Method for manufacturing molded body

Abstract

The present invention pertains to a method for manufacturing a molded body which is integrally molded from a composite material containing reinforcing fibers dispersed in the in-plane direction and a molding material having a higher fluidity than the composite material, the method for manufacturing the molded body comprises the following steps (1)-(3): (1) a step for fixing the composite material to a first molding die having a cavity having a larger area than the composite material in plan view by means of a plurality of fixing members provided in the first molding die; (2) a step in which a second molding die is moved toward the composite material fixed to the first molding die, and the second molding die is brought into contact with the composite material; and (3) a step for integrally molding the composite material and the molding material by pressing the composite material and the molding material using the first molding die and the second molding die.

Description

Technical Field

[0001] The present invention relates to a method for producing a molded body integrally molded from a composite material and an injection molding material having a higher fluidity than the composite material. Background Art

[0002] Composite materials using reinforcing fibers such as carbon fiber and glass fiber as reinforcing materials have high tensile strength and tensile elastic modulus, small linear expansion coefficient, and therefore excellent dimensional stability, as well as excellent heat resistance, chemical resistance, fatigue resistance, wear resistance, electromagnetic wave shielding and X-ray transmittance. Therefore, composite materials are widely used in automobiles, sports and leisure, aerospace, general industrial uses, etc.

[0003] In addition, a method of integrally manufacturing a molded body from a plurality of different materials has been studied.

[0004] For example, Patent Document 1 discloses a mold device that presses and clamps the peripheral edge of a skin part into a pin support hole while fitting a pin into the pin support hole, and presses and holds the skin part using a pressing surface of a skin part pressing frame and a skin part loading surface of a lower mold. After a molten thermoplastic resin is supplied between the skin part held by the lower mold and the molding surface of the upper mold, if mold closing begins, the molten thermoplastic resin flows, and the skin part is pressed by the mold closing, so that the skin part is stretched along the shape of the mold and retracted into the mold, and at the same time, the peripheral edge of the skin part slides between the pin and the pin support hole and between the pressing surface and the skin part loading surface, and is pulled into the mold.

[0005] Patent document 2 discloses that as a mold for producing a fiber-reinforced thermoplastic resin molded product by press-molding a sheet having a discontinuous fiber-reinforced thermoplastic resin layer laminated on a portion of at least one side of a continuous fiber-reinforced thermoplastic resin layer, the following mold is used: a frame-shaped weir portion is provided on the outer periphery of the mold cavity of the mold, the weir portion prevents the discontinuous fiber-reinforced thermoplastic resin layer from flowing out of the mold cavity when the upper mold and the lower mold are closed, and the weir portion forms a gap that allows the continuous fiber-reinforced thermoplastic resin layer to extend out of the mold cavity.

[0006] Patent document 3 discloses the following: an auxiliary mold that can slide up and down is arranged in close contact with the outer peripheral wall of the lower mold of a stamping mold, and the thermoplastic resin melt between the upper mold and the lower mold of the stamping mold is press-formed to serve as a base material. When the surface part is crimped to the base material, the auxiliary mold is used to prevent the melt from leaking from between the upper mold and the lower mold.

[0007] Patent document 4 describes a method for providing a method for manufacturing an injection molded product containing a plurality of sheets at a lower cost. In patent document 4, a plurality of reinforcing component resin-impregnated sheets having holes are arranged, a movable mold is moved to close the mold, and resin is injected to fill the spaces between the reinforcing component resin-impregnated sheets with the resin.

[0008] Prior art literature

[0009] Patent Literature

[0010] Patent Document 1: Japanese Patent No. 3413356

[0011] Patent Document 2: Japanese Patent No. 5855401

[0012] Patent Document 3: Japanese Patent Application Laid-Open No. 9-117922

[0013] Patent Document 4: Japanese Patent Application Publication No. 2020-179549 Summary of the invention

[0014] Problems to be solved by the invention

[0015] However, when a plurality of materials having different fluidities are integrally molded in a molding die, there is a problem that the material with high fluidity flows in the molding die, causing positional displacement of the material with low fluidity in the molding die.

[0016] The method of Patent Document 1 fixes the skin material by holding it at the outer periphery of the mold. However, the method of Patent Document 1 cannot be applied to molding when a material with low fluidity is completely placed in the mold cavity, such as in insert molding.

[0017] In the method of Patent Document 2, although a weir portion is provided on the outer periphery of the cavity to prevent the discontinuous fiber-reinforced thermoplastic resin layer from flowing out, there is no description of a method for fixing the sheet.

[0018] In the method of Patent Document 3, the skin material is held outside the molding die by a clamp. However, when a material with low fluidity is completely placed in the mold cavity such as insert molding, the method of Patent Document 3 cannot be applied during molding.

[0019] In the method of Patent Document 4, as the resin-impregnated sheet for the reinforcing component, a sheet impregnated with polypropylene resin in a plain weave of glass fiber with a linear diameter of about 17 μm is used. When using a material in which reinforcing fibers are continuously oriented in a specific direction like a plain weave, if there is a slight deviation (even a deviation of several mm) in the configuration when the injection material is injected for press molding, it is difficult to obtain the target physical properties. Therefore, in order to prevent the resin-impregnated sheet for the reinforcing component from deviating, countermeasures such as designing the molding die are required. In particular, when the resin is to be impregnated between multiple reinforcing components, the process is too complicated.

[0020] The object of the present invention is to provide a method for manufacturing a molded body, which can prevent the composite material from being displaced in the molding die when a composite material and a molding material having a higher fluidity than the composite material are integrally molded without fixing the composite material on the periphery of the mold cavity of the molding die.

[0021] Means for solving problems

[0022] In order to solve the above-mentioned problems, the present invention provides the following means.

[0023] <1>

[0024] A method for producing a molded body, wherein the molded body is integrally molded from a composite material and a molding material, the composite material containing reinforcing fibers dispersed in an in-plane direction, the molding material having a higher fluidity than the composite material,

[0025] The method for producing the molded body comprises the following steps (1) to (3):

[0026] (1) fixing the composite material to the first molding die by a plurality of fixing members provided in the first molding die, wherein the first molding die has a cavity having an area larger than that of the composite material when viewed from above;

[0027] (2) a step of moving a second molding die toward the composite material fixed to the first molding die so that the second molding die comes into contact with the composite material;

[0028] (3) A step of integrally molding the composite material and the molding material by pressing the composite material and the molding material using the first molding die and the second molding die.

[0029] <2>

[0030] like <1> The method for manufacturing a molded body is characterized in that:

[0031] The method further includes a step of releasing the fixing of the composite material by the fixing member.

[0032] <3>

[0033] like <1> or 2> the method for manufacturing a molded body, characterized in that,

[0034] Prior to the step (1), the method includes laminating the molding material on the composite material.

[0035] <4>

[0036] like <3> The method for manufacturing a molded body is characterized in that:

[0037] In the step (1), the composite material is fixed to the first molding die so that the molding material is in contact with the first molding die.

[0038] <5>

[0039] like <1> or <2> The method for manufacturing a molded body is characterized in that:

[0040] In the step (1), the composite material is fixed to the first molding die so that the molding material is arranged on the side opposite to the first molding die.

[0041] <6>

[0042] like <1> or <2> The method for manufacturing a molded body is characterized in that:

[0043] After the step (1) and before the step (2), the method includes laminating the molding material on the composite material.

[0044] <7>

[0045] like <1> or <2> The method for manufacturing a molded body is characterized in that:

[0046] The molding material is an injection molding material, and the process includes, after the step (2) and before the step (3), injecting the molding material between the first molding die and the second molding die.

[0047] <8>

[0048] like <2> The method for manufacturing a molded body is characterized in that:

[0049] The molding material is an injection molding material, and the step of injecting the molding material between the first molding die and the second molding die is included after the step (2) and before releasing the fixing of the composite material by the fixing member.

[0050] <9>

[0051] like <7> or <8> The method for manufacturing a molded body is characterized in that:

[0052] The forming material is injected between the first forming mold and the composite material.

[0053] <10>

[0054] like <7> or <8> The method for manufacturing a molded body is characterized in that:

[0055] The forming material is injected between the second forming mold and the composite material.

[0056] <11>

[0057] like <1> to <10> The method for producing a molded body as described in any one of the preceding claims is characterized in that:

[0058] The first molding die and the second molding die are a pair of male and female molding dies.

[0059] <12>

[0060] like <11> The method for manufacturing a molded body is characterized in that:

[0061] The first molding die is a fixed die, and the second molding die is a movable die.

[0062] <13>

[0063] like <11> or <12> The method for manufacturing a molded body is characterized in that:

[0064] The first forming mold is a lower mold, and the second forming mold is an upper mold.

