JP2014184725A - Shaping/molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a shaping/molding method in which a molded article having high strength can be shaped into a three-dimensional shape by using a molded original fabric material in a high degree of shape freedom and in high efficiency.SOLUTION: A shaping/molding method 100 comprises the steps of: cutting a molded original fabric material 1, which is obtained by sticking a resin material 4 based on a thermoplastic resin to at least one surface of a fabric base material 3 containing a plurality of reinforcing fiber bundles; stacking the cut molded original fabric materials on one another to obtain a stacked molded material 5; and inserting an inserting component 101 being a functional part having various functions between a pair of the stacked molded materials 5. Since the inserting component 101 is inserted between the pair of the stacked molded materials 5 and the functional part is incorporated beforehand, the production efficiency can be improved when a required product is produced by using the shaping/molding method. Furthermore, the flexural strength thereof can be improved and the cost required to obtain the fabric base material can be reduced.

Description

本発明は、強化炭素繊維とマトリクス樹脂とからなり、例えば、自動車や航空機などの繊維強化樹脂製部材を賦形型を使用して３次元形状に賦形する賦形成形方法に関する。   The present invention relates to a forming method for forming a fiber reinforced resin member such as an automobile or an aircraft into a three-dimensional shape using a forming die, which is made of a reinforced carbon fiber and a matrix resin.

従来より、炭素繊維を強化繊維とする繊維強化樹脂の成形法として平板状の積層成形品を型上に配置し、金型内部を真空状態にして樹脂を注入し、前記平板状の積層成形品に樹脂を拡散、含浸させるレジントランスファーモールディング成形法が知られている。   Conventionally, as a method of molding a fiber reinforced resin using carbon fiber as a reinforcing fiber, a flat laminated product is placed on a mold, the mold is evacuated, and the resin is injected into the flat laminated product. A resin transfer molding method in which a resin is diffused and impregnated is known.

特許文献１には、このレジントランスファーモールディング成形法に用いるのに好適な３次元形状を有する平板状の積層成形品を、高精度、かつ自動的に製造することのできる賦形成形方法が開示された。   Patent Document 1 discloses a forming method capable of automatically and accurately producing a flat laminated molded product having a three-dimensional shape suitable for use in this resin transfer molding method. It was.

しかしこの特許文献１に開示された賦形成形方法は強化繊維と熱硬化性樹脂からなる平板状の積層成形品を用いるものであって、その成形性には限界があった。しかも一旦硬化後は熱で溶かすことも、溶剤に溶かすこともできずリサイクルできないという問題がある。   However, the forming method disclosed in Patent Document 1 uses a flat laminated molded product made of reinforced fibers and a thermosetting resin, and its moldability is limited. Moreover, once cured, there is a problem that it cannot be recycled because it cannot be dissolved by heat or dissolved in a solvent.

これに対し特許文献２には複数本の強化繊維束を含む織物基材の少なくとも一方の表面に熱可塑性樹脂材料を付着させた後に、該織物基材を構成する複数本の強化繊維束の相対位置に変動を与えることで、変形性に優れ複雑な形状に追従させることができ、かつ、その形状の保持性に優れる強化繊維織物を用いた平板積層成形品、繊維強化樹脂成形品、ならびにそれらの製造方法が開示された。   On the other hand, in Patent Document 2, a thermoplastic resin material is attached to at least one surface of a fabric base material including a plurality of reinforcing fiber bundles, and then the relative strength of the plurality of reinforcing fiber bundles constituting the fabric base material is determined. By changing the position, it is possible to follow a complex shape with excellent deformability, and a flat plate molded product, a fiber reinforced resin molded product using a reinforced fiber fabric with excellent shape retention, and those The manufacturing method of was disclosed.

特開２００３−２１１４４７号公報Japanese Patent Laid-Open No. 2003-21447 特開２００７−５６４４１号公報JP 2007-56441 A

特許文献２に開示された強化繊維織物を成形原反材として積層してなる積層成形材を溶融温度に加熱後、固化温度の成形型で圧縮する成型法では、熱可塑性樹脂を炭素繊維に完全に含侵させることが困難であり、十分な成形品強度が得られないという問題がある。
本発明は以上の従来技術における問題に鑑み、成形原反材を用い強度の強い成形品を形状自由度高くかつ効率よく３次元形状に賦形する賦形成形方法を提供することを目的とする。 In a molding method in which a laminated molding material obtained by laminating a reinforcing fiber fabric disclosed in Patent Document 2 as a molding raw material is heated to a melting temperature and then compressed with a molding die at a solidification temperature, the thermoplastic resin is completely converted into carbon fibers. There is a problem that it is difficult to impregnate, and a sufficient molded product strength cannot be obtained.
The present invention has been made in view of the above problems in the prior art, and an object of the present invention is to provide a forming method for forming a strong molded product into a three-dimensional shape efficiently with a high degree of freedom using a forming raw material. .

本発明の賦形成形方法は、複数本の強化繊維束を含む織物基材の少なくとも一方の表面に熱可塑性樹脂を主成分とする樹脂材料が付着された成形原反材を裁断し積層した積層成形材を成形型に投入配置し、加圧、加熱して複数本の強化繊維束を含む織物基材に付着している樹脂材料を溶融して繊維間及び成形原反材の層間を接着する賦形成形方法において、賦形をする成形型を溶融温度に昇温する工程と、成形型の所要部位にインサート部品をインサ−トする工程と、積層成形材を予熱して成形型へ投入配置する予熱工程と、成形型を型締し加圧する工程と、成形型を固化温度に冷却して型を開き離型する工程とを有することを特徴とする。
本発明の賦形成形方法によって、成形型を熱可塑性樹脂材の溶融温度に加熱することによって熱可塑性樹脂を強化繊維に完全に含侵させて繊維積層によって強化して十分な成形品強度の熱可塑性樹脂材を成形することが可能となる。しかも長い昇温時間によってサイクルタイムが過長になることを予熱することによって防止することができる。また積層成形材の所要部位にインサート部品をインサ−トして成形することによって、各種の機能を備える機能部を予め繊維強化樹脂成形品に組み込み、所要の製品を得るために要する時間を節減することができ、さらにサイクルタイムを短縮することができる。 The forming method of the present invention is a laminate in which a forming raw material having a resin material mainly composed of a thermoplastic resin attached to at least one surface of a woven fabric substrate including a plurality of reinforcing fiber bundles is cut and laminated. The molding material is placed and placed in a molding die, pressurized and heated to melt the resin material adhering to the textile substrate including a plurality of reinforcing fiber bundles and bond the fibers and the layers of the molding raw material. In the forming method, the step of raising the forming mold to the melting temperature, the step of inserting the insert part into the required part of the mold, the pre-heating of the laminated molding material, and placement into the mold A preheating step, a step of clamping and pressurizing the mold, and a step of cooling the mold to a solidification temperature to open and release the mold.
By the forming method of the present invention, the mold is heated to the melting temperature of the thermoplastic resin material to completely impregnate the thermoplastic resin into the reinforcing fibers and strengthened by the fiber lamination to heat the molded article with sufficient strength. It becomes possible to mold a plastic resin material. In addition, it can be prevented by preheating that the cycle time becomes excessive due to the long heating time. In addition, by inserting and inserting insert parts into the required parts of the laminated molding material, functional parts having various functions are incorporated in the fiber reinforced resin molded product in advance, thereby reducing the time required to obtain the required product. And cycle time can be further reduced.

