Manufacturing method of molded article, and manufacturing apparatus of molded article

Abstract

To provide a manufacturing method of a molded article in which generation of a crease on a member to be processed can be suppressed.SOLUTION: A manufacturing method of a molded article has: a workpiece arrangement step of arranging a member to be processed on a molding tool; a step of covering a bag sheet on an upper surface of the member to be processed arranged on an upper surface of the molding tool; and a step of decompressing the inside of a space covered by the bag sheet, where the member to be processed is a sheet-like member having a wider area than the top surface of the molding tool, and the workpiece arrangement step is executed in the state where a compressible member for supporting a peripheral part of the member to be processed is arranged around the molding tool.

Description

[Technical field]

[0001] The present invention relates to a method and an apparatus for manufacturing a molded product. [Background technology]

[0002] For example, the following Patent Document 1 describes a molding system for composite components. The molding process using this system includes a step of placing an uncured composite component on a mold. The molding process also includes a step of covering the composite component with an elastomer backing plate. The molding process also includes a step of reducing the pressure in the space covered by the elastomer backing plate. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5615864 Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-mentioned decompression step, if the ends of the composite component come into contact with the mold before the interior of the composite component comes into contact with the mold, there is a risk of wrinkles being generated in the composite component. [Means for solving the problem]

[0005] Means for solving the above problems and their effects will be described below. 1. A method for manufacturing a molded product, comprising the steps of: placing a workpiece to be processed so that it is in contact with the surface of a mold; covering the workpiece with a bag sheet from the side of the workpiece opposite the mold; and reducing the pressure within the space covered by the bag sheet, wherein the workpiece is a sheet-like member having an area larger than the surface of the mold, and the workpiece placing step is performed with a compressible member disposed around the mold to support the peripheral portion of the workpiece. In the above method, the workpiece is placed in contact with the surface of the mold with the compressible member disposed around the mold. Therefore, the compressible member restricts the peripheral portion of the workpiece from being positioned on the mold side. Then, with the workpiece covered with the bag sheet, the pressure in the space covered by the bag sheet is reduced. As a result, the compressible member is compressed, so that the workpiece gradually comes into contact with the mold from the inside rather than the outer periphery. This allows the outer periphery of the workpiece to be brought into contact with the mold last. This makes it possible to suppress the generation of wrinkles in the workpiece. 2. A method for manufacturing a molded product as described in claim 1, wherein the processing object placing step is a step of placing the processing object part on the molding mold, the bag sheet covering step is a step of covering the upper surface of the processing object part placed on the upper surface of the molding mold with a bag sheet, and the processing object part is a sheet-like part having an area larger than the upper surface of the molding mold.

[0006] In the above method, the workpiece is placed on the mold with the compressible member disposed around the mold. Therefore, the compressible member limits the lowering of the position of the peripheral portion of the workpiece. Then, with the workpiece covered with the bag sheet, the pressure in the space covered by the bag sheet is reduced. As a result, the compressible member is compressed, and the workpiece gradually comes into contact with the mold from the inside rather than the outer periphery. This allows the outer periphery of the workpiece to come into contact with the mold last. This makes it possible to suppress the generation of wrinkles in the workpiece.

[0007] 3. The method for producing a molded product according to 1 or 2 above, wherein in the processing object placement step, at least a part of the compressible member supports the processing object member via a support member.

[0008] In the above-described method, the compressible member can be prevented from being displaced by being pulled by the bag sheet, compared to a case in which the support member is not provided, and therefore, the compressible member can be easily displaced in the compression direction during the decompression step, compared to a case in which the support member is not provided.

[0009] 4. A method for producing a molded product as described in claim 3, wherein the support member is a frame member having an opening larger in dimensions than the molding die, and the length of a direction from the edge of the opening of the frame member to the inside of the opening is positive in a direction from the edge of the opening to the outline of an imaginary rectangle is smaller at a point where the distance between the imaginary rectangle and the outer periphery of the molding die is greater than at a point where the distance between the imaginary rectangle and the outer periphery of the molding die is smaller, and the imaginary rectangle is a rectangle inscribed by the outer periphery of the molding die.

[0010] In the above method, the shape of the opening is determined according to the outer circumferential shape of the casting mold, which makes it possible to prevent the distance between the edge of the opening and the casting mold from varying from place to place. 5. A method for manufacturing a molded product as described in 3 or 4 above, wherein the support member is a frame member, the frame member has an opening having dimensions larger than those of the mold, and the edge of the opening of the frame member and the outer periphery of the mold have a similar shape.

