Method and apparatus for manufacturing a composite material molded article

Abstract

The purpose of the present invention is to provide a method and a device for producing a composite material molded article, the method and device making it possible to efficiently mold a to-be-molded material that contains a thermoplastic resin material and a fiber material into a high-quality composite material molded article through heating and pressurizing. The method for producing a composite material molded article involves heating and pressurizing a to-be-molded material 20 that contains a thermoplastic resin material and a fiber material to produce a fiber-reinforced composite material molded article 50, the method comprising: a preforming step in which the to-be-molded material 20 is accommodated in a preforming mold with a release sheet 30 positioned between the to-be-molded material 20 and the preforming mold 1a, and the fiber material is impregnated with the thermoplastic resin material through heating and pressurizing, to preform an impregnated intermediate material 40; a transfer step in which the impregnated intermediate material 40 is removed and transferred in a heated state from the preforming mold 1a in a state where the release sheet 30 is in contact therewith; and a molding step in which the impregnated intermediate material 40 is accommodated in a molding mold 10a, and the impregnated intermediate material 40 is molded into a composite material molded article 50 through pressurizing.

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for manufacturing a fiber-reinforced composite material molded product by heating and pressing a molded material containing a thermoplastic resin material and a fiber material.

Background Art

[0002] Fiber-reinforced composite materials composed of thermoplastic resin materials and fiber materials have excellent properties such as light weight, high strength, and high elastic modulus, and are used in a wide range of fields such as aircraft, automobiles, and sports equipment. As methods for molding such composite materials, there are various molding methods. As a method for manufacturing small and medium-sized molded products, the heat and pressure molding method is used because it can efficiently mold various molded products.

[0003] Examples of the heat and pressure molding method include the Heat&Cool molding method and the stamping molding method.

[0004] In the Heat&Cool molding method, a laminate in which thermoplastic UD (unidirectional) prepreg sheets are laminated in an arbitrary direction, or a laminate in which a reinforcing fiber fabric and a thermoplastic resin sheet are alternately laminated, etc. are used as the molded material. First, the molded material is put into a molding die, heated and pressed to be molded into a predetermined shape while melting the thermoplastic resin material. Next, the molding die is cooled and pressed to solidify the thermoplastic resin to obtain a molded product. It is a molding method excellent in resin impregnation and moldability into a complex shape.

[0005] In the stamping molding method, a laminate in which thermoplastic UD (unidirectional) prepreg sheets are laminated in an arbitrary direction, etc. is used as the molded material. First, the molded material is heated and pressed to form a plate-shaped molded body (plate-shaped molded body) in which the thermoplastic resin material is impregnated into the fiber bundles. Next, the plate-shaped molded body is heated in a heating furnace by infrared rays or the like to be in a molten state. Then, the plate-shaped molded body is put into a molding die and cooled while being pressed to obtain a molded product having a predetermined shape. The stamping molding method is a method capable of molding composite material molded products in a short time, including complex shapes.

[0006] As the plate-shaped molded body, for example, one obtained by laminating a reinforcing fiber fabric, impregnating it with a thermoplastic resin material, and integrating it into a plate shape, or one obtained by randomly scattering chopped tapes obtained by slitting a thermoplastic UD prepreg sheet into strip shapes and laminating them, and integrating them into a plate shape by heating and pressing, etc. are used.

[0007] As a method for obtaining a high-quality thermoplastic resin composite molded product, for example, the methods described in Patent Documents 1 and 2 have been proposed.

[0008] In Patent Document 1, a material to be molded composed of a reinforcing fiber material and a thermoplastic resin material is placed between a pair of molding dies, the molding die is installed between a pair of heating press dies, heated and pressurized, and then the molding die is installed between a pair of cooling press dies and cooled and pressurized to impregnate the reinforcing fiber material with the thermoplastic resin material, integrate it, and mold it.

[0009] Further, in Patent Document 2, the entire fiber-reinforced thermoplastic resin before molding is wrapped with a heat-resistant bagging material made of a material having a melting point higher than the melting point of the thermoplastic resin, the inside of the heat-resistant bagging material is sealed with a sealing material, the air inside the heat-resistant bagging material containing the fiber-reinforced thermoplastic resin is discharged, the inside is depressurized to a sub-vacuum state, the heat-resistant bagging material is placed in a mold heated together with the fiber-reinforced thermoplastic resin, the mold is closed and pressure-molded, and after a predetermined time has elapsed, it is cooled. A method for manufacturing a fiber-reinforced thermoplastic resin molded body is described.

Prior Art Documents

Patent Documents

[0010]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0011] In the above-mentioned Heat&Cool molding method, a laminate is set in a pre-heated mold and subjected to heat and pressure treatment for a required pressure and required time. Then, it is rapidly cooled under a required pressure state, and when a predetermined cooling temperature is reached, the molded body is taken out. Therefore, a high-quality molded body can be obtained, but it is necessary to repeatedly heat and cool the mold, and the deterioration of the mold tends to progress. In addition, it is difficult to shorten the molding processing time, and there are demerits such as high processing costs such as electricity charges.

[0012] In the above-mentioned stamping molding method, it is necessary to manufacture a plate-shaped molded body. As a method for manufacturing a plate-shaped molded body, for example, by performing continuous heat and pressure treatment and cooling and pressure treatment using a double belt device or the like, a laminate is continuously supplied to create a plate-shaped molded body impregnated with a thermoplastic resin material. Such a manufacturing method can manufacture a plate-shaped molded body in a short time and has high productivity.

[0013] However, the double belt device is expensive in terms of equipment cost. In addition, heat-resistant thermoplastic resin materials used in aircraft and the like have a molding temperature of around 400 °C, so the cost burden such as electricity charges is large, and there is a demerit that the consumption of the belt due to high-temperature heating becomes intense and the manufacturing cost increases.

[0014] In addition, in order to improve the impregnation of the thermoplastic resin material into the fiber material, the heating temperature is increased to lower the viscosity of the resin material, or the pressure during the heat treatment is increased. However, when there is no restriction on the side ends of the continuously conveyed laminate and it is in a free state, the molten resin material flows out from the side ends of the laminate together with the fiber material, resulting in uneven fiber orientation and Vf (fiber volume content) values at the side ends of the laminate, leading to a decrease in quality.

[0015] In addition, as a method for manufacturing a plate-shaped molded body, there is a method of manufacturing a plate-shaped molded body by performing a heat and pressure treatment while sandwiching a plate-shaped laminate with a release sheet and stacking a plurality of sheets in the thickness direction using a Heat&Cool molding method. Even if the molding time requires a long time, by stacking a plurality of laminates and performing a heat and pressure treatment at once, there is an advantage that the unit price and processing time per sheet can be reduced. However, it takes time and effort to stack a plurality of laminates in the thickness direction while sandwiching them with a release sheet. If the number of stacked sheets is increased, the heating time increases accordingly, and as a result, mass production is difficult.

[0016] In addition, in the stamping molding method, the plate-shaped molded body is heated in the air by a device such as far-infrared rays. However, depending on the type of thermoplastic resin material, there is also a problem that deterioration due to heating occurs.

[0017] In the molding method described in Patent Document 1, it is necessary to manufacture a molding die with a uniform thickness, and it is difficult to manufacture a molding die corresponding to a molded product with a complex shape such as ribs or bosses rising. There are problems in molding a composite material molded product with a complex shape. Also, in the cooling process, there is no regulation for the end portion of the molded product, and the state of the end portion of the molded product cannot be controlled, so it cannot be finished into a predetermined shape, and there is a possibility that the orientation disorder of the reinforcing fibers will increase.

[0018] In Patent Document 2, since the entire fiber-reinforced thermoplastic resin is encapsulated with a heat-resistant backing material and placed in a mold for heat and pressure molding, when manufacturing a shape such as ribs or bosses rising, or a shape having a curved surface that cannot be developed into a sheet, that is, a non-developable surface, there is a possibility that wrinkles or tears may occur in the heat-resistant backing material and molding may not be possible.

[0019] From the above, it can be said that a method for molding a composite material composed of a thermoplastic resin material and a fiber material with high quality, short time, and low cost has not yet been established.

[0020] Therefore, an object of the present invention is to provide a method and an apparatus for manufacturing a composite material molded product that can efficiently form a molded product of a high-quality composite material by heating and pressing a material to be molded including a thermoplastic resin material and a fiber material.

Means for Solving the Problems

[0021] In the method for manufacturing a composite material molded product according to the present invention, in the method for manufacturing a composite material molded product in which a material to be molded including a thermoplastic resin material and a fiber material is heated and pressed to manufacture a fiber-reinforced composite material molded product, the material to be molded is accommodated in the preliminary molding die with a release sheet made of a flexible material disposed therebetween, and in a preliminary molding step of impregnating the fiber material with the thermoplastic resin material by heating and pressing to preform an impregnated intermediate material, and after taking out the impregnated intermediate material in a heated state from the preliminary molding die with the release sheet in contact therewith To turn from the end a transfer step of peeling and transferring the release sheet, and a molding step of accommodating the transferred impregnated intermediate material in a heated state in a molding die and molding the impregnated intermediate material into a composite material molded product at least by pressing.

