JP2005288756A - Method for producing fiber-reinforced resin molding - Google Patents

Method for producing fiber-reinforced resin molding Download PDF

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JP2005288756A
JP2005288756A JP2004103981A JP2004103981A JP2005288756A JP 2005288756 A JP2005288756 A JP 2005288756A JP 2004103981 A JP2004103981 A JP 2004103981A JP 2004103981 A JP2004103981 A JP 2004103981A JP 2005288756 A JP2005288756 A JP 2005288756A
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mold
prepreg
lower mold
upper mold
reinforced resin
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Fumitaka Shima
文陵 島
Katsuji Kanamori
克二 金森
Koji Hisamoto
浩二 久本
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Teijin Ltd
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Toho Tenax Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a fiber-reinforced resin molding which can easily mold a molding having a complex shape without a defect such as a void. <P>SOLUTION: The method for producing the fiber-reinforced resin molding has a step (D) for inserting a flexible cowl plate having a radius of curvature smaller than that of the bottom surface of a flexible upper mold between a lower mold and the upper mold which is fitted into the lower mold and the bottom surface of which is formed to have a radius of curvature smaller than that of the inner bottom surface of the lower mold and a prepreg below the cowl plate, a step (E) in which the upper mold is pressed in the lower mold direction, the prepreg is pressed to a point or along a line, the cowl plate is molded to imitate the lower mold while being deformed, and the space between the upper mold and the lower mold is decompressed, and a step (F) for curing the prepreg by heating. The cowl plate can be excluded. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、複雑な形状を有する繊維強化樹脂成形体の製造方法に関する。   The present invention relates to a method for producing a fiber-reinforced resin molded body having a complicated shape.

繊維強化樹脂成形体は、軽量で高い剛性を有しており、浴槽や洗面台等の家具類、スポーツ用品、自動車部品、航空機部品等比較的大型の部品に用いられている。   Fiber reinforced resin moldings are lightweight and have high rigidity, and are used for relatively large parts such as furniture such as bathtubs and washstands, sports equipment, automobile parts, aircraft parts, and the like.

比較的大型で複雑な形状を有する繊維強化樹脂複合材料を製造する方法としては、一般にバッグ成形法が用いられている。   As a method for producing a fiber reinforced resin composite material having a relatively large and complicated shape, a bag molding method is generally used.

バッグ成形法として、型のキャビティ内表面に複数のプリプレグを互に重ね合わせて敷設し、その内側に配置した膨張バッグ内に流体を充填することによりバッグを膨張させてプリプレグを型の内表面に密着させ、その状態で加熱することによりプリプレグを硬化させる方法（特許文献１）が提案されている。   As a bag molding method, a plurality of prepregs are laid on top of each other on the inner surface of the mold cavity, and the bag is inflated by filling a fluid in the inflatable bag placed inside thereof, so that the prepreg is placed on the inner surface of the mold. There has been proposed a method (Patent Document 1) in which the prepreg is cured by bringing it into close contact and heating in that state.

或は、バッグ成形法として、型とバッグの間を減圧した後バッグに気体を充填する方法（特許文献２）が開示されている。   Alternatively, as a bag forming method, there is disclosed a method (Patent Document 2) in which gas is filled in a bag after reducing the pressure between the mold and the bag.

しかしながら、従来のバッグ成形法においては、型に敷設するプリプレグの重ね合わせ部分に空隙を生じたり、上下に重ね合わせているプリプレグの上下の長さが等しくない場合に重ね合わせ部が波打ったりし、得られる成形体の表面が平滑にならない場合や成形体内に空隙が生じる等の問題、更にコスト高となる問題がある。
特開平９−７０８４３号公報（請求項１） 特開平５−３２９８５６号公報（請求項１） However, in the conventional bag forming method, a gap is generated in the overlapping part of the prepregs laid on the mold, or the overlapping part is undulated when the vertical lengths of the prepregs stacked vertically are not equal. However, there are problems such as the case where the surface of the resulting molded body is not smooth, the formation of voids in the molded body, and the problem of increased cost.
JP-A-9-70843 (Claim 1) JP-A-5-329856 (Claim 1)

本発明の目的は、煩雑な操作を行うことなく、複雑な形状で、空隙等の欠陥の無い表面が平滑な繊維強化樹脂成形体を容易に製造する方法を提供することにある。   An object of the present invention is to provide a method for easily producing a fiber reinforced resin molded article having a complicated shape and a smooth surface free from defects such as voids without performing complicated operations.