[0011] According to the above-mentioned configuration, since the edge of the opening of the frame member and the outer periphery of the molding die have similar shapes, it is possible to minimize variation in the distance between the edge of the opening and the molding die. 6. The method for producing a molded product according to any one of the above 1 to 5, wherein the compressible members arranged in the processing object arranging step include members spaced apart from each other.

[0012] In the above method, at least some of the compressible members are positioned apart from each other, so that even if they expand in opposite directions as they are compressed during the decompression process, they can be prevented from interfering with each other.

[0013] 7. The method for producing a molded product according to any one of the above-mentioned 1 to 6, wherein the compressible member has portions with different cross-sectional areas at different positions in the compression direction, the cross-sectional areas being cross-sectional areas in a plane perpendicular to the compression direction.

[0014] In the above configuration, the compressible member has a portion with a small cross-sectional area in the compression direction. Therefore, the pressure required to start compression can be reduced compared to when the cross-sectional area is uniform in the compression direction. Therefore, the compressible member can be smoothly compressed in the decompression process.

[0015] 8. The method for producing a molded product according to any one of 1 to 7 above, wherein the compressible member compresses to a different extent in response to an applied pressure depending on the position in a plane perpendicular to the compression direction. In the decompression step, the ease with which the workpiece bends to contact the side wall of the mold may vary depending on the area of ​​the mold surface that contacts the workpiece. In that case, the timing at which the workpiece contacts the side wall of the mold may vary depending on the area. Therefore, in the above method, the compressible member is arranged so that the amount of compression in response to the applied pressure varies depending on the position on the plane. This allows the compressible member that is easily compressed to be arranged in a place that is difficult to bend, thereby promoting bending of the difficult-to-bend place.

[0016] 9. A method for manufacturing a molded product described in any one of 3 to 7 above, wherein the compressible member compresses differently in response to an applied pressure depending on the position in a plane perpendicular to the compression direction, and the frame member is separable into a plurality of regions in the plane.

[0017] In the decompression step, the ease with which the workpiece bends to contact the side wall of the mold may vary depending on the area of ​​the mold surface that contacts the workpiece. In that case, the timing at which the workpiece contacts the side wall of the mold may vary depending on the area. Therefore, in the above method, the compressible member is arranged so that the amount of compression in response to the applied pressure varies depending on the position on the plane. This allows the compressible member that is easily compressed to be arranged in a place that is difficult to bend, and thus promotes bending of the difficult to bend place.

[0018] 10. An apparatus for manufacturing a molded product in the method for manufacturing a molded product described in any one of 1 to 9 above, comprising: a pump that sucks in fluid from the space covered by the bag sheet in the decompression step; the molding die; and the compressible member.

[0019] By using the above manufacturing apparatus, the above methods 1 to 9 can be realized. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a top view showing a planar configuration of a manufacturing apparatus according to a first embodiment. [Diagram 2] FIG. 2 is a cross-sectional view showing a cross-sectional configuration of a manufacturing apparatus according to the embodiment. [Diagram 3] FIG. 2 is a cross-sectional view showing a cross-sectional configuration of a manufacturing apparatus according to the embodiment. [Figure 4] FIG. 2 is a plan view showing a planar configuration of a frame member according to the embodiment. [Diagram 5] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 6] 5A to 5C are side views showing a manufacturing process of the molded product according to the embodiment. [Figure 7] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 8] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 9]5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 10] 5A to 5C are side views showing a manufacturing process of the molded product according to the embodiment. [Figure 11] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 12] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 13] 4 is a cross-sectional view showing the effect of the embodiment. FIG. [Figure 14] FIG. 11 is a top view showing the planar configuration of a manufacturing apparatus according to a second embodiment. [Figure 15] FIG. 2 is a plan view showing a planar configuration of a frame member according to the embodiment. [Figure 16] FIG. 11 is a side view showing the configuration of the bellows dam according to the third embodiment. [Figure 17] FIG. 2 is a perspective view showing the bellows dam of the embodiment. [Figure 18a] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 18b] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 18c] 5A to 5C are cross-sectional views showing a manufacturing process of the molded product according to the embodiment. [Figure 19a] FIG. 11 is a cross-sectional view showing a cross-sectional configuration of a manufacturing device according to a modified example of the above embodiment. [Figure 19b] FIG. 11 is a cross-sectional view showing a cross-sectional configuration of a manufacturing device according to a modified example of the above embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] <First embodiment> Hereinafter, the first embodiment will be described with reference to the drawings. FIG. 1 shows a molded product manufacturing apparatus according to this embodiment.

