WO2018088135A1 - Article moulé et procédé de moulage par compression - Google Patents

Article moulé et procédé de moulage par compression Download PDF

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Publication number
WO2018088135A1
WO2018088135A1 PCT/JP2017/037346 JP2017037346W WO2018088135A1 WO 2018088135 A1 WO2018088135 A1 WO 2018088135A1 JP 2017037346 W JP2017037346 W JP 2017037346W WO 2018088135 A1 WO2018088135 A1 WO 2018088135A1
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WO
WIPO (PCT)
Prior art keywords
thermoplastic resin
mold
protrusion
continuous
temperature
Prior art date
Application number
PCT/JP2017/037346
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English (en)
Japanese (ja)
Inventor
安田　和治
普 菅野
英明 市来
大賀 齋藤
Original Assignee
旭化成株式会社
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Application filed by 旭化成株式会社 filed Critical 旭化成株式会社
Priority to KR1020197003964A priority Critical patent/KR20190028487A/ko
Publication of WO2018088135A1 publication Critical patent/WO2018088135A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics

Definitions

  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • “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.
  • 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.
  • 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.
  • 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.
  • the height of more than 5% is a region of continuous reinforcing fibers is not less than 20% of the base of the protrusion
  • the length L a is greater than or equal to 20% of the length L r of the bottom side To do.
  • 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.
  • 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.
  • continuous means that continuous reinforcing fibers are continuously present from the substrate portion.
  • the continuous reinforcing fibers remain continuously from the substrate portion when the molded product is incinerated.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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).
  • 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.
  • thermoplastic resin in the protrusion and the thermoplastic resin in the substrate are the same.
  • 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.
  • 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.
  • one compression molding method 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.
  • thermoplastic resin 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.
  • 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.
  • the thermoplastic resin is a crystalline thermoplastic resin
  • the melting point is used as a reference
  • the thermoplastic resin is an amorphous resin
  • glass is used.
  • the transition temperature is used as a reference.
  • the mold is closed after the continuous fiber reinforced thermoplastic resin composite material is inserted into the mold.
  • a method of relaxing the mold clamping force and releasing the gas from the die mating surface is used as a simple method.
  • 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 is used 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.
  • thermoplastic resin ⁇ 10 ° C. or lower or a melting point of Cool to 10 ° C. or lower to solidify the thermoplastic resin.
  • 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.
  • the thermoplastic resin is a crystalline thermoplastic resin
  • the melting point is used as a reference
  • the thermoplastic resin is an amorphous resin. Is based on the glass transition temperature.
  • the molded article of the present invention it is possible to obtain a protrusion having excellent shapeability and strength.
  • a molded product having protrusions excellent in formability and strength can be produced with high productivity.
  • 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.
  • 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.
  • 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).
  • 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.
  • 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.
  • the protrusions can have appropriate strength.
  • 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.
  • it is most preferably 5% or more in all 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.
  • 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.
  • the thermoplastic resin is easier to insert up to the tip of the protrusion than the continuous reinforcing fiber.
  • continuous reinforcing fibers are difficult to move and therefore difficult to insert into the protrusions.
  • the longer the insertion distance the stronger the protrusions.
  • 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.
  • 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.
  • the thermoplastic resin in the protrusion and the thermoplastic resin in the substrate are the same.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the mold 100 including the mold parts 10 and 20 is opened.
  • 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.
  • 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.
  • the composite material may be inserted at room temperature into the mold, but may be preheated before being inserted into the mold.
  • a plate-like prepreg when 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.
  • 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.
  • 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
  • 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
  • the difference between the heating temperature and the cooling temperature is preferably 100 ° C. or more
  • the heating rate is 150 ° C./min.
  • 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.
  • 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
  • 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.
  • 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.
  • 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.
  • 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.
  • 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”.
  • a method of evacuating the mold and removing the gas generated from the composite material there is a method of evacuating the mold and removing the gas generated from the composite material.
  • 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.
  • 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.
  • a dividing surface of a mold constituting the mold cavity may be used.
  • 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.
  • 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.
  • the mold cavity surface may be raised 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.
  • the cavity surface may be heated by circulating superheated steam at 300 ° C. or higher through the cavity surface before insertion of the fabric.
  • the superheated steam inserted into the mold can be removed from the vacuum line after insertion for a desired time.
  • the compression molding process 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.
  • 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.
  • 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.
  • 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.
  • thermoplastic resin melts and flows in the mold and flows together
  • at least a part of the composite material is inserted in the protrusion in advance.
  • the number of fabrics suitable for the desired molded product thickness is used as the mold cavity.
  • 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.
  • 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.
  • 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).
  • the fabric 70 is inserted in the same procedure as the compression molding method.
  • 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.
  • FIG. 11 shows a schematic cross-sectional view of an embodiment of a stamping die.
  • 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.
  • 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.
  • 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.
  • 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.
  • the spring 40 can be separated.
  • 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.
  • FIG. 12 is a schematic cross-sectional view for explaining details of the mold, and some components are omitted.
  • 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
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the distance from the cavity surface of one passage or the heater differs depending on the location.