[0022] In the apparatus for manufacturing a composite material molded product according to the present invention, in the apparatus for manufacturing a composite material molded product in which a material to be molded including a thermoplastic resin material and a fiber material is heated and pressed to manufacture a fiber-reinforced composite material molded product, a preliminary molding die that accommodates the material to be molded with a release sheet made of a flexible material disposed therebetween, and a preliminary molding unit having preliminary molding means for heating and pressing the preliminary molding die accommodating the material to be molded to impregnate the fiber material with the thermoplastic resin material and form an impregnated intermediate material, and after taking out the impregnated intermediate material in a heated state from the preliminary molding die with the release sheet in contact therewith To turn from the end a transfer unit that peels and transfers the release sheet, a molding die that accommodates the transferred impregnated intermediate material in a heated state, and a molding unit having molding means for molding the impregnated intermediate material into a composite material molded product by at least pressing the molding die accommodating the impregnated intermediate material.

Advantages of the Invention

[0023] In the present invention, a composite material molded product is molded by heating and pressing a material to be molded containing a thermoplastic resin material and a fiber material to preform an impregnated intermediate material and then maintaining the impregnated intermediate material in a heated state in a molded shape. Therefore, the composite material molded product can be efficiently manufactured with high quality.

Brief Description of the Drawings

[0024]

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Modes for Carrying Out the Invention

[0025] Hereinafter, embodiments of the present invention will be described in detail. The embodiments described below are preferred specific examples for implementing the present invention, and thus various technical limitations are imposed. However, the present invention is not limited to these forms unless specifically stated to limit the invention in the following description.

[0026] In the manufacturing method of the composite material molded product according to the present invention, a molding material containing a thermoplastic resin material and a fiber material is heated and pressurized to manufacture a fiber-reinforced composite material molded product. Specifically, in a state where a release sheet is disposed between the molding material and a preliminary molding die, the molding material is accommodated in the preliminary molding die, and in the preliminary molding step of impregnating the fiber material with the thermoplastic resin material by heating and pressurizing and performing preliminary molding on the impregnated intermediate material, a transfer step of taking out and transferring the impregnated intermediate material heated from the preliminary molding die with the release sheet in contact therewith, and a molding step of accommodating the transferred impregnated intermediate material in a molding die in a heated state and molding the impregnated intermediate material into a composite material molded product by pressurization.

[0027] FIG. 1 is an explanatory view showing an example of the manufacturing process of the composite material molded product according to the present invention. In this example, it includes a preliminary molding section 1 for performing a preliminary molding step and a molding section 10 for performing a molding step. The molding material 20 is accommodated in the preliminary molding section 1 together with the release sheet 30, and is heated and pressurized in the preliminary molding section 1 to be preliminarily molded into the impregnated intermediate material 40. The impregnated intermediate material 40 is taken out and transferred from the preliminary molding section 1 while keeping the release sheet 30 in contact therewith in a heated state. The transferred impregnated intermediate material 40 has the release sheet 30 peeled off, and is accommodated in the molding section 10 while maintaining the heated state in the molded shape, and is cooled and pressurized in the molding section 10 to form the composite material molded product 50.

[0028] FIG. 2 is an explanatory view of the preforming die 1a installed in the preforming section 1. FIG. 2(a) is a schematic cross-sectional view of the preforming die 1a, and FIG. 2(b) shows a cross-sectional view taken along the line A-A' of FIG. 2(a). The preforming die 1a includes a preforming upper die 2, a preforming lower die 3, and a preforming side-end die 4. The preforming upper die 2 and the preforming lower die 3 are arranged oppositely, and a preforming region is formed between the preforming upper surface portion 2a which is the lower surface of the preforming upper die 2 and the preforming lower surface portion 3a which is the upper surface of the preforming lower die 3. The preforming side-end die 4 is for treating the outflow of the molten thermoplastic resin material from the portion where the release sheet is not arranged. In this example, it is arranged on the upper surface of the preforming lower die 3 so as to surround the preforming region. The preforming side-end die 4 can be integrated with the preforming lower die 3, but by arranging the preforming side-end die 4 separately from the preforming lower die 3, as will be described later, the flow of the thermoplastic resin material at the peripheral portion of the impregnation intermediate material 40 arranged opposite to the preforming side-end die 4 can be suppressed, and the quality can be improved.

[0029] A plurality of heating rods 5 are built in the preforming upper die 2 and the preforming lower die 3 along the preforming region, and the preforming region is heated to a predetermined temperature by controlling the heating of the heating rods 5. An ejector pin 7 is inserted into the preforming lower die 3 so as to be able to move in and out in the vertical direction. A gap adjusting fixture 6 is arranged on the upper surface of the preforming side-end die 4.

[0030] The upper part of the preforming upper die 2 and the lower part of the preforming lower die 3 are respectively supported and fixed to the press device 9 via heat insulating materials 8. By operating the press device 9 to relatively move the preforming upper die 2 toward the preforming lower die 3, the preforming region is pressurized. In this example, as a preforming means, a device for performing heat treatment by the heating rods 5 and pressure treatment by the press device 9 is provided.

[0031] The molding unit 10 that performs the molding process includes an upper molding die 11 and a lower molding die 12 as a molding die 10a. The upper molding die 11 and the lower molding die 12 are arranged opposite to each other, and a molding area is formed between the upper molding die 11 and the lower molding die 12. Inside the upper molding die 11 and the lower molding die 12, a plurality of cooling pipes 13 are piped along the molding area, and the molding area is cooled by circulating a cooling medium through the cooling pipes 13. An ejector pin 14 is inserted and arranged in the lower molding die 12 so as to be able to move in and out in the vertical direction.

[0032] The upper part of the upper molding die 11 and the lower part of the lower molding die 12 are respectively supported and fixed to the press device 16 via heat insulating materials 15. By operating the press device 16 to relatively move the upper molding die 11 toward the lower molding die 12, the molding area is pressurized. In this example, as the molding means, a device that performs a cooling process by the cooling pipes 13 and a pressurizing process by the press device 16 is provided.

[0033] The transfer unit (not shown) that performs the transfer process is arranged between the pre-molding unit 1 and the molding unit 10, and is configured to take out and transfer the impregnated intermediate material 40 in a state where the release sheet 30 is in contact with it from the pre-molding die 1a in a heated state. As the transfer unit, known transfer means such as a conveyor and an actuator can be used.

[0034] The material to be molded 20 is accommodated in the pre-molding area in the pre-molding unit 1 with the release sheet 30 in contact with both surfaces. The material to be molded 20 is accommodated in a state where the release sheet 30 is arranged between the pre-molding die 1a. FIG. 3 is a side view showing a state in which the material to be molded 20 and the release sheet 30 are laminated. In this example, the material to be molded 20 is formed by alternately laminating a sheet-like fiber material 21 and a sheet-like thermoplastic resin material 22, and the release sheet 30 is arranged on both surfaces thereof.

[0035] As the material to be formed, a material containing at least a thermoplastic resin material and a fiber material is used. Examples of the thermoplastic resin material include polypropylene, polyethylene, polystyrene, polyamide (such as nylon 6, nylon 66, nylon 12, etc.), polyacetal, polycarbonate, acrylonitrile-butadiene-styrene copolymer (ABS), polyethylene terephthalate, polybutylene terephthalate, polyetherimide, polyethersulfone, polyphenylene sulfide, polyether ketone, polyether ether ketone, etc. Further, two or more of these thermoplastic resins may be mixed to form a polymer alloy for use. The thermoplastic resin material may be in any form such as liquid, powder, granular, fibrous, cloth-like, sheet-like, and is not particularly limited.

[0036] The fiber material is a material in which a plurality of reinforcing fibers such as high-strength and high-modulus inorganic fibers and organic fibers used in FRP such as carbon fiber, glass fiber, ceramic fiber, aramid fiber, polyoxymethylene fiber, aromatic polyamide fiber, PBO (polyparaphenylene benzobisoxazole) fiber, and metal fiber are bundled. Also, a plurality of various fiber bundles may be combined. Note that the fineness is not particularly limited.

[0037] As the form of the material to be formed, for example, a thermoplastic UD (Unidirectional; one-way) prepreg sheet in which a thermoplastic resin material is impregnated in a plurality of fiber materials arranged in one direction is used, and a form of a laminate in which the thermoplastic UD prepreg sheets are laminated in an arbitrary direction can be mentioned. Also, it may be in the form of a laminate in which a woven fabric is used as the fiber material and the woven fabric and the thermoplastic resin sheet are laminated alternately. Further, it may be in the form of a sheet-like laminate in which chopped tapes obtained by slitting the thermoplastic UD prepreg sheet into strip shapes are randomly scattered and laminated. Furthermore, it may be in the form of a non-woven fabric made of a fiber material and a fibrous thermoplastic resin material.

[0038] In order to maintain the laminated state, for the laminate, for example, something like a bar heater, which is welded in a dot shape and integrated, can be used.

[0039] As the thermoplastic UD prepreg sheet, it may be a prepreg sheet in which the thermoplastic resin material is impregnated in the fiber material with almost no voids, or a semi-prepreg sheet in which the thermoplastic resin material is unevenly distributed between the layers in which the fiber material is arranged and the thermoplastic resin material is semi-impregnated in the fiber material.

[0040] Examples of the release sheet include a resin sheet or a metal sheet having heat resistance and releasability with a release agent applied to the surface. Since the material of the release sheet is heated to the melting temperature of the thermoplastic resin material, it is preferable to select a material that can maintain the form of the release sheet at that heating temperature. For example, when the thermoplastic resin material is a PP (polypropylene) resin, a PA6 (polyamide 6) resin, etc., since the heating temperature is in the range of 200°C to 260°C, it is preferable to select a fluorine-based resin sheet as the release sheet. When the thermoplastic resin material is a PPS (polyphenylene sulfide) resin, a PEEK (polyether ether ketone) resin, etc., since the heating temperature is in the range of 300°C to 400°C, it is preferable to select a thermosetting PI (polyimide) resin sheet as the release sheet.