[0022] The molded product according to the present embodiment is obtained by molding a composite material made of a thermosetting resin and carbon fibers. More specifically, the molded product is obtained by molding a sheet-shaped member, which is a prepreg as the sheet-shaped composite material, by the manufacturing apparatus shown in FIG.

[0023] The forming die 10 shown in Fig. 1 is for forming the above-mentioned sheet-like member. In Fig. 1, the positive direction of the z-axis is the vertical upward direction. The x-axis and y-axis are horizontal directions. Fig. 1 is a plan view of the manufacturing apparatus as viewed from above.

[0024] In this embodiment, as an example, since the molded product has an arch-like shape, the upper surface shape of the molding die 10 is arch-like. A plurality of compressible members 20 are arranged around the molding die 10. The compressible members 20 are members that contract when pressure is applied. More specifically, the compressible members 20 are members that contract by releasing the fluid contained therein when pressure is applied. As an example, the compressible members 20 are sponges.

[0025] FIG. 2 shows a cross section taken along line 2-2 of FIG. As shown in FIG. 2 , the compressible member 20 includes an upper member 22 and a lower member 24. The lower member 24 has a rectangular parallelepiped shape, for example. The upper member 22 has a quadrangular pyramid shape, for example. The upper member 22 is disposed on the lower member 24. More specifically, the bottom surface of the upper member 22 is in contact with the top surface of the lower member 24. The shape of the bottom surface of the upper member 22 may be similar to the shape of the top surface of the lower member 24. The area of ​​the bottom surface of the upper member 22 may be equal to or smaller than the area of ​​the top surface of the lower member 24. Also, the area of ​​the bottom surface of the upper member 22 may be equal to or larger than the area of ​​the top surface of the lower member 24.

[0026] As shown in FIG. 2, the manufacturing apparatus includes a pump 12 that draws gas from the side of a floor surface 14 on which the molding die 10 and the compressible member 20 are placed. FIG. 3 shows the state of the production apparatus before the sheet-like member is placed on the forming die 10. In FIG.

[0027] 3, prior to placing the sheet-like member in the mold 10, a frame member 30 is placed on the upper surface of the compressible member 20. The frame member 30 is a plate-like member that supports the ends of the sheet-like member.

[0028] FIG. 4 shows a plan view of the frame member 30. As shown in FIG. As shown in Fig. 4, frame member 30 has an opening 32. Opening 32 has a shape similar to the upper surface of molding die 10. This is designed to suppress variation in the distance between frame member 30 and molding die 10. Fig. 4 shows that the distances in the X direction and Y direction between frame member 30 and molding die 10 at two different positions are equal to each other, δ1.

[0029] 4 shows a virtual rectangle VR in which the top surface of the mold 10 is inscribed. As shown in FIG. 4, the length in the direction from the edge of the opening 32 to the contour of the virtual rectangle VR, where the direction from the edge of the opening 32 to the inside of the opening 32 is positive, is smaller at a point where the distance between the top surface of the mold 10 and the virtual rectangle VR is larger than at a point where the distance is smaller. The length in the direction from the edge of the opening 32 to the virtual rectangle VR is the length in the direction perpendicular to the sides of the virtual rectangle VR. The distance between the virtual rectangle VR and the top surface of the mold 10 is the length of a perpendicular line drawn from the top surface of the mold 10 to the side of the virtual rectangle VR.

[0030] 4 illustrates a portion A2 where the distance between the imaginary rectangle VR and the upper surface of the mold 10 is large, and a portion A1 where the distance between the imaginary rectangle VR and the upper surface of the mold 10 is small. Note that the length of portion A2 in the direction proceeding from the edge of the opening 32 to the contour of the imaginary rectangle VR is negative. 5 shows the state in which the sheet-like member 40 is placed on the molding die 10. Note that FIG. 5 corresponds to the 2-2 cross section of FIG. 1. As shown in FIG. 5, the sheet-like member 40 covers the entire upper surface of the molding die 10, and its end is placed on the frame member 30. In other words, the end of the sheet-like member 40 is supported by the frame member 30.

