WO2023132299A1 - Frtp molded article production method, frtp molded article production device, resin molded article production method and resin molded article production device - Google Patents

Abstract

Provided are a method and a device with which a fiber-reinforced thermoplastic (FRTP) molded article or a resin molded article are easily produced via a simpler process.　A starting material comprising a carbon sheet 81 and resin pellets 82 is placed on a heater plate 21, the starting material is heated using a heater 23, pressure is applied to the starting material via a flat top plate 41, and an FRTP block is formed. An FRTP shaped article molding space 52 is delimited by the flat heater plate 21, a mold frame 31 and the flat top plate 41. The thermoplastic resin is impregnated into the carbon sheet by applying heat and pressure thereto, a resin layer is formed on the front and rear surface thereof, and at the same time, a formed CFRTP is molded into the shape of an FRTP block molding space 51 or the FRTP shaped article molding space 52.

Description

FRTP molded product manufacturing method, FRTP molded product manufacturing device, resin molded product manufacturing method, and resin molded product manufacturing device

The present invention relates to a method and apparatus for manufacturing fiber reinforced thermoplastic (FRTP) molded articles, and a method and apparatus for manufacturing resin molded articles using thermoplastic resin as a raw material. .

Fiber Reinforced Plastics (FRP) are widely used mainly in fields where both strength and weight reduction are required. Most of the currently used FRPs use a thermosetting resin as a base material (matrix resin). However, in recent years, fiber reinforced thermoplastics (FRTP: Fiber Reinforced Thermo Plastics) using thermoplastic resin as the matrix resin have been developed from the viewpoint of cost, equipment and time required for molding, ease of production, etc. being used.

When manufacturing a molded product using FRTP, the following steps are usually required. For example, when using a carbon fiber reinforced thermoplastic (CFRTP: Carbon FRTP) that uses carbon fiber as a reinforcing fiber, first, carbon fiber materials such as carbon fiber, carbon fiber bundles, carbon fiber fabrics or carbon fiber nonwoven fabrics ( Reinforcing fiber material) is impregnated with a thermoplastic resin, or furthermore, a thermoplastic resin is fused and laminated on the front and back to manufacture a primary molded product in the form of a sheet, such as a so-called prepreg. (For example, Patent Document 1). Next, the sheet-like member is subjected to press working or the like to produce a target object (product) having a desired shape as a secondary molded product.

On the other hand, methods such as injection molding, blow molding, and extrusion molding, in which molten resin is injected into a mold, are widely used for the production of resin molded products made from general thermoplastic resins that do not contain fiber materials.

JP 2021-91204 A

　There is a desire to manufacture the above-mentioned FRTP molded products in a simpler process.

In addition, conventional methods for manufacturing resin molded products, such as injection molding, require complicated resin injection mechanisms such as thick molds and screws, nozzles, etc., which complicates the device configuration and manufacturing process. was In addition, unnecessary resin material that does not form a molded product accumulates in nozzles and runners, resulting in wasted resin material. In addition, there are cases where so-called sink marks and marks of gates (nozzles) are not aesthetically pleasing, and there is also a problem in terms of the quality of the molded product. Therefore, these improvements are desired.

In order to achieve the above object, the method for producing an FRTP molded product of the present invention comprises:
placing a first material comprising a fibrous material and a second material comprising a thermoplastic resin material in a molding space having a desired shape;
heating the disposed first material and the second material such that at least the second material melts;
In parallel with the heating step, the arrangement is such that the melted second material impregnates at least the first material, and the first material and the second material fill the molding space. pressing the first material and the second material that have been formed;
cooling the molding space such that the first material and the second material solidify;
characterized by having

According to such a manufacturing method, the impregnation of the second material, which is a thermoplastic resin material, into the first material including the fibrous material, the formation of the FRTP thereby, and the molding of the FRTP molded product are performed in a series of manufacturing processes. The processing can be performed collectively, and the FRTP molded product can be easily manufactured in a simpler process.

In addition, according to such a manufacturing method, it is possible to easily manufacture various FRTPs in a simple process by combining any fiber material (reinforcing fiber) and any thermoplastic resin. In addition, depending on the conditions such as strength and weight required for the FRTP molded product to be manufactured, the type of fiber material (carbon fiber, glass fiber, etc.), the amount of fiber material to be input (number of carbon sheets), etc. can be easily adjusted. The FRTP molded product can be manufactured by the same process even when any combination of raw materials is used.

The heating step heats the arranged first material and second material from the side of the surface on which the first material and the second material are placed in the molding space,
In the pressurizing step, the placed first material and second material may be pressurized from the side of the surface opposite to the surface on the heating side in the molding space.

By heating and pressurizing in this way, the formed FRTP can be filled without gaps from the heating surface side (for example, the vertical lower surface) of the molding space, and an appropriate FRTP molded product without voids can be molded. can be done.

Preferably, the pressing step gradually presses the first material and the second material according to the states of the heated first material and the second material.

By applying pressure in this way, the impregnation of the thermoplastic resin into the fibrous material of the first material can be enhanced, and the fibrous material of the first material is not impregnated with the thermoplastic resin and voids are formed. can be prevented from occurring. As a result, the strength, elastic modulus, airtightness, and other characteristics of the FRTP molded product can be maintained at high performance, and a high-quality FRTP molded product can be produced.

Further, the placing step, the heating step, the pressurizing step, and the cooling step are repeated to newly solidify the first material and the second material that have already been solidified. The material and the second material may be sequentially laminated.

Preferably, in the heating step and the pressurizing step during the repetition,
At least the second material melts and impregnates the first material of the newly arranged first material and the second material, and the molding space is filled with the first material and the second material. ,
In the already solidified first material and second material, at least the second material in the vicinity of the surface in contact with the newly arranged first material and second material is melted, and the portion away from the surface The first material and the second material of are subjected to the heating and the pressing with a heat distribution and a pressure to maintain the solidified state.

According to such a manufacturing method, it is possible to easily manufacture an FRTP molded product in which a reinforcing fiber layer and a resin layer are laminated in a mille-feuille shape.

In the placing step, the first material and the second material may be placed in the substantially rectangular parallelepiped molding space to manufacture a substantially rectangular parallelepiped FRTP block.

Further, in the arranging step, the first material and the second material are arranged inside a mold having a molding space of a desired shape inside to manufacture an FRTP modeled product of the desired shape. can be

With such a manufacturing method using a mold, it is possible to easily form raised characters such as so-called engraved characters and engraved patterns on the surface of FRTP molded products in a simple process. Since the manufacturing method according to the present invention is a method similar to injection molding in which a mold is filled with a molten thermoplastic resin, it is possible to form raised characters and the like with high accuracy compared to ordinary press molding.

Furthermore, the mold used in this embodiment does not have a special structure related to the injection of raw materials like the mold used for injection molding, and has a simple structure divided into two upper and lower parts, or a mold divided into an arbitrary number. Any form of mold consisting of molded mold parts can be used. Therefore, the cost of the mold is low, and the initial investment for the mold is low.

The first material may not contain the thermoplastic resin of the second material. According to the manufacturing method of the present invention, the first material formed substantially only of a fiber material is used, in other words, without manufacturing or using a prepreg in which the fiber material is previously impregnated with a resin, the fiber FRTP moldings can be manufactured directly using a first material made entirely of material.

Specifically, the fiber material includes at least one of carbon fiber, glass fiber, aramid fiber and quartz glass (quartz) fiber.

The first material includes a sheet-shaped member in which carbon fibers or carbon fiber bundles are bound with carbonized resin, a carbon fiber fabric in which carbon fibers are plain woven or twilled, a carbon fiber nonwoven fabric formed by entangling carbon fibers, and carbonized by heat treatment. It may include any of the sheet-shaped members formed by forming the carbon fiber precursor into a sheet.