[0041] When a metal sheet is selected as the release sheet, although it has sufficient heat resistance, it is necessary to select a material for the release agent applied to the surface to have durability against the heating temperature in the preforming process.

[0042] In addition, the release sheet in contact with the impregnation intermediate material is preferably made of a flexible material. When peeling the release sheet from the impregnation intermediate material, by gradually peeling the release sheet from the end, it is possible to smoothly peel without collapsing the formed shape of the impregnation intermediate material and without causing wrinkles or creases in the release sheet.

[0043] FIG. 4 is a process explanatory diagram regarding the preforming process, and FIG. 5 is a process explanatory diagram regarding the forming process. In the preforming process, with the release sheets 30 attached to both sides of the material to be formed 20, it is accommodated in the preforming die 1a (FIG. 4(a)). The material to be formed 20 is accommodated with the release sheet 30 disposed between the preforming upper die 2 and the preforming lower die 3. By setting the preforming die 1a in a state preheated to a temperature equal to or higher than the melting temperature of the thermoplastic resin material in advance, preforming can be efficiently performed.

[0044] Next, the preforming upper die 2 and the preforming lower die 3 are closed and set in a pressurized state (FIG. 4(b)). Then, with the heat of the preforming upper die 2 and the preforming lower die 3 conducting and the thermoplastic resin material melted, a pressurizing process is performed. By the pressurizing process, the material to be formed 20 is formed into an impregnated intermediate material 40 in which the thermoplastic resin material impregnates and integrates with the fiber material. After forming the impregnated intermediate material 40, the preforming upper die 2 and the preforming lower die 3 are opened, and the heated impregnated intermediate material 40 is lifted by the ejector pin 7 with the release sheet 30 in contact therewith and separated from the preforming lower die 3 (FIG. 4(c)). The impregnated intermediate material 40 is taken out, the release sheets 30 adhered to both sides are peeled off, and it is transferred to the forming portion 10 while maintaining the heated state in the formed shape (FIG. 4(d)).

[0045] When taking out the formed impregnated intermediate material 40 from the preforming portion 1, since the release sheet 30 is disposed between the preforming upper die 2 and the preforming lower die 3, it is possible to take out the impregnated intermediate material 40 while remaining in the heated state without adhering to the preforming upper die 2 and the preforming lower die 3. The impregnated intermediate material 40 has adhesiveness because the thermoplastic resin material is in a melted or softened state when heated, but can be taken out while maintaining the formed shape without adhering to the preforming upper die 2 and the preforming lower die 3 due to the release sheet 30.

[0046] In the preforming process, it is preferable to set the area of the processing region where the material to be formed is heated and pressed to be smaller than the area of the working region where the preforming die 1a performs heating and pressing. In the above-described example, the areas of the upper and lower surfaces of the material to be formed 20 that are heated and pressed are set to be smaller than the area of the working region where the preforming upper die 2, the preforming lower die 3, and the preforming side end die 4 define the preforming region for heating and pressing. By setting it in this way, the housing operation of the material to be formed can be performed smoothly, and when heated and pressed, the flow of the thermoplastic resin material occurs and the penetration into the fiber material proceeds easily, and it becomes possible to reduce the generation of voids in the impregnated intermediate material.

[0047] In the forming process, the impregnated intermediate material 40 in the heated state with the formed shape is housed in the forming die 10a (Fig. 5(a)). Next, the forming upper die 11 and the forming lower die 12 are closed to set them in a pressurized state (Fig. 5(b)). At this time, the forming upper die 11 and the forming lower die 12 are set to a temperature below the temperature at which the thermoplastic resin material solidifies. Thereby, the impregnated intermediate material 40 is solidified to form the composite material molded product 50. After forming the composite material molded product 50, the forming upper die 11 and the forming lower die 12 are opened, and the composite material molded product 50 is lifted by the ejector pin 14 and separated from the forming lower die 12 (Fig. 5(c)). Then, the formed composite material molded product 50 is taken out (Fig. 5(d)). In this way, since the pre-formed heated impregnated intermediate material is formed, it becomes possible to efficiently manufacture the composite material molded product with high quality.

[0048] In the forming process, it is preferable to set the area of the processing region where the impregnated intermediate material is pressurized to be smaller than the area of the working region where the forming die 10a performs pressurization. In the above-described example, the areas of the upper and lower surfaces of the impregnated intermediate material 40 that are pressurized are set to be smaller than the area of the working region where the forming upper die 11 and the forming lower die 12 define the forming region for pressurization. By setting it in this way, the housing operation of the impregnated intermediate material can be performed smoothly, and when pressurized, the impregnated intermediate material flows, and it becomes possible to obtain a molded product with high shape accuracy and few voids.

[0049] In the process explanatory diagrams from FIG. 4 to FIG. 5, a series of manufacturing processes of the material to be formed are described. The material to be formed can be sequentially fed into the preforming section 1 for processing, enabling continuous forming processing of the material to be formed. That is, immediately after transferring the impregnated intermediate material 40 preformed in the preforming section 1 to the forming section 10, by feeding the next material to be formed 20 into the preforming section 1, continuous forming processing becomes possible. In such continuous processing, the forming processing time is limited by the time taken for the preforming process or the forming process. For example, as the processing time for one sheet, if it takes 1 minute for the preforming process, 10 seconds for the transfer process, and 1 minute for the forming process, one composite material formed product can be manufactured in approximately 1 minute and 10 seconds. Also, as the processing time for one sheet, if it takes 1 minute for the preforming process, 10 seconds for the transfer process, and 3 minutes for the forming process, one composite material formed product can be manufactured in approximately 3 minutes and 10 seconds.

[0050] The impregnated intermediate material formed in the preforming process is preferably formed into a developable surface shape. A developable surface shape is a shape that can be unfolded into a plane without stretching or shrinking, and examples include a planar shape, i.e., a flat plate shape, or a shape that can be unfolded into a plane by bending or cutting.

[0051] For example, in the case of a flat plate shape, by pressing the upper and lower surfaces of the flat plate shape in the thickness direction with the preforming upper die 2 and the preforming lower die 3 in the preforming process, non-uniform stretching and shrinking deformation, shear deformation, etc. associated with the pressure deformation can be prevented. Therefore, the impregnated intermediate material can be prevented from generating non-uniform parts such as fiber material entanglement as much as possible. Also, if the release sheet 30 is arranged on at least both the upper and lower surfaces of the flat plate shape, since the flat plate shape is a developable surface shape, wrinkles and tears are less likely to occur in the release sheet during the pressure deformation. Due to this effect, a high-quality impregnated intermediate material can be formed, and the merit of being able to repeatedly use the release sheet can be obtained.

[0052] In the above example, in the preforming process, the release sheets 30 are arranged on the upper and lower surfaces of the material to be formed 20, and the release sheets 30 are not arranged on the peripheral end surfaces other than the upper and lower surfaces. Therefore, the molten thermoplastic resin material may flow out from the peripheral edge of the material to be formed 20, resulting in quality deterioration such as disturbance of the fiber material at the peripheral edge and adhesion to the preforming side mold 4. Therefore, in the preforming process, such a pressing operation is performed so that the thermoplastic resin material does not flow out more than necessary to the peripheral edge, and the peripheral edge treatment of the impregnated intermediate material is carried out.

[0053] As a method for treating the peripheral edge of the impregnated intermediate material, the pressing operation of the preforming mold is performed until the shape thickness in the pressing direction of the impregnated intermediate material reaches the set thickness, and the pressing operation of the preforming mold is stopped after the shape thickness reaches the set thickness.

[0054] Here, the set thickness is the thickness of the impregnated intermediate material in which the thermoplastic resin material is impregnated and integrated into the fiber material, and it is preferably set as the thickness in the state of being impregnated without voids.

[0055] When forming a plate shape with a constant thickness as the impregnated intermediate material, the weight Wm (g) of the material to be formed accommodated in the preforming mold, the density ρm (g / cm 3 ) of the impregnated intermediate material when formed without voids, and the area Am (cm 2 ) of the impregnated intermediate material to be formed, the thickness t (mm) of the impregnated intermediate material when the thermoplastic resin material impregnates and forms the fiber material without voids is obtained by the following formula. t = (Wm / ρm) / A

[0056] Here, the density ρm (g / cm 3 ) of the impregnated intermediate material when formed without voids is obtained as follows from the material to be formed accommodated. When the material to be formed is composed only of the fiber material and the thermoplastic resin material, the density of the fiber material is ρc (g / cm 3 ), the basis weight of the fiber material is Wc (g / m 2 ), the density of the thermoplastic resin material is ρr (g / cm3), and the basis weight of the thermoplastic resin material is Wr (g / m 2) When doing so, the density ρm (g / m 3 ) of the impregnation intermediate material is obtained by the following formula. ρm = (Wc + Wr) / {(Wc / ρc) + (Wr / ρr)}

[0057] In the above-described example, the set thickness is set using the gap adjusting jig 6 as a gap adjusting part for adjusting the interval between the preforming upper die 2 and the preforming lower die 3. A gap adjusting jig 6 corresponding to the set thickness is set between the preforming upper die 2 and the preforming side end die 4 of the preforming part 1. When the preforming part 1 is clamped at the set pressing force, a gap is generated between the preforming upper die 2 and the preforming side end die 4 by the gap adjusting jig 6. Therefore, until the interval between the preforming upper die 2 and the preforming lower die 3 is adjusted and the material to be formed becomes the set thickness, it is pressurized, and it is surely preformed into the impregnation intermediate material of the set thickness. And when it becomes the state formed to the set thickness, the set pressing force by clamping is applied to the gap adjusting jig 6, and the pressing operation to the impregnation intermediate material is stopped. The impregnation intermediate material is no longer pressurized, and the flow of the thermoplastic resin material to the peripheral part is suppressed.