[0065] <14>

[0066] like <1> to <13> The method for producing a molded body as described in any one of the preceding claims is characterized in that:

[0067] The fixing member is a hole forming member that forms a hole in the molded body.

[0068] <15>

[0069] like <1> to <14> The method for producing a molded body as described in any one of the preceding claims is characterized in that:

[0070] The reinforcing fibers are randomly dispersed in two dimensions in the in-plane direction of the composite material.

[0071] <16>

[0072] like <12> The method for manufacturing a molded body is characterized in that:

[0073] The molding material is an injection molding material, and the step of injecting the injection molding material between the first molding die and the second molding die is included after the step (2) and before the step (3).

[0074] Injection is performed from the first forming die.

[0075] <17>

[0076] like <16> The method for manufacturing a molded body is characterized in that:

[0077] The exterior surface is formed by using the second molding die, and the injection molding material is filled between the second molding die and the composite material.

[0078] <18>

[0079] like <17> The method for manufacturing a molded body is characterized in that:

[0080] The composite material is provided with flow holes at one or more positions for allowing the injection molding material to pass through,

[0081] The injection molding material injected from the first molding die flows through the flow hole, and is injected between the first molding die and the second molding die.

[0082] <19>

[0083] like <18> The method for manufacturing a molded body is characterized in that:

[0084] The first molding die has a first gate in a region where the composite material is arranged in a plan view, and the first gate is a gate for injecting an injection molding material into the molding die.

[0085] <20>

[0086] like <16> The method for manufacturing a molded body is characterized in that:

[0087] The design surface is formed by using the second molding die, and a resin sheet is arranged between the second molding die and the composite material.

[0088] <21>

[0089] like <17> or <20> The method for manufacturing a molded body is characterized in that:

[0090] The exterior surface has a corrugated shape formed by the second forming die.

[0091] <22>

[0092] like <1> to <12> The method for producing a molded body as described in any one of the preceding claims is characterized in that:

[0093] The first forming mold is a fixed mold, and the second forming mold is a movable mold.

[0094] The molded body is manufactured by moving the second mold in a horizontal direction to open and close the mold.

[0095] There are at least two fixing members at different positions in the height direction.

[0096] <23>

[0097] like <1> to <12> The method for producing a molded body as described in any one of the preceding claims is characterized in that:

[0098] The first forming mold is a fixed mold, and the second forming mold is a movable mold.

[0099] The molded body is manufactured by moving the second mold in a horizontal direction to open and close the mold.

[0100] There are at least two fixing members with different positions in the horizontal direction.

[0101] <24>

[0102] like <1> to <23> The method for producing a molded body as described in any one of the preceding claims is characterized in that:

[0103] The composite material has a shape cut out by pattern cutting.

[0104] <25>

[0105] like <19> The method for manufacturing a molded body is characterized in that:

[0106] A second gate for injecting the injection molding material is provided in an area other than an area where the composite material is arranged when the first molding die is viewed from above,

[0107] The number n1 of the first gates and the number n2 of the second gates satisfy 0<n1<n2.

[0108] <26>

[0109] like <19> or <25> The method for manufacturing a molded body is characterized in that:

[0110] The first molding die has a second gate for injecting the injection molding material in a region other than a region where the composite material is arranged in a plan view.

[0111] A discharge amount V1 of the injection molding material ejected from the first gate and a discharge amount V2 of the injection molding material ejected from the second gate satisfy 0<V1<V2.

[0112] Effects of the Invention

[0113] According to the method for manufacturing a molded body of the present invention, when a composite material and a molding material having a higher fluidity than the composite material are integrally molded, the composite material does not need to be fixed at the periphery of the mold cavity of the molding die, and the composite material can be prevented from being displaced in the molding die. By using a composite material containing reinforcing fibers dispersed in the in-plane direction, even if the composite material flows slightly during molding, the basic mechanical properties will not change significantly. In addition, compared with the case of using continuous fibers such as plain weave fabrics, shape tracking is also improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0114] Figure 1 This is a cross-sectional view of a molded body 1 according to the first embodiment of the present invention.

[0115] Figure 2 It is a schematic diagram which shows the manufacturing method of the compact 1 of 1st Embodiment.

[0116] Figure 3 It is a schematic diagram which shows the manufacturing method of the compact 1 of 1st Embodiment.

[0117] Figure 4 It is a schematic diagram which shows the manufacturing method of the compact 1 of 1st Embodiment.

[0118] Figure 5 It is a schematic diagram which shows the manufacturing method of the compact 1 of 1st Embodiment.

[0119] Figure 6 It is a schematic diagram which shows the manufacturing method of the compact 1 of 1st Embodiment.

[0120] Figure 7 It is a cross-sectional view of a molded body 101 according to a second embodiment of the present invention.

[0121] Figure 8 It is a schematic diagram showing a method for producing a molded body 101 according to the second embodiment.

[0122] Fig. 9 It is a schematic diagram showing a method for producing a molded body 101 according to the second embodiment.

[0123] Fig.10 It is a schematic diagram showing a method for producing a molded body 101 according to the second embodiment.

[0124] Fig.11 It is a schematic diagram showing a method for producing a molded body 101 according to the second embodiment.

[0125] Fig.12 It is a schematic diagram showing a method for producing a molded body 101 according to the second embodiment.

[0126] Fig.13 It is a schematic diagram showing a method for producing a molded body 101 according to the second embodiment.

[0127] Fig.14 It is a schematic diagram showing a method for producing a molded body 201 according to the third embodiment.

[0128] Fig.15 It is a schematic diagram showing a method for producing a molded body 201 according to the third embodiment.

[0129] Fig.16 It is a schematic diagram showing a method for producing a molded body 201 according to the third embodiment.

[0130] Fig.17 It is a schematic diagram showing a method for producing a molded body 201 according to the third embodiment.

[0131] Fig.18 It is a schematic diagram showing a method for producing a molded body 201 according to the third embodiment.

[0132] Fig.19 It is a schematic diagram showing a method for producing a molded body 201 according to the third embodiment.

[0133] Fig. 20 It is a schematic diagram showing a method for producing a molded body 301 according to the fourth embodiment.

[0134] Fig.21 It is a schematic diagram showing a method for producing a molded body 301 according to the fourth embodiment.

[0135] Fig. 22 It is a schematic diagram showing a method for producing a molded body 301 according to the fourth embodiment.

[0136] Fig.23 It is a schematic diagram showing a method for producing a molded body 301 according to the fourth embodiment.

[0137] Fig.24 It is a schematic diagram showing a method for producing a molded body 301 according to the fourth embodiment.

[0138] Fig.25 It is a schematic diagram showing a method for producing a molded body 301 according to the fourth embodiment.

[0139] Fig.26 It is a horizontal cross-sectional view showing a first molding die 410 and a second molding die 420 which are provided so as to be openable and closable in the horizontal direction.

[0140] Fig. 27 It is a perspective view showing a box-shaped molded body 100 .

[0141] Fig.28 is a schematic diagram of the composite material in the shape after pattern cutting.

[0142] Fig.29 This is a front view of the first molding die showing a state in which the composite material after pattern cutting is fixed by a fixing member.

[0143] Fig.30 1 is a horizontal cross-sectional view showing a first molding die 510 and a second molding die 520 to which a composite material is fixed by a fixing member 512 .

[0144] Fig.31 1 is a top view of the first molding die 610 . DETAILED DESCRIPTION

[0145] Hereinafter, embodiments of the present invention will be described in detail.

[0146] [First embodiment]

[0147] Figure 1 is a schematic cross-sectional view of a molded body 1 according to a first embodiment of the present invention, Figure 2 to Figure 6 Schematic diagram showing a method for producing a molded body 1. The molded body 1 is formed by integrally molding a reinforcing portion 2 formed of a composite material 2A and a main body portion 3 formed of a molding material 3B having higher fluidity than the composite material 2A.

[0148] [Composite Materials]

[0149] The composite material 2A includes reinforcing fibers and a matrix resin. In the composite material 2A, the reinforcing fibers are dispersed in the matrix resin in an in-plane direction.

[0150] [Reinforcement Fiber]

[0151] The reinforcing fiber is preferably at least one selected from carbon fiber, aramid fiber, and glass fiber, and more preferably carbon fiber or glass fiber.

[0152] [Carbon Fiber]

[0153] 1. Carbon fiber overall

[0154] As carbon fibers, polyacrylonitrile (PAN) carbon fibers, petroleum coal tar carbon fibers, rayon carbon fibers, cellulose carbon fibers, lignin carbon fibers, phenolic carbon fibers, etc. are generally known. In the present invention, any of these carbon fibers can be preferably used. Among them, in the present invention, polyacrylonitrile (PAN) carbon fibers are preferably used from the perspective of excellent tensile strength. As PAN carbon fibers, for example, carbon fiber "Tenax" (registered trademark) STS40-24KS (average fiber diameter 7 μm) manufactured by Teijin Limited can be used.

