Press molding apparatus and manufacturing method of press-molded body

Abstract

To provide a press molding apparatus, etc., capable of, in press molding of fiber-reinforced composite material, shortening a heating and cooling cycle and fabricating a high-quality press-molded body even without a separate preheater.SOLUTION: A press molding apparatus (1) comprises a fixed mold (2) and a movable mold (3). The fixed mold (2) includes a fixed mold base part (21) and a fixed mold middle part (22) disposed sandwiching a fixed mold gap (2s) along with the fixed mold base part (21), and the movable mold (3) includes a movable mold base part (31) and a movable mold middle part (32) disposed sandwiching a movable mold gap (3s) along with the movable mold base part (31).SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a press molding apparatus and a method for manufacturing a press molded article made of a composite material such as a composite material, and in particular to a press molding apparatus for a composite material at a press molding temperature of 150° C. or higher. [Background technology]

[0002] Traditionally, composite materials have been developed as alternatives to metallic materials for forming automobile parts, electric motorcycles, separators for EV hydrogen engines, aircraft components, drone parts, prosthetic limbs, etc. In recent years, composite materials using thermoplastic resins or thermosetting resins in particular have been attracting attention because they can be mass-produced by press molding and can be made into complex shapes.

[0003] Examples of composite materials using resins for press molding include GMT (glass mat reinforced thermoplastics), carbon fiber reinforced composite materials, natural fiber reinforced composite materials, aramid fiber reinforced composite materials, etc. For molding these composite materials, press molding methods such as those disclosed in Patent Document 1 are disclosed. However, the press molding temperature for composite materials is high, at over 150°C, which means that the heating and cooling cycles are long, resulting in low manufacturing efficiency and high manufacturing costs.

[0004] Furthermore, in order to manufacture high-quality press-molded bodies, it is desirable to preheat the material for the press-molded body before setting it in the press molding device (Patent Document 2, etc.). However, depending on the shape of the material and the type of fibers, etc. contained in the composite material, some materials are difficult to preheat (nonwoven fabrics, chopped materials, etc.), and even if preheating is possible, some materials are difficult to set in the mold after preheating, which has led to the problem that high-quality press-molded bodies cannot be obtained because they cannot be preheated.

[0005] Furthermore, when the upper and lower dies are entirely closed along guide pins or the like (when the dies are completely closed), there is a problem that it becomes difficult to adjust the guide pins, i.e., to position the die parts and the press-molded body. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2015-112827 A [Patent Document 2] International Publication No. 2018 / 003433 Summary of the Invention [Problem to be solved by the invention]

[0007] The present invention has been made in consideration of the above-mentioned circumstances, and has an objective of providing a press molding apparatus that can shorten the heating and cooling cycle in press molding of composite materials and produce high-quality press-molded bodies without a separate preheating device. Here, a "high-quality press-molded product" refers to one in which the composite fibers and resin are thoroughly mixed and there is little exposure of the fibers on the surface of the press-molded product, or one which has a complex shape (including bosses, ribs, thin sections, undercut shapes, etc.) or which is molded with high precision even if there are problems with the homogeneity of the material. [Means for solving the problem]

[0008] The press molding apparatus (1) for press-molding a composite press-molded body of the present invention includes a fixed mold (2) and a movable mold (3). The fixed mold (2) has a fixed mold base (21) and a fixed mold intermediate part (22) arranged to sandwich a fixed mold gap (2s) with the fixed mold base (21). The movable mold (3) has a movable mold base (31) and a movable mold intermediate part (32) arranged to sandwich a movable mold gap (3s) with the movable mold base (31). the fixed mold intermediate part (22) and the movable mold intermediate part (32) are arranged so as to face each other and be able to come into contact with each other, the fixed mold base part (21) has a fixed mold base cooling passage (211), the movable mold base part (31) has a movable mold base cooling passage (311), the fixed mold intermediate part (22) has a fixed mold intermediate part heating and cooling passage (221) on the side of the fixed mold gap (2s), and the movable mold is disposed on the side away from the fixed mold gap (2s), The movable mold intermediate portion (32) has a movable mold intermediate portion heating and cooling flow path (321) on the movable mold gap (3s) side, and has a movable mold intermediate portion heater (322) on the side away from the movable mold gap (3s) on the side of the fixed mold (2), and a heating fluid flows through the fixed mold intermediate portion heating and cooling flow path (221) until a predetermined temperature is reached during preheating and heating, and a cooling fluid flows through the movable mold intermediate portion heating and cooling flow path (221) during cooling, A heating fluid flows through the mold intermediate heating and cooling flow passage (321) during preheating and heating until a predetermined temperature is reached, and a cooling fluid flows through it during cooling. The width of the fixed mold gap (2s) and the movable mold gap (3s) can be adjusted, and the gap width can be set to 0 to eliminate the gap, thereby bringing the fixed mold base (21) and the fixed mold intermediate part (22) into contact with each other, and the movable mold base (31) and the movable mold intermediate part (32) into contact with each other.