本発明者は鋭意研究の結果、その下底面が下型内底面の曲率半径よりも小曲率半径に形成された可撓性を有する上型、或はその下底面が下型内底面の曲率半径よりも小曲率半径に形成された可撓性を有するカウルプレートを用い、最初に型内の１点又は点の集合した１線を中心とし、この点又は線から型の押圧部分を下型内底面に沿って広げるように上型或はカウルプレートを変形させながらプリプレグを下型に倣わせて成形することにより、成形体に空隙や波打部分を生じることなく容易に複雑な形状の繊維強化樹脂成形体を製造できることを見出し本発明の完成に到った。   As a result of diligent research, the present inventor has found that an upper mold having flexibility in which the lower bottom surface is formed with a smaller radius of curvature than the curvature radius of the inner bottom surface of the lower mold, or the lower bottom surface is a curvature radius of the inner bottom surface of the lower mold. Using a flexible cowl plate formed with a smaller radius of curvature than the first, centered on one point or a line of points in the mold, and the pressed part of the mold from this point or line into the lower mold By deforming the upper die or cowl plate so that it spreads along the bottom surface, the prepreg is shaped to follow the lower die, making it easy to reinforce complex shaped fibers without creating voids and undulations in the molded product. The present inventors have found that a resin molded body can be produced and have completed the present invention.

上記課題を解決する本発明は、以下に記載するものである。   The present invention for solving the above problems is described below.

〔１〕 下型と、該下型内に嵌入される可撓性を有する上型であってその底面が下型内底面の曲率半径よりも小曲率半径に形成された上型との間にプリプレグを挿入する工程（Ａ）と、次いで上型を下型方向に押付けプリプレグを１点又は線に沿って押圧し、上型を変形させながら下型に倣わせて成形すると共に上型と下型との間を減圧にする工程（Ｂ）と、その後加熱してプリプレグを硬化させる工程（Ｃ）とを有する繊維強化樹脂成形体の製造方法。   [1] Between a lower mold and an upper mold having flexibility that is inserted into the lower mold, the bottom surface of which is formed with a smaller radius of curvature than the curvature radius of the inner bottom surface of the lower mold Step (A) of inserting the prepreg, and then pressing the upper mold in the lower mold direction, pressing the prepreg along one point or line, forming the upper mold while following the lower mold while deforming the upper mold and lower The manufacturing method of the fiber reinforced resin molding which has the process (B) which makes pressure reduction between molds, and the process (C) which heats after that and hardens a prepreg.

〔２〕 下型と、該下型内に嵌入される可撓性を有する上型であってその底面が下型内底面の曲率半径よりも小曲率半径に形成された上型との間に、前記上型底面よりも小曲率半径の可撓性カウルプレートを、更に該カウルプレートの下方にプリプレグを挿入する工程（Ｄ）と、次いで上型を下型方向に押付けプリプレグを１点又は線に沿って押圧し、カウルプレートを変形させながら下型に倣わせて成形すると共に上型と下型との間を減圧にする工程（Ｅ）と、その後加熱してプリプレグを硬化させる工程（Ｆ）とを有する繊維強化樹脂成形体の製造方法。   [2] Between a lower mold and an upper mold having flexibility and fitted into the lower mold, the bottom surface of which is formed with a smaller radius of curvature than the radius of curvature of the inner bottom surface of the lower mold A step (D) of inserting a flexible cowl plate having a smaller radius of curvature than the bottom surface of the upper die, and further inserting a prepreg below the cowl plate, and then pressing the upper die toward the lower die at one point or line (E) in which the pressure is applied along the lower die while deforming the cowl plate and the pressure between the upper die and the lower die is reduced, and then the prepreg is cured by heating (F) And a method for producing a fiber-reinforced resin molded body.

〔３〕 繊維強化樹脂成形体が３次元構造を有する〔１〕又は〔２〕に記載の繊維強化樹脂成形体の製造方法。   [3] The method for producing a fiber-reinforced resin molded product according to [1] or [2], wherein the fiber-reinforced resin molded product has a three-dimensional structure.

本発明によれば、プリプレグの重ね合わせ部分の波打や、空隙等が発生することなく表面の平滑な繊維強化樹脂複合材料からなる複雑な形状の成形品を得ることができる。   According to the present invention, it is possible to obtain a molded product having a complicated shape made of a fiber-reinforced resin composite material having a smooth surface without generating undulations or voids in the overlapping portion of the prepreg.

本発明の繊維強化樹脂成形体の製造方法により自動連続成形が可能となり製造コストを低減することができる。   Automatic continuous molding becomes possible by the method for manufacturing a fiber-reinforced resin molded body of the present invention, and the manufacturing cost can be reduced.