In addition, the FRTP molded product manufacturing apparatus according to the present invention is
molding space means having a desired shape in which a first material comprising a fibrous material and a second material comprising a thermoplastic resin material are arranged;
a heater that heats the arranged first material and the second material so that at least the second material melts;
In parallel with the heating by the heater, the melted second material impregnates at least the first material, and the first material and the second material fill the molding space. and pressurizing means for pressurizing the first material and the second material,
Said molding space means further has the function of cooling said first material and said second material so that they solidify.

The molding space means includes a heater plate defining a lower surface of the molding space and having the heater embedded therein, a mold frame defining a side surface of the molding space, and an upper plate defining an upper surface of the molding space. is a substantially rectangular parallelepiped space having
the pressurizing means pressurizes the first material and the second material placed in the molding space by driving the upper plate with an upper plate driving means;
FRTP blocks of substantially rectangular parallelepiped shape may be manufactured.

In addition, the molding space means may be a mold having a molding space with a desired shape inside, and the FRTP modeled product with the desired shape may be manufactured.

In addition, the method for producing a resin molded product of the present invention includes:
One or more forming at least a part of the vertical lower side of the mold using a mold in which a molding space of a desired shape is formed by combining and closing a plurality of partial molds placing a resin material, which is a thermoplastic resin, in the partial mold of
heating the disposed resin material so that the resin material melts;
In parallel with the heating step, through one or more partial molds different from the partial molds in which the resin material is arranged so that the resin material is filled in the molding space, a step of pressurizing the arranged resin material;
cooling the molding space so that the resin material solidifies;
have

Preferably, the step of heating heats the arranged resin material from the side of the surface on which the resin material is placed in the molding space, and the step of pressurizing the arranged resin material. is pressed from the side of the surface opposite to the surface on the side to be heated in the molding space.

Further, preferably, in the step of pressurizing, the arranged resin material is applied by gradually moving the partial molds until the plurality of partial molds are combined and the molding space is closed. In the step of pressing and heating, the resin material is heated according to the state in which the molding space is closed.

In addition, the resin molded product manufacturing apparatus of the present invention is
One or a plurality of molds that form at least a part of the vertically lower side of the mold, in which a molding space of a desired shape is formed inside by combining and closing a plurality of partial molds molding space means in which the partial mold can be installed, and a resin material, which is a thermoplastic resin, is arranged in the partial mold;
a heater that heats the resin material so that the arranged resin material melts;
In parallel with the heating by the heater, through one or a plurality of the partial molds different from the partial mold in which the resin material is arranged so that the resin material is filled in the molding space, and pressurizing means for pressurizing the arranged resin material,
The molding space means further has a function of cooling the resin material so that it solidifies.

According to such a resin molded product manufacturing method or a resin molded product manufacturing apparatus, a simple mold can be used, and a complicated resin injection mechanism such as a screw and a nozzle is unnecessary, and the manufacturing process is simple. This eliminates the need for wasteful resin material that is consumed at locations other than the molded product, and reduces or prevents the occurrence of sink marks, gate traces, and the like.

FIG. 1 is a perspective view showing the overall configuration of a fiber-reinforced thermoplastic molded article manufacturing apparatus (FRTP molded article manufacturing apparatus) and a resin molded article manufacturing apparatus according to the present invention. 2 is a front view of the manufacturing apparatus shown in FIG. 1. FIG. FIG. 3 is a flow chart showing a method of manufacturing a CFRTP block. FIG. 4 is a diagram for explaining a step of attaching a flat heater plate and a flat upper plate in the method of manufacturing the CFRTP block. FIG. 5 is a diagram for explaining a step of arranging reinforcing fibers and thermoplastic resin on a flat heater plate in a method of manufacturing a CFRTP block. FIG. 6 is a diagram for explaining the step of lowering the mold in the method of manufacturing the CFRTP block. FIG. 7 is a diagram for explaining the steps of heating and pressurizing the raw material in the method of manufacturing the CFRTP block. FIG. 8 is a diagram for explaining a state in which a CFRTP layer is formed in the CFRTP block manufacturing method. FIG. 9 is a first diagram for explaining the step of raising the formwork in the CFRTP block manufacturing method. FIG. 10 is a second view for explaining the step of raising the mold in the CFRTP block manufacturing method. FIG. 11 is a diagram for explaining a step of extracting a CFRTP block in the CFRTP block manufacturing method. FIG. 12 is a flow chart showing a method for manufacturing a CFRTP modeled product and a method for manufacturing a resin molded product. 13A and 13B are diagrams for explaining a step of attaching the heater plate with screw holes and the upper plate with screw holes in the manufacturing method shown in FIG. 14A and 14B are diagrams for explaining a step of attaching a mold in the manufacturing method shown in FIG. 12. FIG. 15 is a diagram for explaining a step of arranging reinforcing fibers and a thermoplastic resin or a thermoplastic resin in a mold in the manufacturing method shown in FIG. 12. FIG. FIG. 16 is a diagram for explaining the step of lowering the mold in the manufacturing method shown in FIG. 12. FIG. FIG. 17 is a diagram for explaining the steps of heating and pressurizing raw materials in the manufacturing method shown in FIG. FIG. 18 is a diagram for explaining a state in which a CFRTP modeled product (resin molded product) is produced in the manufacturing method shown in FIG. 12 . FIG. 19 is a diagram for explaining the step of lifting the mold and taking out the CFRTP modeled product (resin molded product) in the manufacturing method shown in FIG. 12 . FIG. 20 is a diagram for explaining a mold having recesses for forming engraved characters (embossed characters). FIG. 21 is a diagram showing a CFRTP modeled product with raised characters, which is an example of an actually manufactured CFRTP modeled product (resin molded product).

Embodiments of the present invention will be described with reference to FIGS. 1 to 21. FIG.
In the first embodiment and the second embodiment, a fiber-reinforced thermoplastic (FRTP) molded article in which the reinforcing fiber and the thermoplastic resin are combined is manufactured using the reinforcing fiber material and the thermoplastic resin material as raw materials. A manufacturing apparatus and manufacturing method will be described. In particular, in the present embodiment, an apparatus and method for manufacturing an FRTP molded article using a reinforcing fiber sheet formed by forming reinforcing fibers (FRP fibers) in a sheet shape as a reinforcing fiber material will be described. In addition, in the third embodiment, a manufacturing apparatus and a manufacturing method for manufacturing a molded product using a thermoplastic resin material as a raw material will be described.

FRTP molded product manufacturing equipment (resin molded product manufacturing equipment)
First, an FRTP molded product manufacturing apparatus 1 for manufacturing an FRTP molded product will be described with reference to FIGS. 1 and 2. FIG. The configuration of the resin molded product manufacturing apparatus according to the present invention is also substantially the same as the FRTP molded product manufacturing apparatus 1 shown here. This is a description of a molded product manufacturing apparatus. FIG. 1 is a perspective view showing the overall configuration of the FRTP molded product manufacturing apparatus 1, and FIG. 2 is a front view of the FRTP molded product manufacturing apparatus 1 viewed from the Y direction (front direction) in FIG. As shown in FIG. 1, the FRTP molded product manufacturing apparatus 1 has a body frame 10, a heater unit 20, a formwork unit 30 and an upper plate unit 40. As shown in FIG.

The FRTP molded product manufacturing apparatus 1 is used for manufacturing a rectangular parallelepiped resin block (FRTP block) using a mold unit 30 described later as a first embodiment, and for manufacturing a metal block (FRTP block) described later as a second or third embodiment. A part of the heater unit 20 and the upper plate unit 40 is replaced (changed) when a molded product of arbitrary shape (this is called an FRTP molded product or a resin molded product) is manufactured using a mold. In this application, the term "FRTP molded article" is used as a concept including "FRTP block" and "FRTP molded article".

When manufacturing the FRTP block of the first embodiment, the molding space 51 (see FIG. 6) in which the FRTP block is formed is surrounded by the plate surfaces of the heater unit 20, the mold unit 30 and the upper plate unit 40. formed by On the other hand, when manufacturing the FRTP molded product of the second embodiment or when manufacturing the resin molded product of the third embodiment, the mold 60 (see FIG. 14) according to the shape of the molded product (molded product) ) is installed between the heater unit 20 and the upper plate unit 40, and the inside of the mold 60 is used as a molding space 52 (see FIG. 17) for the FRTP modeled product (resin molded product).