[0009] A method for manufacturing a press-molded body of a composite material by the above-mentioned press molding apparatus (1) of the present invention includes steps A, B, C, D, E, and F. Step A is a step of preheating the fixed mold intermediate part (22) and the movable mold intermediate part (32), configuring the fixed mold gap (2s) and the movable mold gap (3s), bringing the fixed mold intermediate part (22) and the movable mold intermediate part (32) into contact with each other in a mold intermediate closed state, flowing a cooling fluid through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), and heating the fixed mold intermediate part (22). A step B is a step of flowing a heating fluid through the heat cooling flow passage (221) and the movable mold intermediate portion heating / cooling flow passage (321), and turning on the fixed mold intermediate portion heater (222) and the movable mold intermediate portion heater (322) to heat the molded body. The step B is a step of applying a material for a press molded body to the movable mold (3), and is configured to have the fixed mold gap (2s) and the movable mold gap (3s). The mold is opened so that the fixed mold intermediate portion (22) and the movable mold intermediate portion (32) are not in contact with each other, and the fixed mold base cooling flow passage (211) and the movable mold base cooling flow passage (311) are opened. a step C of flowing a cooling fluid through the fixed mold intermediate portion heating / cooling passage (221) and the movable mold intermediate portion heating / cooling passage (321), turning on the fixed mold intermediate portion heater (222) and the movable mold intermediate portion heater (322) to heat, and applying the material of the press-molded body to the movable mold (3) side; a step C of heating the material of the press-molded body, in which the fixed mold intermediate portion (22) and the movable mold intermediate portion (32) are configured to have the fixed mold gap (2s) and the movable mold gap (3s), and a mold intermediate closed state is established in which the fixed mold intermediate portion (22) and the movable mold intermediate portion (32) are brought into contact with each other; a step of flowing a cooling fluid through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), flowing a heating fluid through the fixed mold intermediate portion heating / cooling passage (221) and the movable mold intermediate portion heating / cooling passage (321), and turning on the fixed mold intermediate portion heater (222) and the movable mold intermediate portion heater (322) for heating; a step D of pressing the press-molded body, which includes setting the gap widths of the fixed mold gap (2s) and the movable mold gap (3s) to 0 to eliminate the gaps, bringing the fixed mold intermediate portion (22) and the movable mold intermediate portion (32) into contact with each other,a mold is closed so that the fixed mold base (21) and the fixed mold intermediate part (22) and the movable mold base (31) and the movable mold intermediate part (32) are in contact with each other, a cooling fluid is caused to flow through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), a heating fluid is caused to flow through the fixed mold intermediate part heating / cooling passage (221) and the movable mold intermediate part heating / cooling passage (321), and the fixed mold intermediate part heater (222) and the movable mold intermediate part heater (322) are turned ON. This is a step of cooling the intermediate portion (32) and the press-molded body, in which the gap widths of the fixed mold gap (2s) and the movable mold gap (3s) are set to 0 to eliminate any gaps, the fixed mold intermediate portion (22) and the movable mold intermediate portion (32) are brought into contact with each other, a mold is closed in which the fixed mold base portion (21) and the fixed mold intermediate portion (22) are brought into contact with each other, and the movable mold base (31) and the movable mold intermediate portion (32) are brought into contact with each other, a cooling fluid is caused to flow through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), and the fixed mold intermediate portion heating and cooling passage (221) are caused to flow through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311). Step F is a step of removing the press-molded body, in which the fixed mold gap (2s) and the movable mold gap (3s) are formed, the molds are opened so that the fixed mold intermediate part (22) and the movable mold intermediate part (32) are not in contact with each other, a cooling fluid is caused to flow through the fixed mold base cooling flow path (211) and the movable mold base cooling flow path (311), and the fixed mold intermediate part heater (222) and the movable mold intermediate part heater (322) are turned off. a step of flowing a cooling fluid through the fixed mold intermediate portion heating / cooling passage (221) and the movable mold intermediate portion heating / cooling passage (321), turning off the fixed mold intermediate portion heater (222) and the movable mold intermediate portion heater (322), and removing the press-molded body from the movable mold (3), wherein the supply of the heating fluid or cooling fluid flowing through the fixed mold intermediate portion heating / cooling passage (221) and the movable mold intermediate portion heating / cooling passage (321) is stopped when the fixed mold intermediate portion heating / cooling passage (221) and the movable mold intermediate portion heating / cooling passage (321) reach a predetermined temperature. Effect of the Invention

[0010] The press molding apparatus of the present invention for producing a press-molded body can provide a press molding apparatus that can shorten the heating and cooling cycle of press molding and produce high-quality press-molded bodies without a separate preheating device. It is possible to press mold even materials that are difficult to preheat (such as nonwoven fabrics or chopped materials) or materials for which it is difficult to set the preheated materials in the mold. In addition, there is little exposure of fibers, etc. on the surface of the pressed molded body, so it is possible to mold the pressed body with high precision even if the shape is complex. Since the heating and cooling cycle of press molding can be shortened and positioning during pressing is easy, the production efficiency of press-molded products can be improved while at the same time reducing production costs. Furthermore, since the material of the press-molded body is heated while the fixed mold intermediate part and the movable mold intermediate part are in contact and the upper and lower molds are not entirely closed (middle mold closure), positioning of the mold parts and the press-molded body is easier than when the molds are completely closed. [Brief description of the drawings]