以下、本発明について図面を参照して詳細に説明する。   Hereinafter, the present invention will be described in detail with reference to the drawings.

図２は本発明の繊維強化樹脂成形体の製造方法の一例を示す。尚、図１は同平面図である。図２中で、１は弾性変形が困難な金属製の下型で上面が開放された矩形の中空部３１を有する。下型１の内底面３２は略平面に形成され、その曲率半径は大きい。この下型１の内面は、後述する成形によりプリプレグ４の外面形状が所望の形状となるよう形成されている。   FIG. 2 shows an example of a method for producing a fiber-reinforced resin molded body of the present invention. FIG. 1 is a plan view of the same. In FIG. 2, reference numeral 1 denotes a metal lower mold that is difficult to be elastically deformed and has a rectangular hollow portion 31 having an open upper surface. The inner bottom surface 32 of the lower mold 1 is formed in a substantially flat surface and has a large curvature radius. The inner surface of the lower mold 1 is formed so that the outer surface shape of the prepreg 4 becomes a desired shape by molding described later.

２は前記下型１の中空部３１に嵌入される下部上型で、弾力性があるシリコン樹脂製で、その底面３３は下型内底面３２よりも曲率半径が小さく形成されている。また、下部上型２の上面３４は平面に形成されている。３は上部上型で、その下面３５は平面に形成されている。この上部上型３はシリコン樹脂製で弾力性があり、下部上型２を押圧する。５はカウルプレートで、ＦＲＰ製である。その底部３６は下部上型２の下面３３よりも曲率半径が小さく、且つ、その外側面と垂直面とのなす平均角度θが約１０度となるよう形成されている。このカウルプレート５は、後述する成形の過程で、その底部３６の曲率半径が大きくなり、且つ、平均角度θが約０度となった際に、プリプレグ４の内面形状が所望の形状となるよう形成されている。この状態でまずプリプレグ４を前記下型１の内底面３２に沿って敷設する（工程Ｄ）。   Reference numeral 2 denotes a lower upper die that is fitted into the hollow portion 31 of the lower die 1 and is made of elastic silicon resin. The bottom surface 33 is formed to have a smaller radius of curvature than the inner bottom surface 32 of the lower die. Further, the upper surface 34 of the lower upper mold 2 is formed in a plane. Reference numeral 3 denotes an upper upper mold, and a lower surface 35 thereof is formed in a plane. The upper upper mold 3 is made of silicon resin and has elasticity, and presses the lower upper mold 2. A cowl plate 5 is made of FRP. The bottom portion 36 is formed to have a smaller radius of curvature than the lower surface 33 of the lower upper mold 2 and an average angle θ between the outer surface and the vertical surface is about 10 degrees. The cowl plate 5 has a shape of the inner surface of the prepreg 4 that becomes a desired shape when the radius of curvature of the bottom portion 36 becomes large and the average angle θ becomes about 0 degrees in the molding process described later. Is formed. In this state, first, the prepreg 4 is laid along the inner bottom surface 32 of the lower mold 1 (step D).

図３は、上部上型３を下型１方向に押付け上部上型３、下部上型２を下型１の中空部３１に挿入する状態を示す。更に、下型１、下部上型２、上部上型３、カウルプレート５及びプリプレグ４をバッグ１１とグランドシート１２で覆い、シール材１３で密封する。形成した密封空間から空気吸引口１４を通じて空気を吸引することにより密封空間を減圧にする。その結果、大気圧がバッグ１１を押圧し、バッグ１１からの押圧力で、上部上型３が下部上型２を押圧し、下部上型２がカウルプレート５を押圧し、カウルプレート５がプリプレグ４を押圧し、これらが下型１方向に移動する。この結果、プリプレグ４は下型１の内底面３２とＸで線状に接する。尚、θは約１０度である（工程Ｅの初期段階）。図３中のその他の符号は図２と同様である。   FIG. 3 shows a state in which the upper upper mold 3 is pressed in the direction of the lower mold 1 and the upper upper mold 3 and the lower upper mold 2 are inserted into the hollow portion 31 of the lower mold 1. Further, the lower mold 1, the lower upper mold 2, the upper upper mold 3, the cowl plate 5 and the prepreg 4 are covered with a bag 11 and a ground sheet 12 and sealed with a sealing material 13. By sucking air through the air suction port 14 from the formed sealed space, the sealed space is decompressed. As a result, the atmospheric pressure presses the bag 11, and the upper upper mold 3 presses the lower upper mold 2 with the pressing force from the bag 11, the lower upper mold 2 presses the cowl plate 5, and the cowl plate 5 is prepreg. 4 are pressed, and these move in the direction of the lower mold 1. As a result, the prepreg 4 is in linear contact with the inner bottom surface 32 of the lower mold 1 at X. Θ is about 10 degrees (initial stage of step E). Other reference numerals in FIG. 3 are the same as those in FIG.