[0058] Therefore, it is possible to prevent the thermoplastic resin material and the fiber material near the peripheral part from flowing out from the peripheral part of the impregnation intermediate material and adhering to and pressing the preforming side end die 4. When the thermoplastic resin material and the fiber material at the peripheral part flow out and adhere to and press the preforming side end die 4, the impregnation intermediate material is in a state of being pressed against the preforming side end die 4 and stretched, and it becomes difficult to take out the impregnation intermediate material from the preforming die 1. In addition, since the preforming side end die 4 is arranged separately from the preforming lower die 3, by finely adjusting the arrangement of the preforming side end die 4, it is also possible to prevent the thermoplastic resin material and the fiber material flowing out from the periphery of the material to be formed 20 from adhering to the preforming side end die 4. Further, the gap adjusting jig 6 can also be attached to a position facing the preforming side end die 4 of the preforming upper die 2.

[0059] As a method for treating the periphery of the impregnated intermediate material, in the preforming step, when heating and pressing the material to be formed to impregnate the fiber material with the thermoplastic resin material, the impregnated intermediate material may be preformed while cooling at least the portion of the material to be formed where the release sheet is not disposed.

[0060] FIG. 6 is an explanatory view of a preforming die 101 provided with a cooling portion. FIG. 6(a) is a plan view, FIG. 6(b) is a cross-sectional view taken along line B-B' of FIG. 6(a), and FIG. 6(c) is a cross-sectional view taken along line C-C' of FIG. 6(a). In this example, the preforming portion 100 includes a preforming upper die 102 and a preforming lower die 103 as the preforming die 101, similar to the preforming die 1a shown in FIG. 2. A preforming side end die 104 is disposed on the upper surface 103a of the preforming lower die 103 so as to surround the preforming region. Heating rods 105 are inserted into the preforming upper die 102 and the preforming lower die 103, and the entire preforming die 101 can be heated by heating the heating rods 105. Further, ejector pins 107 are inserted into the preforming lower die 103, and the impregnated intermediate material can be lifted and taken out by moving the ejector pins 107 up and down. Such a configuration is the same as that of the preforming portion 1.

[0061] The preforming side end die 104 incorporates cooling pipes 106, and four cooling pipes 106 are piped along the four side portions of the preforming side end die 104 arranged in a rectangular shape. Refrigerant such as water or oil is circulated through the cooling pipes 106 to cool the preforming side end die 104. The cooling temperature needs to be at least equal to or lower than the melting temperature of the thermoplastic resin material, and the cooling temperature is set so as to prevent the outflow of the thermoplastic resin material from the peripheral portion where the release sheet is not disposed and the accompanying disorder of the fiber material orientation when the material to be formed is heated and pressed.

[0062] FIG. 7 is a process explanatory view of the preforming step using the preforming die 101 shown in FIG. 6. Note that the forming step is the same as the step described in FIG. 5, and thus is omitted.

[0063] In the preforming process, with the release sheets 30 in contact with both surfaces of the material to be formed 20, it is placed in the preforming die 101 installed in the preforming section 100 (Fig. 7(a)). The material to be formed 20 is placed with the release sheet 30 disposed between the upper preforming die 2 and the lower preforming die 3. By setting the preforming die 101 in a state preheated to a temperature equal to or higher than the melting temperature of the thermoplastic resin material in advance, preforming can be efficiently performed. And it is preferable to cool the preforming side end die 104 that contacts at least the peripheral portion of the material to be formed 20 where the release sheet 30 is not disposed to a temperature below the melting temperature.

[0064] Next, the upper preforming die 102 and the lower preforming die 103 are closed to set them in a pressurized state (Fig. 7(b)). Then, by performing a pressurizing process in a state where the heat of the upper preforming die 102 and the preforming section 103 is conducted and the thermoplastic resin material is melted, the material to be formed 20 is formed into an impregnated intermediate material 40 in which the thermoplastic resin material is impregnated into the fiber material and integrated. At that time, the peripheral portion of the impregnated intermediate material 40 is cooled by the preforming side end die 104, preventing the outflow of the thermoplastic resin material and the accompanying disorder in the orientation of the fiber material.

[0065] After forming the impregnated intermediate material 40, the upper preforming die 102 and the lower preforming die 103 are opened, and the heated impregnated intermediate material 40 is lifted by the ejector pin 107 and separated from the lower preforming die 103 (Fig. 7(c)). At that time, since the peripheral portion of the impregnated intermediate material 40 is cooled, it can be smoothly taken out without adhering to the preforming side end die 104. The impregnated intermediate material 40 is taken out, and the release sheets 30 adhered to both sides are gradually peeled off from the ends so as to be turned up, and it is transferred to the forming section 10 while maintaining the heated state in the formed shape (Fig. 7(d)).

[0066] As described above, by performing peripheral processing such as a method of stopping the pressurization operation at a set thickness and a method of cooling at least a portion where the release sheet is not disposed on the impregnated intermediate material, a release sheet is disposed on the pressurized surface of the impregnated intermediate material, and even if the release sheet is not disposed on other non-pressurized surfaces, the impregnated intermediate material can be smoothly taken out while preventing adhesion of the resin material or the like while maintaining the heated state in the formed shape. Therefore, it has become possible to perform a molding cycle in a short time.

[0067] As such a method of peripheral processing, processing other than the above-described pressurization stop processing at a set thickness and the cooling processing of the portion where the release sheet is not disposed may be performed, or these processes may be combined and used, and it is not particularly limited.

[0068] As described above, when the impregnated intermediate material is formed into a plate shape, release sheets are disposed on both surfaces that come into contact with the preforming upper mold and the preforming lower mold, and the arrangement of the release sheet can be omitted on the side surfaces that are the peripheral portions that do not come into contact with the preforming upper mold and the preforming lower mold. Therefore, it becomes possible to transfer the impregnated intermediate material in a heated state while holding it between two release sheets.

[0069] In addition, since the release sheet does not need to be forcibly bent or cut in a state of being in close contact with the impregnated intermediate material, the handling of the release sheet becomes easy, and there is also an advantage that it can be repeatedly used without wrinkles or cuts occurring in the release sheet. Furthermore, when transferring the material to be formed in the preforming process and the forming process, the release sheet can be used as it is depending on the shape of the composite molded product.

[0070] FIG. 8 and FIG. 9 are process explanatory views of transferring the impregnated intermediate material using the release sheet. FIG. 10 is a schematic configuration diagram regarding the preforming mold 201 installed in the preforming unit 200 used in the process shown in FIG. 8, FIG. 10(a) is a plan view, FIG. 10(b) is a cross-sectional view taken along line D-D' of FIG. 10(a), and FIG. 10(c) is a cross-sectional view taken along line E-E' of FIG. 10(a). FIG. 11 is an explanatory view regarding the preforming side end mold of the preforming mold 201 shown in FIG. 10.

[0071] In this example, the preform mold 201 includes a preform upper mold 202 and a preform lower mold 203. On the upper surface 203a of the preform lower mold 203, preform side molds 204a and 204b are arranged so as to surround the preform area. Heating rods 205 are inserted into the preform upper mold 202 and the preform lower mold 203, and the entire preform mold 201 can be heated by heating the heating rods 205. Further, an ejector pin 207 is inserted into the preform upper mold 202, and as will be described later, the impregnation intermediate material can be placed on the release sheet 231 by moving the ejector pin 207 up and down.

[0072] The material to be molded 220 is placed on a continuous release sheet 231, and a release sheet 230 is arranged above it. The release sheet 231 is fed from a feed roller 232, conveyed to the preform area on the upper surface 203a of the preform lower mold 203 by conveying rollers 233 and 234, and wound up by a take-up roller 235.

[0073] The preform side molds 204a and 204b are arranged in a rectangular shape, and a pair of preform side molds 204b are arranged on a pair of side portions along the conveyance direction of the release sheet 231, and a pair of preform side molds 204a are arranged on a pair of side portions crossing the conveyance direction.

[0074] The pair of preform side molds 204a are supported and fixed to the tip of an operation bar 208b that is movably attached to the preform upper mold 202 in the vertical direction. Around the operation bar 208b, a biasing member 208a made of a compression spring is attached. Both ends of the biasing member 208a are in pressure contact with the preform upper mold 202 and the preform side mold 204a, respectively, and bias the preform upper mold 202 and the preform side mold 204a in a direction to separate them from each other. Inside the preform side mold 204a, a cooling pipe 206a is piped, and refrigerant is supplied from a cooling device (not shown) and circulated.

[0075] A pair of preformed side molds 204b are arranged on both sides along the conveyed release sheet 231, and cooling pipes 206b are piped inside. As shown in FIG. 11, the preformed side mold 204b is provided with a supply pipe 206c and a discharge pipe 206d that communicate with the internal cooling pipe 206b, and refrigerant is supplied and circulated from a cooling device (not shown).