また本発明の賦形成形方法は、複数本の強化繊維束を含む織物基材の少なくとも一方の表面に熱可塑性樹脂を主成分とする樹脂材料が付着された成形原反材を裁断し積層した積層成形材を成形型に投入配置し、加圧、加熱して複数本の強化繊維束を含む織物基材に付着している樹脂材料を溶融して繊維間及び成形原反材の層間を接着する賦形成形方法において、賦形をする成形型を溶融温度に昇温する工程と、積層成形材を予熱して成形型へ投入配置する予熱工程と、成形型を型締し加圧する工程と、成形型を固化温度に冷却して型を開き離型する工程と、を行い平板形状の平板積層成形品を成形する工程と、前記平板積層成形品を所定の形状に裁断する工程と、賦形をする成形型を溶融温度に昇温する工程と、前記成形型の所要部位にインサート部品をインサ−トする工程と、前記平板積層成形品を予熱して成形型へ投入配置する予熱工程と、成形型を型締し加圧する工程と、成形型を固化温度に冷却して型を開き離型する工程とを有することを特徴とする。
炭素繊維間への熱可塑性樹脂の含浸には通常約５〜３０分の時間を要する。
しかし、本発明の賦形成形方法によって、事前に平板形状の積層成形材を準備することによって、その時間を削減して賦形成形の成形サイクルタイムを短縮することができる。
平板積層成形品の所要部位にインサート部品をインサ−トして成形することによって、各種の機能を備える機能部を予め繊維強化樹脂成形品に組み込み、所要の製品を得るための生産効率を向上することができる。 In addition, the forming method of the present invention cuts and laminates a forming raw material in which a resin material mainly composed of a thermoplastic resin is attached to at least one surface of a woven fabric substrate including a plurality of reinforcing fiber bundles. Laminate molding material is placed in the mold and pressed and heated to melt the resin material adhering to the textile substrate containing multiple reinforcing fiber bundles and bond the fibers and the layers of the molding material In the forming method, the step of heating the forming mold to be shaped to the melting temperature, the preheating step of preheating and placing the laminated molding material into the mold, and the step of clamping and pressurizing the mold Cooling the mold to the solidification temperature, opening the mold and releasing the mold, forming a flat plate-shaped flat laminate product, cutting the flat plate-molded product into a predetermined shape, and applying A step of raising the forming mold to the melting temperature, A step of inserting a sheet component, a preheating step of preheating and placing the flat plate molded product into a mold, a step of clamping and pressurizing the mold, and cooling the mold to a solidification temperature. And a step of opening and releasing the mold.
The impregnation of the thermoplastic resin between the carbon fibers usually takes about 5 to 30 minutes.
However, by preparing a plate-shaped laminated molded material in advance by the forming method of the present invention, the time can be reduced and the forming cycle time of the forming shape can be shortened.
By inserting insert parts into the required part of the flat plate molded product and molding it, functional parts having various functions are incorporated in the fiber reinforced resin molded product in advance to improve the production efficiency for obtaining the required product. be able to.

インサート部品を織物基材と積層する熱可塑性樹脂と同一の熱可塑性樹脂部品とするのがよい。それにより積層成形材に対しインサート部品を強固に接合することができる。   The insert part may be the same thermoplastic resin part as the thermoplastic resin that is laminated with the textile substrate. Thereby, the insert part can be firmly bonded to the laminated molding material.

インサート部品を穴付き板金若しくは孔部を備える異種の樹脂材料部品とすることによって積層成形材を形成する織物基材と積層する熱可塑性樹脂が板金の穴や若しくは異種の樹脂材料部品の孔部に廻り込み、これによって積層成形材とインサート部との相互の接合機械強度を向上することができる。   By making the insert part a sheet metal with a hole or a different kind of resin material part having a hole, the thermoplastic resin to be laminated with the fabric base material forming the laminated molding material is placed in the hole of the sheet metal or the hole of the different resin material part. This makes it possible to improve the bonding mechanical strength between the laminated molding material and the insert portion.

インサート部品が樹脂フイルムである場合には、光輝性や反射特性等樹脂フイルムの各種機能を得られる繊維強化樹脂成形品の表面性状として付与することができる。また強化繊維束が炭素繊維束であれば、軽く高強度の成形品を得ることができる。   When the insert part is a resin film, it can be imparted as a surface property of a fiber-reinforced resin molded product that can obtain various functions of the resin film such as glitter and reflection characteristics. If the reinforcing fiber bundle is a carbon fiber bundle, a light and high-strength molded product can be obtained.

また成形型が製品部型と、製品部型の背面に蓄熱盤を備え、製品部型のヒ−タ−と、蓄熱盤からの熱伝導で製品部型の型温を昇温させることによって、蓄熱盤の存在により、製品部型の昇温が早くなり、製品部型のヒ−タ−の容量を低減することができる。   In addition, the mold has a product part mold and a heat storage panel on the back of the product part mold, and by heating the product part mold heater and heat conduction from the heat storage panel, the mold temperature of the product part mold is raised. Due to the presence of the heat storage panel, the temperature of the product part mold is increased, and the capacity of the product part heater can be reduced.

成形型を水冷却によって急冷することができ、成形型を熱可塑性樹脂材の固化温度に冷却する冷却時間を要して、サイクルタイムが過長になることを防止することができる。また成形型の冷却後にエア−で水を抜き取り、成形型の昇温を開始することによって、エア−で水を除去することで、再度の昇温開始を早めることができ、さらに成形サイクルタイムを短縮することができる。   The mold can be rapidly cooled by water cooling, and a cooling time for cooling the mold to the solidification temperature of the thermoplastic resin material is required, so that the cycle time can be prevented from being excessively long. Also, after cooling the mold, water is extracted with air and the mold is started to warm up. By removing water with air, the start of temperature rise can be accelerated, and the molding cycle time can be further reduced. It can be shortened.

積層成形材又は平板積層成形品を予熱すると共に予成型した後に成形型へ投入配置することにより、簡易に効率よく成形型へ投入配置することが可能となる。また積層成形材又は平板積層成形品を予成型した予成型品を準備しておくことによって、さらに成形効率を向上することができる。予成型の態様としては、例えば成形型への積層成形材又は平板積層成形品の投入配置部分の内側形状に沿う形状に積層成形材又は平板積層成形品を予熱すると共に絞り加工を行う。   By preheating and pre-molding the laminated molding material or the flat-plate laminated molded product, it is possible to easily and efficiently place and arrange it in the molding die. Further, by preparing a pre-formed product obtained by pre-forming a laminated molded material or a flat plate-formed product, the molding efficiency can be further improved. As a form of the pre-molding, for example, the laminated molding material or the flat laminate molded product is preheated to a shape along the inner shape of the input arrangement portion of the laminated molding material or the flat laminate molded product into the mold, and the drawing process is performed.

予熱工程を、予熱対象を近赤外線放射装置から放射される近赤外線で加熱し、遠赤外線温度センサ−で前記予熱対象の温度を検知し、近赤外線の強度を調整して前記予熱対象を所定の温度に昇温させ設定温度で安定させる工程であり、前記近赤外線の強度の調整を近赤外線放射装置への通電圧の連続降下で行うことによって、近赤外線で、予熱対象の分子を加熱し中芯まで加熱でき、また遠赤外線センサ−によって非接触で正確な温度を検知することができる。   In the preheating step, the preheating target is heated by near infrared radiation emitted from a near infrared radiation device, the temperature of the preheating target is detected by a far infrared temperature sensor, the intensity of near infrared light is adjusted, and the preheating target is adjusted to a predetermined temperature. It is a process of raising the temperature to be stabilized at the set temperature, and by adjusting the intensity of the near infrared ray by continuously dropping the conduction voltage to the near infrared emitting device, the molecule to be preheated is heated in the near infrared ray. The core can be heated, and the far-infrared sensor can detect the exact temperature without contact.