図４は、バッグ１１とグランドシート１２及びシール材１３による密封空間から空気が空気吸引口１４を通じて更に吸引され密封空間が更に減圧となっている状態を示す。その結果、バッグ１１からの押圧力で、上部上型３、下部上型２、カウルプレート５がそれぞれ変形しながら下型１方向に更に移動し、プリプレグ４を下型１の内底面３２に押圧する。プリプレグ４は、下型１の内底面３２に倣わせて成形される。即ち、プリプレグ４は、下型内底面３２との接触部分を線状部Ｘから、下型内の一方の隅部Ｙ１と、もう一方の隅部Ｙ２にまで順次拡大するよう成形される。この結果、下型内底面３２とカウルプレート５との間に存在する空気は順次排出されプリプレグ４と下型内底面３２との間には空隙が生じない。また、プリプレグ４の底面は波打ちが無く平滑に成形される。この間、下部上型の底部３３は、その曲率半径が次第に大きくなるように変形している。また、カウルプレート５もその底部３６の曲率半径が大きくなるように変形し、且つ、その外側面と垂直面とのなす平均角度θが小さく（約５度）なるよう変形している（工程Ｅの中期段階）。   FIG. 4 shows a state where air is further sucked through the air suction port 14 from the sealed space formed by the bag 11, the ground sheet 12, and the sealing material 13, and the sealed space is further decompressed. As a result, the upper upper mold 3, the lower upper mold 2, and the cowl plate 5 are further moved in the direction of the lower mold 1 by the pressing force from the bag 11, and the prepreg 4 is pressed against the inner bottom surface 32 of the lower mold 1. To do. The prepreg 4 is molded following the inner bottom surface 32 of the lower mold 1. That is, the prepreg 4 is formed so that the contact portion with the lower mold inner bottom surface 32 is sequentially expanded from the linear portion X to one corner Y1 in the lower mold and the other corner Y2. As a result, the air existing between the lower mold inner bottom surface 32 and the cowl plate 5 is sequentially discharged, and no gap is generated between the prepreg 4 and the lower mold inner bottom surface 32. Further, the bottom surface of the prepreg 4 is formed smoothly without undulations. During this time, the bottom 33 of the lower upper mold is deformed so that its radius of curvature gradually increases. The cowl plate 5 is also deformed so that the radius of curvature of the bottom portion 36 is increased, and the average angle θ between the outer surface and the vertical surface is decreased (about 5 degrees) (step E). Middle stage).

図５は、バッグ１１とグランドシート１２及びシール材１３による密封空間が更に減圧となっている状態を示す。その結果、バッグ１１からの押圧力で、上部上型３、下部上型２は、それぞれ更に下型１方向に移動し、且つ下型１方向の厚みを減じ、横方向（下型１方向と直交する方向）に幅を拡大するよう変形している。また、下部上型の底部３３は、その曲率半径が更に大きくなり略下型内底面３２の曲率半径と等しくなっている。カウルプレート５は下型１方向に移動し、その底部３６の曲率半径が更に大きくなって略下型内底面３２の曲率半径と等しくなり、且つ、その外側面と垂直面とのなす平均角度θが殆ど０度となるよう変形している。プリプレグ４は、上記カウルプレート５の移動及び変形による押圧力を受けて、その外面を下型１の側部Ｚ１と、もう一方の側部Ｚ２を含めた下型１の内面に倣わせて所望の形状に成形される。この結果、プリプレグ４と下型内面との間には空隙が生じない。また、プリプレグ４の外面は波打ちが無く平滑である。更に、プリプレグ４は、その内面をカウルプレート５の外面に倣わせて所望の形状に成形される。この結果、プリプレグ４とカウルプレート５との間には空隙が生じない。また、プリプレグ４の内面は波打ちが無く平滑である。（工程Ｅの終期段階）。   FIG. 5 shows a state where the sealed space by the bag 11, the ground sheet 12, and the sealing material 13 is further depressurized. As a result, the upper upper die 3 and the lower upper die 2 are further moved in the lower die 1 direction by the pressing force from the bag 11, and the thickness in the lower die 1 direction is reduced. It is deformed so as to increase the width in the direction orthogonal to the above. In addition, the bottom 33 of the lower upper mold has a larger radius of curvature and is substantially equal to the radius of curvature of the lower inner surface 32 of the lower mold. The cowl plate 5 moves in the direction of the lower mold 1, the curvature radius of the bottom portion 36 is further increased to be substantially equal to the curvature radius of the lower mold inner bottom surface 32, and the average angle θ between the outer surface and the vertical surface is formed. Is deformed to be almost 0 degrees. The prepreg 4 receives a pressing force due to the movement and deformation of the cowl plate 5, and the outer surface thereof is made to follow the inner surface of the lower die 1 including the side portion Z1 of the lower die 1 and the other side portion Z2. It is formed into a shape. As a result, no gap is generated between the prepreg 4 and the lower mold inner surface. Further, the outer surface of the prepreg 4 is smooth with no undulations. Further, the prepreg 4 is formed into a desired shape with its inner surface following the outer surface of the cowl plate 5. As a result, no gap is generated between the prepreg 4 and the cowl plate 5. Further, the inner surface of the prepreg 4 is smooth with no undulations. (The final stage of process E).