[0031] FIG. 6 shows a side view of the mold 10 and the sheet-like member 40 in a state in which the sheet-like member 40 is placed on the mold 10. In FIG. 6, a plurality of slits 42 are provided at the end of the sheet-like member 40. This is to make it easier to fold the sheet-like member 40 at the point where it contacts the edge of the upper surface of the mold 10.

[0032] 7 shows a state in which the bag sheet 50 is placed over the sheet-like member 40. The bag sheet 50 has flexibility. It is desirable for the bag sheet 50 to have stretchability. The bag sheet 50 is larger in size than the sheet-like member 40. The bag sheet 50 is sized so that an end portion thereof can contact the floor surface 14 on which the forming mold 10 is placed. In the state shown in Fig. 7, the bag sheet 50 contacts the floor surface 14, whereby a space for accommodating the forming mold 10, the compressible member 20, the frame member 30, and the sheet-like member 40 is formed by the bag sheet 50 and the floor surface 14.

[0033] FIG. 8 shows a state in which the space defined by the bag sheet 50 and the floor surface 14 is depressurized by sucking gas therein with the pump 12. As shown in FIG. 8, the compressible member 20 is compressed by depressurizing the space. More specifically, when the space is depressurized, the bag sheet 50 attempts to displace downward, so the frame member 30 pushes the compressible member 20 downward. Therefore, the compressible member 20 is compressed so as to shrink in the z-axis direction. This causes the frame member 30 to displace downward. As a result, the region near the end of the sheet-like member 40 gradually comes into contact with the mold 10, starting from the region near the top surface of the mold 10.

[0034] 8, when the end of the sheet-like member 40 is in close contact with the side wall 10a of the mold 10, the frame member 30 is located below the edge of the sheet-like member 40. This is possible by adjusting the compressibility of the compressible member 20.

[0035] Fig. 9 shows a state in which a sheet-like member 40(2) is placed on a sheet-like member 40(1) formed by the process shown in Fig. 8. The numbers in parentheses following the sheet-like member 40 are given to identify the sheet-like member 40. In particular, the larger the number in parentheses, the later the member is formed in the forming process.

[0036] Fig. 10 is a side view of the state shown in Fig. 9. As shown in Fig. 10, the slits 42(2) of the sheet-shaped member 40(2) are provided in a position different from the slits 42(1) of the sheet-shaped member 40(1).

[0037] 11 shows a state in which the bag sheet 50 is placed over the sheet-like member 40(2). When the bag sheet 50 comes into contact with the floor surface 14, the bag sheet 50 and the floor surface 14 form a space for accommodating the mold 10, the compressible member 20, the frame member 30, and the sheet-like members 40(1) and 40(2).

[0038] 12 shows a state in which the space defined by the bag sheet 50 and the floor surface 14 is depressurized by sucking gas from the space with the pump 12. By depressurizing the space, the frame member 30 moves downward. As a result, the area near the end of the sheet-like member 40(2) gradually comes into contact with the sheet-like member 40(1) from the area near the top surface of the mold 10.

[0039] By repeating these steps, a plurality of sheet-like members 40 are molded to conform to the shape of the molding die 10. Then, when a predetermined number of sheet-like members 40 have been molded, they are subjected to steps such as heating and pressurization to complete a molded product.

[0040] "Actions and Effects of the Present Embodiment" When the sheet-like member 40 is placed on the mold 10, the end of the sheet-like member 40 is supported by the frame member 30. The frame member 30 is placed on the compressible member 20. After that, the bag sheet 50 is placed over the sheet-like member 40, and the space between the bag sheet 50 and the floor surface 14 is decompressed. As a result, the portion of the sheet-like member 40 that protrudes from the upper surface of the mold 10 contacts the side wall 10a of the mold 10 in order from the side closest to the upper surface of the mold 10. This makes it possible to mold the sheet-like member 40 while suppressing the occurrence of wrinkles.

[0041] In contrast, if the end of the sheet-like member 40 is not supported by the frame member 30 prior to the depressurization, there is a risk that the end of the sheet-like member 40 will come into contact with the side wall 10a of the molding die 10 first, as shown on the left side of Fig. 13. In that case, there is a risk that wrinkles will form in the sheet-like member 40, as shown on the right side of Fig. 13.

[0042] In this manner, in this embodiment, the formation of wrinkles in the sheet-like member 40 can be suppressed, and therefore the above-described series of manufacturing steps can be automated to manufacture molded products with stable quality. According to the present embodiment described above, the following actions and effects can be obtained.