近赤外線強度を、電圧の連続降下で調整し所定の温度に昇温させることによって近赤外線で、予熱対象の分子を加熱し、予熱対象を効率よく中芯まで加熱することができる。   By adjusting the near-infrared intensity with a continuous voltage drop and raising the temperature to a predetermined temperature, the molecules to be preheated can be heated with the near infrared rays, and the preheated object can be efficiently heated to the center.

積層成形材又は平板積層成形品を熱盤上に炭素繊維面を下向きとして配置して加熱することによって、積層成形材又は平板積層成形品の樹脂が熱盤に溶融接着することを防止することができる。   It is possible to prevent the resin of the laminated molded material or the flat plate molded product from being melt-bonded to the hot plate by placing the laminated molded material or the flat plate molded product on the hot plate with the carbon fiber surface facing downward. it can.

熱盤上に配置した積層成形材又は平板積層成形品を溶融させて耐熱部材で押圧して繊維間及び成形原反材の層間を溶融接着させ、その後耐熱部材を取り外す工程を含むことによって、耐熱部材から受ける押圧力によって繊維間及び成形原反材の層間を効率よく溶融接着し、さらに成形サイクルタイムを短縮することができる。   By including the process of melting the laminated molding material or flat plate molded article placed on the hot plate and pressing it with a heat-resistant member to melt and bond between the fibers and the interlayer of the molding raw material, and then removing the heat-resistant member By the pressing force received from the member, it is possible to efficiently melt and bond between the fibers and between the layers of the forming raw material, and further shorten the forming cycle time.

上部型と下部型とよりなる成形型によって積層成形材又は平板積層成形品を圧縮する工程を有し、下部型のブロックとこれに対抗する対抗型で挟みながら積層成形材を圧縮成形することによって、成形型へ投入した積層成形材又は平板積層成形品の移動を防止して精度の良い圧縮成形が可能となる。その結果、成形サイクルタイムを短縮することができる。   A step of compressing a laminated molded material or a flat laminated molded product with a molding die comprising an upper die and a lower die, and compressing and molding the laminated molding material while sandwiching it between the block of the lower die and the opposing die. Thus, it is possible to prevent the movement of the laminated molding material or the flat laminated molded article put into the mold and to perform compression molding with high accuracy. As a result, the molding cycle time can be shortened.

上部型のブロックと下部型のブロックとによって積層成形材又は平板積層成形品を挟持する工程と、上部型のブロックと下部型のブロックとによって挟持した積層成形材又は平板積層成形品を凹型へ移動して積層成形材又は平板積層成形品を絞り変形させる工程を有することによって、型の上下ブロックで挟んで凹型へ移動し絞ることによって積層成形材又は平板積層成形品の移動を防止して効率よく精度の高い絞り加工が可能となり、複雑形状の成形品の成形サイクルタイムを短縮することができる。   The process of sandwiching the laminated molded material or flat plate molded product between the upper mold block and the lower mold block, and moving the laminated molded material or flat plate molded product sandwiched between the upper mold block and the lower mold block to the concave mold By having the step of drawing and deforming the laminated molding material or flat plate molded product, the movement of the laminated molding material or flat plate molded product is efficiently prevented by moving and squeezing between the upper and lower blocks of the mold and moving to the concave mold. High-precision drawing is possible, and the molding cycle time of a molded product having a complicated shape can be shortened.

上部型のブロックを下降し、下部型のブロックを押し上げて積層成形材又は平板積層成形品を挟持することによって、型移動の相対速度を向上して、成形サイクルタイムの更なる短縮が可能となる。   By lowering the upper die block and pushing up the lower die block to sandwich the laminated molding material or flat plate molded article, the relative speed of mold movement can be improved and the molding cycle time can be further shortened. .

以上の本発明の賦形成形方法によって製造された繊維強化樹脂成形品は、高強度軽量で効率よく安価に製造でき、しかも複雑形状の附形も可能であることから、各種用途に適用が可能となる。   The fiber reinforced resin molded product produced by the above forming method of the present invention can be applied to various applications because it can be manufactured with high strength, light weight, efficiency and low cost, and also can be shaped with complex shapes. It becomes.

本発明に係る賦形成形方法によれば、特に曲げ強度の強い繊維強化樹脂成形品を成形原反材を用いて形状自由度高くかつ効率よく３次元形状に賦形して低コストに製造することができる。   According to the forming method according to the present invention, a fiber reinforced resin molded product having particularly high bending strength is formed into a three-dimensional shape with a high degree of freedom in shape and using a forming raw material, and manufactured at low cost. be able to.

図１（ａ）本発明の賦形成形方法で製造する繊維強化樹脂成形品の製造に用いる成形原反材の概念図である。（ｂ）図１（ａ）に示す成形原反材を構成する織物基材の概念図である。FIG. 1A is a conceptual diagram of a forming raw material used for manufacturing a fiber-reinforced resin molded product manufactured by the forming method of the present invention. (B) It is a conceptual diagram of the textile base material which comprises the shaping | molding raw material shown to Fig.1 (a). 本発明の賦形成形方法で製造する繊維強化樹脂成形品の断面模式図である。It is a cross-sectional schematic diagram of the fiber reinforced resin molded product manufactured with the shaping method of this invention. 本発明の第一の実施の形態の賦形成形方法で用いる賦形成形装置の説明図である。It is explanatory drawing of the shaping apparatus used with the shaping method of 1st embodiment of this invention. （ａ）本発明の第二の実施の形態の賦形成形方法の一工程を示す説明図である。（ｂ）本発明の実施の形態の賦形成形方法の他の工程を示す説明図である。（ｃ）本発明の実施の形態の賦形成形方法のさらに他の工程を示す説明図である。(A) It is explanatory drawing which shows 1 process of the shaping method of 2nd embodiment of this invention. (B) It is explanatory drawing which shows the other process of the shaping method of embodiment of this invention. (C) It is explanatory drawing which shows the other process of the shaping method of embodiment of this invention. 本発明の第四の実施の形態の賦形成形方法で用いる賦形成形装置の説明図である。It is explanatory drawing of the shaping apparatus used with the shaping method of 4th embodiment of this invention. 本発明の第五の実施の形態の賦形成形方法で用いる賦形成形装置の説明図である。It is explanatory drawing of the shaping apparatus used with the shaping method of 5th embodiment of this invention. 本発明の実施例の工程図である。It is process drawing of the Example of this invention.

本発明の賦形成形方法で製造する繊維強化樹脂成形品は、図１（ａ）に示す成形原反材１を用い本発明の賦形成形方法によって効率よく製造される。
図１（ａ）に示すように、成形原反材１は、複数本の強化繊維束２を含む織物基材３の少なくとも一方の表面に熱可塑性樹脂を主成分とする樹脂材料４が付着してなる。 The fiber reinforced resin molded product manufactured by the forming method of the present invention is efficiently manufactured by the forming method of the present invention using the forming raw material 1 shown in FIG.
As shown in FIG. 1 (a), in the forming raw material 1, a resin material 4 containing a thermoplastic resin as a main component adheres to at least one surface of a woven fabric base 3 including a plurality of reinforcing fiber bundles 2. It becomes.