工程Ｅの終期段階を経たプリプレグ４は、図示していないが、更に加熱してプリプレグを硬化させる工程（工程Ｆ）に供され、繊維強化樹脂成形体が得られる。   Although not shown, the prepreg 4 that has undergone the final stage of the process E is further subjected to a process of heating and curing the prepreg (process F) to obtain a fiber-reinforced resin molded body.

尚、本発明の一例を上記の通り説明したがこれに限らず、本発明は下記するものであることができる。   Although an example of the present invention has been described as described above, the present invention is not limited thereto, and the present invention can be as follows.

本発明において、下部上型２、上部上型３は、バッグから加わる押圧力で弾性変形するものであり、上記説明ではシリコン樹脂製のものを用いているが、その他の可撓性材質のものであっても良い。また、図６が示すように上部上型３の上端周縁に比較的薄い気密カバー部１５を形成して、下型１と上部上型３との間をシールできるようにすることにより、リユーザブルバッグとして機能させることもできる。この場合は、バッグ１１、グランドシート１２は不要になる。   In the present invention, the lower upper mold 2 and the upper upper mold 3 are elastically deformed by the pressing force applied from the bag. In the above description, silicon resin is used, but other flexible materials are used. It may be. Further, as shown in FIG. 6, a relatively thin airtight cover 15 is formed around the upper edge of the upper upper mold 3 so that the space between the lower mold 1 and the upper upper mold 3 can be sealed. It can also function as. In this case, the bag 11 and the ground sheet 12 are unnecessary.

尚、上記例においては上型に２つの分割型を用いて説明したが、分割型の分割数は任意であり、分割の無い上型であっても良い。   In the above example, the upper mold is described using two divided molds, but the number of divisions of the divided mold is arbitrary, and the upper mold without division may be used.

本発明におけるカウルプレートは、下部上型２、上部上型３よりは弾性変形し難い可撓性材質のものが好ましい。上記説明では、カウルプレートにＦＲＰ製のものを用いているが、弾性変形が可能な程度の肉薄の金属製のものであっても良い。   The cowl plate in the present invention is preferably made of a flexible material that is less elastically deformed than the lower upper mold 2 and the upper upper mold 3. In the above description, the cowl plate made of FRP is used, but it may be made of a metal that is thin enough to be elastically deformed.

更に、上記説明では、繊維強化樹脂成形体を製造する初期段階でプリプレグ４の底部と下型内底面とが線状に接触しているが、上型底面を下方に突出した円錐状、角錐状等に形成して点接触するようにしても良い。   Further, in the above description, the bottom of the prepreg 4 and the bottom surface of the lower mold are in linear contact with each other in the initial stage of manufacturing the fiber reinforced resin molded product, but the cone shape and the pyramid shape projecting downward from the upper mold bottom surface. It may be formed in a point contact.

尚、プリプレグ４としては公知のプリプレグを制限なく用いることができ、１プライから数十プライに積層されたプリプレグを用いることができる。プリプレグへ加える圧力は０．０５〜７ＭＰａとすることが好ましい。プリプレグを加熱硬化させる際の加熱温度としては９０〜１８０℃程度、加熱時間は１２０〜４８０分程度とすることが好ましい。これらは当業者が公知の範囲である。   As the prepreg 4, a known prepreg can be used without limitation, and a prepreg laminated from 1 ply to several tens of plies can be used. The pressure applied to the prepreg is preferably 0.05 to 7 MPa. The heating temperature for heat-curing the prepreg is preferably about 90 to 180 ° C., and the heating time is about 120 to 480 minutes. These are ranges known to those skilled in the art.