[0011] [Figure 1] 1 is an example of a press molding apparatus of the present invention, showing a case where a fixed mold intermediate part and a movable mold intermediate part are not in contact with each other (a mold open state). [Diagram 2] 1 is an example of a press molding apparatus of the present invention, showing the case where a fixed mold intermediate part and a movable mold intermediate part are in contact with each other (mold intermediate closed state). [Diagram 3] This is an example of a press molding apparatus of the present invention, and shows the case where the fixed mold intermediate part and the movable mold intermediate part, the fixed mold base part and the fixed mold intermediate part, and the movable mold base part and the movable mold intermediate part are in contact (mold closed state). [Figure 4] 1 is a graph showing the change in temperature over time when the temperature is increased from 50° C. to 150° C. with the press molding apparatus in a state where the mold is open. [Diagram 5] 1 is a graph showing the change in temperature over time when the temperature is increased from 50° C. to 220° C. with the press molding apparatus in a state where the mold is open. [Figure 6] 1 is a graph showing the change in temperature over time when the temperature is increased from 50° C. to 300° C. with the press molding apparatus in a state where the mold is open. [Figure 7] 1 is a graph showing the change in temperature over time when the temperature is increased from 50° C. to 150° C. with the press molding device in a state where the mold is partially closed. [Figure 8] 1 is a graph showing the change in temperature over time when the temperature is increased from 50° C. to 220° C. in a press molding apparatus with the mold half-closed. [Figure 9] 1 is a graph showing the change in temperature over time when the temperature is increased from 50° C. to 300° C. with the press molding device in a state where the mold is partially closed. [Figure 10] 13 is a graph showing changes in temperature over time when steam is passed through a fixed mold intermediate heating / cooling passage and a movable mold intermediate heating / cooling passage of a press molding apparatus. [Figure 11] 11(a) and (b) are 3D images, and FIG. 11(c) and (d) are photographs showing examples of press-molded bodies produced by the press-molding apparatus of the present invention. [Figure 12] An example of the press molding apparatus of the present invention is shown in Fig. 12. (a) is a photograph of the mold open state, and (b) is a photograph of the mold half-closed state. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The press molding apparatus and the method for producing a press-molded product of the present invention will be described below with reference to Fig. 1 to Fig. 12. Although the description will be given with reference numerals, the present invention is not limited by the reference numerals.

[0013] (Press molding equipment) The press molding apparatus 1 of the present invention is used for press molding a press-molded body of a composite material such as a fiber-reinforced composite material.

[0014] When the composite material is a fiber-reinforced composite material, it contains fibers and synthetic resin.

[0015] Examples of fibers include glass fibers contained in GMT (glass mat reinforced thermoplastics), carbon fibers, natural fibers, aramid fibers, etc. In addition, metal fibers such as aluminum fibers, graphite fibers, organic fibers such as PBO (polyparaphenylene benzobisoxazole), polyphenylene sulfide, polyester, acrylic, nylon, and polyethylene, and inorganic fibers such as silicon carbide and silicon nitride can be used.

[0016] An example of the synthetic resin is a polypropylene resin, which is a thermoplastic resin. Other examples of the thermoplastic resin include polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), and liquid crystal polyesters, polyolefins such as polyethylene (PE) and polybutylene, polyarylene sulfides such as polyoxymethylene (POM), polyamide (PA), and polyphenylene sulfide (PPS), fluorine-based resins such as polyketone (PK), polyether ketone (PEK), polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyether nitrile (PEN), and polytetrafluoroethylene, and crystalline resins such as liquid crystal polymer (LCP). In addition to styrene-based resins, amorphous resins such as polycarbonate (PC), polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polyphenylene ether (PPE), thermoplastic polyimide (PI), polyamideimide (PAI), polyetherimide (PEI), polysulfone (PSU), polyethersulfone, and polyarylate (PAR), as well as phenol-based resins, phenoxy resins, and further thermoplastic elastomers such as polystyrene-based, polyolefin-based, polyurethane-based, polyester-based, polyamide-based, polybutadiene-based, polyisoprene-based, fluorine-based resins, and acrylonitrile-based, and copolymers and modified products thereof can be used.

[0017] As the synthetic resin, a thermosetting resin such as phenol resin (PF), epoxy resin (MF), alkyd resin, silicone resin, polyurethane (PUP), thermosetting polyimide, melamine resin, urea resin, etc. can be used.

[0018] The reinforcing fiber content in the fiber-reinforced composite material (before press molding) can be appropriately set within a range of about 20% by mass to 75% by mass. In order to mold a molded product with high physical strength, the reinforcing fiber content in the fiber-reinforced composite material can be set to 50% by mass or more, or 60% by mass or more.

[0019] Examples of the composite material include fiber-reinforced composite materials as well as materials containing super engineering plastics and synthetic resins.

[0020] (Fixed and movable molds) 1 and 2, a press molding apparatus 1 includes an opposing fixed mold 2 and a movable mold 3. Specifically, a fixed mold intermediate part 22 and a movable mold intermediate part 32 are disposed to face each other and be in contact with each other.

[0021] (Fixed mold) The fixed mold 2 has a fixed mold base portion 21 and a fixed mold intermediate portion 22 that is provided together with the fixed mold base portion 21 with a fixed mold gap 2s therebetween.

