric into the cavity. The superheated steam inserted into the mold can be removed from the vacuum line after insertion for a desired time.

According to the compression molding method of the present embodiment, since the compression molding process includes a step of releasing a gas component, the composite material enters deep into the protrusions, so that the thermoplastic resin fiber composite molded article having excellent strength is obtained. Can be obtained.

Next, another embodiment of the compression molding method of the present invention will be described.
The present embodiment includes a step of inserting the composite material into a recess corresponding to the protrusion of the mold, instead of the gas releasing step of the compression molding method of the above-described embodiment.
That is, the compression molding method of the present embodiment is a compression molding method in which a thermoplastic resin composite material composed of continuous reinforcing fibers and a thermoplastic resin is compression-molded to obtain a molded product having a substrate portion and a protruding portion. ,
When inserting the continuous fiber reinforced thermoplastic resin composite material into the mold, insert at least part of the continuous fiber reinforced thermoplastic resin composite material into the recess corresponding to the protrusion of the mold and heat the mold while compressing. Molding is performed by heating above the glass transition temperature or melting point of the plastic resin, and then cooling the mold to the glass transition temperature of the thermoplastic resin at −10 ° C. or below or the melting point −10 ° C. or below to solidify the thermoplastic resin. It is characterized by this.

In order to insert the continuous reinforcing fiber into the protrusion, there are a method in which the thermoplastic resin melts and flows in the mold and flows together, and a method in which at least a part of the composite material is inserted in the protrusion in advance. .

As a method for inserting a part of the continuous fiber reinforced thermoplastic resin composite material into the concave portion of the mold, for example, when a plurality of fabrics are used in a stacked manner, the number of fabrics suitable for the desired molded product thickness is used as the mold cavity. However, it is possible to insert at least one of them into a mold and push it into the recess using a thin metal plate or the like.

The composite material may be inserted into at least one of the plurality of recesses, and more preferably two or more.
Furthermore, it is sufficient that it is inserted into at least one of the same type of recesses, more preferably two or more, and most preferably inserted into all of the same type of recesses.

The insertion amount of the continuous fiber reinforced thermoplastic resin composite material into the recess of the mold varies depending on the volume of the recess and the details of the manufacturing conditions, but the average value of the height of the continuous reinforcing fiber is 5% of the height of the protrusion. It is preferable to adjust so that it may become above. Further, it is preferable to adjust so that the composite material is continuous with the continuous reinforcing fiber inside the substrate portion at 20% or more of the bottom side of the protrusion.

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

[Hybrid molding]
The compression molding method of the present invention can be used as a hybrid molding method by further combining an injection molding process. FIG. 10 shows a schematic diagram of hybrid molding. Elements similar to those in FIG. 9 are denoted by the same reference numerals and description thereof is omitted (the same applies hereinafter).
As shown in FIGS. 10a and 10b, the fabric 70 is inserted in the same procedure as the compression molding method.
As shown in FIG. 10c, a mold part 201 of a mold 200 for performing hybrid molding is provided with a runner part 90 for filling a thermoplastic resin from an injection molding machine 80 by a known method.
After filling with the thermoplastic resin, the mold is released as shown in FIG. 10d, and the hybrid molded product 72 composed of the fabric 70 and the thermoplastic resin 81 is taken out as shown in FIG. 10e.
In this hybrid molding method, before filling the thermoplastic resin with an injection molding machine, a step of releasing the gas generated in the mold exemplified in the first embodiment may be provided. As a specific method for releasing the gas, the method of the above embodiment can be used in the same manner.

[Mold]
Next, an embodiment of a mold that can be used in the compression molding method of the present invention will be described with reference to the drawings. The metal mold | die which can be used for the compression molding method of this invention is not limited to what is demonstrated below. FIG. 11 shows a schematic cross-sectional view of an embodiment of a stamping die.
As shown in FIG. 11, the mold 100 includes a mold part 10 that is an upper mold, a mold part 20 that is a lower mold, and heat insulating

plates

15 and 25. A cavity 30 is formed by the mold part 20. A composite material or the like is placed in the cavity 30 to mold a molded product.

The mold part 10 includes a first temperature adjusting unit 13 including a plurality of cooling medium passages capable of cooling at least the cavity surface 31 in the vicinity of the cavity surface 31, and a cavity surface 31 of the first temperature adjusting unit 13. On the opposite side, a second temperature adjusting means 14 comprising a plurality of rod-shaped cartridge heaters capable of at least heating the cavity surface 31 is provided.
Similarly, the mold portion 20 also includes a first temperature adjusting means 23 including a plurality of cooling medium passages capable of cooling at least the cavity surface 32 in the vicinity of the cavity surface 32, and a cavity of the first temperature adjusting means 23. On the opposite side of the surface 32, a second temperature adjusting means 24 comprising a plurality of bar-shaped cartridge heaters capable of at least heating the cavity surface 32 is provided.

The mold part 10 has a structure divided into a first part 11 having a first temperature control means 13 and a second part 12 having a second temperature control means 14, and the first part 11 and the second part 12. However, the spring 40 can be separated.
Similarly, the mold part 20 has a structure divided into a first part 21 having a first temperature adjusting means 23 and a second part 22 having a second temperature adjusting means 24. The second portion 22 is configured to be separated by a spring 40.

The mold part 20 is provided with a decompression path 33 for decompressing the cavity 30 during mold clamping. The decompression path 33 is connected by a vacuum line 60 to decompression means (not shown) installed outside the molding die. A sealing packing 50 is provided between the mold part 10 and the mold part 20.

Next, the details of the mold part will be described with reference to FIG. FIG. 12 is a schematic cross-sectional view for explaining details of the mold, and some components are omitted.
As shown in FIG. 12, the

mold portions

10 and 20 have a distance L0 from the cavity surface 31 to the first temperature adjusting means 13, and a distance L1 from the cavity surface 31 to the surface 16 opposite to the cavity surface 31. It is preferable that the following relationship is satisfied.
(L1 / L0)> 3

When the molding die is composed of a plurality of mold parts, it is sufficient that at least one mold part satisfies the above numerical range, and it is more preferable that all the mold parts satisfy the above numerical range.

Here, the distance L0 from the cavity surface to the first temperature adjusting means means the distance from the cavity surface to the center of the first temperature adjusting means in a cross section perpendicular to the cavity surface of the mold.
Further, the distance L2 from the first temperature adjusting means to the second temperature adjusting means is the second temperature adjusting means from the center of the first temperature adjusting means in the cross section perpendicular to the cavity surface of the mold. Means the distance to the center of
Further, the distance L1 from the cavity surface to the surface opposite to the cavity surface means a distance in a cross section perpendicular to the cavity surface of the mold.

When the cavity surface has an uneven shape and the distance from the cavity surface to the first temperature adjusting means varies depending on the location, the distance L0 from the cavity surface to the center of the first temperature adjusting means is the shortest distance among them. Means.
Further, when the cavity surface has an uneven shape and the first temperature adjusting means is provided at the same distance from the cavity surface along the uneven shape, the first temperature adjusting means to the second temperature adjusting means. The distance L2 is different depending on the location. In this case, the distance L2 from the first temperature adjusting means to the second temperature adjusting means means the shortest distance among different L2.
In addition, when the cavity surface is uneven, the distance L1 from the cavity surface to the surface opposite to the cavity surface means an average distance of different L1.