[0155] 2. Carbon fiber sizing agent

[0156] The carbon fibers may have a sizing agent attached to their surfaces. When using carbon fibers to which a sizing agent is attached, the type of the sizing agent may be appropriately selected according to the type of carbon fibers and the type of resin used in the composite material or injection molding material, and is not particularly limited.

[0157] [Fiberglass]

[0158] 1. Glass fiber overall

[0159] The glass fiber can be any glass fiber as long as it is a material generally called glass fiber. The glass composition of A glass, C glass, E glass, etc. specified in JIS R3140: 2006 is not particularly limited, and it may contain components such as TiO2, SO3, P2O5, etc. as appropriate. As the glass fiber, for example, glass fiber E-glass RS240 QR-483 (count: 2400 g / 1000 m) manufactured by Nitto Bosho Co., Ltd. can be used.

[0160] 2. Sizing agent for glass fiber

[0161] The glass fiber may have a sizing agent attached to the surface. When using glass fibers with a sizing agent attached, the type of the sizing agent can be appropriately selected according to the type of glass fiber and the type of resin, and is not particularly limited. Glass fibers may preferably be pre-treated with a coupling agent known in the past such as an organosilane compound, an organotitanium compound, an organoborane compound, and an epoxy compound.

[0162] [Dispersion in the in-plane direction]

[0163] The reinforcing fibers contained in the composite material are preferably dispersed in the in-plane direction.

[0164] The reinforcing fibers are dispersed in the in-plane direction, which means that the reinforcing fibers are dispersed so that the fiber axes of the reinforcing fibers face the in-plane direction. The angle formed between the fiber axes of the reinforcing fibers and the in-plane direction is preferably 45° or less.

[0165] 1. In-plane direction

[0166] The composite material 2A is preferably a plate-shaped material. The in-plane direction refers to any direction parallel to a plane perpendicular to the plate thickness direction of the composite material 2A.

[0167] 2. Random dispersion in two dimensions

[0168] The reinforcing fibers are preferably randomly dispersed in two dimensions in the in-plane direction of the composite material 2A. When the composite material 2A is press-formed without flowing, the morphology of the reinforcing fibers is substantially maintained before and after forming, so the reinforcing fibers included in the reinforcing portion 2 formed by forming the composite material 2A are also preferably randomly dispersed in two dimensions in the in-plane direction.

[0169] Here, two-dimensionally randomly dispersed means that the reinforcing fibers are not oriented in a specific direction such as one direction in the in-plane direction of the composite material 2A or the reinforcing portion 2, but are randomly oriented, and are arranged in the sheet surface in a manner that does not show specific directionality as a whole. The composite material 2A (or the reinforcing portion 2) obtained using the two-dimensionally randomly dispersed discontinuous fibers does not have anisotropy in the plane, but is substantially isotropic.

[0170] It should be noted that, for the orientation degree representing the degree of two-dimensional random dispersion of reinforcing fibers in the in-plane direction of the composite material 2A or the reinforcing portion 2, the ratio of the tensile elastic modulus in two mutually orthogonal directions of the composite material 2A is evaluated. For any direction of the composite material 2A (or the reinforcing portion 2), and the direction orthogonal thereto, if the ratio (Eδ) obtained by dividing the large value of the tensile elastic modulus values ​​measured respectively by the small value is 5 or less, more preferably 2 or less, and further preferably 1.5 or less, it can be evaluated that the reinforcing fibers are two-dimensionally randomly dispersed. In the case where the reinforcing portion 2 is a curved surface, as an evaluation method for the degree (orientation degree) of two-dimensional random dispersion of the reinforcing fibers of the reinforcing portion 2 in the in-plane direction, the molded body 1 can be heated to a softening temperature or more and restored to a flat plate shape, and cured after only the reinforcing portion 2 is taken out. Afterwards, a test piece is cut out from the reinforcing portion 2 restored to a flat plate shape, and the tensile elastic modulus in two mutually orthogonal directions of the test piece is obtained, thereby enabling the evaluation of the two-dimensional random dispersion of the reinforcing portion 2.

[0171] [Fiber length of reinforcing fibers contained in composite materials]

[0172] The weight average fiber length LwA of the reinforcing fibers contained in the composite material 2A is preferably 1 mm or more, and more preferably 3 mm or more.

[0173] If LwA is 100 mm or less, the fluidity of the material is not easily reduced when the composite material 2A is press-formed and manufactured, and it is easy to form the reinforcing portion 2 into a desired shape. In addition, when LwA is 1 mm or more, the mechanical strength of the obtained reinforcing portion 2 is not easily reduced, so it is preferred.

[0174] The weight average fiber length LwA of the reinforcing fibers contained in the composite material 2A does not change before and after molding, so if the weight average fiber length of the reinforcing fibers contained in the reinforcement portion 2 is investigated, the weight average fiber length LwA of the reinforcing fibers contained in the composite material 2A can be known.

[0175] The weight average fiber length LwA of the reinforcing fibers contained in the composite material 2A is preferably 3 mm or more and 100 mm or less, more preferably 3 mm or more and 80 mm or less, and even more preferably 5 mm or more and 60 mm or less.

[0176] The weight average fiber length of the reinforcing fibers can be determined by the formula (1) described below.

[0177] [Molding materials]

[0178] The molding material 3B forming the main body 3 contains a matrix resin. Furthermore, the molding material 3B preferably contains reinforcing fibers. The reinforcing fibers contained in the molding material 3B are preferably the above-mentioned carbon fibers or glass fibers.

[0179] The fluidity of the molding material 3B is higher than that of the composite material 2A. The molding material 3B having higher fluidity than the composite material 2A can be produced by making the fiber volume ratio (Vf) of the molding material 3B lower than the fiber volume ratio (Vf) of the composite material 2A. In addition, by making the weight average fiber length of the reinforcing fibers contained in the molding material 3B shorter than the weight average fiber length of the reinforcing fibers contained in the composite material 2A, the fluidity of the molding material 3B can be made higher than that of the composite material 2A.

[0180] [Fiber length of reinforcing fibers contained in molding material]

[0181] The molding material 3B includes reinforcing fibers of weight average fiber length LwB, preferably LwB<LwA. When LwB<LwA, the mechanical strength of the reinforcing portion 2 formed by the composite material 2A is higher than the mechanical strength of the main body 3 formed by the molding material 3B, so the molding 1 can be reinforced by the reinforcing portion 2.

[0182] In addition, the molding material 3B may also be an injection molding material. When the molding material 3B is injected into the molding die to mold the main body 3, the molding material 3B immediately before injection is referred to as the injection molding material. When there is a kneading step of the molding material 3B before injection, the molding material 3B after kneading is referred to as the injection molding material.

[0183] The weight average fiber length LwB of the reinforcing fibers contained in the molding material 3B is preferably less than 3 mm. The weight average fiber length LwB is more preferably 0.01 mm or more and less than 3 mm. The lower limit of the weight average fiber length LwB is preferably 0.01 mm or more, more preferably 0.05 mm or more, and further preferably 0.1 mm or more. If the weight average fiber length LwB is 0.01 mm or more, the mechanical strength of the main body 3 can be ensured. On the other hand, the upper limit of the weight average fiber length LwB is preferably less than 3 mm, more preferably less than 2 mm, and further preferably less than 1 mm.

[0184] When the weight average fiber length LwB is 1.0 mm or less, the body 3 can be manufactured using the injection molding material kneaded with the molding material 3B. Usually, the weight average fiber length LwB of the reinforcing fibers contained in the injection molding material kneaded with the molding material 3B is less than 1 mm.

[0185] The weight average fiber length of the reinforcing fibers can be determined by the formula (1) described below.

[0186] [Weight average fiber length Lw]

[0187] Generally, if the fiber length of each reinforcing fiber is L i , the weight average fiber length Lw is calculated by the following formula (1). In addition, the unit of the weight average fiber length Lw is mm.

[0188] [Number 1]

[0189]

[0190] Here, "I" represents the number of measured reinforcing fibers.

[0191] The reinforcing fibers can be extracted from the reinforcing portion 2 and the main body portion 3 by, for example, performing a heat treatment at about 500° C. for one hour and removing the matrix resin in a furnace.

[0192] The weight average fiber length Lw can be measured by using a vernier caliper or the like to measure the fiber lengths L1 to L2 of 100 fibers (I=100) randomly selected from the reinforcing portion 2 and the main body portion 3 after the above-mentioned heat treatment. 100 The thickness was measured in units of 1 mm and was determined based on the formula (1).