[0076] The upper part of the preformed upper mold 202 and the lower part of the preformed lower mold 203 are respectively supported and fixed to the press device 210 via heat insulating materials 209. By operating the press device 210 to move the preformed upper mold 202 toward the preformed lower mold 203, the preforming area is pressurized.

[0077] In the preforming process, first, as shown in FIG. 9(a), the material to be formed 220 is placed on the continuous release sheet 231, and the release sheet 230 is arranged above the material to be formed 220. Therefore, the material to be formed 220 is sandwiched from above and below by the release sheets 230 and 231. In the preforming part 200, the preformed upper mold 202 is set at the standby position where it has risen, and accordingly, the preformed side mold 204a has also risen and is in a state of being separated from the preformed lower mold 203.

[0078] Next, the conveyance operation of the release sheet 231 is performed to carry the material to be formed 220 into the preforming area (FIG. 9(b)). Since the preformed side mold 204a is in the raised state, the material to be formed 220 is carried in together with the release sheet 231. Preformed side molds 204b are arranged on both sides of the preforming area, and the material to be formed 220 is placed between the preformed side molds 204b. And a release sheet 231 is arranged between the material to be formed 220 and the upper surface of the preformed lower mold 203.

[0079] Next, the preforming upper die 202 descends so that the preforming side end die 204a is disposed on both sides of the material to be formed 220 and contacts the release sheet 231 (FIG. 9(c)). By further descending the preforming upper die 202, the lower surface of the preforming upper die 202 is pressed against the release sheet 230, and the release sheet 230 is disposed between the material to be formed 220 and the preforming upper die 202 (FIG. 9(d)). At this time, the preforming side end die 204a is pressed against and adhered to the release sheet 231, and the preforming side end dies 204a and 204b are disposed so as to surround the peripheral portion of the material to be formed 220. As the preforming upper die 202 descends, the operation bar 208b to which the preforming side end die 204a is attached is pushed into the preforming upper die 202. Therefore, the biasing member 208a mounted between the preforming upper die 202 and the preforming side end die 204a is compressed.

[0080] In the preforming die 201, the material to be formed 220 set in the internal preforming region is heated and pressed by the preforming upper die 202 and the preforming lower die 203, and a refrigerant is circulated through the preforming side end dies 204a and 204b to cool the peripheral portion where the release sheet is not disposed. Then, the impregnated intermediate material 240 in which the thermoplastic resin material of the material to be formed 220 is melted and impregnated and integrated with the fiber material is preformed.

[0081] Next, as shown in FIG. 9(a), the preforming upper die 202 is raised to separate the lower surface from the release sheet 230. At this time, the preforming side end die 204a is maintained in a state where the operation bar 208b is pulled out from the preforming upper die 202 by the biasing force of the biasing member 208a and is adhered to the release sheet 231.

[0082] Next, with the preformed upper mold 202 separated from the release sheet 230, the ejector pin 207 is lowered to abut against the release sheet 230, and the preformed upper mold 202 is further raised (Fig. 9(b)). As the preformed upper mold 202 rises, with the release sheet 230 pressed by the ejector pin 207 together with the impregnated intermediate material 240, the preformed side end mold 204a rises and separates from the impregnated intermediate material 240, and the preformed upper mold 202 and the preformed side end mold 204a can be raised while maintaining the impregnated intermediate material 240 in the heated state with the formed shape (Fig. 9(c)).

[0083] Next, the conveyance operation of the release sheet 231 is performed to transfer the impregnated intermediate material 240 to the next forming step (Fig. 9(d)). At this time, by peeling the release sheet 230 from the impregnated intermediate material 240, the impregnated intermediate material 240 can be carried into the forming step while maintaining the heated state with the formed shape. As a peeling means for the release sheet 230, for example, by providing a gripping member for gripping the tip of the release sheet 230 and a moving mechanism for moving it to the side opposite to the conveyance direction, the release sheet 230 can be easily peeled. Also, when not forming a complex shape, the release sheet 230 may be put into the forming step as it is attached and then formed.

[0084] As described above, since the impregnated intermediate material 240 is taken out from the preforming part 200 with the release sheet in contact and transferred to the forming step, preforming can be efficiently performed, and the impregnated intermediate material 240 can be easily handled.

[0085] Also, in the transfer process, after separating the preformed side end mold 204a, which is the mold part at the side end of the preforming mold 201 that contacts at least the part of the impregnated intermediate material 240 where the release sheet is not arranged, the impregnated intermediate material 240 is taken out. Therefore, the impregnated intermediate material 240 can be taken out while maintaining the heated state with the formed shape.

[0086] When the material to be formed is heated and pressed to form an impregnated intermediate material, the impregnated intermediate material is formed into a shape that spreads from the shape of the material to be formed before pressing. Therefore, the impregnated intermediate material comes into contact with the preliminary mold in a pressurized state, and a force acts to push and expand the preliminary mold when it spreads. The impregnated intermediate material thus formed is in a state of being pressed against and stretched by the preliminary mold. Furthermore, since the thermoplastic resin material easily flows and the shape easily collapses in the heated state, it is difficult to remove the formed impregnated intermediate material from the preliminary mold without collapsing the formed shape. Therefore, by moving the mold part of the preliminary mold that contacts at least the part where the release sheet of the impregnated intermediate material is not disposed, and separating the impregnated intermediate material from the mold part, it becomes possible to easily remove the impregnated intermediate material with the release sheet in contact.

[0087] Also, by using a flexible material for the release sheet, in the transfer process, after removing the impregnated intermediate material with the release sheet in contact, the release sheet can be peeled off from the impregnated intermediate material so as to gradually turn up from the end. Thus, it is possible to transfer and input the impregnated intermediate material into the molding process without collapsing its shape. Therefore, it becomes possible to efficiently mold high-quality molded products.

[0088] When the composite material molded product has a complex shape, for example, a shape having ribs or boss shapes, or a shape having an R-shaped corner part, it is not possible to perform a molding process of pressing and molding the preformed impregnated intermediate material with the release sheet in contact. Therefore, after removing the impregnated intermediate material from the preliminary mold with the release sheet in contact, the release sheet is peeled off, and only the impregnated intermediate material is pressure-molded in the molding process, so that it becomes possible to obtain a complex composite material molded product.

[0089] FIG. 12 is a process explanatory diagram regarding a modified example of the molding process. In this example, it shows a process of transferring and molding the impregnated intermediate material 240 molded in the preliminary molding process described in FIGS. 8 to 9. In the molding process, the impregnated intermediate material 240 is subjected to a molding process using a molding die body 250 that houses the impregnated intermediate material 240, a heating press part 260 that presses the molding die body 250, and a cooling press part 270 that presses the molding die body 250.

[0090] The forming body 250 includes a forming upper body 251 and a forming lower body 252, and an impregnation intermediate material 240 is accommodated between the forming upper body 251 and the forming lower body 252. The forming upper body 251 and the forming lower body 252 are detachably attached to a heating press part 260 and a cooling press part 270, respectively. For example, they can be attached by known means such as a mechanical locking mechanism or magnetic force by an electromagnet.

[0091] The heating press part 260 includes a heating press upper mold 261 with built-in heating rods and a heating press lower mold 262 with built-in heating rods. The upper part of the heating press upper mold 261 is fixed to a press device 264 via a heat insulating material 263, and the lower part of the heating press lower mold 262 is fixed to the press device 264 via the heat insulating material 263. The forming upper body 251 is detachably attached to the lower surface of the heating press upper mold 261, and the forming lower body 252 is detachably attached to the upper surface of the heating press lower mold 262.

[0092] The cooling press part 270 includes a cooling press upper mold 271 with cooling pipes piped inside and a cooling press lower mold 272 with cooling pipes piped inside. The upper part of the cooling press upper mold 271 is fixed to a press device 274 via a heat insulating material 273, and the lower part of the cooling press lower mold 272 is fixed to the press device 274 via the heat insulating material 273. The forming upper body 251 is detachably attached to the lower surface of the cooling press upper mold 271, and the forming lower body 252 is detachably attached to the upper surface of the cooling press lower mold 272.

[0093] In the forming process, with the heating press section 260 open, a forming upper die body 251 and a forming lower die body 252 are respectively attached to a heating press upper die 261 and a heating press lower die 262 (Fig. 12(a)). Note that the heating press section 260 has been heat-treated in advance, and the attached forming upper die body 251 and forming lower die body 252 are in a uniformly heated state. The forming die body 250 is preferably set to a state where it is heated to a temperature equal to or higher than the melting temperature of the thermoplastic resin material. Then, the impregnated intermediate material 240 transferred from the pre-forming process is put into the forming lower die body 252 and accommodated at a predetermined position.

[0094] Next, the heating press upper die 261 descends, and the forming upper die body 251 moves toward the forming lower die body 252 and comes into contact with the impregnated intermediate material 240 (Fig. 12(b)). Further, the heating press upper die 261 is lowered to press the forming upper die body 251 against the impregnated intermediate material 240, and the forming die body 250 is pressurized to close the mold (Fig. 12(c)).

[0095] Since the forming die body 250 is heated to a temperature equal to or higher than the melting temperature of the thermoplastic resin, when forming from the impregnated intermediate material 240 into a composite material molded product, the flow becomes smooth, and a more complex shape can be formed with less disturbance in fiber orientation.