織物基材３は、図１（ｂ）に示すように互いに平行となるよう一方向に引き揃えられた複数本の強化繊維束２を直交する二方向に織成してなる二方向性織物である。二方向性織物は、強化繊維束２間の相対位置の変化による変形がしやすく立体形状に変形しやすいこと、少ない枚数で力学的に擬似等方性を有する積層成形材を得やすい利点がある。
強化繊維束２は、炭素繊維束、黒鉛繊維束、ガラス繊維束、または、アラミド繊維束などを用いることができ、炭素繊維束であることが好ましい。炭素繊維束を用いることにより、最終製品である繊維強化樹脂成形品の力学特性を高いものとすることができる。 As shown in FIG. 1B, the fabric base 3 is a bi-directional fabric formed by weaving a plurality of reinforcing fiber bundles 2 aligned in one direction so as to be parallel to each other in two orthogonal directions. The bi-directional woven fabric has the advantage that it is easy to be deformed due to a change in the relative position between the reinforcing fiber bundles 2 and is easily deformed into a three-dimensional shape, and that it is easy to obtain a laminated molding material that is mechanically pseudo-isotropic with a small number of sheets. .
The reinforcing fiber bundle 2 may be a carbon fiber bundle, a graphite fiber bundle, a glass fiber bundle, an aramid fiber bundle, or the like, and is preferably a carbon fiber bundle. By using the carbon fiber bundle, the mechanical properties of the fiber reinforced resin molded product as the final product can be improved.

織物基材３の表面に付着している樹脂材料４は、織物基材３の層間を接着する作用を得ることができる熱可塑性樹脂を主成分とする。熱可塑性樹脂としては、例えば、ポリプロピレン、アクリル、ポリアミド、ポリエチレンテレフタレ−ト、ポリフェニレンサルファイドなどがある。樹脂材料４が熱可塑性樹脂を主成分とするものとすることによって成形原反材１を積層して、立体形状へと変形させた後に織物基材３の層間を接着させる場合の取り扱い性が向上し、生産性が向上する。なお、主成分とは樹脂材料４を構成する成分の中で、その割合が最も多い成分である。   The resin material 4 adhering to the surface of the woven fabric base 3 is mainly composed of a thermoplastic resin capable of obtaining the action of bonding the layers of the woven fabric base 3. Examples of the thermoplastic resin include polypropylene, acrylic, polyamide, polyethylene terephthalate, polyphenylene sulfide, and the like. By making the resin material 4 a thermoplastic resin as a main component, the handling property in the case of bonding the layers of the fabric base material 3 after laminating the forming raw material 1 and deforming it into a three-dimensional shape is improved. And productivity is improved. The main component is a component having the largest ratio among the components constituting the resin material 4.

図２は本発明の賦形成形方法で製造する繊維強化樹脂成形品の断面模式図である。
この実施の形態の繊維強化樹脂成形品１００は、複数本の強化繊維束を含む織物基材３の少なくとも一方の表面に熱可塑性樹脂を主成分とする樹脂材料４が付着された成形原反材１を裁断し積層した一対の積層成形材５に各種の機能を備える機能部であるインサート部品１０１をインサ−トしてなる。この様に積層成形材５にインサート部品１０１をインサ−トすることによって各種の機能を備える機能部を予め繊維強化樹脂成形品１００に組み込み、所要の製品を得るための生産効率を向上することができる。また曲げ強度を向上し、さらに織物基材に要するコストを低減できる。 FIG. 2 is a schematic cross-sectional view of a fiber-reinforced resin molded product produced by the forming method of the present invention.
The fiber reinforced resin molded article 100 of this embodiment is a molding raw material in which a resin material 4 mainly composed of a thermoplastic resin is attached to at least one surface of a woven fabric base 3 including a plurality of reinforcing fiber bundles. The insert part 101 which is a functional part having various functions is inserted into a pair of laminated molding materials 5 cut and laminated 1. In this way, by inserting the insert part 101 into the laminated molding material 5, functional parts having various functions can be incorporated in the fiber reinforced resin molded product 100 in advance to improve the production efficiency for obtaining a required product. it can. Further, the bending strength can be improved and the cost required for the woven fabric substrate can be reduced.

インサート部品１０１を織物基材３と積層する熱可塑性樹脂と同一の熱可塑性樹脂部品とすることにより積層成形材５に対しインサート部品１０１を強固に接合することができる。   By making the insert part 101 the same thermoplastic resin part as the thermoplastic resin laminated with the fabric base material 3, the insert part 101 can be firmly joined to the laminated molding material 5.

インサート部品１０１は図示されるようにを穴部１０１ａを有する金属製の穴付き板金１０１若しくは孔部１０１ｂを備える異種の樹脂材料部品１０１とすることによって積層成形材５を形成する織物基材３と積層する熱可塑性樹脂が穴付き板金１０１の穴部１０１ａや若しくは異種の樹脂材料部品１０１の孔部１０１ｂに廻り込み、これによって積層成形材５とインサート部１０１との相互の接合機械強度を向上することができる。織物基材３の強化繊維束が炭素繊維束であれば、軽く高強度の繊維強化樹脂成形品１００を得ることができる。   As shown in the figure, the insert part 101 is made of a metal base plate 101 having a hole 101a or a different kind of resin material part 101 having a hole 101b. The laminated thermoplastic resin goes around the hole 101a of the sheet metal 101 with a hole or the hole 101b of the different kind of resin material part 101, thereby improving the bonding mechanical strength between the laminated molding material 5 and the insert part 101. be able to. If the reinforcing fiber bundle of the fabric base material 3 is a carbon fiber bundle, a light and high-strength fiber-reinforced resin molded product 100 can be obtained.

次に繊維強化樹脂成形品１００を製造するための本発明の第一の実施の形態の賦形成形方法を図３を参照して詳述する。
先ず成形原反材１を積層し、予備積層成形型（図示せず）で予備圧縮成形した積層成形材５を予備加熱型６で予備加熱する。
予備加熱にあたっては上部より近赤外線放射装置７によって近赤外線で予備加熱型６内の熱盤８上に載置された積層成形材５とインサート部品１０１とをする。遠赤外線温度センサ−（図示せず）で積層成形材５とインサート部品１０１との温度を検知し、近赤外線放射装置７による近赤外線の強度を調整し所定の温度に積層成形材５とインサート部品１０１とを昇温させる。
一方３次元形状を有する賦形型である成形型９を予熱して成形原反材１の溶融温度に昇温する。次に積層成形材５とインサート部品１０１とを予熱された成形型９に収納し、成形型９によって積層成形材５とインサート部品１０１とを圧縮する。これによって織物基材３に付着している樹脂材料４を軟化して積層成形材５の層間を接着し、形状を保持させる。
その後成形型９を固化温度に急冷して型を開き離型する。以上の各工程によって成形原反材１を積層した積層成形材５とインサート部品１０１とを３次元形状に賦形する。 Next, the forming method of the first embodiment of the present invention for producing the fiber reinforced resin molded article 100 will be described in detail with reference to FIG.
First, the forming raw material 1 is laminated, and a laminated molding material 5 preliminarily compression-molded with a preliminary lamination mold (not shown) is preheated with a preheating mold 6.
In the preheating, the laminated molding material 5 and the insert component 101 placed on the heating plate 8 in the preheating mold 6 are made with near infrared rays by the near infrared radiation device 7 from above. The far-infrared temperature sensor (not shown) detects the temperature of the laminated molding material 5 and the insert part 101, adjusts the intensity of near infrared rays by the near-infrared radiation device 7, and keeps the laminated molding material 5 and the insert part at a predetermined temperature. 101 and the temperature is raised.
On the other hand, the forming die 9 which is a shaping die having a three-dimensional shape is preheated and the temperature is raised to the melting temperature of the forming raw material 1. Next, the laminated molding material 5 and the insert part 101 are stored in a preheated mold 9, and the laminated molding material 5 and the insert part 101 are compressed by the molding die 9. As a result, the resin material 4 adhering to the fabric base material 3 is softened, the layers of the laminated molding material 5 are bonded, and the shape is maintained.
Thereafter, the mold 9 is rapidly cooled to the solidification temperature, and the mold is opened and released. The laminated molding material 5 in which the molding raw material 1 is laminated and the insert part 101 are shaped into a three-dimensional shape by the above steps.