[0193] In the case of containing short reinforcing fibers that cannot be measured with a vernier caliper, after removing the matrix resin, the obtained reinforcing fibers can be put into water added with a surfactant, and fully stirred by ultrasonic vibration. The dispersion of the reinforcing fibers after stirring is randomly collected with a measuring spoon to obtain an evaluation sample, and the length of the reinforcing fibers with a number of 3000 fibers (I=3000) is measured using an image analyzer Luzex AP manufactured by Nireco. The measured values ​​of the fiber length L1 to L 3000 , the weight average fiber length Lw is calculated in the same manner as in the above formula (1).

[0194] [Volume ratio of reinforcing fibers in composite materials and molding materials]

[0195] For the composite material 2A and the molding material 3B, the volume ratio (Vf) of the reinforcing fibers can be calculated by the following formula (2).

[0196] The volume ratio of the reinforcing fibers is not particularly limited, but the volume ratio (Vf) of the reinforcing fibers is preferably 10 to 60% by volume, more preferably 20 to 50% by volume, and further preferably 25 to 45% by volume.

[0197] Volume ratio of reinforcing fiber (Vf) = 100 × volume of reinforcing fiber / (volume of reinforcing fiber + volume of resin) Formula (2)

[0198] In the present invention, it is preferred that the volume ratio Vfb of the reinforcing fibers of the forming material 3B and the volume ratio Vfa of the carbon fibers of the composite material 2A satisfy the relationship Vfa≥Vfb in the manufacturing process. For example, when a material obtained by crushing the scraps of the composite material 2A recovered from the manufacturing process or product is used as the forming material 3B, or when a material obtained by crushing the scraps and then adding a thermoplastic resin is used as the forming material 3B to manufacture the main body 3, Vfa>Vfb in most cases. That is, if a manufacturing method of Vfa≥Vfb is adopted, the scraps remaining after cutting out the composite material 2A can be effectively utilized, or the material can be easily reused.

[0199] Vfa is preferably 20% to 45% by volume, more preferably 25% to 40% by volume.

[0200] Vfb is preferably 1 to 40% by volume, more preferably 5 to 30% by volume, and still more preferably 10 to 25% by volume.

[0201] [Analysis of reinforcing fiber volume ratio (Vf)]

[0202] The analysis of the reinforcing fiber volume ratio is not limited, and can be measured as follows.

[0203] A sample was cut out from the reinforcement part 2 or the main body part 3, and the resin was burned off in a furnace at 500°C for 1 hour. The mass of the sample before and after the treatment was weighed to calculate the mass of the reinforcement fiber and the resin. Next, the volume ratio of the reinforcement fiber to the resin was calculated using the specific gravity of each component.

[0204] Vf = 100 × reinforcing fiber volume / (reinforcing fiber volume + resin volume)

[0205] [Resin]

[0206] The matrix resin included in the composite material 2A and the matrix resin included in the molding material 3B may be thermosetting or thermoplastic.

[0207] 1. Thermoplastic resin

[0208] 1.1 Overview

[0209] When the resin used is a thermoplastic resin, its type is not particularly limited, and a resin having a desired softening point or melting point can be appropriately selected and used. As the thermoplastic resin, a thermoplastic resin having a softening point in the range of 180° C. to 350° C. is generally used, but is not limited thereto.

[0210] Examples of thermoplastic resins include polyolefin resins, polystyrene resins, polyamide resins, polyester resins, polyacetal resins (polyoxymethylene resins), polycarbonate resins, (meth)acrylic resins, polyarylate resins, polyphenylene ether resins, polyimide resins, polyether nitrile resins, phenoxy resins, polyphenylene sulfide resins, polysulfone resins, polyketone resins, polyether ketone resins, thermoplastic urethane resins, fluororesins, and thermoplastic polybenzimidazole resins.

[0211] The thermoplastic resin used in the composite material 2A and the forming material 3B may be only one kind or two or more kinds. As a method of using two or more kinds of thermoplastic resins in combination, for example, a method of using thermoplastic resins having different softening points or melting points in combination, a method of using thermoplastic resins having different average molecular weights in combination, etc. can be cited, but it is not limited thereto.

[0212] When a thermoplastic resin is used, a polyolefin resin is more preferably used, and a polypropylene resin is further preferably used.

[0213] 1.2 Composite materials and resins for molding materials

[0214] The resin contained in the composite material 2A is preferably a thermoplastic resin. When the resin contained in the composite material 2A is a thermoplastic resin, it is more preferable that the composite material 2A and the resin contained in the molding material 3B are the same type of thermoplastic resin.

[0215] 2. Thermosetting resin

[0216] The resin contained in the composite material 2A may also be a thermosetting resin. In this case, the composite material 2A may also use a sheet molding compound using reinforcing fibers. Since the sheet molding compound has high formability, even a complex shape can be easily formed. The flowability and shapeability of the sheet molding compound are higher than those of continuous fibers, and ribs and protrusions can be easily produced.

[0217] [Other reagents]

[0218] The resin used in the composite material 2A and the forming material 3B may contain various fibrous or non-fibrous fillers of organic fibers or inorganic fibers, flame retardants, UV resistant agents, stabilizers, release agents, pigments, softeners, plasticizers, surfactants and other additives within the scope that does not impair the purpose of the present invention.

[0219] [Preferred combinations of resin and fiber]

[0220] [fiber]

[0221] The reinforcing fibers contained in the composite material 2A are preferably glass fibers and / or carbon fibers, and the reinforcing fibers contained in the molding material 3B are preferably glass fibers.

[0222] As the reinforcing fibers included in the composite material 2A, carbon fibers may be partially used, and glass fibers may be used in the portion other than the portion using carbon fibers. The portion where carbon fibers are used in the composite material 2A is preferably the portion surrounding the hole 2H described later in the reinforcing portion 2.

[0223] [Resin]

[0224] The resin contained in the composite material 2A may be a thermoplastic resin or a thermosetting resin, and the resin contained in the molding material 3B may be a thermoplastic resin or a thermosetting resin. Alternatively, the molding material 3B may contain a thermoplastic resin, while a thermosetting sheet molding compound may be used in the composite material 2A.

[0225] The volume Va of the composite material 2A used in the reinforcement part 2 and the volume Vb of the molding material 3B used in the main body part 3 preferably satisfy the relationship Vb ≥ Va. Va:Vb is preferably 10:90 to 50:50, more preferably 20:80 to 40:60.

[0226] [Manufacturing method]

[0227] Next, a method for producing the molded article 1 will be described. In the present embodiment, the molded article 1 is integrally molded by a composite material 2A including reinforcing fibers dispersed in the in-plane direction and a molding material 3B having higher fluidity than the composite material 2A.

[0228] The method for manufacturing the molded body 1 includes the following steps (1) to (3):

[0229] (1) A process of fixing the composite material 2A to the first forming mold 10 by means of a plurality of fixing parts 12 provided on the first forming mold 10, wherein the first forming mold 10 has a mold cavity 11 whose area is larger than that of the composite material 2A when viewed from above; (2) A process of moving the second forming mold 20 toward the composite material 2A fixed to the first forming mold 10 so that the second forming mold 20 contacts the composite material 2A; (3) A process of integrally forming the composite material 2A and the forming material 3B by pressing the first forming mold 10 and the second forming mold 20.

[0230] It should be noted that the forming material 3B can be put into the forming mold at any time before step (3). For example, before step (1), a step of laminating the forming material 3B on the composite material 2A can be included. That is, in step (1), preferably, in a state where the composite material 2A and the forming material 3B are laminated, the laminate of the composite material 2A and the forming material 3B is fixed in the mold cavity 11 of the first forming mold 10 by a plurality of fixing members 12.

[0231] In this case, in step (1), the composite material 2A is preferably fixed to the first molding die 10 so that the molding material 3B is in contact with the first molding die 10 .

[0232] When the resin contained in the composite material 2A or the molding material 3B is a thermoplastic resin, cold press molding is preferably used.

[0233] The manufacturing method of the formed body 1 by cold pressing has the following steps (0) to (3): (0) a step of heating the composite material 2A and the forming material 3B to a first specified temperature; (1) a step of fixing the composite material 2A and the forming material 3B to the first forming mold 10 by means of a plurality of fixing parts 12 arranged on the first forming mold 10, wherein the first forming mold 10 has a mold cavity 11 whose area is larger than that of the composite material 2A when viewed from above; (2) a step of moving the second forming mold 20 toward the composite material 2A fixed to the first forming mold 10 so that the second forming mold 20 contacts the composite material 2A; (3) a step of pressing the composite material 2A and the forming material 3B by means of the first forming mold 10 and the second forming mold 20 to form them as a whole.