[0096] Next, the heating press section 260 is set to an open state, and the clamped forming die body 250 is transferred to the cooling press section 270 (Fig. 12(d)). The cooling press section 270 has been cooled in advance to a temperature at which the thermoplastic resin material solidifies. Then, the cooling press upper die 271 descends to set the forming die body 250 in a pressurized state and perform a cooling process (Fig. 12(e)). After the cooling process, with the forming upper die body 251 attached to the cooling press upper die 271, it is raised, the forming die body 250 is opened, and the molded product 280 is taken out.

[0097] Since the cooling process is performed while the forming die body remains as it is, the thermoplastic resin material can be solidified without mold collapse to obtain a molded product, and the forming process can be processed in a short time.

[0098] FIG. 13 is a process explanatory diagram regarding another modification of the molding process. In this example, it shows the process of transferring and molding the impregnated intermediate material 240 molded in the preliminary molding process described with reference to FIGS. 8 to 9. In the molding process, the impregnated intermediate material 240 is molded using a molding die body 310 that houses the impregnated intermediate material 240 and a press section 300 that presses the molding die body 310.

[0099] The molding die body 310 is composed of a molding upper die body 311 and a molding lower die body 312, and is pre-heat treated to a temperature equal to or higher than the melting temperature of the thermoplastic resin material by a heating device (not shown). The press section 300 includes a press upper die 301 with a flow pipe arranged inside and a press lower die 302 with a flow pipe arranged inside. The upper part of the press upper die 301 is fixed to the press device 304 via a heat insulating material 303, and the lower part of the press lower die 302 is fixed to the press device 304 via the heat insulating material 303.

[0100] First, the press section 300 is set in an open state, the pre-heat treated molding die body 310 is placed between the press upper die 301 and the press lower die 302, the molding die body 310 is opened, and the impregnated intermediate material 240 is put in (FIG. 13(a)). Then, the impregnated intermediate material 240 is accommodated between the molding upper die body 301 and the molding lower die body 302, set in a closed state, placed at a predetermined position on the upper surface of the press lower die 302, and the press upper die 301 is lowered to press the molding upper die body 311 (FIG. 13(b)). Note that flow pipes are arranged in the press upper die 301 and the press lower die 302, and a refrigerant at a temperature at which the thermoplastic resin material can solidify is flowing.

[0101] When the mold body 310 is clamped with the press part 300 in a pressurized state, since the mold body 310 is in a heated state in the initial stage, the thermoplastic resin material of the impregnation intermediate material flows during that time and complex shape forming is smoothly performed. And since the upper press die 301 and the lower press die 302 are cooled, the mold body 310 is gradually cooled and the thermoplastic resin material solidifies (Fig. 13(c)). After the cooling process, the upper press die 301 is raised to set the press upper die 300 in an open state (Fig. 13(d)), and the mold body 310 in the clamped state is taken out (Fig. 13(e)). Then, the mold body 310 is opened to take out the molded product 320.

[0102] In this example, in the molding process, the impregnation intermediate material can be once heated to enhance fluidity and be molded with good fiber orientation corresponding to a complex shape, and then by performing a cooling process, it is possible to shorten the molding time.

[0103] Note that in the process shown in Fig. 12, the heating molding time can be controlled, but in the process shown in Fig. 13, it is different in that the molding time cannot be controlled because the heating state is determined by the heat transfer time of the cooling temperature set in the lower press die. On the other hand, in the process shown in Fig. 13, compared with the process shown in Fig. 12, since the molding can be performed with one press part, the molding cost can be reduced.

Example

[0104] [Example 1] [Materials Used] Fiber material: Carbon fiber bundle (manufactured by Toray Industries, Inc.; T700SC - 60E - 12000 filaments / bundle, single filament diameter 0.007 mm) Thermoplastic resin material: PA6 resin film (manufactured by Mitsubishi Chemical Corporation; Diamiron, width 180 mm, thickness 0.02 mm, melting point 220 °C)

[0105] [Manufacturing Method of Thermoplastic Thin - Layer Semipreg Sheet] In a known apparatus for manufacturing a thermoplastic thin-layer semi-prepreg sheet (for example, in the apparatus described in FIGS. 5 and 6 of Japanese Patent Application Laid-Open No. 2017-31342, the extrusion molding apparatus portion in the apparatus configuration shown in FIG. 5 is removed, and a mechanism for introducing a thermoplastic resin film is attached), a known fiber-opening apparatus (for example, the fiber-opening apparatus shown in FIGS. 15A and 15B of Japanese Patent No. 5553074) is attached to both sides of the thermoplastic thin-layer semi-prepreg sheet, respectively, in the apparatus configuration.

[0106] In addition, in the apparatus described in FIG. 5 of Japanese Patent Application Laid-Open No. 2017-31342, the heating rolls are configured in a two-row configuration, but in this embodiment, the apparatus configuration is such that one row of heating rolls and two rows of cooling rolls are used.

[0107] As the conveyor belt, a fluorine belt (G-type belt) manufactured by Nakakoh Belt Co., Ltd. was used. The set temperature of the heating roll was set to 270 ° C, and the pressure applied between the heating rolls was set to a linear pressure of 25 kgf / cm. Further, the heating roll was rotationally driven by a drive motor so that the processing speed became 20 m / min, and the cooling roll was configured to rotate freely.

[0108] In each fiber-opening apparatus, five carbon fiber bundles were each opened to 38 mm to form a fiber-opened yarn sheet having a width of 190 mm and a basis weight of about 21 g / m 2 Each fiber-opened yarn sheet was slightly shifted in the width direction so that the ends of the respective fiber-opened fiber bundles did not overlap in the thickness direction, and was continuously introduced from both sides to the heating roll shown in FIG. 5 of Japanese Patent Application Laid-Open No. 2017-31342.

[0109] Then, a PA6 resin film was introduced on the fiber-opened yarn sheet from one of the series of heating rolls shown in FIG. 5 of Japanese Patent Application Laid-Open No. 2017-31342. When the PA6 resin film was in a molten state, it was pressed while being sandwiched by the fiber-opened yarn sheet by the series of heating rolls to make it in a semi-prepreg state in which the fiber-opened yarn sheet was slightly impregnated with the PA6 resin film.

[0110] Thereafter, the sheet was cooled by passing through a cooling roll, peeled from the conveyor belt, slit at both ends, and continuously wound around a 3-inch paper tube as a thermoplastic thin-layer prepreg sheet.

[0111] In this production, it was carried out for 50 minutes to obtain a thermoplastic thin-layer prepreg sheet with a width of 160 mm and a length of 1000 m. The obtained thermoplastic thin-layer prepreg sheet had a basis weight of 65 g / m 2 (fiber basis weight of about 42 g / m 2 ), the thickness in the impregnated state was approximately 0.043 mm in calculation, and the fiber volume content was about 54%. The thickness of the thermoplastic thin-layer prepreg sheet was measured at 10 points using an outside micrometer (manufactured by Mitutoyo Corporation) with a minimum scale of 0.001 mm, and the average value of the measurement results was about 0.063 mm.

[0112] <Manufacturing method of the material to be formed> The obtained thermoplastic thin-layer prepreg sheets were laminated 8 times with 4 sheets each in the order of [45 / 0 / -45 / 90], and then laminated 8 times with 4 sheets each in the order of [90 / -45 / 0 / 45] so as to be laminated symmetrically in the thickness direction. A total of 64 sheets were hand-laid up to form a laminate with a size of 490 mm × 490 mm to create a sheet-like laminate.

[0113] In addition, a heating rod with a diameter of 3 mm was used, the tip of the heating rod was heated to 270 °C, and spot welding was performed every time 4 to 5 thermoplastic thin-layer prepreg sheets were laminated to integrate them as a laminate. This laminate was used as the material to be formed.

[0114] <Manufacturing method of the composite material molded product> A composite material molded product (rectangular laminate) with a thickness of 2.75 mm and a size of approximately 500 mm in width × 500 mm in length, laminated in a pseudo-isotropic manner, was manufactured.

[0115] As a preform mold, the device configuration shown in Fig. 1 was used, and an upper mold and a lower mold for obtaining a flat impregnated intermediate material with a width of 495 mm × a length of 495 mm were adopted. In the preform side end mold arranged on the upper surface of the lower mold, a cooling pipe was built in to provide a cooling function. Also, when the preform mold was clamped, a gap adjusting jig was adopted so that the impregnated intermediate material was not clamped to a thickness of 2.75 mm or less.

[0116] As a release sheet, a fluorine sheet containing glass cloth (thickness 0.1 mm) manufactured by Zhongxing Belt Co., Ltd. was used and arranged on the surfaces on both sides of the material to be molded. The release sheet was formed in a rectangular shape with a length of approximately 495 mm × a width of approximately 495 mm and sized to fit smoothly into the preform mold. Considering the thickness of the impregnated intermediate material after preforming and the thickness of the release sheet, a SUS spacer with a thickness of 2.95 mm was used as the gap adjusting jig.

[0117] The upper and lower heating and pressurizing surfaces of the preform mold were heated to 250 °C, and the preform side end mold was cooled by circulating cooling oil so that it reached 100 °C.

[0118] As a forming mold, the device configuration shown in Fig. 1 was used, and an upper mold and a lower mold capable of manufacturing a flat composite material molded product with a width of 500 mm × a length of 500 mm were adopted. The temperature of the forming mold was controlled to reach 150 °C.

[0119] After putting the material to be molded with release sheets arranged on both sides into the preform mold, the preform mold was clamped. Then, after performing a pressurizing operation at 0.5 MPa for 1 minute, a pressurizing operation was performed at 5 MPa for about 2 minutes to mold the impregnated intermediate material.