The body frame 10 of the FRTP molded product manufacturing apparatus 1 is a housing in which the heater unit 20, the mold unit 30 and the upper plate unit 40 are installed. are arranged in a positional relationship of

The heater unit 20 is a unit that is installed at the bottom of the body frame 10, constitutes the bottom of the molding spaces 51 and 52 that form the FRTP molded product, and heats the raw material contained in the molding spaces 51 and 52. The heater unit 20 has a flat heater plate 21 or a heater plate 22 with screw holes and a heater 23 .

The flat heater plate 21 is a plate-like member made of metal with a flat upper surface, and is used when manufacturing FRTP blocks. When manufacturing an FRTP block, the space above the flat heater plate 21 is surrounded by the flat heater plate 21, the mold unit 30, and the flat upper plate 41 of the upper plate unit 40, forming an FRTP block molding space 51. . Flat heater plate 21 defines the lower surface of molding space 51 .

A heater 23 controlled by a control unit (not shown) is embedded inside the flat heater plate 21 . The heater 23 has a configuration in which a plurality of rod-shaped heating wires that generate heat by resistance heating when energized are arranged in parallel in a lateral direction (X direction in FIG. 1) parallel to the upper surface of the flat heater plate 21. . When manufacturing the FRTP block, a reinforcing fiber material and a thermoplastic resin material, which are raw materials, are placed (arranged) on the upper surface of the flat heater plate 21, and the heater 23 generates heat, thereby heating the flat heater plate 21 and forming a flat heater. The raw material on the plate 21, in other words the raw material in the FRTP block molding space 51, is heated from below.

As shown in FIG. 13, the heater plate 22 with screw holes is a plate-like member made of metal having screw holes 220 formed on its upper surface. It is used when manufacturing In this embodiment, the mold 60 is composed of a lower mold 62 and an upper mold 64, and the lower mold 62 is attached to the heater plate 22 with screw holes as shown in FIG. The lower mold 62 is attached to the heater plate 22 with screw holes by fitting the screws (not shown) engaged with the lower mold 62 into the screw holes 220 in the upper surface of the heater plate 22 with screw holes. When manufacturing an FRTP modeled product (resin molded product) using the mold 60, the FRTP modeled product molding space (resin molding A product molding space) 52 is formed.

As shown in FIG. 4, a plurality of screw holes 220 are formed at predetermined intervals in the heater plate 22 with screw holes of this embodiment. Such a heater plate 22 with screw holes is preferable because the lower molds 62 of various molds 60 with different sizes can be passed through. On the other hand, if the heater plate 22 with screw holes is a dedicated heater plate 22 corresponding to a specific mold 60 (lower mold 62), the screw holes 220 are necessary for mounting the lower mold 62. It suffices if it is formed only at the location.

A heater 23 controlled by a control unit (not shown) is embedded in the heater plate 22 with screw holes in the same configuration as the flat heater plate 21 described above. When manufacturing an FRTP modeled product (resin molded product) using the mold 60, the lower mold 62 (inside the mold 60) contains a reinforcing fiber material and a thermoplastic resin material (in the case of manufacturing a resin molded product, Only the thermoplastic resin material) is placed (arranged), the heater 23 generates heat, the heater plate 22 with screw holes is heated, the lower mold 62 is heated, and the raw material in the mold 60 is, in other words, For example, the raw material in the FRTP modeled product molding space (resin molded product molding space) 52 is heated from below.

Heating the FRTP block molding space 51 and the FRTP modeled product molding space 52 by the heater 23 causes the thermoplastic resin material to melt and be appropriately combined with the reinforcing fiber material to be in a melted or flexible state, and the molding spaces 51 and 52 A controller (not shown) fills the molding spaces 51 and 52 in order from below along the shape of .

Specifically, the heating by the heater 23 is such that the molding spaces 51 and 52, the raw material, and the already formed FRTP portion are at an appropriate temperature (heat) and an appropriate temperature distribution (heat) in relation to the pressure acting on them. distribution), or to follow appropriate changes in temperature (heat) or temperature distribution (heat distribution).

In this way, the raw material introduced into the FRTP block molding space 51 and the FRTP modeled product molding space 52 is exposed to a desired temperature (heat) profile and pressure profile to fill the molding spaces 51 and 52 and form a desired shape. FRTP block or FRTP modeled product.

Further, the heating by the heater 23 of the resin molded article molding space 52 according to the third embodiment, which will be described later, heats the thermoplastic resin material to be in a melted state or a flexible state, and the molding space is heated along the shape of the molding space 52 . It is controlled by a control unit (not shown) so that the space (gap) in the mold is filled in order from the lower side of 52 .

Specifically, the heating by the heater 23 is performed so that the molding space 52 and the raw material have an appropriate temperature (heat) and an appropriate temperature distribution (heat distribution) in relation to the pressure acting on them, or It is controlled so as to follow appropriate changes in temperature (heat) or temperature distribution (heat distribution). That is, the raw material introduced into the resin molded article molding space 52 is exposed to a desired temperature (heat) profile and pressure profile and filled into the molding space 52 to form a resin molded article having a desired shape.

The formwork unit 30 is a unit that arranges the formwork 31 that defines the FRTP block molding space 51 or forms the surrounding environment of the FRTP modeled product molding space (resin molded product molding space) 52 at a desired position. The formwork unit 30 has a formwork 31 and a formwork driving section 38 .

As shown in FIG. 6, the formwork 31 is formed by connecting two pairs of metal plate members that face each other so as to be orthogonal to each other so as to form corners that close four sides of the periphery. It is a cylindrical member. That is, the formwork 31 is a rectangular frame-shaped member that is open in the vertical direction. The height of the formwork 31 is at least equal to or higher than the height of the FRTP block or FRTP modeled product (resin molded product) to be manufactured. The formwork 31 is vertically moved by the formwork drive unit 38 .

As shown in FIG. 10, the lower edge of the formwork 31 is formed with a flat plate-shaped locking portion (barb) 32 that protrudes inward along the lower edge by a slight width. When the FRTP block is formed in the FRTP block molding space 51, the engaging portion 32 is engaged with the lower peripheral edge of the FRTP block. As a result, the FRTP block rises with the formwork 31 when the formwork 31 moves upward. The locking portion 32 is a hook portion for that purpose.

The mold drive unit 38 is controlled by a control unit (not shown) to move the mold 31 vertically within a predetermined range. The form drive unit 38 is configured by an arbitrary drive mechanism such as an actuator, motor, servo mechanism, or the like. The lower limit of the moving range of the driven mold 31 is the position where the bottom edge of the mold 31 (the edge of the lower opening) contacts the upper surface of the flat heater plate 21 or the heater plate 22 with screw holes of the heater unit 20. be.

There are no particular restrictions on the upper limit of the movement range of the mold 31, but at least between the bottom edge of the mold 31 and the upper surface of the flat heater plate 21 or the heater plate 22 with screw holes, the manufactured FRTP molded product is laterally positioned. The formwork 31 has to be raised to a height where there is an opening that can be removed from. Specifically, when manufacturing an FRTP block, the bottom edge of the formwork 31 needs to rise above the flat top plate 41 of the top plate unit 40, which defines the top surface of the FRTP block. be. In addition, when manufacturing an FRTP modeled product (resin molded product) using the mold 60, the FRTP modeled product (resin molded product) is removed from the mold 60 and removed from the side direction. 31 (bottom side of formwork 31) needs to be raised.

The upper plate unit 40 is a unit that defines the upper surface of the FRTP molded product and presses the raw material in the molding spaces 51 and 52 with a predetermined pressure. The top plate unit 40 has a flat top plate 41 or a top plate with screw holes 42 and a top plate drive section 48 .