[0234] (0) Step of heating the composite material 2A to a first predetermined temperature

[0235] The composite material 2A is preferably preheated to a first predetermined temperature. When the thermoplastic resin contained in the composite material 2A is crystalline, the first predetermined temperature is a temperature above the melting point and below the decomposition temperature of the thermoplastic resin. When the thermoplastic resin contained in the composite material 2A is amorphous, the first predetermined temperature is a temperature above the glass transition temperature and below the decomposition temperature of the thermoplastic resin.

[0236] In the case of cold press forming, the temperature of the first forming die 10 and the second forming die 20 is adjusted to the second predetermined temperature. When the thermoplastic resin contained in the composite material 2A is crystalline, the second predetermined temperature is a temperature lower than the melting point of the thermoplastic resin. When the thermoplastic resin contained in the composite material 2A is amorphous, the second predetermined temperature is a temperature lower than the glass transition temperature of the thermoplastic resin.

[0237] In this way, by adjusting the temperature of the composite material 2A and the first forming die 10, cold pressing can be appropriately performed.

[0238] First, if Figure 2 As shown, the composite material 2A is fixed in the mold cavity 11 of the first forming mold 10 by a plurality of fixing members 12 .

[0239] The fixing member 12 may be, for example, a slide core that forms a hole 1H in the molded body 1. For example, the hole 2H may be provided in advance in the composite material 2A, and the composite material 2A may be fixed by inserting the fixing member 12 into the hole 2H. Alternatively, the composite material 2A may be fixed by piercing the pin-shaped fixing member 12 into the composite material 2A. In this case, the hole 2H may not be provided in the composite material 2A.

[0240] It should be noted that the composite material 2A may be pre-shaped so as to be arranged in the cavity 11 of the first molding die 10 along the cavity 11 of the first molding die 10 .

[0241] Then, if Figure 3 As shown, the second forming die 20 is moved toward the composite material 2A fixed to the first forming die 10 so that the second forming die 20 comes into contact with the composite material 2A.

[0242] Then, if Figure 4 As shown, the composite material 2A and the forming material 3B are integrally formed by pressing with the first forming die 10 and the second forming die 20. The forming pressure is not particularly limited, but is preferably less than 20 MPa, and more preferably 10 MPa or less.

[0243] Thus, when the composite material 2A and the molding material 3B are pressed, the molding material 3B having higher fluidity than the composite material 2A flows in the molding die. In this case, since the composite material 2A is fixed by the fixing member 12, the positional displacement of the composite material 2A can also be prevented.

[0244] When the composite material 2A and the molding material 3B are pressed, the hole 2H is formed at the position of the composite material 2A corresponding to the fixing member 12, and the hole 3H is formed at the position of the molding material 3B corresponding to the fixing member 12. That is, the fixing member 12 is a hole forming member that forms the hole 1H in the molding 1.

[0245] Furthermore, a hole 22 for inserting the fixing member 12 may be provided at a position of the second molding die 20 that faces the fixing member 12 .

[0246] Thereafter, the second molding die 20 is moved in a direction away from the first molding die 10 to remove the molded body 1 from the first molding die 10. Thus, the molded body 1 is completed.

[0247] It should be noted that if Figure 5 As shown, the fixing member 12 may be moved to pull the fixing member 12 out from the integrally formed composite material 2A and the formed material 3B. As a result, the fixing of the composite material 2A by the fixing member 12 is released. That is, it may also include a step of releasing the fixing of the composite material 2A by the fixing member 12. It should be noted that the step of releasing the fixing of the composite material 2A by the fixing member 12 may be after step (2), before step (3), or after step (3).

[0248] It should be noted that, in the case where the holes 1H are not formed in the molded body 1, before the composite material 2A and the molded material 3B are pressed and integrally molded, Figure 6 As shown, the fixing member 12 can be moved. That is, after step (2) and before step (3), the fixing member 12 can be released from the fixing of the composite material 2A. In this case, even if a hole 2H is formed at a position corresponding to the fixing member 12 in the composite material 2A, when the composite material 2A and the forming material 3B are pressed and integrally formed by the first forming die 10 and the second forming die 20, the forming material 3B flows into the inside of the hole 2H, thereby filling the hole 2H.

[0249] By integrally molding the reinforcement portion 2 and the main body portion 3 in this manner, it is possible to obtain a molded body 1 having excellent bonding strength between the reinforcement portion 2 and the main body portion 3 .

[0250] Furthermore, by pressing the composite material 2A and the molding material 3B having higher fluidity than the composite material 2A while the plate-like composite material 2A is arranged in the molding die, it is possible to produce the molded body 1 having a complex shape with ribs and protrusions.

[0251] [Second Embodiment]

[0252] Next, a method for producing a molded body according to the second embodiment will be described. Note that the same reference numerals are used for the last two digits of the same configuration as those of the first embodiment, and description thereof will be omitted.

[0253] In addition, in the second embodiment, the composite material 102A and the molding material 103B may be integrally molded by cold pressing as in the first embodiment.

[0254] Figure 7 is a schematic cross-sectional view of a molded body 101 according to a second embodiment of the present invention, Figure 8 to Figure 13 It is a schematic diagram showing a method for producing the molded body 101 .

[0255] In the first embodiment, the molding material 3B is arranged in contact with the first molding die 10, but in the second embodiment, the molding material 103B is arranged in contact with the second molding die 20. That is, the composite material 102A is fixed to the first molding die 10 in such a manner that the molding material 103B is arranged on the side opposite to the first molding die 10.

[0256] The manufacturing method of the molded body 101 of the second embodiment includes the following steps (1) to (3): (1) a step of fixing the composite material 102A to the first molding die 10 by means of a plurality of fixing parts 12 arranged on the first molding die 10, wherein the first molding die 10 has a mold cavity 11 whose area is larger than that of the composite material 102A when viewed from above; (2) a step of moving the second molding die 20 toward the composite material 102A fixed to the first molding die 10 so that the second molding die 20 contacts the composite material 102A; (3) a step of pressing the composite material 102A and the molding material 103B by means of the first molding die 10 and the second molding die 20 to form them as one piece.

[0257] Specifically, first, Figure 8 As shown, in the mold cavity 11 of the first forming mold 10 , the composite material 102A is fixed by a plurality of fixing members 12 .

[0258] Then, if Fig. 9 As shown, before step (2), the forming material 103B is stacked on the composite material 102A fixed to the first forming mold 10.

[0259] It should be noted that the step of laminating the forming material 103B on the composite material 102A may be included before the step (1). In this case, in the step (1), the laminate of the composite material 102A and the forming material 103B is preferably fixed to the first forming die 10 in such a manner that the forming material 3B is arranged on the side opposite to the first forming die 10. That is, in the step (1), Fig. 9 As shown, the stack of the composite material 102A and the forming material 103B can be fixed in the cavity 11 of the first forming die 10 by a plurality of fixing members 12 in such a manner that the forming material 103B is arranged on the side opposite to the first forming die 10 .

[0260] Then, if Fig.10 As shown, the second forming die 20 is moved toward the composite material 102A fixed to the first forming die 10, so that the second forming die 20 and the composite material 102A come into contact. At this time, the second forming die 20 may also come into contact with the forming material 103B stacked on the composite material 102A.

[0261] Then, if Fig.11 As shown, the composite material 102A and the forming material 103B are pressed and integrally formed by the first forming die 10 and the second forming die 20. At this time, the hole 102H is formed at the position corresponding to the fixing part 12 of the composite material 102A, and the hole 103H is formed at the position corresponding to the fixing part 12 of the forming material 103B.

[0262] Thereafter, the second molding die 20 is moved in a direction away from the first molding die 10 to remove the molded body 101 from the first molding die 10. Thus, the molded body 101 is completed.

[0263] It should be noted that if Fig.12 As shown in FIG. 1 , the fixing member 12 may be moved to pull the fixing member 12 out of the integrally formed composite material 102A and the formed material 103B. As a result, the fixing of the composite material 102A by the fixing member 12 is released. That is, the process of releasing the fixing of the composite material 102A by the fixing member 12 may also be included. It should be noted that the process of releasing the fixing of the composite material 102A by the fixing member 12 may be after process (2) and before process (3), or after process (3).

[0264] It should be noted that, when the holes 101H are not formed in the molded body 101, Fig.13As shown, before the composite material 102A and the forming material 103B are pressed and integrally formed, the fixing member 12 may be moved. That is, after step (2) and before step (3), the fixing of the composite material 102A by the fixing member 12 may be released. In this case, even if a hole 102H is formed at a position corresponding to the fixing member 12 in the composite material 102A, when the composite material 102A and the forming material 103B are pressed and integrally formed by the first forming die 10 and the second forming die 20, the forming material 103B flows into the inside of the hole 102H, thereby filling the hole 102H.