[0022] The material of the fixed mold base 21 is preferably carbon steel such as S45C. The size of the fixed mold base 21 depends on the size of the press-molded body, but is, for example, about 50 cm×70 cm×10 cm thick. The material of the fixed mold intermediate portion 22 is exemplified by various carbon steels, and pre-hardened steel such as PXA30 (manufactured by Daido Steel Co., Ltd., carbon steel) is often used from the viewpoint of mirror surface quality and hardness. The size of the fixed mold intermediate portion 22 depends on the size of the press molded body, but is, for example, about 40 cm×50 cm×9 cm thick.

[0023] A fixed mold gap 2s is provided between the fixed mold base 21 and the fixed mold intermediate part 22. The fixed mold gap 2s provides a heat insulating effect by sandwiching air between the fixed mold base 21 and the fixed mold intermediate part 22. The fixed mold gap 2s is provided by attaching a fixed mold elastic body 23 such as a spring or coil to the side of the fixed mold base 21 and / or the side of the fixed mold intermediate part 22. The fixed mold elastic body 23 is preferably attached to the side of the fixed mold base 21 through which a cooling fluid always flows. The width of the fixed mold gap 2s (the distance between the fixed mold base 21 and the fixed mold intermediate portion 22) is, for example, about 0 mm to 10 mm, and more preferably about 0 mm to 6 mm. When a heat insulating effect is required, the range of 4 mm to 6 mm is preferable. If it is 10 mm or more, it tends to be difficult to position the mold parts. The width of the fixed die gap 2s can be adjusted by a fixed die elastic body 23 such as a spring or coil, a thickness adjustment bolt, etc. When a certain level of press force is applied between the fixed die 2 and the movable die 3, the fixed die gap 2s becomes 0 mm, the gap disappears, and the fixed die base part 21 and the fixed die intermediate part 22 come into contact with each other (see FIG. 3).

[0024] A fixed mold insert 24 can be provided on the side of the fixed mold intermediate portion 22 opposite to the fixed mold base portion 21. The fixed mold insert 24, together with a movable mold insert 34 described below, is combined with the mold for formed body 4 and is used to form the flat portion, the side wall, and the undercut portion.

[0025] The fixed mold middle section 22 may be equipped with a thermocouple 25 for measuring the mold temperature.

[0026] A stationary mold base cooling flow passage 211 through which a cooling fluid always flows during operation is provided in the stationary mold base 21. The cooling fluid may be anything that can serve as a cooling medium, and examples thereof include cold water. An example of the fixed mold base cooling flow passage 211 is a configuration in which 24 pipes with a diameter of 11 mm are arranged (12 pipes in two stages) within the surface of the fixed mold base 21. In this case, the speed of the cooling fluid depends on the pipe diameter, the desired cooling temperature, the area of ​​the press molded body, etc., but from the viewpoint of cooling efficiency, it is preferable to set the speed so that the flow is turbulent rather than laminar.

[0027] A fixed mold intermediate portion heating / cooling flow path 221, through which a heating fluid or a cooling fluid flows, is provided on the side of the fixed mold gap 2s in the fixed mold intermediate portion 22. A heating fluid can be flowed through the fixed mold intermediate portion heating / cooling flow path 221 until a predetermined temperature is reached during preheating and heating, and a cooling fluid can be flowed through the fixed mold intermediate portion heating / cooling flow path 221 during cooling.

[0028] The heating fluid may be any fluid capable of acting as a heating medium, such as hot water, hot oil, and steam. The cooling fluid may be any fluid capable of acting as a cooling medium, such as cold water. An example of the fixed mold intermediate heating / cooling flow path 221 is a configuration in which 10 pipes with a diameter of 11 mm are arranged (10 in one row) on the surface of the fixed mold intermediate section 22 on the side of the fixed mold gap 2s. When the heating fluid is steam, the flow rate is adjusted by pressure. The speed of the cooling fluid depends on the pipe diameter, the desired cooling temperature, the area of ​​the press molded body, etc., but from the viewpoint of cooling efficiency, it is preferable to set it so that the flow is turbulent rather than laminar.

[0029] The fixed mold intermediate part 22 is provided with a fixed mold intermediate part heater 222 on the side away from the fixed mold gap 2s and on the side of the movable mold 3. The fixed mold intermediate part heater 222 may be any heater capable of desired heating, and an example of such a configuration is one in which 12 heaters (12 heaters in one row) having a length of 400 mm, a diameter of Φ8 mm, 10 A, 220 V, and 2000 W are arranged on the surface of the fixed mold intermediate part 22 on the side away from the fixed mold gap 2s. An example of such a configuration is one in which a hole is made in the fixed mold intermediate part 22 at the position of the fixed mold intermediate part heater 222, and the fixed mold intermediate part heater 222 is arranged in the hole.

[0030] (movable mold) The movable mold 3 has a movable mold base portion 31 and a movable mold intermediate portion 32 that is provided together with the movable mold base portion 31 with a movable mold gap 3s therebetween.

[0031] The material of the movable mold base 31 may be, for example, various carbon steels, and carbon steel of material S45C, which is recognized by the IS standard as carbon steel for machine construction, is preferable. The size of the movable mold base 31 is, for example, about 50 cm×70 cm×thickness 10 cm. Examples of the material for the movable mold intermediate portion 32 include various carbon steels, and pre-hardened steels such as PXA30 (manufactured by Daido Steel Co., Ltd., carbon steel) are often used from the viewpoints of mirror surface quality and hardness. The size of the movable mold intermediate portion 32 depends on the size of the press molded body, but is, for example, about 40 cm×50 cm×9 cm thick.