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

Further, when the first part and the second part are integrally formed of the same material, the boundary between the first part and the second part is the second from the center of the first temperature control means in the cross section perpendicular to the cavity surface. The position is L0 away from the temperature adjusting means side.

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

The first temperature control means is preferably closer to the cavity surface, but it is necessary to provide it at a certain distance due to the strength of the mold and design restrictions. The distance L0 from the cavity surface to the first temperature adjusting means is preferably 30 mm or less, more preferably 20 mm or less, and even more preferably 10 mm or less, although it depends on the size of the first temperature means. Although there is no particular limitation on the lower limit value of L0, although it depends on the size of the first temperature means, the distance from the end of the first temperature means to the mold cavity surface is limited due to restrictions on the strength of the mold. 3 mm or more is preferable and 6 mm or more is more preferable.

In the mold of the present embodiment, the relationship between the distance L0 from the cavity surface to the first temperature adjusting means and the distance L1 from the cavity surface to the surface opposite to the cavity surface is (L1 / L0)> 3. More preferably, (L1 / L0)> 5, and most preferably (L1 / L0)> 10.
By setting (L1 / L0)> 3, the capacity of the heat storage part, which is higher than that of the cooling part, is increased, so that rapid heating at the time of mold heating can be performed efficiently. Furthermore, the closer the first temperature control means for cooling is to the cavity surface, the quicker the molded product can be cooled during cooling. Further, the smaller the cooling portion, the quicker the mold can be heated when the mold is heated.
Here, a cooling part is a part cooled by the 1st temperature control means, Comprising: At least 1st part is shown. Further, the heat storage portion is a portion heated by the second temperature adjusting means and indicates at least the second portion.

Furthermore, the distance L2 from the first temperature adjusting means to the second temperature adjusting means is L2> L0, and preferably 2 <L2 / L0 <10.
By setting L2> L0, it is possible to satisfactorily prevent cooling to the second temperature adjusting means at the time of cooling, while preventing disturbance of the control power of the second temperature adjusting means at the time of heating. Can do.
In temperature control of the cavity surface, when the temperature above and below the cavity temperature is slight, L0 and L2 should be as close as possible. However, when molding a composite material, the difference between the upper limit value and the lower limit value of the mold cavity temperature is as large as, for example, 50 ° C. or more, preferably 100 ° C. or more, and more preferably 150 ° C. or more. It is preferable.

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

Moreover, in the case of the structure provided with the 1st part which has a cooling medium channel | path which is a 1st temperature control means, and the 2nd part which has a 2nd temperature control means, as shown in FIG. The relationship between I) and the volume V0 of the mold part to be heated is preferably (V0 / V (I))> 1.3. Further, (V0 / V (I)) <3 is preferable. In order to rapidly heat and cool the first part, it is better to make V (I) smaller, and the volume V (II) of the second part is better from the viewpoint of accumulating heat. /V(I))>1.3 is preferred. On the other hand, the volume of V (I) is limited in reducing the volume due to problems such as mold strength and cavity surface shape constraints. If the volume V (II) of the second part is too large, there are limitations due to problems such as long time for initial heating or large release of heat out of the mold. Further, the reduction of V (I) is limited due to limitations due to strength and cavity shape, and (V0 / V (I)) <3 is preferable.
That is, the heating of the cavity surface can rapidly heat and melt the thermoplastic resin of the material installed in the cavity by rapidly supplying the cavity surface by supplying heat from the second part that serves as a heat storage part that stores a certain amount of heat. . Here, the larger the capacity of the heat storage portion, the more effectively the cavity surface can be heated. However, the capacity of the heat storage portion can be appropriately determined according to the size of the mold and the molding equipment from the viewpoint of the amount of energy consumed for heating due to the equipment.

That is, the heating of the cavity surface can heat and melt the thermoplastic resin of the material installed in the cavity by rapidly heating the cavity surface by supplying heat from the second part having the role of a heat storage part that stores a certain amount of heat. .
On the other hand, for cooling the cavity surface, for example, when the first temperature adjusting means is a plurality of cooling medium passages, the cavity surface is rapidly cooled by circulating the cooling medium through the cooling medium passages near the cavity surface. The molten thermoplastic resin can be cooled and solidified. At this time, in order to cool only the vicinity of the cavity surface, it is preferable that the mold capacity of the portion having the refrigerant passage is smaller, and the cooling medium passage is preferably closer to the cavity surface.

The same material may be used for the first part and the second part, but materials having different thermal conductivities may be used. Volume V (I) of the first part and the thermal conductivity C (I) (J / s · m · K) of the material of the first part, and Volume V (II) of the second part and the heat conduction of the material of the second part The rate C (II) (J / s · m · K) is preferably
{V (II) × (1 / C (II))} / {V (I) × (1 / C (I))}> 3
More preferably, {V (II) × (1 / C (II))} / {V (I) × (1 / C (I))}> 5
Most preferably, {V (II) × (1 / C (II))} / {V (I) × (1 / C (I))}> 10
It is.
By setting {V (II) × (1 / C (II))} / {V (I) × (1 / C (I))}> 3, the cavity surface can be quickly cooled during cooling. During heating, the temperature can be quickly raised by heat storage in the second part.

Further, the thermal conductivity C (I) (J / s · m · K) of the material of the first part is equal to the thermal conductivity C (II) (J / s of the material of the second part having the second temperature adjusting means. -It is preferable that it is 3.5 times or more of m * K). That is, the higher the thermal conductivity during cooling, the faster the cooling, and the higher the thermal conductivity during heating, the quicker the heat can be removed from the heat storage section. In particular, a higher effect can be obtained by separating the first portion when it is cooled. When not separating at the time of cooling, if the thermal conductivity of the first part is good, the second part having the function of the heat storage part may be cooled at the time of cooling, and it is necessary to optimize the material appropriately.

More preferably, the first part and the second part have a separable structure. After the cavity is heated to a desired temperature, the mold is slightly opened while the cavity is closed to separate the first part 11 and the second part 12, and the first part 21 and the second part 22. It is also effective to increase the molding cycle by providing a heat insulating layer.
As a concrete method, the first part and the second part can be separated while the cavity is closed by inserting the spring 40 between the first part and the second part to slightly open the mold. Can do. Separation may be performed with at least one of the plurality of mold parts.

¡Cooling water is injected into the cooling medium passage etc. with the mold separated, and the first part including the metal mold is rapidly cooled. At this time, the mold cavity surface is kept closed by using a spring or a hydraulic cylinder so as not to open the cavity. The cooling water is stopped after the mold cavity surface has become below the heat deformation temperature of the thermoplastic resin for a certain time, compressed air is introduced into the cooling medium passage as necessary, and the water in the cooling medium passage is discharged.