  • 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.
  • L0 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.
  • 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.
  • (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.
  • 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.
  • a cooling part is a part cooled by the 1st temperature control means, Comprising: At least 1st part is shown.
  • the heat storage portion is a portion heated by the second temperature adjusting means and indicates at least the second portion.
  • the distance L2 from the first temperature adjusting means to the second temperature adjusting means is L2> L0, and preferably 2 ⁇ L2 / L0 ⁇ 10.
  • 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.
  • L0 and L2 should be as close as possible.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the cavity surface 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.
  • 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 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.
  • the cavity surface can be quickly cooled during cooling. During heating, the temperature can be quickly raised by heat storage in the second part.
  • 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.
  • the first part and the second part have a separable structure.
  • 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.
  • 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.
  • 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.
  • thermoplastic resin of the composite material 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.
  • air 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.
  • a molded product impregnated with the thermoplastic resin can be obtained more quickly.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the second temperature control means there are no particular restrictions on the second temperature control means.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 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
  • 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.
  • 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 those used as a normal fiber reinforced composite material can be used.
  • 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.
  • glass fibers, carbon fibers, and aramid fibers are preferable.
  • a sizing agent may be used.
  • the sizing agent is preferably composed of a silane coupling agent, a lubricant and a binding agent.
  • those described in Patent Document 1 can be used as appropriate.
  • 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.
  • the sizing agent is preferably composed of a lubricant and a binding agent.
  • a lubricant 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.
  • 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 in the present invention refers to all those generally referred to as thermoplastic resins.
  • 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 copo
  • 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
  • the thermoplastic resin may contain a filler and / or an additive.
  • 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.
  • 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. .
  • polyester resins those described in Patent Document 1 can be used as appropriate.
  • 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 ⁇ -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.
  • the details of the other lactam, diamine (monomer), and dicarboxylic acid (monomer) those described in Patent Document 1 can be used as appropriate.
  • polyamides include, for example, polyamide 4 (poly ⁇ -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.
  • polyamide 4 poly ⁇ -pyrrolidone
  • polyamide 6 polycaproamide
  • polyamide 11 polyundecanamide
  • polyamide 12 polydodecanamide
  • polyamide 46 polytetramethylene adipa) Amide
  • polyamide 66 polyhexamethylene adipamide
  • copolymerized polyamide examples 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.
  • thermoplastic resin fiber composite material Although the specific manufacturing method of the mixed fiber used for a thermoplastic resin fiber composite material is not restrict
  • 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
  • fluids such as air, nitrogen gas, and water vapor
  • examples include a method of fluid entanglement after opening, or after opening both continuous reinforcing fibers and thermoplastic resin fibers (fluid entanglement after opening).
  • 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.
  • the method of patent document 2 can be used suitably.
  • 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.
  • 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.
  • 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.
  • 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.
  • the method described in Patent Document 1 can be used as appropriate.
  • 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.
  • thermoplastic resin of a cutting edge part may be burnt, and the physical property fall of the composite material after shaping
  • 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.
  • 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.
  • 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 ⁇ m 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.
  • 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.
  • GPC gel permeation chromatography
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the temperature of a blade is below melting
  • 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.
  • thermoplastic resin 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.
  • a bar cartridge heater (trade name “GLE4103”, capacity 1000 W, ⁇ 10 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.
  • sizing agent A solid content conversion
  • Silane coupling agent 0.6% by mass of ⁇ -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.)]
  • 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.
  • 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.
  • 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
  • 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 Tempoture rise
  • 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
  • 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
  • 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.
  • 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
  • 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.
  • 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.
  • 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.
  • 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] 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.
  • 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.
  • FIG. 16 shows an outline of this tensile strength test.
  • 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.
  • 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.
  • 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.
  • FIG. 17 shows an outline of this tensile strength test.
  • 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.
  • 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.
  • 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.
  • 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
  • thermoplastic resin fiber composite molded article that requires high-level mechanical properties, such as various machines and structural parts such as automobiles.
  • 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.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Le problème décrit par la présente invention est de fournir : un article moulé qui comprend une saillie ayant une excellente aptitude à la formation et une excellente résistance en conséquence de l'utilisation d'un matériau composite de fibre de résine thermoplastique ; et un procédé de moulage avec une productivité favorable. La solution selon l'invention porte sur un article moulé contenant un matériau composite de résine thermoplastique renforcé par des fibres continues qui comprend des fibres de renforcement continues et une résine thermoplastique. L'article moulé a un substrat (420) et une saillie (403), des fibres de renforcement continues (170) étant présentes à l'intérieur de la saillie (403) et du substrat (420) et la valeur moyenne d'une hauteur (hf) des fibres de renforcement continues (170) à l'intérieur de la projection (403) est de 5 % ou plus d'une hauteur (h) de la saillie (403).
PCT/JP2017/037346 2016-11-11 2017-10-16 Article moulé et procédé de moulage par compression WO2018088135A1 (fr)