また、上記説明では、カウルプレートを用いているが、本発明の繊維強化樹脂成形体の製造方法では、このカウルプレートを省くこともできる。以下、この場合について、図面により説明する。   In the above description, a cowl plate is used. However, in the method for manufacturing a fiber-reinforced resin molded body of the present invention, the cowl plate can be omitted. Hereinafter, this case will be described with reference to the drawings.

図８は本発明の繊維強化樹脂成形体の製造方法の他の一例を示す。尚、図７は同平面図である。図８中で、５１は弾性変形が困難な金属製の下型で上面が開放された矩形の中空部８１を有する。下型５１の内底面８２は略平面に形成され、その曲率半径は大きい。この下型５１の内面は、後述する成形によりプリプレグ５４の外面形状が所望の形状となるよう形成されている。   FIG. 8 shows another example of the method for producing a fiber-reinforced resin molded body of the present invention. FIG. 7 is a plan view of the same. In FIG. 8, reference numeral 51 denotes a metal lower mold which is difficult to be elastically deformed and has a rectangular hollow portion 81 whose upper surface is opened. The inner bottom surface 82 of the lower mold 51 is formed in a substantially flat surface and has a large curvature radius. The inner surface of the lower mold 51 is formed so that the outer surface shape of the prepreg 54 becomes a desired shape by molding described later.

５２は前記下型５１の中空部８１に嵌入される上型で、弾力性があるシリコン樹脂製で、その底面８３は下型内底面８２よりも曲率半径が小さく形成されている。この上型５２は、その外側面と垂直面とのなす平均角度δが約１０度となるよう形成されている。この上型５２は、後述する成形の過程で、その底部８３の曲率半径が大きくなり、且つ、平均角度δが約０度となった際に、プリプレグ５４の内面形状が所望の形状となるよう形成されている。この状態でまずプリプレグ５４を前記下型５１の内底面８２に沿って敷設する（工程Ａ）。   An upper die 52 is fitted into the hollow portion 81 of the lower die 51 and is made of elastic silicon resin. A bottom surface 83 of the lower die 83 has a smaller radius of curvature than the inner bottom surface 82 of the lower die. The upper mold 52 is formed such that an average angle δ formed between the outer surface and the vertical surface is about 10 degrees. The upper die 52 has a shape in which the inner surface of the prepreg 54 has a desired shape when the radius of curvature of the bottom 83 becomes large and the average angle δ becomes about 0 degrees in the molding process described later. Is formed. In this state, first, the prepreg 54 is laid along the inner bottom surface 82 of the lower mold 51 (step A).

図９は、上型５２を下型５１方向に押付け上型５２を下型５１の中空部８１に挿入する状態を示す。更に、下型５１、上型５２及びプリプレグ５４をバッグ６１とグランドシート６２で覆い、シール材６３で密封する。形成した密封空間から空気吸引口６４を通じて空気が吸引され密封空間が減圧となっている。その結果、バッグ６１からの押圧力で、上型５２がプリプレグ５４を押圧し、それぞれが下型５１方向に移動している。この結果、プリプレグ５４は下型５１の内底面８２とＸで線状に接するように移動する。尚、δは約１０度である（工程Ｂの初期段階）。図９中のその他の符号は図８と同様である。   FIG. 9 shows a state in which the upper die 52 is pressed in the direction of the lower die 51 and the upper die 52 is inserted into the hollow portion 81 of the lower die 51. Further, the lower mold 51, the upper mold 52 and the prepreg 54 are covered with a bag 61 and a ground sheet 62 and sealed with a sealing material 63. Air is sucked through the air suction port 64 from the formed sealed space, and the sealed space is decompressed. As a result, the upper mold 52 presses the prepreg 54 with the pressing force from the bag 61, and each moves in the direction of the lower mold 51. As a result, the prepreg 54 moves so as to be in linear contact with the inner bottom surface 82 of the lower mold 51 at the X. Note that δ is about 10 degrees (the initial stage of the process B). Other reference numerals in FIG. 9 are the same as those in FIG.