The cooling of the first part can be achieved by circulating the cooling medium when the first temperature control means is constituted by a plurality of cooling medium passages. It depends on whether or not rapid cooling is possible.
Therefore, it is preferable to have a structure that allows the cooling medium to flow through each cooling medium passage independently. As a specific example, a manifold capable of simultaneously circulating a cooling medium having the same temperature can be given. The manifold may be installed on the inflow side of the cooling medium passage outside the mold, and the cooling medium may be simultaneously circulated from the manifold to each cooling medium passage. Further, if the manifold is installed on the cooling medium discharge side and discharged, More efficient.
The flow rate greatly affects the cooling efficiency, and the refrigerant may be circulated using a pressure pump or the like as necessary. It is also possible to use a commercially available pressurized temperature controller.

Water, chiller liquid, carbon dioxide gas, compressed gas, etc. can be raised as a medium to circulate in the cooling medium passage. Further, one type of medium may be used, but media having different temperatures may be distributed in multiple stages. For example, when the cavity temperature is heated to 300 ° C., 150 ° C. pressurized hot water flows for several seconds, then 60 ° C. temperature-controlled water and 10 ° C. cooling water flow in multiple stages, and the mold reaches a constant temperature. Then, it may be adjusted so that the cavity surface has a uniform temperature by flowing pressurized hot water at 150 ° C. again.

When a composite material is placed in a cavity and heat compression molding is performed in the cavity to melt and solidify the thermoplastic resin of the composite material to obtain a molded product, it is possible to obtain a molded product capable of impregnating the thermoplastic resin into continuous reinforcing fibers. The characteristics are greatly affected. When air is present in the mold, the air remains as voids in the molded product when the thermoplastic resin melts, causing a fine unimpregnated portion to be formed in the continuous reinforcing fibers. By removing the gas bodies generated from these air and resin in the mold, a molded product impregnated with the thermoplastic resin can be obtained more quickly. As a method for releasing the gas component generated in the mold, a pressure reducing path that can reduce the pressure of the cavity to a vacuum during mold clamping may be provided. After the mold is closed and the composite material is heated at a high temperature, the mold pressure is May be released once to release the gas component generated from the composite material out of the mold.

The mold cavity temperature when the mold pressure is once released is preferably a glass transition temperature of the thermoplastic resin of −50 ° C. or higher, a glass transition temperature of + 50 ° C. or lower, a melting point of −100 ° C. or higher, and a melting point of + 50 ° C. or lower. More preferably, the temperature is −30 ° C. or more and the glass transition temperature + 30 ° C. or less, the melting point is −80 ° C. or more and the melting point + 10 ° C. or less, and the glass transition temperature is −30 ° C. or more and the glass transition temperature or less, the melting point −80 ° C. or more and the melting point or less. preferable. The mold clamping pressure release for degassing may be performed a plurality of times while raising the mold temperature, but at least the first mold pressure release is preferably performed at the glass transition temperature or below or below the melting point.

As one form of use of the mold used in the present invention, it is required to heat the composite material in the mold to melt the thermoplastic resin. Depending on the type of thermoplastic resin, the second temperature adjusting means is the average temperature of the second part, in the case of non-crystalline resin, preferably above the glass transition temperature of the thermoplastic resin material installed in the cavity, preferably It is set to glass transition temperature + 30 ° C. or higher, most preferably glass transition temperature + 50 ° C. or higher. In the case of a crystalline resin, the melting point is set to be equal to or higher than the melting point of the thermoplastic resin material placed in the cavity, preferably higher than the melting point + 30 ° C., and most preferably higher than the melting point + 50 ° C.
The average temperature of the second part is the average temperature of the second part of the mold. As an example of the measuring method, a thermometer is placed in the mold in the vicinity of the second temperature adjusting means and at a position 10 to 30 mm apart. The method of measuring the temperature is used. When a cartridge heater is used as the second temperature control means, the temperature control detects the aforementioned temperature and controls the power on / off or adjusts the capacity of the power by PID control (Proportional-Integral-Differential Controller) There are ways to do it.

There are no particular restrictions on the second temperature control means. In addition to the rod-shaped cartridge heater, there are heaters that use electric resistance even with heating media such as heating oil and water vapor, but the mold is the melting point of the thermoplastic resin. In order to maintain the above high temperature, a heater is preferable from the viewpoint of versatility and performance. Examples of the heater include a ceramic heater and a sheathed heater. A rod-shaped cartridge heater is preferably used in terms of simplicity and performance.

In the present embodiment, the mold part 10 and the mold part 20 have been described so that the first parts 11 and 21 and the

second parts

12 and 22 can be separated from each other, but the spring 40 is not provided. It may be formed integrally with an adhesive or the like.

Since the

heat insulating plates

15 and 25 have a role of suppressing heat flow due to heat conduction to the molding machine, it is preferable to provide them at the connecting portion between the mold 100 and the molding machine.

Although the molding die as described above can be applied to compression molding, a thermoplastic resin can be melt-filled after compression molding by providing a mechanism capable of injection molding as appropriate, for example, a sprue forming part, a runner forming part, etc. It is also applicable to hybrid molding with injection molding.

[Continuous fiber reinforced thermoplastic resin composite]
Continuous fiber reinforced thermoplastic resin composite material consisting of continuous reinforcing fiber and thermoplastic resin is a composite yarn in which continuous reinforcing fiber and thermoplastic resin fiber are mixed uniformly and continuously, and coated with thermoplastic resin on continuous reinforcing fiber Examples of the composite yarn include a composite yarn obtained by impregnating a continuous reinforcing fiber with a thermoplastic resin, a fabric made of the composite yarn, or a plate-like prepreg obtained by impregnating a continuous reinforcing fiber with a thermoplastic resin. The prepreg manufacturing method is not particularly specified, but a powdered material of thermoplastic resin is added to the continuous reinforcing fiber and is preliminarily formed into a plate by hot pressing, or the continuous reinforcing fiber and the thermoplastic resin film are hot pressed. A plate or the like can be used. Furthermore, a continuous reinforcing fiber and a thermoplastic resin fiber are mixed, a mixed yarn is woven, and a fabric is made and heated to a temperature higher than the glass transition temperature or melting point of the thermoplastic resin to impregnate the thermoplastic resin with the reinforcing fiber. A plate-like product obtained by cooling and solidifying can be used.

<Continuous reinforcing fiber>
As the continuous reinforcing fiber, those used as a normal fiber reinforced composite material can be used. For example, glass fiber, carbon fiber, aramid fiber, ultra high strength polyethylene fiber, polybenzazole fiber, liquid crystal polyester fiber, polyketone Examples include at least one selected from the group consisting of fibers, metal fibers, and ceramic fibers. In view of mechanical properties, thermal properties, and versatility, glass fibers, carbon fibers, and aramid fibers are preferable.
When glass fiber is selected as the continuous reinforcing fiber, a sizing agent may be used. The sizing agent is preferably composed of a silane coupling agent, a lubricant and a binding agent.
Regarding the details of the glass fiber and the sizing agent, those described in Patent Document 1 can be used as appropriate.

-Form of continuous reinforcing fiber-
The number of single yarns of continuous reinforcing fibers is preferably 30 to 15,000 from the viewpoints of spreadability and handling properties in the fiber blending process.

When carbon fiber is selected as the continuous reinforcing fiber, the sizing agent is preferably composed of a lubricant and a binding agent.
There are no particular limitations on the type of sizing agent, lubricant, and binding agent, and known materials can be used. As a specific material, the thing of patent document 1 can be used.