[0265] [Third Embodiment]

[0266] Figures 14 to 19 Schematic diagram showing a method for producing a molded body 201 according to a third embodiment of the present invention. In addition, the same reference numerals are used for the last two digits of the same configuration as those of the first embodiment, and description thereof will be omitted.

[0267] In the third embodiment, an injection molding material 203B is used as a molding material having higher fluidity than the composite material. In the third embodiment, after step (2) and before step (3) of the first embodiment, a step of injecting the molding material (injection molding material 203B) between the first molding die 210 and the second molding die 220 is included.

[0268] Specifically, the manufacturing method of the molded body 201 of the third embodiment includes the following steps (1) to (3): (1) a step of fixing the composite material 202A to the first molding die 210 by means of a plurality of fixing parts 212 arranged on the first molding die 210, wherein the first molding die 210 has a mold cavity 211 whose area is larger than the composite material 202A when viewed from above; (2) a step of moving the second molding die 220 toward the composite material 202A fixed to the first molding die 210 so that the second molding die 220 contacts the composite material 202A; (3) a step of injecting the injection molding material 203B between the first molding die 210 and the second molding die 220; and (4) a step of pressing the composite material 202A and the injection molding material 203B into an integral shape by means of the first molding die 210 and the second molding die 220.

[0269] It should be noted that the following steps may also be included before step (1):

[0270] (0) A step of heating the composite material 202A to a first predetermined temperature.

[0271] In this case, the first molding die 210 and the second molding die 220 are set to the second predetermined temperature.

[0272] Specifically, first, Fig.14 As shown, the composite material 202A is fixed in the mold cavity 211 of the first forming mold 210 by a plurality of fixing components 212 .

[0273] Then, if Fig.15 As shown, the second forming die 220 is moved toward the composite material 202A fixed to the first forming die 210 so that the second forming die 220 is in contact with the composite material 202A.

[0274] Then, if Fig.16 As shown, the injection molding material 203B is injected between the first molding die 210 and the composite material 202A from the gate 213 provided in the first molding die 210. It should be noted that the injection molding material 203B may be injected before or after the pressure is applied to a portion of the composite material 202A from the second molding die 220. In order to suppress the positional deviation of the composite material 202A in the molding die, it is preferred that the injection molding material 203B is injected immediately after the second molding die 220 contacts at least a portion of the composite material 202A and begins to apply pressure to the composite material 202A. In addition, the method of injecting the injection molding material 203B into the molding die is not particularly limited, and it can be carried out using a conventionally known method.

[0275] At this time, the composite material 202A is pressed against the second molding die 220 by the pressure of the injection molding material 203B.

[0276] The injection molding material 203B is a kneaded material, and is preferably filled between the first molding die 210 and the composite material 202A. By pressing the injection molding material 203B after filling it into the molding die, positional deviation of the composite material 202A can be suppressed.

[0277] When the injection molding material 203B is put into the molding die, it is preferably heated to a temperature above the melting point and below the decomposition temperature of the thermoplastic resin when the thermoplastic resin contained in the injection molding material 203B is crystalline, and it is preferably heated to a temperature above the glass transition temperature and below the decomposition temperature of the thermoplastic resin when the thermoplastic resin is amorphous.

[0278] In order to fill the injection molding material 203B between the first molding die 210 and the composite material 202A, the second molding die 220 may be temporarily stopped from descending before the molding die is completely closed. The position where the second molding die 220 is stopped from descending is preferably after the second molding die 220 contacts the composite material 202A. The composite material 202A contacts the second molding die 220 to suppress the movement of the composite material 202A, thereby suppressing the positional deviation of the composite material 202A during pressing.

[0279] Then, if Fig.17 As shown, the composite material 202A and the injection molding material 203B are pressed in a molding die to be integrally formed.

[0280] At this time, holes 202H are formed at positions of composite material 202A corresponding to fixing member 212, and holes 203H are formed at positions of injection molding material 203B corresponding to fixing member 212. That is, fixing member 212 is a hole forming member that forms hole 201H in molded body 201.

[0281] In addition, a hole 222 for inserting the fixing member 212 may be provided at a position of the second molding die 220 that faces the fixing member 212 .

[0282] Thereafter, the second molding die 220 is moved in a direction away from the first molding die 210 to remove the molded body 201 from the first molding die 210. Thus, the molded body 201 is completed.

[0283] In this way, the injection molding material 203B is injected into the mold while the composite material 202A is fixed by the fixing member 212 . Therefore, even if the injection molding material 203B flows in the mold, positional displacement of the composite material 202A can be prevented.

[0284] In addition, if Fig.18 As shown, the fixing member 212 may be moved to pull the fixing member 212 out from the integrally formed composite material 202A and the injection molding material 203B. Thus, the fixing of the composite material 202A by the fixing member 212 is released. That is, the process of releasing the fixing of the composite material 202A by the fixing member 212 may also be included. It should be noted that the process of releasing the fixing of the composite material 202A by the fixing member 212 may be after process (3) and before process (4), or after process (4). The process of injecting the injection molding material 203B between the first molding die 210 and the composite material 202A may be included after process (2) of bringing the second molding die 220 into contact with the composite material 202A and before the process of releasing the fixing of the composite material 202A.

[0285] In addition, when the holes 201H are not formed in the molded body 201, before the composite material 202A and the injection molding material 203B are pressed and integrally molded, as shown in FIG. Fig.19As shown, the fixing member 212 may be moved. That is, after step (3) and before step (4), the fixing member 212 may be released from fixing the composite material 202A. In this case, even if a hole 202H is formed at a position corresponding to the fixing member 212 in the composite material 202A, when the composite material 202A and the injection molding material 203B are pressed and integrally molded by the first molding die 210 and the second molding die 220, the injection molding material 203B flows into the inside of the hole 202H, thereby filling the hole 202H.

[0286] [Fourth Embodiment]

[0287] Figure 20 to Figure 25 Schematic diagram showing a method for producing a molded body 301 according to a fourth embodiment of the present invention. In addition, the same reference numerals are used for the last two digits of the same configuration as those of the third embodiment, and description thereof will be omitted.

[0288] The fourth embodiment is different from the third embodiment in that the injection molding material 303B is injected between the second molding die 320 and the composite material 302A.

[0289] Specifically, first, Fig. 20 As shown, the composite material 302A is fixed in the mold cavity 311 of the first forming mold 310 by a plurality of fixing components 312 .

[0290] Then, if Fig.21 As shown, the second forming die 320 is moved toward the composite material 302A fixed to the first forming die 310 so that the second forming die 320 is in contact with the composite material 302A.

[0291] Then, if Fig. 22 As shown, the injection molding material 303B is injected from the gate 323 provided in the second molding die 320 into between the second molding die 320 and the composite material 302A.

[0292] Then, if Fig.23 As shown, the composite material 302A and the injection molding material 303B are pressed in a molding die to be integrally formed.

[0293] At this time, the hole 302H is formed at a position corresponding to the fixing member 312 of the composite material 302A, and the hole 303H is formed at a position corresponding to the fixing member 312 of the injection molding material 303B.

[0294] In addition, a hole 322 for inserting the fixing member 312 may be provided at a position of the second molding die 320 that faces the fixing member 312 .

[0295] Thereafter, the second molding die 320 is moved in a direction away from the first molding die 310 to remove the molded body 301 from the first molding die 310. Thus, the molded body 301 is completed.

[0296] In addition, if Fig.24 As shown, the fixing member 312 may be moved to pull the fixing member 312 out from the integrally formed composite material 302A and the injection molding material 303B. As a result, the fixing of the composite material 302A by the fixing member 312 is released. That is, the process of releasing the fixing of the composite material 302A by the fixing member 312 may also be included. It should be noted that the process of releasing the fixing of the composite material 302A by the fixing member 312 may be after process (3) and before process (4), or after process (4). The process of injecting the injection molding material 303B between the second molding die 320 and the composite material 302A may be included after process (2) of bringing the second molding die 320 into contact with the composite material 302A and before the process of releasing the fixing of the composite material 302A.

[0297] In addition, when the hole 301H is not formed in the molded body 301, Fig.25 As shown, before the composite material 302A and the injection molding material 303B are pressed and integrally formed, the fixing member 312 may be moved. That is, after step (3) and before step (4), the fixing of the composite material 302A by the fixing member 312 may be released. In this case, even if a hole 302H is formed at a position corresponding to the fixing member 312 of the composite material 302A, when the composite material 302A and the injection molding material 303B are pressed and integrally formed by the first molding die 310 and the second molding die 320, the injection molding material 303B flows into the inside of the hole 302H, thereby filling the hole 302H.