図１０は、バッグ６１とグランドシート６２及びシール材６３による密封空間から空気が空気吸引口６４を通じて更に吸引され密封空間が更に減圧となっている状態を示す。その結果、バッグ６１からの押圧力で、上型５２が変形しながら下型５１方向に移動し、プリプレグ５４を下型５１の内底面８２に押圧している。プリプレグ５４は、下型５１の内底面８２に倣わせて成形される。即ち、プリプレグ５４は、下型内底面８２との接触部分を線状部Ｘから、下型５１内の両隅部Ｙ１、Ｙ２まで順次拡大するよう成形される。この結果、プリプレグ５４と下型内底面８２との間には空隙が生じない。この間、上型の底部８３は、その曲率半径が次第に大きくなるように変形し、且つ、その外側面と垂直面とのなす平均角度δが小さく（約５度）なるよう変形している（工程Ｂの中期段階）。   FIG. 10 shows a state where air is further sucked through the air suction port 64 from the sealed space formed by the bag 61, the ground sheet 62, and the sealing material 63, and the sealed space is further decompressed. As a result, the upper mold 52 moves in the direction of the lower mold 51 while being deformed by the pressing force from the bag 61, and presses the prepreg 54 against the inner bottom surface 82 of the lower mold 51. The prepreg 54 is molded following the inner bottom surface 82 of the lower mold 51. That is, the prepreg 54 is molded so that the contact portion with the lower mold inner bottom surface 82 is sequentially enlarged from the linear part X to both corners Y1 and Y2 in the lower mold 51. As a result, no gap is generated between the prepreg 54 and the lower mold inner bottom surface 82. During this time, the bottom 83 of the upper mold is deformed so that the radius of curvature gradually increases, and the average angle δ between the outer surface and the vertical surface is decreased (about 5 degrees) (step). B middle stage).

図１１は、密封空間が更に減圧となっている状態を示す。その結果、バッグ６１からの押圧力で、上型５２が更に下型５１方向に移動し、且つ下型５１方向の厚みを減じ、横方向（下型１方向と直交する方向）に幅を拡大するよう変形している。また、上型の底部８３は、その曲率半径が更に大きくなって略下型内底面８２の曲率半径と等しくなり、且つ、その外側面と垂直面とのなす平均角度θが殆ど０度となるよう変形している。プリプレグ５４は、上記上型５２の移動及び変形による押圧力を受けて、その外面を下型５１の側部内面に倣わせて所望の形状に成形され、その内面を上型５２の外面に倣わせて所望の形状に成形される。この結果、プリプレグ５４と下型内面及び上型５２の外面との間には空隙が生じない。また、プリプレグ５４の外面及び内面は波打ちが無く平滑である（工程Ｂの終期段階）。   FIG. 11 shows a state where the sealed space is further depressurized. As a result, the upper mold 52 is further moved in the direction of the lower mold 51 by the pressing force from the bag 61, the thickness in the direction of the lower mold 51 is reduced, and the width is expanded in the lateral direction (a direction orthogonal to the direction of the lower mold 1). It is deformed to do. In addition, the curvature radius of the bottom 83 of the upper mold is further increased to be substantially equal to the curvature radius of the inner bottom surface 82 of the lower mold, and the average angle θ between the outer surface and the vertical surface is almost 0 degrees. It is deformed like this. The prepreg 54 receives a pressing force due to the movement and deformation of the upper mold 52 and is formed into a desired shape with its outer surface imitating the inner surface of the side of the lower mold 51, and its inner surface is imitated to the outer surface of the upper mold 52. And formed into a desired shape. As a result, there is no gap between the prepreg 54 and the lower mold inner surface and the upper mold 52 outer surface. Further, the outer surface and the inner surface of the prepreg 54 are smooth with no undulations (the final stage of the process B).

工程Ｂを経たプリプレグ５４は、更に加熱してプリプレグを硬化させる工程（工程Ｃ）に供される。   The prepreg 54 that has undergone the process B is further subjected to a process of heating and curing the prepreg (process C).

本発明の製造方法により得られる成形品の一例を示す正面図である。It is a front view which shows an example of the molded article obtained by the manufacturing method of this invention. 本発明の工程Ｄにおける断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the process D of this invention. 本発明の工程Ｅの初期段階における断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the initial stage of the process E of this invention. 本発明の工程Ｅの中期段階における断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the intermediate stage of the process E of this invention. 本発明の工程Ｅの終期段階における断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the final stage of the process E of this invention. 本発明において上型をリユーザブルバッグとして用いた場合の一例を示す断面図である。It is sectional drawing which shows an example at the time of using an upper mold | type as a reusable bag in this invention. 本発明の製造方法により得られる成形品の他の一例を示す正面図である。It is a front view which shows another example of the molded article obtained by the manufacturing method of this invention. 本発明の工程Ａにおける断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the process A of this invention. 本発明の工程Ｂの初期段階における断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the initial stage of the process B of this invention. 本発明の工程Ｂの中期段階における断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the middle stage of the process B of this invention. 本発明の工程Ｂの終期段階における断面図の一例を示す図である。It is a figure which shows an example of sectional drawing in the final stage of the process B of this invention.