[0032] A movable mold gap 3s is provided between the movable mold base part 31 and the movable mold intermediate part 32. The movable mold gap 3s provides a heat insulating effect by sandwiching air between the movable mold base part 31 and the movable mold intermediate part 32. The movable mold gap 3s is provided by attaching a movable mold elastic body 33 such as a spring or coil to the side of the movable mold base part 31 and / or the side of the movable mold intermediate part 32. The movable mold elastic body 33 is preferably attached to the side of the movable mold base part 31 through which a cooling fluid always flows. The width of the movable mold gap 3s (the distance between the movable mold base part 31 and the movable mold middle part 32) is, for example, about 0 mm to 10 mm, and more preferably about 0 mm to 6 mm. When a heat insulating effect is required, the range of 4 mm to 6 mm is preferable. If it is 10 mm or more, it becomes difficult to position the mold parts. The width of the movable die gap 3s can be adjusted by a movable die elastic body 33 such as a spring or coil, a thickness adjustment bolt, etc. When a certain level of press force is applied between the fixed die 2 and the movable die 3, the movable die gap 3s becomes 0 mm, the gap disappears, and the movable die base part 31 and the movable die middle part 32 come into contact with each other (see FIG. 3).

[0033] A movable mold insert 34 can be provided on the opposite side of the movable mold intermediate portion 32 from the movable mold base portion 31. The movable mold insert 34, together with the fixed mold insert 24, is combined with the mold for molding 4 and is used to form the flat portion, the side wall, and the undercut portion.

[0034] A movable mold base cooling flow passage 311 through which a cooling fluid always flows during operation is provided in the movable mold base 31. The cooling fluid may be anything that can serve as a cooling medium, and examples thereof include cold water. An example of the movable mold base cooling flow path 311 is a configuration in which 24 pipes with a diameter of 11 mm are arranged (12 pipes in two stages) within the surface of the movable mold base 31. In this case, the speed of the cooling fluid depends on the pipe diameter, the desired cooling temperature, the area of ​​the press molded body, etc., but from the viewpoint of cooling efficiency, it is preferable to set the speed so that the flow is turbulent rather than laminar.

[0035] A movable mold intermediate portion heating / cooling flow path 321 through which a heating fluid or a cooling fluid flows is provided on the movable mold gap 3s side of the movable mold intermediate portion 32. A heating fluid can be flowed through the movable mold intermediate portion heating / cooling flow path 321 until a predetermined temperature is reached during preheating and heating, and a cooling fluid can be flowed through the movable mold intermediate portion heating / cooling flow path 321 during cooling.

[0036] The heating fluid may be any fluid capable of acting as a heating medium, such as hot water, hot oil, and steam. The cooling fluid may be any fluid capable of acting as a cooling medium, such as cold water. An example of the movable mold intermediate portion heating / cooling flow path 321 is a configuration in which 10 pipes with a diameter of 11 mm are arranged (10 in one row) on the surface of the movable mold intermediate portion 32 on the side of the movable mold gap 3s. When the heating fluid is steam, the flow rate is adjusted by pressure. The speed of the cooling fluid depends on the pipe diameter, the desired cooling temperature, the area of ​​the press molded body, etc., but from the viewpoint of cooling efficiency, it is preferable to set it so that the flow is turbulent rather than laminar.

[0037] (Fixed mold middle part and movable mold middle part) The fixed mold intermediate part 22 and the movable mold intermediate part 32 are arranged to face each other and be able to come into contact with each other. In the "mold intermediate closed" and "mold closed" states described below, the fixed mold intermediate part 22 and the movable mold intermediate part 32 are in contact with each other, and in the "mold open" state, the fixed mold intermediate part 22 and the movable mold intermediate part 32 are not in contact with each other and face each other with a predetermined distance between them.

[0038] (Press-molded body manufacturing method) The press molded product of the present invention includes steps A, B, C, D, E and F.

[0039] Step A is a step of preheating the fixed mold intermediate part 22 and the movable mold intermediate part 32. Step A is performed in a mold intermediate closed state in which the fixed mold intermediate part 22 and the movable mold intermediate part 32 are in contact with each other, configured to have a fixed mold gap 2s and a movable mold gap 3s. A cooling fluid is passed through the fixed mold base cooling passage 211 and the movable mold base cooling passage 311, a heating fluid is passed through the fixed mold intermediate part heating / cooling passage 221 and the movable mold intermediate part heating / cooling passage 321, and the fixed mold intermediate part heater 222 and the movable mold intermediate part heater 322 are turned ON to heat. Because there is a fixed mold gap 2s and a movable mold gap 3s, the insulating effect prevents the fixed mold base 21 and the movable mold base 31 from rising in temperature more than necessary, and even if a cooling fluid is flowed through the fixed mold base 21 and the movable mold base 31 to maintain the shape stability of the device, the insulating effect does not cause the temperature rise efficiency of the fixed mold intermediate portion 22 and the movable mold intermediate portion 32 to decrease more than necessary.