When other continuous reinforcing fibers are used, the type and amount of sizing agent used for glass fibers and carbon fibers may be appropriately selected according to the characteristics of the continuous reinforcing fibers. It is preferable to use the kind and the applied amount.

<Thermoplastic resin>
The thermoplastic resin in the present invention refers to all those generally referred to as thermoplastic resins. For example, polystyrene, high impact polystyrene, rubber reinforced styrene resin such as medium impact polystyrene, styrene-acrylonitrile copolymer (SAN resin), acrylonitrile-butyl acrylate rubber-styrene copolymer (AAS resin), acrylonitrile-ethylene Propyl rubber-styrene copolymer (AES), acrylonitrile-polyethylene chloride-styrene copolymer (ACS), ABS resin (for example, acrylonitrile-butadiene-styrene copolymer, acrylonitrile-butadiene-styrene-alphamethylstyrene copolymer) Styrene resin such as acrylonitrile-methyl methacrylate-butadiene-styrene copolymer); acrylic resin such as polymethyl methacrylate (PMMA); low density Olefin resins such as polyethylene (LDPE), high density polyethylene (HDPE), polypropylene (PP); vinyl chloride resins such as polyvinyl chloride and polyvinylidene chloride; ethylene vinyl chloride vinyl acetate copolymer, ethylene vinyl chloride copolymer Polyvinyl chloride resins such as coalescence; Polyester resins such as polyethylene terephthalate (PETP, PET) and polybutylene terephthalate (PBTP, PBT); Polycarbonate resins such as polycarbonate (PC) and modified polycarbonate; Polyamide 66, Polyamide 6, Polyamide Polyamide resins such as 46; polyacetal (POM) resins such as polyoxymethylene copolymers and polyoxymethylene homopolymers; other engineering resins and super engineering resins such as Polyethersulfone (PES), polyetherimide (PEI), thermoplastic polyimide (TPI), polyetherketone (PEK), polyetheretherketone (PEEK), polyphenylene sulfide (PSU), etc .; cellulose acetate (CA), cellulose Cellulose derivatives such as acetate butyrate (CAB) and ethyl cellulose (EC); liquid crystal polymers (LCP) such as liquid crystal polymers and liquid crystal aromatic polyesters; thermoplastic polyurethane elastomers (TPU), thermoplastic styrene butadiene elastomers (SBC), heat Plastic polyolefin elastomer (TPO), thermoplastic polyester elastomer (TPEE), thermoplastic vinyl chloride elastomer (TPVC), thermoplastic polyamide elastomer (TPAE), etc. These thermoplastic elastomers can be mentioned. As the thermoplastic resin in the present invention, the thermoplastic resin as described above may be produced in the molding step of the present invention. You may shape | mold by the method of this invention using the blend body of a 1 type or more thermoplastic resin. The thermoplastic resin may contain a filler and / or an additive.

When the continuous fiber reinforced thermoplastic resin composite material composed of continuous reinforcing fiber and thermoplastic resin is a fabric, the thermoplastic resin is polyolefin resin, polyamide resin, polyester resin, polyether ketone, polyether ether ketone, poly It is preferably at least one selected from the group consisting of ether sulfone, polyphenylene sulfide, and thermoplastic polyetherimide.

-Polyester resin-
The polyester resin means a polymer compound having a —CO—O— (ester) bond in the main chain. Examples thereof include, but are not limited to, polyethylene terephthalate, polybutylene terephthalate, polytetramethylene terephthalate, poly-1,4-cyclohexylene dimethylene terephthalate, polyethylene-2,6-naphthalenedicarboxylate. .
For details of other polyester resins, those described in Patent Document 1 can be used as appropriate.

-Polyamide resin-
The polyamide-based resin means a polymer compound having a —CO—NH— (amide) bond in the main chain. Examples thereof include polyamides obtained by ring-opening polymerization of lactam, polyamides obtained by self-condensation of ω-aminocarboxylic acid, polyamides obtained by condensing diamine and dicarboxylic acid, and copolymers thereof. It is not limited to.
As the polyamide, one kind may be used alone, or two or more kinds may be used as a mixture. Regarding the details of the other lactam, diamine (monomer), and dicarboxylic acid (monomer), those described in Patent Document 1 can be used as appropriate.

Specific examples of polyamides include, for example, polyamide 4 (poly α-pyrrolidone), polyamide 6 (polycaproamide), polyamide 11 (polyundecanamide), polyamide 12 (polydodecanamide), polyamide 46 (polytetramethylene adipa) Amide), polyamide 66 (polyhexamethylene adipamide), polyamide 610, polyamide 612, polyamide 6T (polyhexamethylene terephthalamide), polyamide 9T (polynonamethylene terephthalamide), and polyamide 6I (polyhexamethylene isophthalamide) And copolymerized polyamides containing these as constituents.

Examples of the copolymerized polyamide include a copolymer of hexamethylene adipamide and hexamethylene terephthalamide, a copolymer of hexamethylene adipamide and hexamethylene isophthalamide, and hexamethylene terephthalamide and 2-methylpentanediamine terephthalate. Examples include amide copolymers.

Although the specific manufacturing method of the mixed fiber used for a thermoplastic resin fiber composite material is not restrict | limited, A well-known method can be utilized for the method of mixing. For example, after opening by external force such as electrostatic force, pressure by fluid spraying, pressure applied to rollers, etc., continuous fiber and thermoplastic resin fibers are opened and then combined and aligned. , And fluid entanglement (interlace) methods. Among them, the fluid entanglement method that can suppress damage of continuous reinforcing fibers, has excellent spreadability, and can be mixed uniformly is preferable. As the fluid entanglement method, vortex turbulence caused by fluids such as air, nitrogen gas, and water vapor Create two or more flow zones almost parallel to the yarn axis and guide the fibers into these zones to make non-bulky yarns under tension that does not cause loops or crimps, or continuous reinforcing fibers only Examples include a method of fluid entanglement after opening, or after opening both continuous reinforcing fibers and thermoplastic resin fibers (fluid entanglement after opening). In particular, it is preferable that the thermoplastic resin fiber is subjected to false twisting in a process including thermal processing alone, and then continuously blended by the fluid entanglement method in the same apparatus.
In addition, about the detail of the fiber-mixing method, the method of patent document 2 can be used suitably.

The thermoplastic resin constituting the thermoplastic resin fiber composite material may be one coated with continuous reinforcing fibers in a composite yarn or one impregnated with continuous reinforcing fibers. The coating or impregnation of the thermoplastic resin may be performed at the time of manufacturing the continuous reinforcing fiber, or may be performed in a separate process after the continuous reinforcing fiber is manufactured.