[0298] In the first to fourth embodiments above, a case where a pair of male and female molds, namely a first mold and a second mold, is used, and the first mold is a fixed mold and the second mold is a movable mold is described, but the present invention is not limited thereto. For example, the first mold may be a movable mold and the second mold may be a fixed mold.

[0299] In addition, in the above description, the first forming mold is the lower mold, the second forming mold is the upper mold, and the second forming mold is opened and closed by moving the second forming mold up and down toward the first forming mold. However, for example, the first forming mold may be opened and closed by moving the first forming mold up and down toward the second forming mold. Alternatively, the first forming mold and the second forming mold may be opened and closed by moving at least one of the first forming mold and the second forming mold in the horizontal direction.

[0300] [Opening and closing direction of the molding die]

[0301] When the first molding die is a fixed die and the second molding die is a movable die, and the molded body is manufactured by opening and closing the second molding die by moving it horizontally toward the first molding die, it is preferred that there are at least two fixing parts with different positions in the height direction. Fig.26 4 is a horizontal cross-sectional view showing a first molding die 410 and a second molding die 420 which are configured to be openable and closable in the horizontal direction. Fig.26 In the embodiment, the first forming mold 410 is a fixed mold, and the second forming mold 420 is a movable mold. The first forming mold 410 has a fixing component 412 and a gate 413. A plurality of fixing components 412 are provided in the first forming mold 410 to fix the composite material 402A to the first forming mold 410. The plurality of fixing components 412 are preferably located at different positions in the horizontal direction. By arranging the plurality of fixing components 412 at different positions in the horizontal direction of the first forming mold 410, it is possible to prevent the position of the composite material 412A from being offset relative to the first forming mold 410. The fixing components 412 may also be arranged at different positions in the height direction. Three or more fixing components 412 may also be arranged at different positions in the height direction and the horizontal direction.

[0302] In addition, a hole 422 for inserting the fixing member 412 may be provided at a position of the second molding die 420 that faces the fixing member 412 .

[0303] [Fixed mold and movable mold]

[0304] Depending on the forming mold, the fixed mold may also move. If the fixed mold moves, the forming mold that moves a relatively small distance is the fixed mold, and the forming mold that moves a relatively large distance is the movable mold.

[0305] [Pattern cutting]

[0306] The composite material is preferably cut into a shape by pattern cutting. Pattern cutting means that the composite material is pre-cut into a target shape according to the shape of the formed body. It is not a simple shape such as a square or rectangle. For example, Fig. 27 As shown, in the case of manufacturing a box-shaped molded body 501, as shown in Fig.28 As shown, the composite material 502A can be formed into a shape obtained by adding a margin to the portion constituting the expanded view of the box. Fig.28 In the embodiment, four side portions 502A2 are provided around a portion 502A1 which is a bottom surface of a rectangular box, and a side portion 502A3 is provided at a portion where adjacent side portions 502A2 are joined during molding. Fig.28In the embodiment, the side portion 502A3 is provided only on one of the portions 502A2 that are two adjacent side surfaces, but the side portions 502A3 may be provided on both sides.

[0307] When the resin contained in the composite material is a thermoplastic resin and the forming method uses cold pressing, it is particularly preferred to perform pattern cutting and cut out the composite material. In the case of cold pressing, the resin begins to solidify from the moment the forming mold contacts the composite material, so the fluidity during forming is low compared to thermosetting resins. Therefore, if the composite material is cut into a target shape in advance, it is easy to make a molded body of the target shape. The pattern cutting shape is preferably a shape that is expanded by inverse forming analysis using a computer according to the three-dimensional shape of the manufactured pressed body.

[0308] [Pattern cutting and fixing parts]

[0309] When the composite material is in a shape cut out by pattern cutting, the first molding die is a fixed mold, the second molding die is a movable mold, and the molded body is manufactured by moving the second molding die in a horizontal direction to open and close, the fixing component exerts a more excellent effect.

[0310] Fig.29 FIG. 5 is a front view of the first forming die 510 showing a state where the composite material 502A after pattern cutting is fixed by a fixing member 512. Fig.29 As shown, for example, in a portion 502A1 of the bottom surface of a rectangular box, the composite material is fixed to the first molding die 510 by fixing members 512 at a plurality of locations preferably separated in the horizontal direction.

[0311] Fig.30 5 is a horizontal cross-sectional view showing the first molding die 510 and the second molding die 520 after the composite material is fixed by the fixing member. Fig.30 When opening and closing the composite material, the panel surface should be in the vertical direction (with the left and right direction). Fig.30 In this case, when the composite material 502A after pattern cutting is used, the composite material 502A may sag in an undesirable direction compared to a composite material of a simple shape such as a square or a rectangle. Therefore, by properly fixing the composite material 502A to the first forming die 510 using the fixing member 512, it is possible to properly prevent the composite material 502A from sagging in an undesirable direction.

[0312] exist Fig.29In the embodiment, the composite material may be pre-shaped so that the side portion 502A2 and the edge portion 502A3 above the portion 502A1 fixed to the bottom surface of the first molding die 510 by the fixing member 512 are not oriented toward the second molding die 520 (see Fig.30 ) side and tilt toward the first forming mold 510 side in advance.

[0313] [Injection and design properties of fixed molds]

[0314] Next, injection from a fixed mold and design properties are described.

[0315] In the method for manufacturing a molded body of the present invention, it is preferred that the first molding die is a fixed mold, the second molding die is a movable mold, the molding material is an injection molding material, and after step (2) and before step (3), a step of injecting the injection molding material between the first molding die and the second molding die is included, and the injection is performed from the first molding die which is a fixed mold. Compared with the case of injecting from the movable mold, the injection from the fixed mold is less complicated in terms of equipment and is therefore preferred.

[0316] 1. Formation of the exterior surface

[0317] In the case of injection from the first molding die as a fixed mold, it is preferred to form the appearance surface by the second molding die as a movable mold. This is because traces of the injection gate remain on the surface formed by the first molding die as a fixed mold, while on the other hand, no traces of the injection gate remain on the surface formed by the second molding die as a movable mold. In this case, the design of the molded body can be improved by performing the following design between the composite material and the second molding die. In the present invention, the layer formed between the composite material and the second molding die is sometimes referred to as a skin layer.

[0318] 2. Composite materials and exterior surfaces

[0319] In the case of injection from the first molding die as a fixed mold, it is preferred to fill the injection molding material between the second molding die and the composite material. By filling the injection molding material between the second molding die as a movable mold and the composite material, the fibers contained in the composite material can be hidden. The epidermis layer is formed by filling the injection molding material between the second molding die and the composite material. As described later, the epidermis layer can be formed, for example, by a method of winding the injection molding material from the outside of the composite material, a method of allowing the injection molding material to flow through a flow hole formed in the composite material, a method of pre-arranging a resin sheet between the composite material and the second molding die, etc. The thickness of the epidermis layer is preferably greater than 50 μm and less than 300 μm, and more preferably greater than 70 μm and less than 200 μm.

[0320] 2.1 Location and number of gates

[0321] In order to form the skin layer by injection molding material, it is sufficient to fill the injection molding material into the space between the composite material and the cavity wall of the molding mold. At this time, the number of gates for injecting the injection molding material preferably satisfies 0<n1<n2. Where:

[0322] n1 is the number of first gates provided in the region (XA) where the composite material is arranged when the cavity of the molding die is viewed from above;

[0323] n2 is the number of second gates provided in a region other than the region (XA) where the composite material is arranged when the cavity of the molding die is viewed from above.

[0324] For example, in Fig.31 In the example shown, in the first molding die 610, two gates 613a are provided in the region Y1, two gates 613b are provided in the region XA, and two gates 613c are provided in the region Y2. Region XA is a region where the composite material is arranged, and regions Y1 and Y2 are regions other than the region (XA) where the composite material is arranged. Gate 613b is a first gate provided in region XA, and gates 613a and 613c are second gates provided in regions other than region XA. In this case, n1=2, n2=4, and 0<n1<n2 is satisfied. When 0<n1<n2 is satisfied, the injection molding material injected from gates 613a and 613c extends to the region where the composite material is arranged, thereby promoting the injection molding material to enter between the composite material and the cavity wall of the second molding die (preferably a movable die).

[0325] 2.2 Gate location and discharge volume

[0326] In order to form the skin layer by injection molding material, it is sufficient to fill the injection molding material into the space between the composite material and the cavity wall of the molding mold. At this time, the discharge amount from the gate for injecting the injection molding material preferably satisfies 0<V1<V2. Where:

[0327] V1 is the discharge amount of the injection molding material from the first gate, and the first gate is arranged in the area (XA) where the composite material is arranged when the mold cavity of the molding mold is viewed from above;

[0328] V2 is the discharge amount of the injection molding material from the second gate, and the second gate is provided in a region other than the region (XA) where the composite material is arranged when the cavity of the molding die is viewed from above.