The flat upper plate 41 is a metal plate member with a flat lower surface, and is used when manufacturing FRTP blocks. When manufacturing the FRTP block, the flat upper plate 41 defines the upper surface of the FRTP block molding space 51 and is pushed downward with a predetermined force by the upper plate driving section 48 to press the raw material in the FRTP block molding space 51. pressure.

The upper plate 42 with screw holes is used when a mold 60 is used to manufacture an FRTP modeled product (resin molded product) with a desired shape. An upper die 64 is attached to the upper plate 42 with screw holes as shown in FIG. As shown in FIG. 13, screw holes 420 are formed in the upper plate 42 with screw holes, and screws (not shown) engaged with the upper mold 64 are fitted into the screw holes 420, thereby A mold 64 is attached to the top plate 42 with screw holes.

As shown in FIG. 13, a plurality of screw holes 420 are formed at predetermined intervals in the upper plate 42 with screw holes of the present embodiment. Such an upper plate 42 with screw holes is preferable because the upper molds 64 of various molds 60 having different sizes can be passed through. On the other hand, when the upper plate 42 with screw holes is a dedicated heater plate 22 corresponding to a specific mold 60 (upper mold 64), the screw holes 220 are necessary for mounting the upper mold 64 thereon. It suffices if it is formed only at the location.

When manufacturing an FRTP modeled product (resin molded product) using the mold 60, the lower mold 62 (inside the mold 60) contains a reinforcing fiber material and a thermoplastic resin material (in the case of manufacturing a resin molded product, The raw material in the mold 60, that is, in the FRTP modeled product molding space (resin molded product molding space) 52 is heated from below via the heater unit 20. At this time, the upper plate 42 with screw holes is pushed downward with a predetermined force by the upper plate drive unit 48, the upper mold 64 is pressed against the lower mold 62, and the inside of the mold 60, that is, the FRTP molded article The raw material in the molding space (resin molding molding space) 52 is pressurized.

The upper plate drive unit 48 is controlled by a control unit (not shown) to move the flat upper plate 41 or the screw hole upper plate 42 vertically within a predetermined range. The upper plate driving section 48 is configured by an arbitrary driving mechanism such as an actuator, a motor, a servo mechanism, or the like.

The lower limit of the movement range of the driven flat top plate 41 or screw hole top plate 42 is the lower surface of the flat top plate 41 or screw hole top plate 42 and the flat heater plate 21 or screw hole heater plate 22 of the heater unit 20 . The distance between the upper surface of the object to be formed (FRTP block, FRTP modeled product, resin molded product) or molded part (one layer when laminating to form FRTP block or FRTP modeled product (resin molded product It is the position where the thickness of the thinnest part of the molded part corresponding to ) is. In practice, the lower limit of the movement range of the flat upper plate 41 or the screw hole upper plate 42 is such that the lower surface of the flat upper plate 41 or the screw hole upper plate 42 is the flat heater plate 21 of the heater unit 20 or the screw hole heater. This is the position where the upper surface of the plate 22 is substantially in contact.

There are no particular restrictions on the upper limit of the movement range of the flat top plate 41 or the top plate with screw holes 42, but at least when the formwork 31 moves to the highest position, the flat top plate 41 or the top plate with screw holes 42 can be moved. The flat upper plate 41 or the screw hole upper plate 42 needs to be raised to a height where the lower surface is positioned at approximately the same height as the upper edge of the mold 31 (the edge of the upper opening).

Each part of the FRTP molded product manufacturing apparatus (resin molded product manufacturing apparatus) 1 configured as described above is controlled by a control unit (not shown). Specifically, heating by the heater 23 of the heater unit 20, movement of the formwork 31 by the formwork drive section 38 of the formwork unit 30, flat upper plate 41 and screw hole by the upper plate drive section 48 of the upper plate unit 40 The movement of the upper plate 42, the pressure (pressing) on the raw material in the FRTP block molding space 51 and the FRTP modeled product molding space (resin molded product molding space) 52 by the upper plate driving unit 48 of the upper plate unit 40, etc. are controlled by the control unit controlled by

The FRTP molded product manufacturing apparatus 1 controls the temperature of the heater 23, the temperature of the FRTP block molding space 51 and the FRTP modeled product molding space (resin molded product molding space) 52, the position of the mold frame 31, the flat upper plate 41 and the upper surface with screw holes. It has various sensors for detecting the position of the plate 42, the pressing force on the raw material in the FRTP block molding space 51 and the FRTP modeled product molding space (resin molded product molding space) 52 by the upper plate driving unit 48, etc. Based on the output from these sensors, the control unit controls the FRTP molded product manufacturing apparatus ( It controls each part of the resin molded product manufacturing apparatus) 1.

A method of manufacturing a fiber reinforced thermoplastic (FRTP) molded article (resin molded article) using the FRTP molded article manufacturing apparatus (resin molded article manufacturing apparatus) 1 configured as described above will be described below.

First Embodiment As a first embodiment of the FRTP molded product manufacturing method according to the present invention, a method for manufacturing an FRTP block will be described with reference to FIGS. 3 to 11. FIG. The FRTP block is a substantially rectangular parallelepiped FRTP molded product that is suitable for processing in a later step to form a desired product. In this embodiment, the FRTP block is manufactured using the FRTP molded product manufacturing apparatus 1 described above.

Further, in the present embodiment, FRTP using carbon fiber (carbon fiber) as a reinforcing fiber, and in particular, using a carbon sheet formed into a sheet by joining or weaving carbon fiber, carbon fiber reinforced thermoplastic A method of manufacturing a plastic (CFRTP) molded article is described.

Here, the "carbon sheet (carbon sheet)" used in the present embodiment is a material substantially composed only of carbon fibers, and is a sheet-like member obtained by binding carbon fibers or carbon fiber bundles with a resin carbide or the like. means a sheet-like carbon fiber material such as a carbon fiber fabric such as a plain weave or a twill weave, or a carbon fiber nonwoven fabric formed by interlacing carbon fibers. It also includes a material in which a carbon fiber precursor that is carbonized by heat treatment is formed into a sheet. It also includes a sheet-like member impregnated or coated with a slight amount of resin to bind carbon fibers. On the other hand, members such as so-called prepregs, which already have sufficient strength and workability by impregnating carbon fibers with a sufficient amount of resin or by forming resin layers on the front and back of carbon fibers, are formed into sheets. It shall not be included even if it is formed.

However, with the FRTP molded product manufacturing apparatus 1 described above and the manufacturing method described later, it is possible to manufacture CFRTP molded products even using materials such as prepreg, and it is possible to manufacture CFRTP molded products more easily than before. However, the function and effect of being able to manufacture a CFRTP molded product in a single manufacturing process from a carbon sheet material (reinforcing fiber material) and a thermoplastic resin material without going through intermediate molded products such as prepreg are maximized. In order to enjoy it, it is preferable to use the above-described "carbon sheet" as the reinforcing fiber material, and from such a viewpoint, the "carbon sheet" is defined as described above in the present embodiment.

In addition, as the thermoplastic resin material used in this embodiment, what is used in the form of so-called pellets (resin pellets) is used. It may be arbitrarily selected according to the type of thermoplastic resin, the use of the CFRTP molded product, compatibility with the carbon sheet, and the like.

FIG. 3 is a flow chart showing a method of manufacturing a CFRTP block.
When manufacturing a CFRTP block, first, as shown in FIG. A flat upper plate 41 having no screw holes on the surface is mounted as the upper plate of 40 (step 10).

Then, as shown in FIG. 5, a carbon sheet 81 containing carbon fibers as a reinforcing fiber material and resin pellets 82 as a thermoplastic resin material are put on the flat heater plate 21 (step 11). The number of carbon sheets 81 and the amount of resin pellets 82 to be charged at this time are appropriately determined according to the physical properties of the thermoplastic resin material or the desired (to be manufactured) thickness of the CFRTP molded product.

Next, as shown in FIG. 6, the form drive unit 38 is driven to lower the form 31 until the lower edge of the form 31 touches the upper surface of the flat heater plate 21 (step 12). As a result, an FRTP block molding space 51 is formed on the upper surface of the flat heater plate 21 and is surrounded by the mold 31 on four sides.