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

The method for obtaining the fabric is not particularly limited, and a known method for producing an appropriate fabric selected according to the use and purpose can be used. For example, the woven fabric may be a loom such as a shuttle loom, a rapier loom, an air jet loom, a water jet loom, etc., and may contain composite yarn at least partially. Preferably, it may be obtained by driving a weft into a warp in which fibers including a composite yarn are arranged. The knitted fabric is obtained by knitting a fiber containing a composite yarn at least partially using a knitting machine such as a circular knitting machine, a flat knitting machine, a tricot knitting machine, or a Raschel knitting machine. Non-woven fabric is a sheet-like fiber assembly called a web made of fibers containing at least a part of composite yarn, followed by physical action such as a needle punch machine, stitch bond machine, column flow machine, etc. It is obtained by bonding fibers with an agent.
For other forms of the fabric and the like, the method described in Patent Document 1 can be used as appropriate.

In addition, there are water jet cutters, laser cutters, plotter cutters, ultrasonic cutters, super steel blade press cutters, hot blade press cutters, etc. as methods for cutting the fabric into a desired shape. From the surface, a hot blade press cutter is preferable. The temperature of the blade of the hot blade press cutter is appropriately set depending on the material, but it is not less than the melting point or glass transition temperature of the thermoplastic resin, preferably not less than the melting point + 30 ° C. or glass transition temperature + 30 ° C., more preferably not less than the melting point + 70 ° C. Or it is glass transition temperature +70 degreeC or more.

By the way, when a fabric or prepreg made of a continuous fiber reinforced thermoplastic resin composite material is cut by the above-described water jet cutter or laser cutter before being inserted into a mold, the following problems may occur. That is, when a water jet cutter is used, the abrasive mixed with water may adhere to the composite material or the abrasive may enter the interior, thereby reducing the quality of the composite material. Moreover, when using a laser cutter, the thermoplastic resin of a cutting edge part may be burnt, and the physical property fall of the composite material after shaping | molding may be caused.

In order to prevent the above-mentioned problem, the cut surface of the continuous fiber reinforced thermoplastic resin composite material is cut while melting the thermoplastic resin with a blade having a temperature equal to or higher than the melting point of the thermoplastic resin, and the molten thermoplastic material is cut. It is desirable to solidify the resin.

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

The molecular weight of the thermoplastic resin melted and solidified is measured from a composite material (sample) collected from the cut surface. Specifically, a sample that is cut out from the surface of the cut surface within a thickness region of 500 μm at an arbitrary position of the central portion of the cut surface (the portion excluding the width of 1 mm from the periphery of the cut surface) is used as a sample. This sample was dissolved in 1,1,1,3,3,3-hexafluoro-2-propanol to remove insoluble continuous reinforcing fibers, and the 1,1,1,3,3,3-hexafluoro- The molecular weight of the thermoplastic resin in a state of being dissolved in 2-propanol is measured by a gel permeation chromatography (GPC) apparatus, and the molecular weight of the thermoplastic resin melted and solidified. Similarly, the molecular weight of the thermoplastic resin itself constituting the composite material can be dissolved in 1,1,1,3,3,3-hexafluoro-2-propanol and measured with a gel permeation chromatography (GPC) apparatus.

If the molecular weight of the thermoplastic resin melted and solidified on the cut surface is 20% or more of the molecular weight of the thermoplastic resin itself constituting the composite material, the physical properties of the composite material can be prevented from being lowered, and the cut surface can be processed. Is possible. Within the range of 20% or more, more preferably 40% or more, and further preferably 50% or more.

In the composite material formed as described above, the continuous reinforcing fibers and the thermoplastic resin are continuously and uniformly mixed, and the continuous reinforcing fibers can be uniformly fixed to the thermoplastic resin. Therefore, it is preferable that the composite material includes a composite yarn shape of continuous reinforcing fiber and continuous thermoplastic resin. By using this composite yarn shape, the handleability is excellent in processes such as knitting to form a fabric, and the resulting fabric can be a composite material molded body that exhibits sufficient mechanical properties even in a short time.

In the cutting and melting step, it is desirable to cut the composite material while melting the thermoplastic resin by applying a thermal history with a blade having a temperature equal to or higher than the melting point of the thermoplastic resin. The temperature of the blade is equal to or higher than the melting point of the thermoplastic resin, preferably 50 ° C. higher than the melting point, and more preferably 75 ° C. higher. In addition, it is preferable that the temperature of a blade is below melting | fusing point +150 degreeC from a viewpoint of deterioration of a thermoplastic resin. Examples of the blade include Swedish steel blades, Thomson blades, and super steel blades, and blades made of a material having high hardness and rigidity are preferable.

By cutting a composite material composed of continuous reinforcing fibers and a thermoplastic resin with a blade heated above the melting point of the thermoplastic resin, the composite material is cut and cut while melting the thermoplastic resin. A surface is generated, and the cut surface becomes a cut surface by solidifying the melted thermoplastic resin, whereby a composite material in which the end surface is not loosened can be manufactured.

[Example 1]
(Mold)
The mold shown in FIGS. 11 and 13 was used as the mold. 13 is a cross-sectional view of the first part of the mold of FIG. 11 and corresponding to the AA ′ cross-sectional view of the molded product of FIG. As shown in FIG. 13, the mold used in this embodiment has first temperature adjusting means 313, 323 in the

first parts

310, 320 of the mold, and ribs (403, 405, 407) of the molded product of FIG. ) And a recess corresponding to the truncated cone 412. Since the

second portions

12 and 22 having the second temperature adjusting means 14 and 24 of the mold are the same as those in FIG.
The

first portions

310 and 320 having the cooling

medium passages

313 and 323 are made of Corson alloy (Matelion Brush, Mold Max-V) having a thermal conductivity of 165 J / s · m · K, and the rod-shaped

cartridge heaters

14 and 24 are provided. Carbon steel (S55C) having a thermal conductivity of 40 J / s · m · K was used as the mold parts (10 and 20). The volume V0 (V0 / V (I)) of the substantially heated mold part with respect to the volume V (I) of the first part is 10.
The cooling

medium passages

313 and 323 are provided at an interval of 20 mm (L) at a position where the inner diameter is 8 mm and the distance L0 from the center to the cavity surface is 15 mm.
As the second temperature control means 14 and 24, a bar cartridge heater (trade name “GLE4103”, capacity 1000 W, φ10 mm × 400 mm, watt density 8.3 W / cm ² ) manufactured by Yako Electric Co., Ltd. was used.
The distance L2 from the center of the cooling medium passage to the center of the rod-shaped cartridge heater is 30 mm.

(Base material)
Glass fibers of 400 single yarns with a fineness of 685 dtex to which 1.0% by mass of the following sizing agent A was attached were used as continuous reinforcing fibers.
Composition of sizing agent A (solid content conversion):
Silane coupling agent: 0.6% by mass of γ-aminopropyltriethoxysilane [trade name: KBE-903 (manufactured by Shin-Etsu Chemical Co., Ltd.)]
・ Lubricant: 0.1% by weight of wax [Brand name: Carnauba wax (manufactured by Hiroyuki Kato)]
・ Binder: 5% by mass of acrylic acid / maleic acid copolymer salt [trade name: Aqualic TL (manufactured by Nippon Shokubai Co., Ltd.)]

As the thermoplastic resin fibers, polyamide 66 fibers (trade name: Leona (registered trademark) 470/144 BAU (manufactured by Asahi Kasei Fibers Co., Ltd.), fineness 470 dtex, number of single yarns 144) not subjected to entanglement treatment were used.