[0040] Step B is a step of applying the material of the press-molded body to the movable die 3. Step B is performed in a state where the mold is opened so that the fixed die gap 2s and the movable die gap 3s are formed and the fixed die intermediate part 22 and the movable die intermediate part 32 are not in contact with each other. A cooling fluid is passed through the fixed die base cooling passage 211 and the movable die base cooling passage 311, a heating fluid is passed through the fixed die intermediate part heating / cooling passage 221 and the movable die intermediate part heating / cooling passage 321, and the fixed die intermediate part heater 222 and the movable die intermediate part heater 322 are turned ON to heat. In this state, the material of the press-molded body is applied to the movable die intermediate part 32 side of the movable die 3.

[0041] Step C is a step of heating the material of the press molded body. Step C is performed in a mold intermediate closed state in which the mold is configured to have a fixed mold gap 2s and a movable mold gap 3s and the fixed mold intermediate part 22 and the movable mold intermediate part 32 are in contact with each other. A cooling fluid is passed through the fixed mold base cooling passage 211 and the movable mold base cooling passage 311, a heating fluid is passed through the fixed mold intermediate part heating / cooling passage 221 and the movable mold intermediate part heating / cooling passage 321, and the fixed mold intermediate part heater 222 and the movable mold intermediate part heater 322 are turned ON to heat. Since the material of the press-molded body is a composite of materials with different properties, such as fiber and synthetic resin, it is desirable to ensure that the synthetic resin is sufficiently impregnated into the fiber before press molding, and that there is little difference in the softness of the synthetic resin and the degree of impregnation into the fiber depending on the location of the press-molded product (near the center or near the edge, in a thick part or a thin part, etc.). For this reason, steps B and C are carried out after step A.

[0042] Step D is a step of pressing the press-molded body. Step D is performed in a mold-closed state in which the width of the fixed mold gap 2s and the movable mold gap 3s is set to 0 to eliminate the gap, the fixed mold intermediate part 22 and the movable mold intermediate part 32 are brought into contact, and the fixed mold base part 21 and the fixed mold intermediate part 22 are brought into contact with each other, and the movable mold base part 31 and the movable mold intermediate part 32 are brought into contact with each other. A cooling fluid is passed through the fixed mold base cooling passage 211 and the movable mold base cooling passage 311, a heating fluid is passed through the fixed mold intermediate part heating / cooling passage 221 and the movable mold intermediate part heating / cooling passage 321, and the fixed mold intermediate part heater 222 and the movable mold intermediate part heater 322 are turned on. In steps A, B, C, and D, when water (steam) is used as the heating fluid and the predetermined temperature is higher than 150° C., it is desirable to stop the supply of the heating fluid when the heating fluid reaches about 140° C. to 150° C. When the supply is stopped, it is desirable to purge the fixed mold base cooling passage 211 and the movable mold base cooling passage 311 in preparation for the next cooling step.

[0043] Step E is a step of cooling the fixed mold intermediate part 22, the movable mold intermediate part 32, and the press molded body. Step E is performed in a mold closed state in which the gap widths of the fixed mold gap 2s and the movable mold gap 3s are set to 0 to eliminate the gaps, the fixed mold intermediate part 22 and the movable mold intermediate part 32 are brought into contact, and the fixed mold base part 21 and the fixed mold intermediate part 22 are brought into contact with each other, and the movable mold base part 31 and the movable mold intermediate part 32 are brought into contact with each other. A cooling fluid is passed through the fixed mold base cooling passage 211 and the movable mold base cooling passage 311, a cooling fluid is passed through the fixed mold intermediate part heating / cooling passage 221 and the movable mold intermediate part heating / cooling passage 321, and the fixed mold intermediate part heater 222 and the movable mold intermediate part heater 322 are turned off. By setting the gap width of the fixed mold gap 2s and the movable mold gap 3s to 0 and eliminating the gap, the cooling fluid flowing through the fixed mold base cooling passage 211 and the movable mold base cooling passage 311 can also contribute to cooling, improving cooling efficiency. In step E, it is desirable to stop the supply of the cooling fluid when a predetermined temperature is reached.

[0044] Step F is a step of removing the press-molded body. Step F is performed in an open state of the mold, with the molds configured to have a fixed mold gap 2s and a movable mold gap 3s, so that the fixed mold intermediate part 22 and the movable mold intermediate part 32 are not in contact with each other. A cooling fluid is caused to flow through the fixed mold base cooling passage 211 and the movable mold base cooling passage 311, a cooling fluid is caused to flow through the fixed mold intermediate part heating / cooling passage 221 and the movable mold intermediate part heating / cooling passage 321, the fixed mold intermediate part heater 222 and the movable mold intermediate part heater 322 are turned off, and the press-molded body is removed from the movable mold 3.

[0045] As described above, the press molding apparatus and the method for manufacturing a press molded body of the present invention have one of the main features that, when heating with the fixed mold intermediate part 22 and the movable mold intermediate part 32, the heater is arranged on the press molded product side, the heating and cooling flow paths are arranged on the mold base side to allow the heated fluid to flow, and the fixed mold base part 21 and the movable mold base part 31 are insulated by the fixed mold gap 2s and the movable mold gap 3s, respectively. Furthermore, when cooling, the width of the fixed mold gap 2s and the movable mold gap 3s is set to 0, the fixed mold base part 21 and the fixed mold intermediate part 22 are brought into contact with each other, and the movable mold base part 31 and the movable mold intermediate part 32 are brought into contact with each other, and the cooling fluid flowing through the fixed mold base cooling flow path 211 and the movable mold base cooling flow path 311 can also contribute to cooling. Due to these features, it is possible to obtain a high-quality press molded body while shortening the heating and cooling cycle, even if the material is a complex shape or a composite material that is not suitable for preheating.