積層成形材５とインサート部品１０１とを加熱する温度は、樹脂材料４が軟化して積層成形材５の層間を接着させる温度である。積層成形材５とインサート部品１０１とが加圧されながら加熱されることで、積層成形材５を構成する複数本の強化繊維束２を含む織物基材３が互いに強く押付けられ、軟化した樹脂材料４が対向する複数本の強化繊維束を含む織物基材を構成する強化繊維束の単糸の間に浸透する。次いで積層成形材５とインサート部品１０１とが冷却されることにより、樹脂材料４は対向する複数本の強化繊維束を含む織物基材に付着し、積層成形材５の層間を接着する。   The temperature at which the laminated molding material 5 and the insert part 101 are heated is a temperature at which the resin material 4 is softened and the layers of the laminated molding material 5 are bonded together. The laminated base material 5 and the insert component 101 are heated while being pressed, whereby the fabric base materials 3 including the plurality of reinforcing fiber bundles 2 constituting the laminated base material 5 are strongly pressed against each other and softened. 4 penetrates between the single yarns of the reinforcing fiber bundles constituting the fabric base material including a plurality of reinforcing fiber bundles facing each other. Next, the laminated molding material 5 and the insert part 101 are cooled, so that the resin material 4 adheres to the fabric base material including a plurality of opposing reinforcing fiber bundles, and bonds the layers of the laminated molding material 5 together.

この様に積層成形材５とインサート部品１０１とを共に立体形状に変形させ層間を接着することにより、シワが無い立体形状の成形体を製造することができる。またこの成形体は積層成形材５の層間が接着されているために、剛性が高く形状保持性に優れており、取り扱いが効率よく行える。   In this way, by forming the laminated molding material 5 and the insert part 101 together into a three-dimensional shape and bonding the layers, a three-dimensional shaped product having no wrinkles can be manufactured. Further, since this molded body is bonded between the layers of the laminated molding material 5, it has high rigidity and excellent shape retention, and can be handled efficiently.

成形型９は製品部型１０と、蓄熱盤１１とよりなり、製品部型１０に備えたヒ−タ−１２と蓄熱盤１１よりの熱伝導で成形型９の型温を昇温させる。また成形型９は水冷のための冷却通水経路１３を備え、成形型９は冷却通水経路１３に通水することによって急冷される。冷却通水経路１３はエア−を印加することによって効率的に水を抜き取り降下させることができる。すなわち成形型９の型温が所定の冷却温度に達した後、冷却通水経路１３における通水を止めエア−を印加することによって、成形型９の冷却を終了し、成形型９内の製品を取り出した後に、成形型９の再度の昇温を効率的に開始することができる。   The mold 9 includes a product part mold 10 and a heat storage board 11, and raises the mold temperature of the mold 9 by heat conduction from the heater 12 and the heat storage board 11 provided in the product part mold 10. The mold 9 is provided with a cooling water passage 13 for water cooling, and the molding die 9 is rapidly cooled by passing water through the cooling water passage 13. The cooling water passage 13 can efficiently extract and lower water by applying air. That is, after the mold temperature of the mold 9 reaches a predetermined cooling temperature, the cooling of the mold 9 is finished by stopping water flow in the cooling water passage 13 and applying air. After taking out, the temperature rise of the mold 9 can be efficiently started again.

次に本発明の第二の実施の形態の賦形成形方法を図３、図４を参照して詳述する。
第二の実施の形態の賦形成形方法では正方形若しくは直方形の成形原反材１を複数用い、この各成形原反材１を、最上面の成形原反材１のみ織物基材３を上側として樹脂材料４が付着した面を下側にし、それ以外は織物基材３を下側として樹脂材料４が付着した面を上側にして積層し、その積層された積層成形材１４を第一の実施の形態と同様に圧縮成形して平板状の平板積層成形品１５とする。
次いで平板積層成形品１５を成形型９に収納する前に予備加熱型６で予熱する。
予備加熱にあたっては上部より近赤外線放射装置７から放射される近赤外線によって平板積層成形品１５を加熱する。遠赤外線温度センサ−で平板積層成形品１５の温度を検知し、近赤外線放射装置７による近赤外線の強度を調整し所定の温度に平板積層成形品１５を昇温させる。 Next, the forming method according to the second embodiment of the present invention will be described in detail with reference to FIGS.
In the forming method of the second embodiment, a plurality of square or rectangular forming raw material 1 is used, and each forming raw material 1 is the uppermost forming raw material 1 and the fabric base material 3 is the upper side. Are laminated with the surface of the resin material 4 attached on the lower side and the other side of the fabric base material 3 on the lower side with the surface of the resin material 4 attached on the upper side. The flat plate laminated product 15 is formed by compression molding as in the embodiment.
Next, the flat laminated molded product 15 is preheated by the preheating die 6 before being stored in the forming die 9.
In the preliminary heating, the flat laminated product 15 is heated by near infrared rays emitted from the near infrared radiation device 7 from above. The far-infrared temperature sensor detects the temperature of the flat laminate product 15 and adjusts the intensity of near infrared light by the near infrared radiation device 7 to raise the temperature of the flat laminate product 15 to a predetermined temperature.

以上の近赤外線の強度は、近赤外線放射装置７への通電圧の連続降下で調整する。通電圧のＯＮ−ＯＦＦで近赤外線による加熱及びその停止を反復した場合には加熱対象の温度変化の脈動が大きく安定しない。これに対して近赤外線の強度を通電圧のＯＮ−ＯＦＦではなく電圧の連続降下で調整することによって、近赤外線が連続して照射されて温度変化に脈動が生じることはなく、加熱対象の温度を効率的に設定温度で安定させることができる。
また平板積層成形品１５は予備加熱型６内の熱盤８上に炭素繊維面を下向きとして配置して加熱する。これによって平板積層成形品１５の樹脂成分を近赤外線放射装置７によって効率よく軟化させることができる。
またその際、熱盤８上に配置した平板積層成形品１５を耐熱部材（図示せず）で押圧して軟化させ、その後耐熱部材を取り外して予熱するようにすることもできる。この様にすることによって平板積層成形品１５の予熱を効率よく行うことができる。
以上の様にして予熱された平板積層成形品１５とインサート部品１０１である樹脂フイルムとを第一の実施の形態と同様に予熱された成形型９に収納し、第一の実施の形態と同様にして圧縮成形する。
この第二の実施の形態は成形型９が正方形平板状若しくは直方形平板状の平板積層成形品１５を成形し、平板積層成形品１５を用いて最終製品の成形を行う点で第一の実施の形態の賦形成形方法と異なる。また光輝性や反射特性等の各種機能の樹脂フイルムをインサート部品１０１としてインサートすることによって、樹脂フイルムの各種機能を製造する繊維強化樹脂成形品の表面性状として付与することができる。 The intensity of the near infrared light described above is adjusted by a continuous drop of the conduction voltage to the near infrared radiation device 7. When the heating by near infrared rays and the stop thereof are repeated with ON / OFF of the conduction voltage, the pulsation of the temperature change of the heating target is largely unstable. On the other hand, by adjusting the intensity of the near infrared rays not by ON / OFF of the voltage but by the continuous voltage drop, the near infrared rays are continuously irradiated so that no pulsation occurs in the temperature change, and the temperature of the heating target Can be efficiently stabilized at the set temperature.
Further, the flat plate molded product 15 is heated by placing the carbon fiber surface downward on the heating plate 8 in the preheating mold 6. As a result, the resin component of the flat laminate molded product 15 can be efficiently softened by the near infrared radiation device 7.
At that time, the flat laminated product 15 arranged on the hot platen 8 may be pressed and softened by a heat-resistant member (not shown), and then the heat-resistant member is removed and preheated. By doing in this way, the flat laminated product 15 can be preheated efficiently.
The flat laminated product 15 preheated as described above and the resin film as the insert part 101 are accommodated in the preheated mold 9 as in the first embodiment, and the same as in the first embodiment. And compression molding.
The second embodiment is the first embodiment in that the mold 9 forms a flat plate molded product 15 having a square flat plate or a rectangular flat plate, and the final product is formed using the flat plate molded product 15. This is different from the forming method of the form. Further, by inserting a resin film having various functions such as glitter and reflection characteristics as the insert part 101, it can be imparted as a surface property of a fiber reinforced resin molded product for manufacturing various functions of the resin film.