Two bundles of glass fibers with a fineness of 685 dtex and 400 single yarns and two bundles of PA (polyamide) fibers with a fineness of 470 dtex are combined and aligned, then supplied substantially vertically to the fluid entanglement nozzle and fluid entangled under the following conditions Thus, a composite yarn was obtained.
-Fluid entanglement nozzle: Kyocera KC-AJI-L (1.5 mm diameter, propulsion type)
・ Air pressure: 2kg / cm ²
Processing speed: 30 m / min Using a composite yarn as warp and weft, a woven fabric (fabric) having a warp density of 6/5 mm and a weft density of 6/5 mm was woven. There was no generation of fluff or fibrils during weaving, and no lint or fluff was observed on the loom, and weaving was good.

The fabric was cut into 7 sheets so as to be suitable for the shape of the desired compression molded product. Furthermore, using a hot blade heated to a temperature of 330 ° C., six of the seven sheets were stacked and cut. The cut surface was fused and a base material excellent in handling was obtained.

(Compression molding)
A molded article was produced by the compression molding method shown in FIG. 9 according to the following procedure.
The molding machine used was Toshiba Machine (S100V-8A) with a maximum clamping force of 300 tons.
The detailed conditions of the mold, the base material, and each process are shown in Table 1.

[Step 1] (Fabric setting and mold clamping) The mold is opened, and one of the seven fabrics cut into the desired shape is inserted into the mold and the recess corresponding to the rib of the mold All of these were inserted to the depth of the tip of the rib using a thin metal plate. Next, the six stacked fabrics were set at a predetermined position in the mold when the mold temperature was 150 ° C., and clamped with a clamping force of 240 MPa.
[Step 2] (Mold heating) With the mold clamped, the cavity surface is rapidly heated to 300 ° C. using a cartridge heater, and the polyamide resin constituting the fabric is melted in the mold, and the glass fiber Was impregnated.
[Step 3] (Mold Separation, Cooling) The mold clamping force was lowered, and the cavity surface was rapidly cooled by passing cooling water at 25 ° C. through the cooling medium passage with the cavity closed.
Water flow was stopped 5 seconds after the temperature of the cavity surface reached 150 ° C., the mold was opened 10 seconds after the water flow stopped, and water in the cooling medium passage was simultaneously discharged with compressed air.
[Step 4] (Release) Immediately after releasing the mold, the molded product was taken out and returned to Step 1.
The obtained molded product 400 had an outer size of 250 mm × 250 mm and a wall thickness of 2 mm.

[Example 2]
Using the same mold as in Example 1, a molded product was produced in the same manner as in Example 1 except for the following.
As the cloth, seven sheets were stacked and cut with a hot blade, and seven sheets were stacked and inserted into the mold cavity without being pushed into the rib. As a forming method, when the cavity surface reached 240 ° C. between [Step 1] and [Step 2] instead of pushing the fabric into the recess corresponding to the rib of the mold in [Step 1] of Example 1. The degassing was performed using a dimension opening mode in which the mold clamping pressure was released for 0.5 seconds. Thereafter, molding was performed again by applying a clamping force of 240 MPa.

[Example 3]
The same base material as in Example 1 is used, the protrusions other than the substrate and ribs are formed from the base material, and the rib part is a mold that can be formed by injection molding, except for the following steps, as in Example 1. A molded product was produced.
[Step 1] (Set of fabric and mold clamping) Open the mold, prepare 7 sheets of fabric cut into the desired shape and cut with a hot blade, do not push into the rib, Seven sheets were stacked, set at a predetermined position in the mold when the mold temperature was 150 ° C., and clamped with a mold clamping force of 240 MPa.
[Step 2] (Injection molding) A resin composition of polyamide 66 resin [trade name: Leona (registered trademark) 14G50] containing 50% short fibers GF only in the rib portion in a state where the mold is clamped, is set to a cylinder set temperature. Injection filling was performed at 290 ° C., an injection pressure of 20 MPa, an injection speed of 50 mm / sec, and an injection holding pressure of 20 MPa was applied.
[Step 3] (Temperature rise) With the mold clamped, the cavity surface is rapidly heated to 300 ° C. using a cartridge heater, and the polyamide resin constituting the fabric is melted in the mold to produce glass fibers. The injection resin composition and the fabric were joined simultaneously with the impregnation.
[Step 4] (Mold separation, cooling) With the mold clamping force lowered and the cavity closed, each of the first part and the second part is separated by 5 mm, and 25 ° C cooling water is passed through the cooling medium passage. The cavity surface was cooled rapidly. The amount of cooling water during cooling was 15 L / min.
Water flow was stopped 5 seconds after the temperature of the cavity surface reached 150 ° C., the mold was opened 10 seconds after the water flow stopped, and water in the cooling medium passage was simultaneously discharged with compressed air.
[Step 5] (Release) Immediately after mold release, the molded product was taken out and returned to Step 1.

[Example 4]
[Step 1] (Preparation of prepreg) A prepreg plate was prepared in advance by the following procedure using the same fabric as in Example 1 as a substrate. 7 sheets of fabric are sandwiched between two steel plates with a 3.0mm thick formwork, then placed in a compression molding machine heated to 300 ° C and heated for 10 minutes at a compression force of 5MPa, then transferred to a cooling plate and cooled for 5 minutes Then, a prepreg of a plate material having a thickness of 3 mm was produced.
The plate material was heated using an infrared heater, and after 7 minutes, the surface temperature of the plate material reached 300 ° C. and continuously heated for 3 minutes. And compression molded.
The obtained molded product was 250 mm × 250 mm and the wall thickness was 2 mm.

[Comparative Example 1]
A plate material was prepared in advance by the following procedure using the same fabric as in Example 1 as the base material.
7 sheets of fabric are sandwiched between 2 steel plates with a formwork of 2.2 mm thickness, then placed in a compression molding machine heated to 300 ° C. and heated for 10 minutes at a compression force of 5 MPa, then transferred to a cooling plate and cooled for 5 minutes And the board | plate material was produced.
The plate material is heated using an infrared heater, and after 7 minutes, the surface temperature of the plate material reaches 300 ° C, and then continuously heated for 3 minutes, immediately inserted into a mold set at a mold temperature of 150 ° C, and compression molded. did.
The obtained molded product was a flat plate having a size of 250 mm × 250 mm and a thickness of 2 mm.

[Comparative Example 2]
A prepreg plate was prepared in advance by the following procedure using the same fabric as in Example 1 as the substrate.
7 sheets of fabric are sandwiched between 2 steel plates with a formwork of 2.2 mm thickness, then placed in a compression molding machine heated to 300 ° C. and heated for 10 minutes at a compression force of 5 MPa, then transferred to a cooling plate and cooled for 5 minutes Then, a prepreg plate material having a thickness of 2.2 mm was produced.
The plate material was heated using an infrared heater, and after 7 minutes, the surface temperature of the plate material reached 300 ° C. and then continuously heated for 3 minutes, and the mold temperature was immediately set to a mold temperature of 150 ° C. And compression molded.