[0046] (Evaluation test of heating by heaters and heating fluids) Using the press molding apparatus of the present invention, the heating time using the heater and steam (heating fluid) until a predetermined temperature was reached was evaluated. Similarly, the heating time using only a conventional heater was evaluated to verify the shortened time.

[0047] The evaluation was performed with the mold open and with the mold partially closed, and the time taken to reach 150°C from 50°C, 220°C from 50°C, and 300°C from 50°C were measured. The supply of steam was stopped when the mold temperature reached 140°C, compressed air was flowed for 10 seconds to purge, and the valve was closed. The evaluation results are shown in FIGS. As reference data, the heating time using steam only was measured with the mold open and with the mold partially closed, and is shown in Figure 10.

[0048] [Table 1]

[0049] 4 to 9 and Table 1, it can be seen that the time can be significantly reduced by 34 to 101 seconds when the mold is open, and by 53 to 115 seconds when the mold is partially closed. Because the steam is stopped when the mold temperature reaches 140°C, when heating from 50°C to 220°C or from 50°C to 300°C, a time reduction of 1 to 2 minutes is observed once the temperature exceeds 140°C, even though heating is done using only the heater. Also, from Figure 10, it can be seen that when heating to 150°C using steam alone, it takes 1,155 seconds when the mold is open and 917 seconds when the mold is partially closed, which is 6.7 times and 5.3 times longer, respectively, than when using only the heater (172 seconds from Figure 4 and 173 seconds from Figure 7). From the above, it was found that the heating efficiency is lower when using only steam than when using only a heater, but by using a heater and heating with steam in the early stages of heating, the heating time can be significantly shortened and the efficiency of the heater in the latter stages when the steam supply is stopped is also improved. In particular, the thermal efficiency can be further improved by placing the heater on the press-molded body side and the steam flow path on the opposite side to the press-molded body.

[0050] On the other hand, during cooling, cooling fluid flows through the fixed mold intermediate portion heating / cooling passage 221 and the movable mold intermediate portion heating / cooling passage 321, thereby shortening the cooling time.

[0051] An example of a press-molded body (a composite material of polyamide resin and carbon fiber nonwoven fabric, 320 mm x 230 mm) produced by the press molding device of the present invention is shown in Figure 11. Figure 11(a) is a 3D image of the back side, Figure 11(b) is a 3D image of the front side, Figure 11(c) is a photograph of the back side, and Figure 11(d) is a photograph of the front side. Even if there are irregularities, ribs, thick parts and thin parts, a high-quality press-molded product can be obtained.

[0052] An example of the press molding apparatus of the present invention is shown in Fig. 12. Fig. 12(a) shows the mold open state, and Fig. 12(b) shows the mold half-closed state, with a fixed mold gap 2s and a movable mold gap 3s.

[0053] In this specification, the upper side of the press molding apparatus is described as a "fixed mold" and the lower side as a "movable mold", but the upper side may be a movable mold and the lower side a fixed mold. Also, both the upper and lower parts may be movable molds. [Explanation of symbols]

[0054] 1 Press forming equipment 2 Fixed mold 21 Fixed mold base 211 Fixed mold base cooling channel 22 Fixed mold middle part 221 Fixed mold intermediate heating / cooling channel 222 Fixed mold intermediate heater 23 Fixed mold elastic body 24 Fixed mold insert 25 Thermocouple 2s Fixed mold gap 3 Movable mold 31 Movable mold base 311 Movable mold base cooling channel 32 Movable mold middle part 321 Movable mold intermediate heating / cooling channel 322 Movable mold intermediate heater 33 Movable mold elastic body 34 Movable mold insert 3s Movable mold gap 4. Molding mold 5 Drive unit

Claims

1. A press molding apparatus (1) for press-molding a composite material press-molded body, the press molding apparatus (1) comprising: The mold has a fixed mold (2) and a movable mold (3), The fixed mold (2) has a fixed mold base (21) and a fixed mold intermediate part (22) arranged to sandwich a fixed mold gap (2s) between the fixed mold base (21) and the fixed mold intermediate part (22), The movable mold (3) has a movable mold base (31) and a movable mold intermediate part (32) arranged to sandwich a movable mold gap (3s) between the movable mold base (31) and the movable mold intermediate part (32), The fixed mold intermediate part (22) and the movable mold intermediate part (32) are arranged to face each other so as to be in contact with each other, The stationary mold base (21) has a stationary mold base cooling passage (211), The movable mold base (31) has a movable mold base cooling passage (311), The fixed mold intermediate portion (22) has a fixed mold intermediate portion heating / cooling flow path (221) on the side of the fixed mold gap (2s), and has a fixed mold intermediate portion heater (222) on the side of the movable mold (3) away from the fixed mold gap (2s); The movable mold intermediate portion (32) has a movable mold intermediate portion heating / cooling flow path (321) on the movable mold gap (3s) side, and a movable mold intermediate portion heater (322) on the side away from the movable mold gap (3s) and on the fixed mold (2) side, In the stationary mold intermediate heating and cooling flow passage (221), a heating fluid flows until a predetermined temperature is reached during preheating and heating, and a cooling fluid flows during cooling. In the movable mold intermediate heating and cooling flow passage (321), a heating fluid flows until a predetermined temperature is reached during preheating and heating, and a cooling fluid flows during cooling. The press molding device (1) is capable of adjusting the width of the fixed mold gap (2s) and the movable mold gap (3s), and is capable of eliminating the gap by setting the gap width to zero, thereby bringing the fixed mold base (21) and the fixed mold intermediate portion (22) into contact with each other, and the movable mold base (31) and the movable mold intermediate portion (32) into contact with each other.