[0043] (1-1) When the sheet-like member 40 is placed on the upper part of the mold 10, if the end of the sheet-like member 40 is directly supported by the compressible member 20, the sheet-like member 40 may be pulled by the bag sheet 50 and displaced. In that case, a specific area of ​​the sheet-like member 40 may be displaced downward first, causing wrinkles in the sheet-like member 40. In addition, if the end of the sheet-like member 40 is directly supported by the compressible member 20, the compressible member 20 may be pulled by the tension of the bag sheet 50 and displaced away from the mold 10 instead of being compressed downward, and may fall over. Therefore, in this embodiment, the frame member 30 is interposed between the sheet-like member 40 and the compressible member 20. This makes it possible to suppress the above-mentioned problems from occurring.

[0044] (1-2) The opening 32 of the frame member 30 and the top surface of the mold 10 are made similar in shape. This makes it possible to minimize variation in the distance between the edge of the opening 32 and the mold 10. This makes it possible to evenly suck the portion of the sheet-like member 40 that protrudes from the top surface of the mold 10 downward by reducing the pressure in the space defined by the bag sheet 50 and the floor surface 14.

[0045] (1-3) The compressible member 20 is made up of multiple members spaced apart from one another, instead of a single member that surrounds the periphery of the molding die 10. This makes it possible to prevent the members from interfering with each other even if they expand in opposite directions as they are compressed in the decompression process.

[0046] (1-4) The upper member 22 is formed in a quadrangular pyramid shape. As a result, when pressure is applied from above to the compressible member 20, the upper part of the upper member 22 is more easily compressed. Therefore, compared to a case in which the cross-sectional area of ​​the upper member 22 is uniform in the vertical direction, it is possible to reduce the pressure required when compression of the compressible member 20 begins. Therefore, the compressible member 20 can be smoothly compressed in the decompression process.

[0047] In addition, the bottom surface of the upper member 22 is in contact with the lower member 24. Therefore, compared to the case where the top surface of the upper member 22 is in contact with the lower member 24, the posture of the compressible member 20 can be stabilized.

[0048] (1-5) A slit 42 is provided in the portion of the sheet-like member 40 that protrudes from the upper surface of the molding die 10. This makes it possible to easily fold the portion of the sheet-like member 40 that protrudes from the molding die 10.

[0049] (1-6) The slits 42 are provided at different positions in the mutually different sheet-like members 40. This makes it possible to increase the strength of the molded product compared to a case in which the mutually different sheet-like members 40 have the same slits 42.

[0050] <Second embodiment> The second embodiment will be described below with reference to the drawings, focusing on the differences from the first embodiment.

[0051] FIG. 14 shows a top view of the manufacturing apparatus according to this embodiment. In FIG. 14, the compressible member 20 is a member that has a different compression amount with respect to the applied pressure depending on the position where it is placed. In detail, in FIG. 14, the member with darker dots is shown to have a smaller compression amount with respect to the applied pressure than the member with lighter dots. The example shown in FIG. 14 shows an example in which the compressible member 20 is made of two members that have different compression amounts with respect to the applied pressure. As an example, this can be realized by using two types of members with different upper surface areas as the upper member 22. That is, the one with a larger compression amount corresponds to the member with a smaller upper surface area of ​​the upper member 22.

[0052] In the example shown in Figure 14, the compressible members 20 arranged in areas close to the centers of the convex and concave portions on the top surface of the mold 10 are more easily compressed than the compressible members 20 arranged in other areas.

[0053] 15 shows a frame member 30 according to this embodiment. The shape of the frame member 30 according to this embodiment is the same as that of the frame member 30 according to the first embodiment. However, the frame member 30 according to this embodiment is divided into a plurality of parts 30a to 30p. Therefore, each of the parts 30a to 30p is displaced downward independently of each other according to the amount of compression of the compressible member 20 with which it is in contact.