Next, as shown in FIG. 7, heating is started by the heater 23, and the upper plate drive unit 48 is driven to lower the flat upper plate 41 with a predetermined pressure, thereby pressurizing the raw material in the FRTP block molding space 51. (pressing) (step 13). As a result, inside the FRTP block molding space 51, the resin pellets 82 are melted and flowed over the entire upper surface of the flat heater plate 21 without gaps, thereby filling the FRTP block molding space 51 in order from the bottom. . At this time, the molten resin is sequentially filled into the FRTP block molding space 51 from the lower side without gaps, and the flat upper plate 41 is moved by the upper plate driving unit 48 so that the molten resin is impregnated without gaps between the carbon fibers of the carbon sheet 81 . The pressurizing force (pressing force) to the FRTP block molding space 51 via is controlled.

As a result, such molten resin impregnates the carbon sheet 81 between the carbon fibers, and forms resin layers on the upper and lower sides of the carbon sheet 81 .

By heating and pressurizing in step 13, the impregnation of the thermoplastic resin into the carbon fibers of the carbon sheet and the formation of further resin layers on the front and back sides of the carbon sheet are performed collectively. In other words, the structure of the formed CFRTP layer depends on the arrangement of the carbon sheet and the resin pellets when the raw material is put into the FRTP block molding space 51 in step 11, the amount of the resin pellets to be put in, and the heating and pressurization. It can be easily adjusted by the method.

That is, when it is desired to simply produce a carbon sheet impregnated with a thermoplastic resin (a so-called prepreg, which is also a type of CFRTP molded product), an amount of the thermoplastic resin substantially equal to the amount impregnated in the carbon sheet is added to the resin. The material is charged as pellets, and the flat upper plate 41 is lowered until the distance from the flat heater plate 21 reaches a height substantially equal to the thickness of the carbon sheet to press the raw material with high pressure. In this way, a CFRTP molded article (prepreg) having high airtightness and light shielding properties can be produced without voids and ensuring mechanical properties (strength, elastic modulus, etc.).

On the other hand, a desired resin layer can be formed on the front and back sides of the above-described carbon sheet by adding a larger (surplus) amount of thermoplastic resin than the amount impregnated into the carbon sheet as resin pellets. The amount of resin pellets to be added at this time is adjusted so that the amount of thermoplastic resin corresponding to the thickness of the resin layer formed on both the front and back sides of the carbon sheet is added to the amount impregnated into the carbon sheet. do.

In addition, when it is desired to form a resin layer only on the lower surface of the carbon sheet, first, the resin pellets are uniformly arranged on the upper surface of the flat heater plate 21, and the carbon sheet is placed thereon. The flat upper plate 41 is lowered until it contacts the carbon sheet, and then, while applying high pressure, the flat upper plate 41 is moved until the distance from the flat heater plate 21 becomes equal to the combined thickness of the resin layer and the carbon sheet. Gradually lower. As a result, a CFRTP layer (CFRTP molded article) is formed in which the carbon sheet is arranged on the flat upper plate 41 side and the resin layer is arranged on the flat heater plate 21 side.

When it is desired to form a resin layer only on the upper surface of the carbon sheet, the carbon sheet is first placed on the upper surface of the flat heater plate 21, and the resin pellets are evenly placed thereon. With the resin pellets sufficiently melted, the flat upper plate 41 is gradually lowered until the distance from the flat heater plate 21 becomes equal to the combined thickness of the resin layer and the carbon sheet, and the FRTP block molding space 51 is opened. Slowly pressurize the raw material inside with normal or slightly weaker pressure. As a result, the thermoplastic resin placed on the carbon sheet is not pushed out to the bottom side of the carbon sheet, and a CFRTP layer (CFRTP molded product) is formed in which the resin layer is placed only on the top side of the carbon sheet. be done.

When it is desired to form a resin layer on both the top and bottom surfaces (front and back) of the carbon sheet, the resin pellets are first uniformly placed on the upper surface of the flat heater plate 21, the carbon sheet is placed thereon, and then the resin pellets are evenly spread thereon. be placed on.

At this time, under the carbon sheet (flat heater plate 21 side), an amount of resin pellets corresponding to the thickness of the resin layer formed on the underside of the carbon sheet and half of the thermoplastic resin impregnated into the carbon sheet A large predetermined amount of resin pellets are placed. In addition, on the upper side of the carbon sheet (flat top plate 41 side), an amount of resin pellets corresponding to the thickness of the resin layer formed on the upper surface of the carbon sheet and a portion less than half of the thermoplastic resin impregnated in the carbon sheet. Place a fixed amount of resin pellets.

In step 13, the resin pellets placed on the lower side of the carbon sheet (flat heater plate 21 side) are dissolved, and the resin pellets placed on the upper side of the carbon sheet (flat upper plate 41 side) are not dissolved. From the sufficient state, the flat upper plate 41 is lowered to gradually pressurize the raw material in the FRTP block molding space 51 .

As a result, the carbon sheet is first impregnated with the thermoplastic resin in which the resin pellets arranged on the lower side of the carbon sheet are dissolved, and then the resin pellets arranged on the upper side of the carbon sheet are dissolved. part impregnates the carbon sheet. When the impregnation of the thermoplastic resin into the carbon sheet is completed, excess thermoplastic resin that has not been used for impregnation remains on both the upper and lower sides of the carbon sheet, forming a resin layer on each side. .

In the heating and pressing in step 13, depending on the configuration of the CFRTP layer (CFRTP molded article) to be manufactured, the impregnation of the carbon sheet with the thermoplastic resin and the formation of the resin layers on the top and bottom of the carbon sheet are performed respectively. When the above-described state is reached, the flat upper plate 41 stops descending.

When the flat upper plate 41 stops descending, the CFRTP layer 831 is formed in the FRTP block molding space 51 (inside the mold frame 31) as shown in FIG. 8 and as described above. to cool the interior of the FRTP block molding space 51 (step 14). Cooling is natural cooling in this embodiment, but forced cooling may be performed by the cooling device provided in the FRTP molded product manufacturing apparatus 1 .

When the cooling is sufficiently performed, as shown in FIG. 9, the form drive unit 38 and the upper plate drive unit 48 are driven to raise the form 31 and the flat upper plate 41 (step 15). As shown in FIG. 10, since the locking portion 32 is formed at the lower edge of the formwork 31, the formed CFRTP layer 831 is lifted together with the formwork 31 and flat top plate 41 together.

If the object to be manufactured can be a single layer of CFRTP (step 16), the CFRTP layer 831 is taken out as a CFRTP block 831. That is, as shown in FIG. 11, the upper plate driving section 48 is driven until an opening is formed between the lower surface of the flat upper plate 41 and the upper edge of the formwork 31 so that the CFRTP block 831 can be taken out. to lift the upper plate 41 (step 17), and take out the CFRTP block 831 from the opening (step 18).

On the other hand, when manufacturing a multi-layered and thicker CFRTP block (step 16), return to step 11 and repeat steps 11 to 16. As a result, in the FRTP block molding space 51, a CFRTP block of a desired size is formed in which layers of reinforcing fibers are arranged in multiple layers and resin layers are arranged therebetween.

Then, when the CFRTP block 831 having the desired thickness is formed (step 16), the upper plate 41 is lifted (step 17), and the CFRTP block 831 is taken out from between the flat upper plate 41 and the mold 31 (step 18). .

As described above, according to the method for manufacturing the CFRTP block of the present embodiment, the CFRTP block can be easily manufactured in a simple process using the carbon sheet and the resin pellet as raw materials. That is, the carbon fiber of the carbon sheet is impregnated with a thermoplastic resin supplied as pellets, and if necessary, a resin layer is formed on either or both of the front surface and the back surface of the carbon sheet. The manufacturing process of stacking CFRTP layers to form a block can be collectively performed by the above-described series of steps, and the CFRTP block can be easily manufactured by extremely simple steps.