2. A method for producing a composite press-molded body by the press molding apparatus (1) according to claim 1, the method including steps A, B, C, D, E, and F, The process A is a process of preheating the fixed mold intermediate part (22) and the movable mold intermediate part (32), which is configured to have the fixed mold gap (2s) and the movable mold gap (3s), bringing the fixed mold intermediate part (22) and the movable mold intermediate part (32) into contact with each other in a mold intermediate closed state, flowing a cooling fluid through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), flowing a heating fluid through the fixed mold intermediate part heating / cooling passage (221) and the movable mold intermediate part heating / cooling passage (321), and turning on the fixed mold intermediate part heater (222) and the movable mold intermediate part heater (322) to heat the molds, The B step is a step of applying a material for a press-molded body to the movable mold (3), which is configured to have the fixed mold gap (2s) and the movable mold gap (3s), which is in a mold open state so that the fixed mold intermediate part (22) and the movable mold intermediate part (32) are not in contact with each other, which causes a cooling fluid to flow through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), which causes a heating fluid to flow through the fixed mold intermediate part heating / cooling passage (221) and the movable mold intermediate part heating / cooling passage (321), which causes the fixed mold intermediate part heater (222) and the movable mold intermediate part heater (322) to be turned ON to heat the movable mold (3), and which applies the material for the press-molded body to the movable mold (3) side. Process C is a process of heating the material of the press-molded body, which is configured to have the fixed mold gap (2s) and the movable mold gap (3s), which is in a mold intermediate closed state in which the fixed mold intermediate part (22) and the movable mold intermediate part (32) are in contact with each other, which causes a cooling fluid to flow through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), which causes a heating fluid to flow through the fixed mold intermediate part heating / cooling passage (221) and the movable mold intermediate part heating / cooling passage (321), and which turns on the fixed mold intermediate part heater (222) and the movable mold intermediate part heater (322) to heat the body, Step D is a step of pressing the press-molded body, in which the gap widths of the fixed mold gap (2s) and the movable mold gap (3s) are set to 0 to eliminate the gaps, the fixed mold intermediate portion (22) and the movable mold intermediate portion (32) are brought into contact with each other, the fixed mold base portion (21) and the fixed mold intermediate portion (22) are brought into contact with each other, and the movable mold base portion (31) and the movable mold intermediate portion (32) are brought into contact with each other in a mold-closed state, a cooling fluid is caused to flow through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), a heating fluid is caused to flow through the fixed mold intermediate portion heating / cooling passage (221) and the movable mold intermediate portion heating / cooling passage (321), and the fixed mold intermediate portion heater (222) and the movable mold intermediate portion heater (322) are turned ON, Step E is a step of cooling the fixed mold intermediate part (22), the movable mold intermediate part (32), and the press molded body, and is a step of setting the gap widths of the fixed mold gap (2s) and the movable mold gap (3s) to 0 to eliminate the gaps, bringing the fixed mold intermediate part (22) and the movable mold intermediate part (32) into contact with each other, bringing the fixed mold base (21) and the fixed mold intermediate part (22) into contact with each other, and the movable mold base (31) and the movable mold intermediate part (32) into contact with each other in a mold closed state, flowing a cooling fluid through the fixed mold base cooling flow passage (211) and the movable mold base cooling flow passage (311), flowing a cooling fluid through the fixed mold intermediate part heating / cooling flow passage (221) and the movable mold intermediate part heating / cooling flow passage (321), and turning off the fixed mold intermediate part heater (222) and the movable mold intermediate part heater (322). Step F is a step of removing the press-molded body, which is configured to have the fixed mold gap (2s) and the movable mold gap (3s), is in a mold open state so that the fixed mold intermediate part (22) and the movable mold intermediate part (32) are not in contact with each other, a cooling fluid is caused to flow through the fixed mold base cooling passage (211) and the movable mold base cooling passage (311), a cooling fluid is caused to flow through the fixed mold intermediate part heating / cooling passage (221) and the movable mold intermediate part heating / cooling passage (321), the fixed mold intermediate part heater (222) and the movable mold intermediate part heater (322) are turned off, and the press-molded body is removed from the movable mold (3); A method for manufacturing a press-molded body, characterized in that the supply of heating fluid or cooling fluid to the fixed mold intermediate section heating / cooling passage (221) and the movable mold intermediate section heating / cooling passage (321) is stopped when the fixed mold intermediate section heating / cooling passage (221) and the movable mold intermediate section heating / cooling passage (321) reach a predetermined temperature.

Images