[Comparative Example 3]
[Step 1] (Create rib part)
Using a mold similar to that of Example 3, a resin composition of polyamide 66 resin [trade name: Leona (registered trademark) 14G50] containing 50% short fibers GF was set at a cylinder set temperature of 290 ° C., an injection pressure of 20 MPa, and an injection speed of 50 mm. Only the rib part of the molded product obtained by injection filling at / sec and applying an injection holding pressure of 20 MPa was cut out.
[Step 2] (Creation of base material part)
In the same process as Comparative Example 1, a prepreg plate material having a size of 250 mm × 250 mm and a thickness of 2.2 mm was formed.
[Step 3] (Adhesion of base material portion and rib portion)
Both the rib part material obtained in step 1 and step 2 and the plate material of the prepreg are heated using an infrared heater, and after 7 minutes, the surface temperature of the plate material reaches 300 ° C. and continuously heated for 3 minutes. The rib part is first put in the same mold as in Example 1 set immediately at a mold temperature of 150 ° C., then the plate material is inserted, compression molding is performed, and the rib part and the base material part of the injection resin composition are joined. did.

[Comparative Example 4]
As the base material, the same fabric as in Example 2 was used. As the molding method, the same method as in Example 2 was used except that the gas was not removed.

The intensity | strength of the projection part of an Example and a comparative example was evaluated on condition of the following. The results are shown in Table 1.
[Evaluation conditions]
(Tensile strength)
The tensile strength was measured under the following conditions according to ISO 527-1 except for the shape of the test piece. The rib part or flat plate part from the molded product was cut into a rectangular shape with a length of 80 mm and a width of 20 mm, and the apparent strength was measured.
Here, the apparent strength is the strength calculated assuming that the cross-sectional area of the test piece required for calculation of the tensile strength is a rectangle that the rib portion is ignored, and the thickness of the test piece including the rib is other than the rib portion. And the width were measured, and the tensile strength was calculated using this as the cross-sectional area.
・ Test environment: 23 ° C, 50RH%
・ Tensile speed: 5mm / min
・ Chuck interval: 50mm
-Equipment used: Instron 50kN (Instron)
FIG. 16 shows an outline of this tensile strength test. In the figure, reference numeral 500 denotes the above-mentioned test piece. A tensile force is applied to the test piece 500 in the direction indicated by the arrow in the figure, and the tensile strength is measured.

(Bending rigidity)
The bending stiffness was measured under the following conditions according to ISO 178 except for the shape of the test piece.
The rib part or flat plate part from the molded product was cut into a rectangular shape with a length of 80 mm and a width of 50 mm, and the apparent elastic modulus was measured.
Here, the apparent elastic modulus is the strength calculated by assuming that the cross-sectional area of the test piece necessary for calculating the elastic modulus is a rectangular shape in which the rib portion is ignored, and the test piece including the rib is a portion other than the rib portion. The elastic modulus was calculated by measuring the thickness and width and using the thickness and width as the cross-sectional area.
・ Test environment: 23 ° C, 50RH%
・ Test speed: 1 mm / min
-Between spans: 32mm
-Equipment used: Instron 50kN (Instron)
-Elastic modulus calculation section: Strain 0.05% -0.25%
FIG. 17 shows an outline of this tensile strength test. In the figure, reference numeral 600 denotes the above-described test piece. A load is applied to the test piece 600 in the direction of the arrow through the jig 601, and the bending rigidity is measured.

Is the magnitude of the bottom surface of the square pillar outer column _{(a ₁} × _b ₁₎ and a tip surface _{(a ₂} × _b _2). Further, as shown in FIG. 15, the “bottom dimension” of the truncated cone is a diameter d _base of the bottom surface of the truncated cone and a diameter d _top of the upper surface. Further, the “bottom dimension” of the rib is the thickness T ₁ at the base of the rib, and the “top dimension” is the thickness T ₃ of the tip surface of the rib.

<Ratio to the base of the region where the height of the continuous reinforcing fiber is 5% or more>
After obtaining the length in the long side direction of the region where the height of the continuous reinforcing fiber is 5% or more from the side projection image obtained by the digital camera, in the case of the rib, the ratio to the length of the bottom side in the long side direction is In the case of a columnar shape, the ratio to the length of the base (entire circumference) was calculated.

<Appearance>
The appearance was evaluated according to the following evaluation criteria.
A: There was no short part at all, and a molded product as designed was obtained.
B: A short part occurred.

As shown in Table 1, in Examples 1, 2, 3 and 4, the average value of the height of the continuous reinforcing fibers was 5% or more in any of the protrusions, and there was no short portion and the appearance was good. It was. Moreover, the area | region where the height of the continuous reinforcement fiber in a projection part is 5% or more of the height of a projection part was also 20% or more of the base of the projection part. Furthermore, the area | region with respect to the base of the area | region where the continuous reinforcement fiber in a projection part is continuing with the continuous reinforcement fiber of a board | substrate part was also 20% or more.
On the other hand, a short part occurred in Comparative Example 2 in which neither degassing nor pushing was performed using the prepreg and in Comparative Example 4 where neither degassing nor pushing was performed using the fabric.

According to the present invention, it is possible to provide a thermoplastic resin fiber composite molded article that requires high-level mechanical properties, such as various machines and structural parts such as automobiles.
According to still another compression molding method of the present invention, a molded product having a complicated shape and having a high level of mechanical properties can be obtained. It can also be used for electronic devices, structural members and housings of OA / home appliance parts.
Examples of automobile parts that can be used include the following parts and parts thereof.
Specifically, steering shaft, mount, sunroof, step, soof trim, door trim, trunk, boot lid, bonnet, seat frame, seat back, retractor, retractor support bracket, clutch, gear, pulley, cam, AG, elastic beam , Buffing, lamp, reflector, glazing, front end module, back door inner, brake pedal, handle, electrical component, sound absorbing material, door exterior, interior panel, instrument panel, rear gate, ceiling tension, seat, seat frame, wiper support, EPS (Electric Power Steering), small motor, heat sink, ECU (Engine Control Unit) box, ECU housing, steering gear box housing, plastic housing, EV (Electric Vehicle) motor Housing, wire harness, in-vehicle meter, combination switch, small motor, spring, damper, wheel, wheel cover, frame, subframe, side frame, two-wheel frame, fuel tank, oil pan, intake manifold, propeller shaft, drive motor , Monocoque, hydrogen tank, fuel cell electrode, panel, floor panel, outer panel, door, cabin, roof, hood, valve, EGR (Exhaust Gas Recirculation) valve, variable valve timing unit, connecting rod, cylinder bore, member ( Engine mounting, front floor cross, footwell cross, seat cross, inner side, rear cross, suspension, pillar lean force, front side, front panel, upper, duck (Stepanel Cross, Steering), Tunnel, Fastening Insert, Crash Box, Crash Rail, Corrugated, Roof Rail, Upper Body, Side Rail, Braiding, Door Surround Assembly, Airbag Components, Body Pillar, Dash Tupillar Gusset, Suspension Tower , Bumper, body pillar lower, front body pillar, reinforcement (instrument panel, rail, roof, front body pillar, roof rail, roof side rail, rocker, door belt line, front floor under, front body pillar upper, front body pillar lower , Center pillar, center pillar hinge, door outside panel,), side outer panel, front door window Frame, MICS (Minimum Intrusion Cabin System) bulk, torque box, radiator support, radiator fan, water pump, fuel pump, electronically controlled throttle body, engine control ECU, starter, alternator, manifold, transmission, clutch, dash panel, dash panel Insulator pad, door side impact protection beam, bumper beam, door beam, bulkhead, outer pad, inner pad, rear seat rod, door panel, door trim body subassembly, energy absorber (bumper, shock absorption), shock absorber, shock absorption garnish, pillar Garnish, roof side inner garnish, crash box, resin rib, side rail flow Spacer, side rail rear spacer, seat belt pretensioner, airbag sensor, arm (suspension, lower, hood hinge), suspension link, shock absorbing bracket, fender bracket, inverter bracket, inverter module, hood inner panel, hood panel, Cowl louver, cowl top outer front panel, cowl top outer panel, floor silencer, dump seat, hood insulator, fender side panel protector, cowl insulator, cowl top ventilator looper, cylinder head cover, tire deflector, fender support, strut tower bar, mission Center tunnel, floor tunnel, radio core support , Luggage panels, luggage floors, etc.