[0329] For example, in Fig.31In the example shown, three gates 613a are provided in the region Y1, six gates 613b are provided in the region XA, and two gates 613c are provided in the region Y2. At this time, if the total amount of the injection molding material discharged from the gate 613b is set to V1, and the total amount of the injection molding material discharged from the gates 613a and 613c is set to V2, it is preferable to satisfy 0<V1<V2.

[0330] When 0<V1<V2 is satisfied, the injection molding material injected from the gates 613a and 613c spreads to the area XA where the composite material is arranged, thereby promoting the injection molding material to enter between the composite material and the cavity wall of the second molding die (preferably the movable die).

[0331] 2.3 Flow hole

[0332] When the exterior surface is formed by using the first molding die and the injection molding material is filled between the first molding die and the composite material, for example, Fig.26 As shown, it is preferred that at least one flow hole X1 for passing the injection molding material is provided in the composite material, and the injection molding material injected from the gate 413 of the first molding die 410 flows through the above-mentioned flow hole X1, thereby being injected between the composite material and the second molding die 420. The injection molding material injected from the first molding die 410 passes through the flow hole X1, so that the injection molding material can enter between the composite material and the second molding die 420. At this time, it is preferred that the gate 413 is provided in the area where the composite material is arranged in the first molding die 410.

[0333] 2.4 Configuration of resin sheet

[0334] When the second forming die is used to form the appearance surface, it is preferred to configure a resin sheet between the composite material configured in the first forming die and the second forming die. By configuring the resin sheet, the appearance surface can be easily formed on the molded body. If the resin sheet does not contain fibers, the transferability of the forming die mirror surface of the second forming die is good, so it is preferred. The resin sheet can be configured in the first forming die after being stacked with the composite material, or the resin sheet can be stacked on the composite material after the composite material is configured in the first forming die.

[0335] 2.5 Folds

[0336] When the exterior surface is formed by the second forming die, the exterior surface may also have a wrinkle shape formed by the second forming die. By transferring the mold surface of the second forming die to form a wrinkle shape on the molded body, the reinforcing fibers contained in the composite material can be made less noticeable, thereby improving the design. A resin-rich layer may be provided on the surface of the composite material so that the wrinkle shape can be easily transferred to the composite material through the mold surface of the second forming die, and a resin sheet may be provided between the second forming die and the composite material when the composite material is arranged in the first forming die.

[0337] This application is based on Japanese patent application No. 2022-149322 filed on September 20, 2022 and Japanese patent application No. 2022-196925 filed on December 9, 2022, the contents of which are incorporated herein by reference.

[0338] Description of Reference Numerals

[0339] 1. 101, 201, 301, 501 formed body

[0340] 1H, 2H, 3H, 22, 101H, 102H, 103H, 201H, 202H, 203H, 222, 301H, 302H, 303H, 322, 422 holes

[0341] 2 Enhancement

[0342] 2A, 102A, 202A, 302A, 402A, 502A, 602A composite materials

[0343] 3 Main body

[0344] 3B, 103B forming materials

[0345] 10, 210, 310, 410, 510, 610 first forming die

[0346] 11, 211, 311 cavity

[0347] 12, 212, 312, 412, 512 fixed parts

[0348] 20, 120, 220, 320, 420 second forming die

[0349] 203B, 303B injection molding materials

[0350] 213, 323, 413, 613a, 613b, 613c gate

Claims

1. A method for producing a molded body, characterized in that: The molded body is integrally formed of a composite material and a molding material, the composite material includes reinforcing fibers dispersed in an in-plane direction, and the molding material has a higher fluidity than the composite material. The method for producing the molded body comprises the following steps (1) to (3): (1) A process of fixing the composite material to the first forming mold by means of a plurality of fixing parts arranged on the first forming mold, wherein the first forming mold has a mold cavity, and the area of ​​the mold cavity is larger than the area of ​​the composite material when viewed from above; (2) A process of moving the second forming mold toward the composite material fixed to the first forming mold so that the second forming mold contacts the composite material; (3) A process of pressing the composite material and the forming material by means of the first forming mold and the second forming mold to form them as one piece.

2. The method for producing a molded body according to claim 1, wherein: The method further includes a step of releasing the fixing of the composite material by the fixing member.

3. The method for producing a molded body according to claim 1 or 2, wherein: The method includes the step of laminating the molding material on the composite material before the step (1).

4. The method for producing a molded body according to claim 3, wherein: In the step (1), the composite material is fixed to the first molding die so that the molding material is in contact with the first molding die.

5. The method for producing a molded body according to claim 1 or 2, wherein: In the step (1), the composite material is fixed to the first molding die so that the molding material is arranged on the side opposite to the first molding die.

6. The method for producing a molded body according to claim 1 or 2, wherein: The method includes the step of laminating the molding material on the composite material after the step (1) and before the step (2).

7. The method for producing a molded body according to claim 1 or 2, wherein: The molding material is an injection molding material, and The method for producing a molded body includes, after the step (2) and before the step (3), a step of injecting the molding material between the first molding die and the second molding die.

8. The method for producing a molded body according to claim 2, wherein: The molding material is an injection molding material, and The method for manufacturing a molded body includes, after the step (2) and before the step of releasing the fixing of the composite material by the fixing member, a step of injecting the molding material between the first molding die and the second molding die.

9. The method for producing a molded body according to claim 7 or 8, characterized in that: The forming material is injected between the first forming mold and the composite material.

10. The method for producing a molded body according to claim 7 or 8, wherein: The forming material is injected between the second forming mold and the composite material.

11. The method for producing a molded body according to any one of claims 1 to 10, characterized in that: The first molding die and the second molding die are a pair of male and female molding dies.

12. The method for producing a molded body according to claim 11, wherein: The first molding die is a fixed die, and the second molding die is a movable die.

13. The method for producing a molded body according to claim 11 or 12, wherein: The first forming mold is a lower mold, and the second forming mold is an upper mold.

14. The method for producing a molded body according to any one of claims 1 to 13, characterized in that: The fixing member is a hole forming member for forming a hole in the formed body.

15. The method for producing a molded body according to any one of claims 1 to 14, characterized in that: The reinforcing fibers are randomly dispersed in two-dimensional directions in the in-plane direction of the composite material.

16. The method for producing a molded body according to claim 12, wherein: The molding material is an injection molding material, The method for manufacturing a molded body includes the step of injecting the injection molding material between the first molding die and the second molding die after the step (2) and before the step (3), and Injection is performed from the first forming die.

17. The method for producing a molded body according to claim 16, wherein: The exterior surface is formed by using the second molding die, and the injection molding material is filled between the second molding die and the composite material.

18. The method for producing a molded body according to claim 17, wherein: The composite material is provided with flow holes at one or more positions for allowing the injection molding material to pass therethrough, and The injection molding material injected from the first molding die flows through the flow hole and is injected between the first molding die and the second molding die.

19. The method for producing a molded body according to claim 18, wherein: The first molding die has a first gate in a region where the composite material is arranged in a plan view. The first gate is a gate for injecting the injection molding material into the molding die.

20. The method for producing a molded body according to claim 16, wherein: The exterior surface is formed using the second forming die, and a resin sheet is disposed between the second forming die and the composite material.

21. The method for producing a molded body according to claim 17 or 20, wherein: The exterior surface has a corrugated shape formed by the second forming die.

22. The method for producing a molded body according to any one of claims 1 to 12, characterized in that: The first forming mold is a fixed mold, and the second forming mold is a movable mold. The molded body is manufactured by moving the second molding die in a horizontal direction to open and close the mold, and At least two fixing members are provided at different positions in the height direction.

23. The method for producing a molded body according to any one of claims 1 to 12, characterized in that: The first forming mold is a fixed mold, and the second forming mold is a movable mold. The molded body is manufactured by moving the second molding die in a horizontal direction to open and close the second molding die, At least two fixing members are provided at different positions in the horizontal direction.

24. The method for producing a molded body according to any one of claims 1 to 23, characterized in that: The composite material has a shape cut out by pattern cutting.

25. The method for producing a molded body according to claim 19, wherein: The first molding die has a second gate for injecting the injection molding material in a region other than a region where the composite material is arranged when viewed from above, and The number n1 of the first gates and the number n2 of the second gates satisfy 0<n1<n2.

26. The method for producing a molded body according to claim 19 or 25, wherein: The first molding die has a second gate for injecting the injection molding material in a region other than a region where the composite material is arranged in a plan view, and A discharge amount V1 of the injection molding material ejected from the first gate and a discharge amount V2 of the injection molding material ejected from the second gate satisfy 0<V1<V2.

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