次に本発明の第三の実施の形態の賦形成形方法を説明する。
第三の実施の形態の賦形成形方法では、積層成形材１４及びインサート部品１０１又は平板積層成形品１５及びインサート部品１０１の投入配置部分の成形型９内側形状に沿う形状に積層成形材１４及びインサート部品１０１又は平板積層成形品１５及びインサート部品１０１を予熱すると共に予成型として絞り加工を行う点で第一の実施の形態及び第二の実施の形態と異なる。第三の実施の形態の賦形成形方法では、積層成形材１４及びインサート部品１０１又は平板積層成形品１５及びインサート部品１０１を成形型９へ簡易に効率よく投入配置することが可能となる。 Next, the forming method according to the third embodiment of the present invention will be described.
In the forming method of the third embodiment, the laminated molding material 14 and the insert component 101 or the flat plate laminated molded product 15 and the laminated molding material 14 in a shape along the inner shape of the molding die 9 of the input arrangement portion of the insert component 101 and The insert part 101 or the flat plate molded product 15 and the insert part 101 are preheated and different from the first embodiment and the second embodiment in that a drawing process is performed as a preform. In the forming method of the third embodiment, the laminated molding material 14 and the insert component 101 or the flat plate laminated molded product 15 and the insert component 101 can be simply and efficiently placed in the mold 9.

次に本発明の第四の実施の形態の賦形成形方法を図５を参照して詳述する。
この第四の実施の形態の賦形成形方法では、成形型９の製品部型１０を構成する上部型１６と下部型１７によって予熱された平板積層成形品１５及びインサート部品１０１を圧縮するにあたって、下部型１７の中央部ブロック１７ａとこれに対抗する対抗型１８によって挟みながら平板積層成形品１５及びインサート部品１０１を圧縮成形する。 Next, the forming method according to the fourth embodiment of the present invention will be described in detail with reference to FIG.
In the forming method of the fourth embodiment, in compressing the flat plate molded product 15 and the insert component 101 preheated by the upper die 16 and the lower die 17 constituting the product part die 10 of the die 9, The flat plate laminated product 15 and the insert part 101 are compression-molded while being sandwiched between the central block 17a of the lower die 17 and the opposing die 18 opposed thereto.

さらに第五の実施の形態では図６に示すように平板積層成形品１５及びインサート部品１０１を成形型９に投入し、上部型１６の中央部ブロック１６ａを下降し、下部型１７の中央部ブロック１７ａを押し上げて平板積層成形品１５及びインサート部品１０１を挟持する。その上部型１６の中央部ブロック１６ａと下部型１７の中央部ブロック１７ａとによって挟持した平板積層成形品１５及びインサート部品１０１を凹型１９へ移動して絞り変形させて圧縮成形する。   Further, in the fifth embodiment, as shown in FIG. 6, the flat plate molded product 15 and the insert part 101 are put into the molding die 9, the central block 16 a of the upper die 16 is lowered, and the central block of the lower die 17 is lowered. 17a is pushed up and the flat laminated product 15 and the insert part 101 are clamped. The flat plate molded product 15 and the insert part 101 sandwiched between the central block 16a of the upper mold 16 and the central block 17a of the lower mold 17 are moved to the concave mold 19 and are subjected to drawing deformation to be compression molded.

二方向性織物基材３の一方の表面に、ポリフェニレンサルファイド樹脂（ＰＰＳ）を主成分とする樹脂材料４が表面に付着した１００ｍｍ×１００ｍｍの大きさの正方形の成形原反材１を複数用意した。この各成形原反材１は正方形の辺の方向をそれぞれ０°、９０°方向としたときに、繊維軸方向が概ね０°、９０°方向となるものとした。
この各成形原反材１を、最上面の強化繊維織物のみ樹脂材料４が付着した面を下側にし、それ以外は樹脂材料４が付着した面を上側にして積層した積層成形材１４を得た。 On one surface of the bi-directional woven fabric base 3, a plurality of 100 mm × 100 mm square forming raw material 1 having a resin material 4 mainly composed of polyphenylene sulfide resin (PPS) adhered to the surface was prepared. . Each forming raw material 1 had a fiber axis direction of approximately 0 ° and 90 ° when the directions of the square sides were 0 ° and 90 °, respectively.
A laminated molding material 14 is obtained by laminating each of the raw molding materials 1 with the uppermost reinforcing fiber woven fabric having the resin material 4 attached to the lower side and the other side having the resin material 4 attached to the upper side. It was.

その積層成形材１４を熱盤８上に配置し、上部より近赤外線放射装置７によって近赤外線で積層成形材１４を加熱した。遠赤外線温度センサ−で積層成形材１４の温度を検知し、近赤外線放射装置７による近赤外線の強度を調整し積層成形材１４を昇温させ予熱した。
近赤外線の強度は、近赤外線放射装置７への通電圧の連続降下で調整し、また積層成形材１４は熱盤８上に炭素繊維面を下向きとして配置して加熱した。 The laminated molding material 14 was placed on the heating platen 8, and the laminated molding material 14 was heated by near infrared radiation from the upper part by the near infrared radiation device 7. The temperature of the laminated molding material 14 was detected by a far infrared temperature sensor, the intensity of the near infrared rays by the near infrared radiation device 7 was adjusted, and the laminated molding material 14 was heated and preheated.
The intensity of the near infrared ray was adjusted by a continuous drop of the conduction voltage to the near infrared radiation device 7, and the laminated molding material 14 was heated on the heating plate 8 with the carbon fiber surface facing downward.

一方、製品部型１０と、蓄熱盤１１とよりなり、製品部型１０に備えたヒ−タ−１２と蓄熱盤１１よりの熱伝導で成形型９の型温を昇温させてした。この予熱された成形型９に予熱した積層成形材１４を収納し、加圧しながら成形型９の提供する平板状の平板積層成形品形状に変形させた。その後、成形型９を冷却通水経路１３に通水することによって急冷し、さらに冷却通水経路１３にエア−を印加することによって効率的に水を抜き取り降下させた。それにより冷却によって固化した平板積層成形品１５を得た。
表１に以上の各工程における温度、圧力、所要時間を示す。

On the other hand, the product part mold 10 and the heat storage board 11 were used, and the mold temperature of the mold 9 was raised by heat conduction from the heater 12 and the heat storage board 11 provided in the product part mold 10. The preheated laminated molding material 14 was accommodated in the preheated mold 9 and deformed into a flat plate laminated molded product shape provided by the mold 9 while being pressed. Thereafter, the mold 9 was rapidly cooled by passing water through the cooling water passage 13, and by applying air to the cooling water passage 13, water was efficiently extracted and lowered. Thereby, a flat plate molded article 15 solidified by cooling was obtained.
Table 1 shows the temperature, pressure, and required time in each of the above steps.