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KR20200057317A (ko) * 2018-11-16 2020-05-26 한국생산기술연구원 섬유강화 복합소재의 적층형 판재에 대한 압축 성형 금형
CN113829627A (zh) * 2021-10-26 2021-12-24 广州环岛体育运动设备有限公司 一种线拉带充气模型
WO2023227803A1 (fr) * 2022-05-27 2023-11-30 Inertim Research S.L. Procédés de fabrication de structures portantes pour des portes de véhicules
WO2023249586A1 (fr) * 2022-06-24 2023-12-28 Ditas Dogan Yedek Parca Imalat Ve Teknik A.S. Barre de torsion à poids réduit et conductivité thermique améliorée

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JP7335127B2 (ja) * 2019-10-17 2023-08-29 小島プレス工業株式会社 成形金型およびこの成形金型を用いて成形された樹脂部品
CN111426891B (zh) * 2019-11-19 2022-08-12 杭州大和热磁电子有限公司 一种用于电子设备测试的冷却和加热装置及其控制方法

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20200057317A (ko) * 2018-11-16 2020-05-26 한국생산기술연구원 섬유강화 복합소재의 적층형 판재에 대한 압축 성형 금형
KR102143863B1 (ko) * 2018-11-16 2020-08-12 한국생산기술연구원 섬유강화 복합소재의 적층형 판재에 대한 압축 성형 금형
CN113829627A (zh) * 2021-10-26 2021-12-24 广州环岛体育运动设备有限公司 一种线拉带充气模型
WO2023227803A1 (fr) * 2022-05-27 2023-11-30 Inertim Research S.L. Procédés de fabrication de structures portantes pour des portes de véhicules
WO2023249586A1 (fr) * 2022-06-24 2023-12-28 Ditas Dogan Yedek Parca Imalat Ve Teknik A.S. Barre de torsion à poids réduit et conductivité thermique améliorée

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