[0054] Here, the portions of sheet-like member 40 located near the centers of the convex portions and the concave portions on the upper surface of mold 10 are less likely to bend than the portions located in other parts of the upper surface of mold 10. Therefore, wrinkles are more likely to occur in the portions of sheet-like member 40 located near the centers of the convex portions and the concave portions on the upper surface of mold 10. In contrast, in this embodiment, the compressible members 20 arranged near the center of the convex portions and near the center of the concave portions on the upper surface of the mold 10 are made to be easily compressible members. Therefore, when the space partitioned by the bag sheet 50 and the floor surface 14 is decompressed, the speed at which the compressible members 20 are compressed differs. That is, the speed at which the compressible members 20 arranged near the center of the convex portions and near the center of the concave portions on the upper surface of the mold 10 are compressed is greater than the speed at which the compressible members 20 arranged in the areas close to the other portions are compressed. Therefore, it is possible to promote bending of the portions of the sheet-like member 40 arranged near the center of the convex portions and near the center of the concave portions on the upper surface of the mold 10 along the shape of the upper surface of the mold 10. This promotes bending of the portions of the sheet-like member 40 arranged near the center of the convex portions and near the center of the concave portions on the upper surface of the mold 10 before wrinkles are generated in the portions.

[0055] <Third embodiment> The third embodiment will be described below with reference to the drawings, focusing on the differences from the first embodiment.

[0056] In this embodiment, a bellows dam 60 shown in FIG. 16, the bellows dam 60 includes a first plate member 62, a second plate member 64, and a third plate member 66. The first plate member 62 and the second plate member 64 are connected by a hinge portion 70. The second plate member 64 and the third plate member 66 are connected by a hinge portion 72.

[0057] FIG. 17 shows a perspective view of the bellows dam 60. 18a to 18c show the molding process according to this embodiment. FIG. 18a shows a state in which the sheet-like member 40 is placed on the forming mold 10 and then the upper surface of the sheet-like member 40 is covered with a bag sheet 50. FIG.

[0058] FIG. 18b shows the initial stage of the process of depressurizing the space partitioned by the bag sheet 50 and the floor surface 14 by the pump 12. In this state, the second plate member 64 and the third plate member 66 are bent so that the hinge portion 72 is displaced toward the side approaching the first plate member 62. Therefore, the height of the bellows dam 60 rises slightly once. As a result, the end of the sheet-like member 40 is pulled in the direction of the bellows dam 60 by the tension of the bag sheet 50. Meanwhile, the height of the bag sheet 50 near the edge of the upper surface of the mold 10 is reduced by the depressurization. Therefore, pressure is applied from the bag sheet 50 to the portion of the sheet-like member 40 located near the edge of the mold 10. Therefore, the portion of the sheet-like member 40 near the upper surface of the mold 10 is pressed against the side wall 10a of the mold 10.

[0059] 18c shows the middle stage of the process of depressurizing the space partitioned by the bag sheet 50 and the floor surface 14 by the pump 12. In this state, the height of the bellows dam 60 is lowered. Therefore, the bag sheet 50 is lowered further. Therefore, the bag sheet 50 presses the sheet-like member 40, including the area protruding from the upper surface of the mold 10, against the mold 10, up to the part farthest from the upper surface of the mold 10.

[0060] In this manner, by using the bellows dam 60, wrinkles in the sheet-like member 40 can also be suppressed. <Correspondence> The correspondence between the matters in the above embodiment and the matters described in the above "Means for solving the problem" column is as follows. In the following, the correspondence is shown for each number of the means for solving the problem described in the "Means for solving the problem" column. [1,2,10] The processing target member corresponds to the sheet-like member 40. The molding target arrangement process corresponds to the process shown in FIG. 5. The bag sheet covering process corresponds to the process shown in FIG. 7. The depressurization process corresponds to the process shown in FIG. 8. The compressible member corresponds to the compressible member 20. [3] The frame member corresponds to the frame member 30. [4] The virtual rectangle corresponds to the virtual rectangle VR in FIG. 4. [5] Corresponds to the shape of the frame member 30 shown in FIG. 4. [6] Corresponds to FIG. 1 and FIG. 14. [7] Corresponds to the shape of the upper member 22. The compression direction corresponds to the z direction. [8] Corresponds to FIG. 14. The compression direction corresponds to the z direction. [9] Corresponds to FIG. 14 and FIG. 15. The compression direction corresponds to the z direction.

[0061] <Other embodiments> This embodiment can be modified as follows: This embodiment and the following modifications can be combined with each other to the extent that no technical contradiction occurs.

[0062] "About the materials to be processed" The sheet-like member 40 is not limited to a prepreg containing a thermosetting resin and carbon fiber. For example, instead of carbon fiber, the inorganic fiber may contain graphite fiber, silicon carbide fiber, alumina fiber, boron fiber, glass fiber, or the like. In addition, the fiber member provided in the sheet-like member 40 does not necessarily have to be an inorganic fiber. For example, organic fiber such as aramid fiber or polyethylene fiber may be included.