Second Embodiment As a second embodiment of the FRTP molded product manufacturing method according to the present invention, a CFRTP molded product having an arbitrary shape and having raised characters formed on the surface (hereinafter, such a CFRTP molded product is referred to as CFRTP A method of manufacturing a shaped product) will now be described with reference to FIGS. 12-21. In this embodiment, the CFRTP modeled product is a modeled product that can be used as a product as it is, but it is not limited to this, and even if it is like a semi-finished product (nth molded product) for further processing. good. In this embodiment, a CFRTP molded product is manufactured using the FRTP molded product manufacturing apparatus 1 described above.

The carbon sheet and resin pellets used in this embodiment are the same as in the first embodiment. The following description will focus on differences from the first embodiment.
FIG. 12 is a flow chart showing a method for manufacturing a CFRTP shaped article.

When manufacturing a CFRTP modeled product, as shown in FIG. As the upper plate of the upper plate unit 40, the upper plate 42 with screw holes is mounted (step 20).

Furthermore, when manufacturing a CFRTP modeled product, as shown in FIG. Attach the upper mold 64 of 60 (step 21). The lower mold 62 and the upper mold 64 are attached to the heater plate 22 with screw holes and the upper plate 42 with screw holes, respectively, by screws (not shown). In addition, when the screw hole upper plate 42 descends, the lower mold 62 and the upper mold 64 are brought into contact with each other or fitted together, and inside (between the lower mold 62 and the upper mold 64) Their relative positions are adjusted and installed so that the desired shape of the FRTP model molding space 52 is formed.

After attaching the lower mold 62 and the upper mold 64, as shown in FIG. 15, the carbon sheet 81 and the resin pellets 82 are placed on the lower mold 62 (step 22). At this time, the amount of resin pellets 82 to be placed is adjusted to the volume of the CFRTP modeled product (molded product) to be manufactured, and the number of carbon sheets 81 is adjusted to the desired strength of the CFRTP modeled product (to be manufactured). Decide accordingly.

Next, as shown in FIG. 16, the form drive unit 38 is driven to lower the form 31 until the lower edge of the form 31 touches the upper surface of the heater plate 22 with screw holes (step 23). At this time, for the upper plate 42 with screw holes, the upper plate drive unit 48 is driven so that the upper plate 42 with screw holes is arranged near the upper portion of the mold 31 . At this time, the upper mold 64 is not joined or fitted with the lower mold 62 .

Next, as shown in FIG. 17, heating is started by the heater 23, and the upper plate driving section 48 is driven to lower the upper plate 42 with screw holes with a predetermined pressure, and the upper mold 64 is moved to the lower mold 62. , and pressurize (press) the raw material on the lower mold 62 (within the FRTP molded product molding space 52) (step 24). As a result, the resin pellets 82 are melted inside the FRTP modeled product molding space 52 and flowed without gaps throughout the FRTP modeled product molding space 52, and the interior of the FRTP modeled product molding space 52 is filled with the carbon sheet and the thermoplastic resin. filled with At this time, the molten resin fills the entire area of the FRTP modeled product molding space 52 without any gaps, and the screw by the upper plate driving unit 48 is set so that the resin impregnates between the carbon fibers of the carbon sheet 81 without any gaps. The pressurizing force (pressing force) to the FRTP molded article molding space 52 via the holed upper plate 42 is controlled.

When the descent of the upper plate 42 with screw holes stops, as shown in FIG. The interior of the model molding space 52 is cooled (step 25).

After sufficient cooling, as shown in FIG. 19, the mold driving unit 38 and the upper plate driving unit 48 are driven to raise the mold 31 and the upper plate 42 with screw holes, that is, the upper mold 64 is raised. Then, the mold 60 is opened (step 26), and the CFRTP molded article 832 is taken out from the mold 60 (lower mold 62) (step 27).

As described above, according to the method for manufacturing a CFRTP molded article of the present embodiment, a CFRTP molded article (CFRTP molded article) having a desired shape can be easily manufactured in a simple process using a carbon sheet and a resin pellet as raw materials. be able to. That is, the manufacturing process of impregnating the carbon fiber of the carbon sheet with a thermoplastic resin supplied as pellets, molding the formed CFRTP into a desired shape, and obtaining the desired CFRTP modeled product is collectively It can be performed by the series of steps described above, and the CFRTP modeled product can be easily manufactured by extremely simple steps.

An example of a modeled product (molded product) manufactured by the method for manufacturing a CFRTP modeled product according to the present embodiment will be described with reference to FIGS. 20 and 21. FIG.
Using a mold 60 having recesses 620 for forming engraved characters (embossed characters) as shown in FIG. The situation is shown in FIG. As shown in FIG. 21, the upper surface of the CFRTP model 832 has clearly formed embossed characters.

As described above, according to the method for manufacturing a CFRTP modeled product of the present embodiment, raised characters such as so-called engraved characters and engraved patterns as shown in FIG. CFRTP shaped articles can also be easily manufactured with a simple process. In addition, particularly in the method and apparatus according to the present invention, even if the product (modeled product) is partially uneven in thickness or has an extremely shallow concave portion 620 such as for forming raised characters, Since the carbon sheet and thermoplastic resin are molded at once (batch), the resin can be appropriately filled to the entire area (entire space) of the mold, including those details, to produce high-precision CFRTP molded products. can do.

In addition, since the manufacturing method of the present embodiment is a method similar to injection molding in which a mold is filled with a molten thermoplastic resin, it is possible to form raised characters and the like with high precision compared to ordinary press molding. Also from this point of view, it is possible to manufacture a CFRTP modeled product with high accuracy.

Third Embodiment As a third embodiment of the present invention, a method of manufacturing a resin product using a normal thermoplastic resin as a raw material will be described. The resin product manufacturing method of the present embodiment differs from the CFRTP modeled product manufacturing method of the second embodiment only in terms of raw materials. Therefore, here, the main steps and differences of the resin product manufacturing method will be mainly described, and descriptions of detailed configurations, conditions, etc. common to the second embodiment will be omitted.

The raw material used in this embodiment is thermoplastic resin pellets. As a general rule, no fibrous material is contained, but fillers and reinforcing agents containing fibrous materials, coloring agents, and the like may be contained as additives.

A resin-molded product using such a thermoplastic resin (in the third embodiment, even when referred to as a resin-molded product, it means an article molded using a mold (mold). The same concept as "resin modeled product") is also manufactured by the same method as the flow chart in FIG. In the flow chart of the method for manufacturing a CFRTP modeled product shown in FIG. 12, only the step 22 of "inserting the carbon sheet/resin pellet" is different in the third embodiment. In the present embodiment, since raw materials that do not contain a carbon sheet are used, step 22 is a step of "throwing in resin pellets."

When manufacturing a resin modeled product using a thermoplastic resin, first, as shown in FIG. ). Next, as shown in FIG. 14, the lower mold 62 of the mold 60 is attached to the heater plate 22, and the upper mold 64 of the mold 60 is attached to the upper plate 42 with screw holes of the upper plate unit 40 (step 21). ). The lower mold 62 and the upper mold 64 are mounted after their relative positions are adjusted so that the desired shape of the resin molding product molding space 52 is formed in the closed interior when the upper plate 42 is lowered. be done.

Next, as shown in FIG. 15, resin pellets 82 are placed on the lower mold 62 (step 22). The carbon sheet 81 illustrated in FIG. 15 is not placed in this embodiment. The amount of resin pellets 82 to be placed is determined according to the volume of the resin molded product to be manufactured.

Next, as shown in FIG. 16, the form drive unit 38 is driven to lower the form 31 until the lower edge of the form 31 touches the upper surface of the heater plate 22 (step 23). , heating is started by the heater 23, and the upper plate drive unit 48 is driven to lower the upper plate 42 with a predetermined pressure, and the upper metal mold 64 is passed over the lower metal mold 62 (inside the resin molding product molding space 52). are pressurized (step 24). As a result, the resin pellets 82 are melted inside the resin-molded product molding space 52 and flowed over the entire area of the resin-molded product molding space 52 without gaps, so that the interior of the resin-molded product molding space 52 is filled with the thermoplastic resin. state. The pressurizing force (pressing force) applied to the resin-molded product molding space 52 by the upper plate driving unit 48 via the upper mold 64 is adjusted so that the molten resin fills the resin-molded product molding space 52 without any gaps. controlled.