100, 200

Mold

10, 20, 201

Mold part

11, 21, 310, 320

First part

12, 22

Second part

13, 23, 313, 323 First temperature adjusting means (cooling medium passage)
14, 24 Second temperature adjusting means (bar-shaped cartridge heater)
15, 25 Insulating

plate

16, 26 Surface opposite to the cavity surface 30

Cavity

31, 32 Cavity surface 33 Path 40 Spring 50 Seal packing 60 Vacuum line 70

Fabric

71, 78, 400, 440 Molded product 72 Hybrid molded product 77 Prepreg 80 Injection molding machine 90 Runner part L0 Distance from cavity surface to first temperature adjusting means L1 Distance from cavity surface to surface opposite to cavity surface L2 First temperature adjusting means to second temperature adjusting means Distance V0 Volume of mold part V (I) Volume of first part V (II) Volume of second part 170 Continuous reinforcing

fibers

401, 402

Holes

403, 405, 407,

Ribs

409, 410

Boss

411, 412 Frustum 413

Square pyramid

414, 415 Square prism 420 Substrate part 4 The height h _f height L _r length L _a height of continuous reinforcing fibers of length L bottom of the base of the wide side direction height of the projections of the ribs of the continuous reinforcing fiber surface h protrusions 0a substrate portion 5% or more in a region length L _b continuous reinforcing fibers in the protrusions of the base of the wall thickness T ₂ substrate portion of the length T ₁ protrusion area that is continuous with continuous reinforcing fiber substrate portion meat Thickness T ₃ Thickness of tip surface of protrusion

Claims

A molded article comprising a continuous fiber reinforced thermoplastic resin composite material consisting of continuous reinforced fibers and a thermoplastic resin,
The molded product has a substrate portion and a protrusion,
The continuous reinforcing fiber is present in the protrusion and in the substrate;
A molded product in which the average value of the height of the continuous reinforcing fibers in the protrusion is 5% or more of the height of the protrusion.
The molded product according to claim 1, wherein the region in which the height of the continuous reinforcing fiber in the protrusion is 5% or more of the height of the protrusion is 20% or more of the bottom of the protrusion.
The molded article according to claim 1 or 2, wherein the continuous reinforcing fiber in the protrusion is continuous with the continuous reinforcing fiber in the substrate.
The molded article according to claim 3, wherein a region occupied by the continuous reinforcing fibers in the protrusion continuous with the substrate portion in the bottom of the protrusion is 20% or more of the bottom.
The molded article according to any one of claims 1 to 4, wherein a height of the protruding portion is larger than a thickness of the substrate portion, and an average height of the continuous reinforcing fibers is equal to or greater than a thickness of the substrate portion. .
The molded product according to claim 5, wherein the height of the protrusion is at least three times the thickness of the substrate.
The molded article according to any one of claims 1 to 6, wherein the resin in the projection and the resin in the substrate portion are the same.
The molded article according to any one of claims 1 to 7, wherein a density Vf of a continuous fiber having a height of 10% at the top when the height of the protrusion is 100% is 10% or less.
The molded article according to any one of claims 1 to 8, wherein a density Vf of a continuous fiber having a height of 10% at a lower portion when the height of the protrusion is 100% is 30% or more.
10. The height of the protruding portion is not less than twice the thickness of the substrate portion, and the thickness of the base of the protruding portion is not more than the thickness of the substrate portion. Molding.
The molded product according to claim 10, wherein the height of the protrusion is at least three times the thickness of the substrate.
A compression molding method in which a continuous fiber reinforced thermoplastic resin composite material composed of continuous reinforcing fibers and a thermoplastic resin is compression molded to obtain a molded product having a substrate portion and a protrusion,
The continuous fiber reinforced thermoplastic resin composite material is inserted into a mold, and while being compressed, the mold is molded by heating above the glass transition temperature or melting point of the thermoplastic resin, and then molding the mold. A compression molding step of solidifying the thermoplastic resin by cooling to a glass transition temperature of −10 ° C. or lower or a melting point of −10 ° C. or lower of the thermoplastic resin;
A step of releasing a gas component in the mold generated from the continuous fiber reinforced thermoplastic resin composite material out of the mold during the compression molding process.
A compression molding method in which a thermoplastic resin composite material composed of continuous reinforcing fibers and a thermoplastic resin is compression molded to obtain a molded product having a substrate portion and a protrusion,
When inserting the continuous fiber reinforced thermoplastic resin composite material into a mold, while inserting and compressing at least a part of the continuous fiber reinforced thermoplastic resin composite material into the concave portion corresponding to the protruding portion of the mold The mold is molded by heating to a temperature above the glass transition temperature or the melting point of the thermoplastic resin, and then the mold is cooled to a glass transition temperature of −10 ° C. or lower or a melting point −10 ° C. or lower of the thermoplastic resin. A compression molding method for solidifying the thermoplastic resin.
A compression molding method in which a prepreg composed of continuous reinforcing fibers and a thermoplastic resin is compression molded to obtain a molded product having a substrate portion and a protrusion,
The prepreg is softened by preheating above the glass transition temperature or melting point of the thermoplastic resin,
Insert the softened prepreg into a mold,
The mold is heated to a glass transition temperature of the thermoplastic resin of −80 ° C. or higher or a melting point of −80 ° C. or higher to mold the prepreg, and then the mold is transferred to a glass transition temperature of the thermoplastic resin of −10. A compression molding method in which the thermoplastic resin is solidified by cooling to a temperature of ℃ or lower or a melting point of -10 ℃ or lower.
The height of the protruding portion of the molded product is twice or more the thickness of the substrate portion of the molded product, and the thickness of the base of the protruding portion is equal to or less than the thickness of the substrate portion. Item 11. The compression molding method according to Item 10.
As the continuous fiber reinforced thermoplastic resin composite material, at least a part of the thermoplastic resin at the cut surface of at least a part of the composite material is melt-solidified, and the molecular weight of the thermoplastic resin melted and solidified is the heat The compression molding method according to claim 12 or 13, wherein a composite material having a molecular weight of 20% or more of the plastic resin is used.