[0063] The resin material contained in the sheet-shaped member 40 does not necessarily have to be a thermosetting resin. For example, it may be a thermoplastic resin. The sheet-shaped member 40 does not necessarily have to be a prepreg. In addition, the sheet-shaped member 40 does not necessarily have to be a member that contains resin. For example, it may be a composite material such as a dry fabric that does not contain resin. When the workpiece is a sheet-like member 40 in which a plurality of sheets are stacked, it is not essential that the positions of the slits 42 provided in the sheet-like members 40 be different for each sheet-like member 40 . When the workpiece is a sheet-like member 40 consisting of a plurality of overlapping sheets, it is not essential that the sheet-like members 40 are provided with slits 42. When each of the plurality of sheet-like members 40 does not have a slit 42, it is easier to increase the strength of the molded product compared to when each of the sheet-like members 40 has a slit 42. The workpiece is not necessarily a sheet-like member 40 in which a plurality of sheets are stacked.

[0064] "About openings in frame components" It is not essential that the shape of the opening of frame member 30 be similar to the shape of the upper surface of mold 10. For example, if the cross-sectional area of ​​mold 10 increases from the upper surface to the lower surface, the edge of opening 32 may be similar to the shape of the outer periphery of mold 10 midway between the point where the end of sheet-like member 40 comes into contact and the upper surface. The edge of the opening 32 of the frame member 30 is not limited to a shape similar to the shape of the outer periphery of the molding die 10. Even if the shape is not similar, by making the shape correspond to the outer periphery of the molding die 10, it is possible to suppress the variation in the gap between the molding die 10 and the frame member 30 from varying depending on the location. In order to suppress the variation, for example, the amount by which the outline of the imaginary rectangle VR protrudes into the inside of the opening 32 from the edge of the opening 32 of the frame member 30 may be set as follows. That is, the amount of protrusion may be made smaller at a point where the distance between the imaginary rectangle VR and the outer periphery of the molding die 10 is large than at a point where the distance between the imaginary rectangle VR and the outer periphery of the molding die 10 is small.

[0065] "Regarding adjustment of compression amount of compressible members" The cross-sectional shape of the compressible member 20 in a plane perpendicular to the up-down direction is not limited to a shape set for the purpose of smoothly compressing the compressible member 20. For example, the cross-sectional area may be adjusted according to the degree to which the bag sheet 50 is desired to be stretched. In the above configuration, the amount of compression in response to the applied pressure is adjusted by the cross-sectional shape of the compressible member 20 in a plane perpendicular to the up-down direction, but this is not limiting. For example, the amount of compression may be adjusted by using one of a number of members that have the same shape and dimensions but differ in the amount of compression in response to the applied pressure. That is, for example, the compressible member 20 with dark dots in Figure 14 may be made of a material that compresses less than the compressible member 20 with light dots.

[0066] A plurality of compressible members 20 may be prepared that are different in both cross-sectional shape in a plane perpendicular to the vertical direction and material of the compressible members 20. This also makes it possible to adjust the compression amount of the compressible members 20 in response to the applied pressure.

[0067] "About compressible members" The upper member 22 is not limited to a member having a quadrangular pyramid shape. The upper member 22 may have, for example, a quadrangular pyramid shape. The upper member 22 may have, for example, a circular truncated cone shape.

[0068] The cross-sectional area of ​​the compressible member 20 does not necessarily have to be greater than or equal to the cross-sectional area of ​​the lower member in the vertical direction. For example, the upper surface of the upper member 22 may be in contact with the lower member 24.

[0069] It is not essential that the cross-sectional area of ​​the compressible member 20 varies in the vertical direction. The compressible member 20 does not necessarily have to be composed of the upper member 22 and the lower member 24. For example, it may be a member divided into three in the vertical direction.

[0070] The compressible member 20 does not necessarily have to be composed of a member divided in the vertical direction. It is not essential that the compressible member 20 be made up of a plurality of members divided in a plane perpendicular to the up-down direction.