When the lowering of the upper plate 42 with screw holes stops, as shown in FIG. The interior of the model molding space 52 is cooled (step 25). After sufficient cooling, as shown in FIG. 19, the mold driving unit 38 and the upper plate driving unit 48 are driven to raise the mold 31 and the upper plate 42 with screw holes, that is, the upper mold 64 is raised. Then, the mold 60 is opened (step 26), and the resin molded product 832 is taken out from the mold 60 (lower mold 62) (step 27).

According to the method of manufacturing a resin-molded product by such a method, the mold can be made to have a relatively simple structure with a small thickness. That is, in injection molding, since pressure is applied to the molten resin material injected through the nozzle, the pressure is locally applied (concentrated) to a predetermined portion of the cavity according to the shape of the cavity. Therefore, in injection molding, the mold must have a certain thickness in order to ensure strength. However, in the configuration of this embodiment, as shown in FIG. 16 and the like, the entire upper die 64 is pressed toward the lower die 62 via the upper plate 42 by driving the upper plate driving section 48. , the upper die 64 and the lower die 62 are subjected to pressure over the entire surface of the die, and local concentration of the pressure can be prevented. As a result, the overall thickness of the mold can be made simpler than in the case of injection molding.

Also, according to the method of manufacturing a resin-molded product by such a method, unlike conventional molding methods such as injection molding, it is possible to easily manufacture a plurality of molded products at the same time.

Specifically, for example, when there is a request to mold multiple identical molded products at the same time, in conventional injection molding, multiple molded products can be formed in a single injection process. A new mold with a cavity) must be manufactured. However, according to the method of the present invention, in step 21 described above with reference to FIG. It is only necessary to attach the upper plate 42 (upper mold) with screw holes. In other words, it is not necessary for these multiple molds to be integrated, and the same molds are arranged in the number that can be attached to the heater plate 22 and the upper plate 42 with screw holes (depending on the area of the heater plate 22, etc.). All you have to do is

Furthermore, a mold having substantially the same height (a form in which the lower mold and the upper mold are combined at the same time), and can be molded with the same temperature (heat) profile and pressure profile If it is a mold for molding an article, it is also possible to simultaneously mold these by attaching molds for different molded articles to the heater plate 22 and the top plate 42 with screw holes at the same time.

As described above, according to the manufacturing method of the present invention, a desired molded product can be molded in a form that can be variously adapted to the demands related to the manufacturing of the molded product, which is extremely effective in the manufacturing (molding) of the resin molded product. be. This operation and effect are common to the manufacturing apparatus 1 according to the present invention and the FRTP molded article manufacturing method of the second embodiment, and are also the operation and effect of the present invention.

As a result, it is also possible to use, for example, aluminum molds. In addition, it becomes possible to easily form a cavity by cutting such a soft material. As a result, for example, the cost of manufacturing a mold (mold) can be reduced to 1/5 to 1/10 of the cost of manufacturing a mold for injection molding.

Also, unlike injection molding, the apparatus for manufacturing resin molded products according to the present invention does not require a resin injection mechanism such as a nozzle or runner. In injection molding, it is necessary to clean the nozzle each time a so-called material change or color change is performed. However, in the present embodiment, such work is not required, and a resin molded product can be easily manufactured.

Also, in injection molding, a large amount of resin material remains in the resin injection mechanism, or at least unnecessary resin that is not used for molding remains in the runner, resulting in a lot of waste of resin material. However, in this embodiment, since only the material necessary for molding the molded article needs to be put into the mold, no wasted raw material is required, which is extremely effective in terms of cost and environment.

In the case of injection molding, traces (gate traces) of the material injection port of the nozzle are formed on the surface of the product. Since there is no injection from the resin, such gate marks do not occur, and it is possible to mold a resin-molded product that is excellent in terms of quality (beauty).

Furthermore, in resin molding, due to the difference in the amount of shrinkage due to the difference in the thickness of the molded product, there are cases where recesses called "sink marks" occur on the surface of the molded product, for example, where ribs are formed on the back side. In injection molding, the occurrence of sink marks is suppressed by holding pressure, in which cooling is performed while pressure is applied to the nozzle after molding. Therefore, sink marks cannot be sufficiently prevented. However, in the apparatus for manufacturing a resin molded product according to the present invention, as described above, the upper plate driving section 48 is driven to press the entire upper die 64 toward the lower die 62 through the upper plate 42. Therefore, it is possible to apply a sufficient and uniform surface pressure to the entire cavity, and to effectively suppress sink marks. Therefore, according to the manufacturing method and manufacturing apparatus for a resin-molded article according to the present invention, it is possible to manufacture a resin-molded article excellent in appearance in which so-called sink marks are sufficiently suppressed.

Modifications The present invention is not limited to the above-described embodiments, and various suitable modifications are possible.

For example, the fiber-reinforced thermoplastic (FRTP) molded article to be manufactured by the present invention is not limited to those using carbon fiber (carbon fiber) as the reinforcing fiber. Any reinforcing fiber such as glass fiber, aramid fiber, or quartz glass (quartz) fiber may be used as the reinforcing fiber. In addition, as described in the third embodiment, the present invention can also be applied to the production of molded articles made from ordinary thermoplastic resins that do not contain reinforcing fibers. Even when applied to the manufacture of ordinary resin-molded products (resin-molded products), the present invention is superior to conventional molds in terms of ease of production of molds (molds), reduction of initial costs, prevention of waste of raw materials, etc. It is possible to provide an extremely excellent manufacturing apparatus and manufacturing method for the apparatus and method.

The type of reinforcing fiber to be used may be appropriately selected according to the conditions such as the strength required for the FRTP molded product to be manufactured, or the application of the FRTP product. With the manufacturing method and manufacturing apparatus of the present invention, regardless of which reinforcing fiber is selected, a primary molded product such as a so-called prepreg in which the reinforcing fiber is impregnated with a resin in advance before the molding process. without the need to prepare (manufacture) or to prepare (manufacture) a molded product with a resin layer laminated on it. It is possible to make it a product.

Also, the reinforcing fiber material used for manufacturing the FRTP according to the present invention is not limited to a sheet-like material such as the carbon sheet described above. For example, a thread-like fiber material may be used as it is as a reinforcing fiber material, as is often applied when glass fibers are combined with a resin material. In this case, for example, finely cut reinforcing fibers and a thermoplastic resin are uniformly mixed, placed in a molding space or a mold, and heated and pressed by the method of the present embodiment described above to form a block or metal. It can be formed into an FRTP molded product having a desired shape according to the mold.

Further, the above-described FRTP molded product manufacturing apparatus 1 has a mold unit 30. In the second and third embodiments for manufacturing FRTP molded products or resin molded products, this mold unit 30 is , FRTP modeled product molding space (resin modeled product molding space) 52, and is not directly necessary for molding. Therefore, in the apparatus for manufacturing FRTP molded products or resin molded products, if there is no need to adjust the surrounding environment, the formwork unit 30 may not be provided, or the formwork unit 30 may be provided. You don't have to drive it.

Further, in the second and third embodiments for manufacturing an FRTP modeled product or a resin modeled product, the step of lowering the formwork 31 shown in FIG. 16 (step 23 in FIG. 12) and the formwork 31 shown in FIG. The raising step (part of step 26 in FIG. 12) need not be performed.

However, even when manufacturing an FRTP modeled product or a resin modeled product, the mold unit 30 is applied to set the surrounding environment of the FRTP modeled product molding space (resin modeled product molding space) 52 to a desired temperature environment, pressure environment, or dust-proof environment. In some cases, good FRTP modeled products (resin modeled products) can be manufactured by keeping the environment. In such a case, it is preferable to use the mold unit 30 also when manufacturing an FRTP modeled product or a resin modeled product.