[0120] Next, with the upper and lower molds of the preform mold open, the preform side end mold was separated from the impregnated intermediate material to obtain a flat impregnated intermediate material. The size was formed into a substantially rectangular shape of about 495 mm × 495 mm, and it was confirmed that the thermoplastic resin material and the fiber material slightly oozed out from the peripheral part. Then, the impregnated intermediate material was transferred to the forming mold with the release sheet attached.

[0121] The release sheet was peeled off from the impregnated intermediate material and placed in a mold. The mold was clamped and cooled at 150 °C while being pressurized at 5 MPa for 3 minutes. Then, the upper and lower molds of the mold were opened, and a composite material molded product, which is a pseudo-isotropic laminate in which a thermoplastic resin material is impregnated in a carbon fiber bundle and solidified, was obtained.

[0122] <Regarding the impregnated intermediate material> There was almost no adhesion to the preliminary forming side mold, and it could be taken out while maintaining the heated state in the formed shape without mold collapse and put into the mold.

[0123] <State of the composite material molded product (pseudo-isotropic laminate)> A pseudo-isotropic laminate with a thickness of 2.75 mm and no warpage was obtained. The thermoplastic resin material and fiber material slightly flowed out at the peripheral part of the pseudo-isotropic laminate and was formed into a size of about 500 mm × about 500 mm. However, in the area of 490 mm × 490 mm inside the periphery, almost no disturbance of the fiber material was observed, and a high-quality composite material molded product was obtained. Then, the periphery of the pseudo-isotropic laminate was cut off and finished into a pseudo-isotropic laminate with a size of about 480 mm in width × about 480 mm in length.

[0124] [Example 2] <Materials used> The same fiber material and thermoplastic resin material as in Example 1 were used.

[0125] <Manufacturing method of the material to be molded> A known pseudo-isotropic reinforcing sheet material manufacturing apparatus (for example, in the manufacturing apparatus shown in FIG. 4 described in JP-A-2016-27956, an apparatus using a sheet material supply mechanism, a sheet material cutting mechanism, a chopped material conveying mechanism employing two distribution conveyors, a sheet integrating mechanism employing one adhesion roll device, and a sheet winding mechanism) was used.

[0126] A thermoplastic thin-layer semi-prepreg sheet with a width of 160 mm, manufactured in the same manner as in Example 1, was cut into strips with a width of 5 mm along the fiber direction and then cut into lengths of 20 mm along the direction perpendicular to the fiber direction to create chopped tapes in the shape of strips. The supply speed of the thermoplastic thin-layer semi-prepreg sheet was set at approximately 30 m / min.

[0127] Next, the obtained chopped tapes with a width of 5 mm × length of 20 mm were allowed to fall naturally and dispersed onto a wire mesh conveyor belt from two locations by two dispensing conveyors. The conveyor belt ran at a conveying speed of 2 m / min, and the chopped tapes were dispersed over a range with a width of 500 mm. Since the chopped tapes were processed from the thermoplastic thin-layer semi-prepreg sheet with a width of 160 mm at a processing speed of 30 m / min and the quasi-isotropic reinforced sheet material with a width of 500 mm was manufactured at a processing speed of 2 m / min, the average number of layers in the thickness direction of the chopped tapes stacked on the conveyor belt was approximately 5 layers.

[0128] After that, as an adhesive roll device, a mechanism was used that combined a heating roll and a cooling roll and pressed and conveyed the sheet material with a Teflon (registered trademark) belt. The heating roll was heated to 280°C to bond and integrate the stacked chopped tapes together to create a quasi-isotropic reinforced sheet material. Then, it was wound onto a 12-inch paper tube. The basis weight of the quasi-isotropic reinforced sheet material was approximately 320 g / m 2 . The obtained quasi-isotropic reinforced sheet material was cut into a size of width 490 mm × length 490 mm, and a stack of 15 sheets was used as the material to be molded. Incidentally, the weight of the material to be molded was approximately 1150 g.

[0129] <Method for manufacturing a composite material molded product> A composite material molded product (chopped laminate plate-shaped molded body) with a thickness of 3 mm and a size of approximately width 500 mm × length 500 mm, laminated quasi-isotropically, was manufactured.

[0130] For the preform mold and the mold, the same molds as in Example 1 were used. When the preform mold was clamped, a gap adjustment jig was employed so that the impregnated intermediate material was not clamped to a thickness of 3 mm or less.

[0131] As the release sheet, the same one as in Example 1 was used, formed into a size of approximately 495 mm in length and approximately 495 mm in width, and sized to fit smoothly into the preforming mold. The gap adjusting jig used a SUS spacer with a thickness of 3.2 mm in consideration of the thickness of the impregnated intermediate material after preforming and the thickness of the release sheet.

[0132] The upper and lower heating and pressurizing surfaces of the preforming mold were heated to 250 °C, and the preforming side end mold disposed on the upper surface of the lower mold was cooled by circulating cooling oil so as to reach 100 °C.

[0133] Release sheets were disposed on both sides of the material to be formed with a size of 490 mm in width and 490 mm in length and put into the preforming mold. The preforming mold was clamped, and after a pressurizing operation at 0.5 MPa for 1 minute, a pressurizing operation at 5 MPa for about 2 minutes was performed to form the impregnated intermediate material.

[0134] Next, with the upper and lower molds of the preforming mold open, the preforming side end mold was separated from the impregnated intermediate material to obtain a flat impregnated intermediate material with a width of 495 mm and a length of 495 mm. Then, the impregnated intermediate material, which had become easier to move, was taken out of the preforming mold with the release sheet attached and transferred.

[0135] The release sheet was peeled off from the impregnated intermediate material and placed in the forming mold. The forming mold was clamped and cooled at 150 °C while being pressurized at 5 MPa for 3 minutes. Thereafter, with the upper and lower molds of the forming mold open, a composite material molded product, which is a chopped laminate molded body in which the thermoplastic resin material is impregnated in the carbon fiber bundle and solidified, was obtained.

[0136] <Regarding the impregnated intermediate material> The impregnated intermediate material had almost no adhesion to the preforming side end mold and could be taken out while maintaining the heated state in the formed shape without collapsing. The release sheet could be peeled off from the impregnated intermediate material without wrinkles or tears by gradually peeling from the end. And only the impregnated intermediate material could be put into the forming mold without the formed shape collapsing.

[0137] <State of the composite material molded product (quasi-isotropic laminated plate)> A chopped laminate-shaped molded body with a thickness of 3 mm, no warpage, and a size of approximately 500 mm × approximately 500 mm was obtained. Although a small amount of the thermoplastic resin material and the fiber material had flowed out at the peripheral portion of the chopped laminate-shaped molded body, a high-quality composite material molded product was obtained. Then, the periphery of the chopped laminate-shaped molded body was cut off and it could be finished to a size of approximately 490 mm in width × approximately 490 mm in length.

[0138] [Example 3] <Materials used> The same fiber material and thermoplastic resin material as in Example 1 were used.

[0139] <Manufacturing method of the material to be molded> The same quasi-isotropic reinforcing sheet material as in Example 2 was used. The obtained quasi-isotropic reinforcing sheet material was cut into a size of 280 mm in width × 280 mm in length, and a stack of 10 sheets was used as the material to be molded. The weight of the material to be molded was approximately 250 g.

[0140] <Manufacturing method of the composite material molded product> A composite material molded product was manufactured using the mold 400 shown in FIG. 14. The composite material molded product has an outer diameter of 300 mm in width × 300 mm in length, a recess with a width of 100 mm × a length of 100 mm × a depth of 30 mm is formed in the central portion, and is set to have a plate thickness of 1.3 mm and quasi-isotropy. The vertical wall portion of the recess in the central portion is set to have a shape with an inclination of about 5 degrees.

[0141] As a preform mold, using the apparatus configuration shown in FIG. 1, a preform upper mold and a preform lower mold for forming an impregnated intermediate material in a flat plate shape up to 495 mm in width × 495 mm in length were set. A gap adjusting jig was installed on the upper surface of the preform side end mold disposed on the upper surface of the preform lower mold. In this example, since the preform was to be made up to 290 mm in width × 290 mm in length as the impregnated intermediate material, as the gap adjusting jig, considering the thickness of the release sheet, a SUS spacer with a thickness of approximately 2.2 mm was used. Then, the upper and lower heating and pressurizing surfaces of the preform mold were heated to 250°C. In this example, the preform side end mold was not cooled.

[0142] The release sheet was the same as in Examples 1 and 2, and a fluorine sheet containing a glass cloth (thickness: about 0.1 mm) manufactured by Zhongxing Belt Co., Ltd. was used and placed on the surfaces on both sides of the material to be molded. The release sheet was formed to have a size of about 300 mm in length × about 300 mm in width.

[0143] The mold 400 was set in a pre-heated state, and temperature control was performed so that the mold temperature was maintained at 150°C.

[0144] After putting the material to be molded with release sheets on both sides into the preliminary mold, the preliminary mold was clamped. Then, after performing a pressurizing operation at 0.5 MPa for 1 minute, a pressurizing operation at 5 MPa was performed for about 2 minutes to mold the impregnated intermediate material.

[0145] Next, the upper and lower molds of the preliminary mold were opened to obtain a flat impregnated intermediate material. The size was formed into a substantially rectangular shape of about 290 mm × about 290 mm, and the thermoplastic resin and fiber material slightly oozed out from the peripheral portion. Then, the impregnated intermediate material was taken out from the preliminary mold with the release sheet attached, the release sheets attached to both sides of the impregnated intermediate material were peeled off, and the impregnated intermediate material in a heated state was transferred to the mold 400.