[0071] The member that contracts when pressure is applied is not limited to being made of sponge. For example, it may be made of rubber. "About frame components" It is not essential that the frame member 30 has a flat shape. For example, the frame member 30 may have a shape that slopes downward as it is farther away from the forming die 10. Also, for example, the position on the z-axis shown in Fig. 3 may differ depending on the region. In this case, the region corresponding to the portion of the sheet-like member 40 that is less likely to bend may have a smaller value on the z-axis. The method of dividing the frame member into a plurality of parts is not limited to the example shown in FIG. "Support member" The support member does not necessarily have to be a frame member. For example, it may be a plurality of plate-like members spaced apart from each other. Also, for example, it may be a rod-like member parallel to one side of the forming die 10.

[0072] "About the molding die" The shape of the upper surface of the molding die 10 is not limited to the shape shown in FIG. "About the manufacturing method of molded products" The processing object arranging step does not necessarily have to be a step of arranging the sheet-like member 40 on the upper surface of the mold 10. For example, the processing object arranging step may be a step of fixing the mold 10 to the ceiling and contacting the sheet-like member 40 with the lower surface of the mold 10. Figures 19a and 19b show an example of a part of the manufacturing process in this case. Figures 19a and 19b show the process corresponding to Figures 7 and 8. In the example shown in Figures 19a and 19b, the mold 10 is fixed to the ceiling 14a, and a pump 12 is provided on the ceiling 14a. However, it is not essential that the molding die 10 is disposed on the floor surface 14 or the ceiling 14a. For example, the sheet-like member 40 may be molded with the molding die 10 fixed to a side wall of a manufacturing factory. In other words, the compression direction of the compressible member 20 is not limited to the vertical direction and may be the horizontal direction, etc. [Explanation of symbols]

[0073] 10…Mold 10a...Side wall 12…Pump 14…Floor surface 20...Compressible member 22...Upper member 24…Lower member 30...Frame member 30a~30o…Parts 32…Opening 40...Sheet-shaped member 42...Slit 50…Bag sheet 60…Jabara Dam 62...First plate member 64…Second plate member 66...Third plate member 70,72…Hinge section

Claims

1. a processing object placement step of placing a processing object member in contact with a surface of the mold; A step of covering the workpiece with a bag sheet from a side of the workpiece opposite to the mold; and reducing the pressure in the space covered by the bag sheet. the workpiece is a sheet-like member having an area larger than the surface of the mold, A method for manufacturing a molded product, wherein the processing object placement step is carried out in a state where a compressible member for supporting a peripheral portion of the processing object member is placed around the molding die.

2. The processing object placement step is a step of placing the processing object member on the molding die, The step of covering with a bag sheet is a step of covering an upper surface of the workpiece arranged on the upper surface of the mold with a bag sheet, 2. The method for manufacturing a molded product according to claim 1, wherein the workpiece is a sheet-like member having an area larger than an upper surface of the mold.

3. The method for manufacturing a molded product according to claim 1 , wherein in the processing object arranging step, at least a portion of the compressible member supports the processing object member via a support member.

4. the support member is a frame member, The frame member has an opening having a dimension larger than that of the molding die, a length in a direction from the edge of the opening of the frame member to the inside of the opening, the length being smaller at a point where the distance between the virtual rectangle and the outer periphery of the forming mold is larger than a point where the distance between the virtual rectangle and the outer periphery of the forming mold is smaller; The method for producing a molded product according to claim 3 , wherein the imaginary rectangle is a rectangle inscribed with the outer periphery of the molding die.

5. the support member is a frame member, The frame member has an opening having a dimension larger than that of the molding die, 4. The method for producing a molded product according to claim 3, wherein the edge of the opening of the frame member and the outer periphery of the molding die have similar shapes.

6. The method for manufacturing a molded product according to claim 1 , wherein the compressible members arranged in the processing object arrangement step include members spaced apart from each other.

7. The compressible member has a portion having a different cross-sectional area at a different position in a compression direction, The method for producing a molded product according to claim 1 , wherein the cross-sectional area is a cross-sectional area in a plane perpendicular to the compression direction.

8. The method for producing a molded product according to claim 1 , wherein the compressible member compresses to a different amount in response to an applied pressure depending on a position of the compressible member in a plane perpendicular to a compression direction.

9. the compressible member compresses to a different amount in response to an applied pressure depending on a position of the compressible member in a plane perpendicular to a compression direction; The method for manufacturing a molded product according to claim 3 , wherein the support member is separable into a plurality of regions on the plane.

10. 2. A molded product manufacturing apparatus according to claim 1, a pump that sucks the fluid in the space covered by the bag sheet in the depressurizing step; The molding die; the compressible member; A molded product manufacturing apparatus comprising:

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