符号の説明Explanation of symbols

１、５１ 下型
２ 下部上型
３ 上部上型
５２ 上型
４、５４ プリプレグ
５ カウルプレート
１１、６１ バッグ
１２、６２ グランドシート
１３、６３ シール材
１４、６４ 空気吸引口
１５ 気密カバー部
３１、８１ 下型の中空部
３２、８２ 下型内底面
３３ 下部上型の底面
８３ 上型の底面
３４ 上部上型の上面
３５ 下部上型の底面
３６ カウルプレートの底面
Ｘ プリプレグの下側と下型内底面との線状接触部
Ｙ１ 下型内の一方の隅部
Ｙ２ 下型内のもう一方の隅部
Ｚ１ 下型内の一方の側面部
Ｚ２ 下型内のもう一方の側面部
θ カウルプレートの外側面と垂直面とのなす平均角度
δ 上型外側面と垂直面とのなす平均角度
1, 51 Lower mold 2 Lower upper mold 3 Upper upper mold 52 Upper mold 4, 54 Prepreg 5 Cowl plate 11, 61 Bag 12, 62 Ground sheet 13, 63 Sealing material 14, 64 Air suction port 15 Airtight cover section 31, 81 Lower mold hollow portion 32, 82 Lower mold inner bottom surface 33 Lower upper mold bottom surface 83 Upper mold bottom surface 34 Upper upper mold upper surface 35 Lower upper mold bottom surface 36 Cowl plate bottom surface X Lower side of prepreg and lower mold inner bottom surface Y1 One corner in the lower die Y2 The other corner in the lower die Z1 One side in the lower die Z2 The other side in the lower die θ The outer surface of the cowl plate Angle between the upper surface and the vertical surface δ Average angle between the outer surface of the upper mold and the vertical surface

Claims (3)

下型と、該下型内に嵌入される可撓性を有する上型であってその底面が下型内底面の曲率半径よりも小曲率半径に形成された上型との間にプリプレグを挿入する工程（Ａ）と、次いで上型を下型方向に押付けプリプレグを１点又は線に沿って押圧し、上型を変形させながら下型に倣わせて成形すると共に上型と下型との間を減圧にする工程（Ｂ）と、その後加熱してプリプレグを硬化させる工程（Ｃ）とを有する繊維強化樹脂成形体の製造方法。 A prepreg is inserted between a lower mold and an upper mold having flexibility that is inserted into the lower mold and whose bottom surface is formed with a radius of curvature smaller than that of the inner bottom surface of the lower mold. Step (A), and then pressing the upper die in the lower die direction, pressing the prepreg along one point or line, forming the upper die while following the lower die while deforming the upper die and the lower die The manufacturing method of the fiber reinforced resin molding which has the process (B) which makes a pressure reduction between, and the process (C) which heats after that and hardens a prepreg. 下型と、該下型内に嵌入される可撓性を有する上型であってその底面が下型内底面の曲率半径よりも小曲率半径に形成された上型との間に、前記上型底面よりも小曲率半径の可撓性カウルプレートを、更に該カウルプレートの下方にプリプレグを挿入する工程（Ｄ）と、次いで上型を下型方向に押付けプリプレグを１点又は線に沿って押圧し、カウルプレートを変形させながら下型に倣わせて成形すると共に上型と下型との間を減圧にする工程（Ｅ）と、その後加熱してプリプレグを硬化させる工程（Ｆ）とを有する繊維強化樹脂成形体の製造方法。 Between the lower mold and the upper mold having a flexibility inserted into the lower mold, the bottom of which is formed with a radius of curvature smaller than the radius of curvature of the inner bottom of the lower mold, the upper mold A step (D) of inserting a flexible cowl plate having a smaller radius of curvature than the mold bottom, and further inserting a prepreg below the cowl plate, and then pressing the upper mold in the direction of the lower mold along one point or line A step (E) of pressing and molding the lower plate while deforming the cowl plate and reducing the pressure between the upper die and the lower die, and then a step (F) of heating and curing the prepreg. The manufacturing method of the fiber reinforced resin molding which has. 繊維強化樹脂成形体が３次元構造を有する請求項１又は２に記載の繊維強化樹脂成形体の製造方法。
The manufacturing method of the fiber reinforced resin molding of Claim 1 or 2 in which a fiber reinforced resin molding has a three-dimensional structure.
JP2004103981A 2004-03-31 2004-03-31 Method for producing fiber-reinforced resin molding Pending JP2005288756A (en)

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JP2009148931A (en) * 2007-12-19 2009-07-09 Mitsubishi Rayon Co Ltd Manufacturing apparatus and manufacturing method of preform
JP2014237221A (en) * 2013-06-06 2014-12-18 三菱航空機株式会社 Method and device for molding fiber-reinforced plastic member
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