[0146] The impregnated intermediate material was accommodated in the mold 400, the mold 400 was clamped, and cooling treatment was performed at 150°C while pressurizing at 5 MPa for 3 minutes. Then, the upper and lower molds of the mold 400 were opened to obtain a high-quality composite material molded product 410 in which the thermoplastic resin material was impregnated in the fiber material and solidified. The composite material molded product 410 could be finished into a shape having a recess in the central portion with pseudo-isotropy.

[0147] <Regarding the impregnated intermediate material> An impregnation intermediate material having a substantially square shape and slightly expanded from the size at the time of charging the material to be formed was formed. Then, the impregnation intermediate material could be easily taken out while maintaining the heated state without the formed shape collapsing, with the release sheet attached to the preliminary mold. Furthermore, the release sheet could be gradually peeled off from the end by using a flexible material and could be peeled off from the impregnation intermediate material without causing wrinkles or tears. Therefore, the impregnation intermediate material from which the release sheet was peeled could be charged into the mold while maintaining the heated state without the formed shape collapsing.

[0148] <State of the composite material molded product> A composite material molded product having pseudo-isotropy made of a chopped laminate with a thickness of 1.3 mm was obtained in a shape with a size of 300 mm in width × 300 mm in length and a recess with a width of 100 mm × 100 mm × 30 mm in depth at the center. The composite material molded product could be molded with high quality without warping or the like. In this example, since the peripheral portion of the impregnation intermediate material was not cooled and was accommodated in the mold while maintaining the heated state, the impregnation intermediate material was accommodated in the mold in a state where it was formed into a size of about 290 mm × about 290 mm and could be formed into a shape that expanded to a size of about 300 mm × about 300 mm by applying pressure to the mold. And the peripheral portion of the composite material molded product could be finished in a good state without unevenness.

Explanation of reference numerals

[0149] 1... Preforming section, 1a... Preforming mold, 2... Upper preforming mold, 3... Lower preforming mold, 4... Side-end preforming mold, 5... Heating rod, 6... Gap adjusting fixture, 7... Ejector pin, 8... Heat insulating material, 9... Press device, 10... Forming section, 10a... Forming mold, 11... Upper forming mold, 12... Lower forming mold, 13... Cooling pipe, 14... Ejector pin, 15... Heat insulating material, 16... Press device, 20... Material to be formed, 21... Thermoplastic resin material, 22... Fiber material, 30 Release sheet, 40... Impregnated intermediate material, 50... Formed product, 100... Preforming section, 101... Preforming mold, 102... Upper preforming mold, 103... Lower preforming mold, 104... Side-end preforming mold, 105... Heating rod, 106... Cooling pipe, 107... Ejector pin, 200... Preforming section, 201... Preforming mold, 202... Upper preforming mold, 203... Lower preforming mold, 204a, 204b... Side-end preforming mold, 205... Heating rod, 206a~206d... Cooling pipe, 207... Ejector pin, 208a... Biasing member, 208b... Operating bar, 209... Heat insulating material, 210... Press device, 220... Material to be formed, 230... Release sheet, 231... Release sheet, 232... Pay-off roller, 233, 234... Conveyor roller, 235... Take-up roller, 240... Impregnated intermediate material, 250... Forming die body, 251... Upper forming die body, 252... Lower forming die body, 260... Heating press section, 261... Upper heating press mold, 262... Lower heating press mold, 263... Heat insulating material, 264... Press device, 270... Cooling press section, 271... Upper cooling press mold, 272... Lower cooling press mold, 273... Heat insulating material, 274... Press device, 280... Formed product, 300... Press section, 301... Upper press mold, 302... Lower press mold, 303... Heat insulating material, 304... Press device, 310... Forming die body, 311... Upper forming die body, 312... Lower forming die body, 320... Formed product, 400... Forming mold, 410... Formed product

Claims

1. In a method for manufacturing a fiber-reinforced composite material molded product by heating and pressing a molding material containing a thermoplastic resin material and a fiber material, a preliminary molding step of accommodating the molding material in the preliminary mold with a release sheet made of a flexible material disposed between the molding material and the preliminary mold, and impregnating the thermoplastic resin material into the fiber material by heating and pressing to perform preliminary molding on the impregnated intermediate material; a transfer step of peeling and transferring the release sheet so as to turn it from the rear end portion after taking out the impregnated intermediate material in a heated state from the preliminary mold with the release sheet in contact therewith; a molding step of accommodating the transferred impregnated intermediate material in a mold in a heated state and molding the impregnated intermediate material into a composite material molded product at least by pressing A method for manufacturing a composite material molded product including the above steps.

2. The method for manufacturing a composite material molded product according to claim 1, wherein in the preliminary molding step, the shape of the impregnated intermediate material is preliminarily molded into a developable surface shape.

3. The method for manufacturing a composite material molded product according to claim 1 or 2, wherein in the preliminary molding step, the molding material is accommodated in the preliminary mold that has been preheated to a temperature equal to or higher than the melting temperature of the thermoplastic resin material.

4. The method for manufacturing a composite material molded product according to any one of claims 1 to 3, wherein in the preliminary molding step, the pressing operation of the preliminary mold is performed until the shape thickness of the impregnated intermediate material in the pressing direction reaches a set thickness, and the pressing operation of the preliminary mold stops immediately after the shape thickness reaches the set thickness.

5. The method for manufacturing a composite material molded product according to any one of claims 1 to 4, wherein in the preliminary molding step, the molding material is heated and pressed to impregnate the thermoplastic resin material into the fiber material, and at least a portion of the molding material where the release sheet is not disposed is cooled to perform preliminary molding on the impregnated intermediate material.

6. The method for manufacturing a composite material molded product according to claim 5, wherein in the preliminary molding step, before accommodating the molding material in the preliminary mold, a portion of the preliminary mold that contacts at least a portion of the molding material where the release sheet is not disposed is cooled.

7. The method for manufacturing a composite material molded product according to any one of claims 1 to 6, wherein in the transfer step, after separating a mold portion of the preliminary mold that contacts at least a portion of the impregnated intermediate material where the release sheet is not disposed from the impregnated intermediate material, the impregnated intermediate material is taken out.

8. The manufacturing method of the composite material molded article according to any one of claims 1 to 7, wherein in the molding step, the impregnated intermediate material is accommodated in the molding die attached to the heating press die and pressurized, and then the molding die is accommodated in the cooling press die and pressurized.

9. The manufacturing method of the composite material molded article according to claim 8, wherein in the molding step, the impregnated intermediate material is accommodated in the preheated molding die.

10. The manufacturing method of the composite material molded article according to any one of claims 1 to 7, wherein in the molding step, the impregnated intermediate material is accommodated in the preheated molding die, and the molding die containing the impregnated intermediate material is accommodated in the cooling press die and pressurized.

11. The manufacturing method of the composite material molded article according to any one of claims 1 to 10, wherein in the preliminary molding step, the area of the processing region where the material to be molded is heated and pressurized is set to be smaller than the area of the acting region where the preliminary molding die is heated and pressurized.

12. The manufacturing method of the composite material molded article according to any one of claims 1 to 11, wherein in the molding step, the area of the processing region where the impregnated intermediate material is pressurized is set to be smaller than the area of the acting region where the molding die is pressurized.

13. In a manufacturing apparatus for a composite material molded article that manufactures a fiber-reinforced composite material molded article by heating and pressurizing a material to be molded containing a thermoplastic resin material and a fiber material, a preliminary molding die that accommodates the material to be molded with a release sheet made of a flexible material disposed between the material to be molded and the preliminary molding die, and preliminary molding means that heats and pressurizes the preliminary molding die containing the material to be molded to impregnate the fiber material with the thermoplastic resin material and form it into an impregnated intermediate material; a transfer unit that peels and transfers the release sheet so as to turn it from the rear end portion after taking out the impregnated intermediate material in a heated state from the preliminary molding die with the release sheet in contact therewith; a molding die that accommodates the transferred impregnated intermediate material in a heated state, and molding means that at least pressurizes the molding die containing the impregnated intermediate material to form the impregnated intermediate material into a composite material molded article and a manufacturing apparatus for a composite material molded article provided with the above.

14. The manufacturing apparatus for a composite material molded article according to claim 13, wherein the preliminary molding unit includes a preliminary molding upper die and a preliminary molding lower die as the preliminary molding die, and is provided with a gap adjustment unit that adjusts the gap between the preliminary molding upper die and the preliminary molding lower die.

15. The manufacturing apparatus for a composite material molded product according to claim 13 or 14, wherein the preforming part includes cooling means for cooling a part of the preforming die that contacts at least a portion of the molding material where the release sheet is not disposed.

16. The manufacturing apparatus for a composite material molded product according to any one of claims 13 to 15, wherein the preforming part includes separating means for separating a part of the preforming die that contacts at least a portion of the molding material where the release sheet is not disposed from the pre-impregnated intermediate material that has been preformed.

17. The manufacturing apparatus for a composite material molded product according to any one of claims 13 to 16, wherein the transfer part includes peeling means for peeling the release sheet that is in contact with the pre-impregnated intermediate material from the pre-impregnated intermediate material.

18. The manufacturing apparatus for a composite material molded product according to any one of claims 13 to 17, wherein the molding part includes a heating press part for accommodating and heating the molding die, and a cooling press part for accommodating and cooling the molding die.

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