Also, the installation form of the heater 23 with respect to the heater plates 21 and 22 is not limited to the above example, and may be configured in any form.

Also, in the FRTP molded product manufacturing apparatus 1 described above, the heater unit 20 is configured to be installed under the body frame 10 . However, a similar heater unit 20 may be installed on the upper plate unit 40 . With such a configuration, in the second and third embodiments for manufacturing an FRTP modeled product or a resin modeled product, for example, it is possible to heat the raw material accommodated in the molding spaces 51 and 52 from above. A desired temperature (heat) profile can be applied to the raw material contained in the molding spaces 51 and 52 .

Further, in the above-described FRTP molded product manufacturing apparatus 1, the mold 31 and the upper plates 41 and 42 may be driven manually without using an actuator such as the mold drive unit 38 or the upper plate drive unit 48. can be

In addition, in the above-described second and third embodiments, the metal mold (mold) for manufacturing the CFRTP modeled product or the resin modeled product is divided into two upper and lower parts. However, as the mold, a mold may be used in which three or more parts (partial molds) are combined to form a molding space having a desired shape in the closed interior. In this case, the resin material (raw material) may be placed on one or a plurality of partial molds forming at least a portion of the vertically lower side, and all or part of the remaining partial molds may be placed, for example, in the vertical direction. It suffices to press from above.

1... FRTP molded product manufacturing equipment (resin molded product manufacturing equipment)
DESCRIPTION OF SYMBOLS 10... Body frame 20... Heater unit 21... Heater plate 211... Material supply position 22... Heater plate with a screw hole 220... Screw hole 23... Heater 30... Form unit 31... Form 32... Locking part 38... Form drive Part 40 Upper plate unit 41 Flat upper plate 42 Upper plate with screw hole 420 Screw hole 48 Upper plate driving unit 51 FRTP block molding space 52 FRTP molded product molding space (resin molded product molding space)
60... Mold 62... Lower mold (partial mold)
620... Recess 64... Upper mold (partial mold)
81... Carbon sheet 82... Resin material (pellet)
831... CFRTP layer (CFRTP block)
832: CFRTP modeled product with raised characters (resin modeled product)

Claims (17)

1. placing a first material comprising a fibrous material and a second material comprising a thermoplastic resin material in a molding space having a desired shape;
   heating the disposed first material and the second material such that at least the second material melts;
   In parallel with the heating step, the arrangement is such that the melted second material impregnates at least the first material, and the first material and the second material fill the molding space. pressing the first material and the second material that have been formed;
   cooling the molding space such that the first material and the second material solidify;
   A method for producing an FRTP molded product, characterized by having
2. The heating step heats the arranged first material and second material from the side of the surface on which the first material and the second material are placed in the molding space,
   2. The pressurizing step pressurizes the placed first material and second material from the side of the surface opposite to the surface on the heating side in the molding space. A method for manufacturing the described FRTP molded article.
3. 3. The method according to claim 1 or 2, wherein the step of pressurizing gradually presses the first material and the second material according to the states of the first material and the second material to be heated. A method for manufacturing the described FRTP molded article.
4. The placing step, the heating step, the pressurizing step, and the cooling step are repeated to newly solidify the first material and the second material that have already solidified. 3. The method for manufacturing an FRTP molded article according to claim 1, wherein said second material is laminated in order.
5. In the heating step and the pressurizing step during the repetition,
   At least the second material melts and impregnates the first material of the newly arranged first material and the second material, and the molding space is filled with the first material and the second material. ,
   In the already solidified first material and second material, at least the second material in the vicinity of the surface in contact with the newly arranged first material and second material is melted, and the portion away from the surface 5. The FRTP molded article according to claim 4, wherein the heating and the pressing are performed with a heat distribution and a pressing force that maintain the solidified state of the first material and the second material of Production method.
6. 3. The arranging step comprises arranging the first material and the second material in the substantially rectangular parallelepiped molding space to manufacture a substantially rectangular parallelepiped FRTP block. A method for manufacturing FRTP molded articles.
7. The disposing step is characterized in that the first material and the second material are disposed inside a mold having a molding space of a desired shape inside to manufacture an FRTP modeled product of the desired shape. The method for manufacturing the FRTP molded product according to claim 1 or 2.
8. The method for manufacturing an FRTP molded product according to claim 1 or 2, characterized in that the first material does not contain the thermoplastic resin of the second material.
9. The method for manufacturing an FRTP molded product according to claim 1 or 2, wherein the fiber material includes at least one of carbon fiber, glass fiber, aramid fiber and quartz glass (quartz) fiber.
10. The first material includes a sheet-shaped member in which carbon fibers or carbon fiber bundles are bound with carbonized resin, a carbon fiber fabric in which carbon fibers are plain woven or twilled, a carbon fiber nonwoven fabric formed by entangling carbon fibers, and carbonized by heat treatment. 3. The method for producing an FRTP molded article according to claim 1, wherein the sheet-shaped member is formed by forming a carbon fiber precursor into a sheet.
11. molding space means having a desired shape in which a first material comprising a fibrous material and a second material comprising a thermoplastic resin material are arranged;
    a heater that heats the arranged first material and the second material so that at least the second material melts;
    In parallel with the heating by the heater, the melted second material impregnates at least the first material, and the first material and the second material fill the molding space. and pressurizing means for pressurizing the first material and the second material,
    The FRTP molded product manufacturing apparatus, wherein the molding space means further has a function of cooling the first material and the second material so that they solidify.
12. The molding space means is
    a heater plate that defines the lower surface of the molding space and in which the heater is embedded;
    a formwork defining a side surface of the molding space;
    an upper plate defining an upper surface of the molding space;
    is a substantially rectangular parallelepiped space having
    the pressurizing means pressurizes the first material and the second material placed in the molding space by driving the upper plate with an upper plate driving means;
    12. The apparatus for manufacturing an FRTP molded article according to claim 11, which manufactures an FRTP block having a substantially rectangular parallelepiped shape.
13. The FRTP molded article manufacturing apparatus according to claim 11, wherein the molding space means is a mold having a molding space of a desired shape inside, and manufactures an FRTP molded article of the desired shape.
14. One or more forming at least a part of the vertical lower side of the mold using a mold in which a molding space of a desired shape is formed by combining and closing a plurality of partial molds placing a resin material, which is a thermoplastic resin, in the partial mold of
    heating the disposed resin material so that the resin material melts;
    In parallel with the heating step, through one or more partial molds different from the partial molds in which the resin material is arranged so that the resin material is filled in the molding space, a step of pressurizing the arranged resin material;
    cooling the molding space so that the resin material solidifies;
    A method for producing a resin molded product, comprising:
15. The heating step heats the placed resin material from the side of the surface of the molding space on which the resin material is placed,
    15. The resin molded product according to claim 14, wherein the step of pressurizing pressurizes the arranged resin material from the side of the surface facing the surface on the side to be heated in the molding space. Production method.
16. The step of pressurizing pressurizes the arranged resin material by gradually moving the partial molds until the plurality of partial molds are combined and the molding space is closed,
    16. The method of manufacturing a resin molded product according to claim 14, wherein in the heating step, the resin material is heated according to a state in which the molding space is closed.
17. One or a plurality of molds that form at least a part of the vertically lower side of the mold, in which a molding space of a desired shape is formed inside by combining and closing a plurality of partial molds molding space means in which the partial mold can be installed, and a resin material, which is a thermoplastic resin, is arranged in the partial mold;
    a heater that heats the resin material so that the arranged resin material melts;
    In parallel with the heating by the heater, through one or a plurality of the partial molds different from the partial mold in which the resin material is arranged so that the resin material is filled in the molding space, and pressurizing means for pressurizing the arranged resin material,
    The resin molded product manufacturing apparatus, wherein the molding space means further has a function of cooling the resin material so that it solidifies.

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