以上により得られた平板積層成形品１５及びインサート部品１０１を熱盤８上に配置し、上部より近赤外線放射装置７によって近赤外線で平板積層成形品１５及びインサート部品１０１を加熱した。遠赤外線温度センサ−で平板積層成形品１５及びインサート部品１０１の温度を検知し、近赤外線放射装置７による近赤外線の強度を調整し所定の温度に平板積層成形品１５及びインサート部品１０１を昇温させ予熱した。近赤外線の強度は、近赤外線放射装置７への通電圧の連続降下で調整した。
また上部型１６と下部型１７とよりなる製品部型１０内側形状に沿う形状に平板積層成形品１５及びインサート部品１０１の絞り加工を行なった。 The flat plate molded product 15 and the insert component 101 obtained as described above were placed on the heating platen 8, and the flat plate molded product 15 and the insert component 101 were heated in the near infrared by the near infrared radiation device 7 from above. The far-infrared temperature sensor detects the temperatures of the flat plate molded product 15 and the insert component 101, adjusts the intensity of near infrared rays by the near infrared radiation device 7, and raises the flat plate molded product 15 and the insert component 101 to a predetermined temperature. Preheated. The intensity of the near infrared ray was adjusted by a continuous drop of the conduction voltage to the near infrared radiation device 7.
In addition, the flat plate molded product 15 and the insert part 101 were drawn into a shape along the inner shape of the product part mold 10 including the upper mold 16 and the lower mold 17.

一方、上部型１６と下部型１７とよりなる製品部型１０に備えたヒ−タ−１２と蓄熱盤１１よりの熱伝導で上部型１６と下部型１７の型温を昇温させて予熱した。この予熱された上部型１６と下部型１７との内側に予熱した平板積層成形品１５及びインサート部品１０１を収納し、上部型１６の中央部ブロック１６ａと下部型１７の中央部ブロック１７ａとによって平板積層成形品１５及びインサート部品１０１を挟持した。その上部型１６の中央部ブロック１６ａと下部型１７の中央部ブロック１７ａとによって挟持した平板積層成形品１５及びインサート部品１０１を凹型１９へ移動して平板積層成形品１５及びインサート部品１０１を絞り変形させた。さらに平板積層成形品１５及びインサート部品１０１を圧縮成形した。その後、成形型９を冷却通水経路１３に通水することによって急冷し、さらに冷却通水経路１３にエア−を印加することによって効率的に水を抜き取り降下させ、冷却によって固化した。
On the other hand, preheating was performed by raising the mold temperatures of the upper mold 16 and the lower mold 17 by heat conduction from the heater 12 and the heat storage board 11 provided in the product mold 10 including the upper mold 16 and the lower mold 17. . The preheated flat plate laminate 15 and the insert part 101 are accommodated inside the preheated upper die 16 and lower die 17, and a flat plate is formed by the central block 16a of the upper die 16 and the central block 17a of the lower die 17. The laminated molded product 15 and the insert part 101 were sandwiched. The flat plate molded product 15 and the insert part 101 sandwiched between the central block 16a of the upper mold 16 and the central block 17a of the lower mold 17 are moved to the concave mold 19, and the flat plate molded product 15 and the insert part 101 are drawn and deformed. I let you. Furthermore, the flat plate molded product 15 and the insert part 101 were compression molded. Thereafter, the mold 9 was rapidly cooled by passing water through the cooling water passage 13, and by applying air to the cooling water passage 13, water was efficiently extracted and solidified by cooling.

他は実施例１と同様にして、アクリル樹脂を主成分とする樹脂材料４が表面に付着した１００ｍｍ×１００ｍｍの大きさの正方形の成形原反材１を用いて、実施例１と同様の賦形成形を行った。
表２にその各工程における温度、圧力、所要時間を示す。

Others were the same as in Example 1, using a 100 mm × 100 mm square molding raw material 1 having a resin material 4 having an acrylic resin as a main component adhered to the surface. Formed.
Table 2 shows the temperature, pressure, and required time in each process.

得られた平板積層成形品１５及びインサート部品１０１を用いて実施例１と同様に成型を行った。得られた製品は実施例１，２何れの場合も表面性状が良好な３次元形状のインサート部品を接着して各種の機能部を予め組み込んでなる外観の良い繊維強化樹脂製品が得られた。
図７に実施例１，２の各工程及び使用／設備及び使用／型と、各工程における所要時間を示す。
図に示されるようにアクリル樹脂を主成分とする樹脂材料４を用いた場合で１１．５分、ポリフェニレンサルファイド樹脂（ＰＰＳ）を主成分とする樹脂材料４を用いた場合で１３．５分のサイクルタイムでの製造が可能となった。

Molding was performed in the same manner as in Example 1 by using the obtained flat plate molded product 15 and the insert component 101. In each of Examples 1 and 2, the obtained product was a fiber-reinforced resin product having a good appearance, in which various functional parts were previously incorporated by adhering a three-dimensional insert component having a good surface property.
FIG. 7 shows each process and use / equipment and use / type of Examples 1 and 2 and the time required for each process.
As shown in the figure, 11.5 minutes when the resin material 4 mainly composed of acrylic resin is used, and 13.5 minutes when the resin material 4 mainly composed of polyphenylene sulfide resin (PPS) is used. Manufacture with cycle time became possible.

１・・・成形原反材、２・・・強化繊維束、３・・・織物基材、４・・・樹脂材料、５，１４・・・積層成形材、６・・・予備加熱型、７・・・近赤外線放射装置、９・・・成形型、１０・・・製品部型、１１・・・蓄熱盤、１３・・・冷却通水経路、１２・・・ヒ−タ−、１５・・・平板積層成形品、１７・・・下部型、１７ａ・・・下部型中央部ブロック、１６・・・上部型、１６ａ・・・上部型中央部ブロック、１８・・・対抗型、１９・・・凹型。 DESCRIPTION OF SYMBOLS 1 ... Molding raw material, 2 ... Reinforcement fiber bundle, 3 ... Textile base material, 4 ... Resin material, 5,14 ... Laminated molding material, 6 ... Preheating type, DESCRIPTION OF SYMBOLS 7 ... Near-infrared radiation device, 9 ... Mold, 10 ... Product part type, 11 ... Heat storage board, 13 ... Cooling water flow path, 12 ... Heater, 15 ... Plate laminated molded product, 17 ... Lower mold, 17a ... Lower mold center block, 16 ... Upper mold, 16a ... Upper mold center block, 18 ... Counter mold, 19 ... concave type.

Claims (16)

複数本の強化繊維束を含む織物基材の少なくとも一方の表面に熱可塑性樹脂を主成分とする樹脂材料が付着された成形原反材を裁断し積層した積層成形材を成形型に投入配置し、加圧、加熱して複数本の強化繊維束を含む織物基材に付着している樹脂材料を溶融して繊維間及び成形原反材の層間を接着する賦形成形方法において、賦形をする成形型を溶融温度に昇温する工程と、成形型の所要部位にインサート部品をインサ−トする工程と、積層成形材を予熱して成形型へ投入配置する予熱工程と、成形型を型締し加圧する工程と、成形型を固化温度に冷却して型を開き離型する工程とを有することを特徴とする賦形成形方法。 A laminated molding material obtained by cutting and laminating a molding raw material having a resin material mainly composed of a thermoplastic resin attached to at least one surface of a woven fabric substrate including a plurality of reinforcing fiber bundles is placed in a molding die. In the forming method in which pressure is applied and heated to melt the resin material adhering to the textile substrate including a plurality of reinforcing fiber bundles to bond the fibers and the layers of the forming raw material, The step of raising the mold to be melted to the melting temperature, the step of inserting the insert part into the required part of the mold, the preheating step of preheating the laminated molding material and placing it in the mold, and the mold A forming method comprising: a step of tightening and pressurizing; and a step of cooling the mold to a solidification temperature to open and release the mold. 複数本の強化繊維束を含む織物基材の少なくとも一方の表面に熱可塑性樹脂を主成分とする樹脂材料が付着された成形原反材を裁断し積層した積層成形材を成形型に投入配置し、加圧、加熱して複数本の強化繊維束を含む織物基材に付着している樹脂材料を溶融して繊維間及び成形原反材の層間を接着する賦形成形方法において、賦形をする成形型を溶融温度に昇温する工程と、積層成形材を予熱して成形型へ投入配置する予熱工程と、成形型を型締し加圧する工程と、成形型を固化温度に冷却して型を開き離型する工程と、を行い平板形状の平板積層成形品を成形する工程と、前記平板積層成形品を所定の形状に裁断する工程と、賦形をする成形型を溶融温度に昇温する工程と、前記成形型の所要部位にインサート部品をインサ−トする工程と、前記平板積層成形品を予熱して成形型へ投入配置する予熱工程と、成形型を型締し加圧する工程と、成形型を固化温度に冷却して型を開き離型する工程とを有することを特徴とする賦形成形方法。 A laminated molding material obtained by cutting and laminating a molding raw material having a resin material mainly composed of a thermoplastic resin attached to at least one surface of a woven fabric substrate including a plurality of reinforcing fiber bundles is placed in a molding die. In the forming method in which pressure is applied and heated to melt the resin material adhering to the textile substrate including a plurality of reinforcing fiber bundles to bond the fibers and the layers of the forming raw material, A step of raising the temperature of the mold to be melted, a preheating step of preheating the laminated molding material and placing it in the mold, a step of clamping and pressurizing the mold, and cooling the mold to the solidification temperature. A step of opening and releasing the mold to form a flat plate-shaped flat laminate molded product, a step of cutting the flat plate laminated molded product into a predetermined shape, and a forming mold to be heated to a melting temperature. The process of inserting and insert parts into the required part of the mold A preheating step of preheating the flat laminated molded product and placing it in the mold, a step of clamping and pressurizing the mold, and a step of cooling the mold to the solidification temperature and opening and releasing the mold. A forming method characterized by comprising: インサート部品が織物基材と積層する熱可塑性樹脂と同一の熱可塑性樹脂部品である請求項１又は請求項２に記載の賦形成形方法。   The forming method according to claim 1 or 2, wherein the insert part is the same thermoplastic resin part as the thermoplastic resin laminated with the textile substrate. インサート部品が穴付き板金である請求項１又は請求項２に記載の賦形成形方法。   The forming method according to claim 1 or 2, wherein the insert part is a sheet metal with a hole. インサート部品が樹脂フイルムである請求項１又は請求項２に記載の賦形成形方法。   The forming method according to claim 1 or 2, wherein the insert part is a resin film. 強化繊維束が炭素繊維束であることを特徴とする請求項１〜請求項５のいずれか一に記載の賦形成形方法。 The forming method according to any one of claims 1 to 5, wherein the reinforcing fiber bundle is a carbon fiber bundle. 成形型が製品部型と、製品部型の背面に蓄熱盤を備え、製品部型のヒ−タ−と、蓄熱盤からの熱伝導で製品部型の型温を昇温させることを特徴とする請求項１〜請求項６のいずれか一に記載の賦形成形方法。 The mold has a product part mold and a heat storage panel on the back of the product part mold. The product part heater and the heat conduction from the heat storage panel increase the temperature of the product part mold. The shaping method according to any one of claims 1 to 6. 成形型の冷却が水冷であり、成形型の冷却後にエア−で水を抜き取り、成形型の昇温を開始することを特徴とする請求項１〜請求項７のいずれか一に記載の賦形成形方法。 8. The forming according to claim 1, wherein the cooling of the mold is water cooling, and water is extracted by air after the mold is cooled, and the temperature rise of the mold is started. Shape method. 積層成形材又は平板積層成形品を予熱すると共に予成型した後に成形型へ投入配置することを特徴とする請求項１〜請求項８のいずれか一に記載の賦形成形方法。 9. The forming method according to any one of claims 1 to 8, wherein the laminate molding material or the flat laminate molded article is preheated and placed in a molding die after preforming. 予熱工程を、予熱対象を近赤外線放射装置から放射される近赤外線で加熱し、遠赤外線温度センサ−で前記予熱対象の温度を検知し、近赤外線の強度を調整して前記予熱対象を所定の温度に昇温させ設定温度で安定させる工程であり、前記近赤外線の強度の調整を近赤外線放射装置への通電圧の連続降下で行う請求項１〜請求項９のいずれか一に記載の賦形成形方法。。
In the preheating step, the preheating target is heated by near infrared radiation emitted from a near infrared radiation device, the temperature of the preheating target is detected by a far infrared temperature sensor, the intensity of near infrared light is adjusted, and the preheating target is adjusted to a predetermined temperature. The step according to any one of claims 1 to 9, wherein the temperature is raised to a temperature and stabilized at a set temperature, and the intensity of the near infrared ray is adjusted by a continuous drop of a conduction voltage to the near infrared radiation device. Forming method. .
近赤外線の強度の調整を近赤外線放射装置への通電圧の連続降下で行って予熱対象を所定の温度に昇温させることを特徴とする請求項１０記載の賦形成形方法。
11. The forming method according to claim 10, wherein the near-infrared intensity is adjusted by a continuous drop in the voltage applied to the near-infrared radiation device to raise the temperature of the preheating target to a predetermined temperature.
積層成形材又は平板積層成形品を熱盤上に炭素繊維面を下向きとして配置して加熱することを特徴とする請求項１０又は請求項１１記載の賦形成形方法。
12. The forming method according to claim 10 or 11, wherein the laminate molding or the flat laminate molded article is heated on a heating plate with the carbon fiber surface facing downward.
熱盤上に配置した積層成形材又は平板積層成形品を溶融させて耐熱部材で押圧して繊維間及び成形原反材の層間を溶融接着させ、その後耐熱部材を取り外す工程を含む請求項１０〜請求項１２のいずれか一記載の賦形成形方法。 The method includes the steps of melting a laminated molding material or a flat laminate molded article disposed on a heating plate, pressing the heat-resistant member to melt and bond between the fibers and the interlayer of the molding raw material, and then removing the heat-resistant member. The shaping method according to claim 12. 上部型と下部型とよりなる成形型によって積層成形材又は平板積層成形品を圧縮する工程を有し、下部型のブロックとこれに対抗する対抗型で挟みながら積層成形材を圧縮成形することを特徴とする請求項１〜請求項１３のいずれか一記載の賦形成形方法。 It has a step of compressing a laminated molded material or a flat plate molded product by a molding die composed of an upper mold and a lower mold, and compression molding the laminated molded material while sandwiching it between a block of the lower mold and a counter mold opposed thereto. The shaping method according to any one of claims 1 to 13, characterized in that: 上部型のブロックと下部型のブロックとによって積層成形材又は平板積層成形品を挟持する工程と、上部型のブロックと下部型のブロックとによって挟持した積層成形材又は平板積層成形品を凹型へ移動して積層成形材又は平板積層成形品を絞り変形させる工程を有することを特徴とする請求項１４記載の賦形成形方法。 The process of sandwiching the laminated molded material or flat plate molded product between the upper mold block and the lower mold block, and moving the laminated molded material or flat plate molded product sandwiched between the upper mold block and the lower mold block to the concave mold The forming method according to claim 14, further comprising a step of drawing and deforming the laminated molded material or the flat laminated molded product. 上部型のブロックを下降し、下部型のブロックを押し上げて積層体を挟持する請求項１４又は請求項１５記載の賦形成形方法。





The forming method according to claim 14 or 15, wherein the upper die block is lowered and the lower die block is pushed up to sandwich the laminate.

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