JP2020142478A - Molding method - Google Patents
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Abstract
Description
本発明は、成形方法に関する。 The present invention relates to a molding method.
下記特許文献１には、複合材料の補剛材を製造する方法が開示されている。この製造方法では、繊維プレートより形成された複数の構成部材同士を縫合した後に、トランスファー成形によって樹脂を含浸させて成形する。 Patent Document 1 below discloses a method for producing a stiffener of a composite material. In this manufacturing method, a plurality of constituent members formed from a fiber plate are sewn together and then impregnated with a resin by transfer molding.
しかしながら、特許文献１に開示された構成では、複雑な製品形状を作成する場合は、複数の構成部材を繋ぎ合わせて形成することになる。したがって、製品の繊維基材の繊維が各構成部材にて連続しない構成のため、製品自体の剛性が低下する可能性がある。したがって、上記先行技術はこの点で改良の余地がある。 However, in the configuration disclosed in Patent Document 1, when creating a complicated product shape, a plurality of constituent members are joined together to form the product. Therefore, since the fibers of the fiber base material of the product are not continuous in each component, the rigidity of the product itself may decrease. Therefore, the above prior art has room for improvement in this respect.
本発明は上記事実を考慮し、製品の剛性を低下させることなく成形することができる成形方法を得ることを目的とする。 In consideration of the above facts, an object of the present invention is to obtain a molding method capable of molding without lowering the rigidity of the product.
請求項１に記載の発明に係る成形方法は、繊維基材を製品の展開形状に形成する工程及び前記繊維基材における折り曲げ部に縫い目を設ける工程のいずれか一方をとる第１工程と、前記繊維基材を製品の展開形状に形成する工程及び前記繊維基材における折り曲げ部に縫い目を設ける工程のいずれか他方をとる第２工程と、前記製品の形状に対応した成形型内に前記繊維基材を投入して前記折り曲げ部の縫い目に沿って折り曲げると共に、母材樹脂を前記繊維基材と共に前記製品形状に成形する第３工程と、を有している。 The molding method according to the invention according to claim 1 includes a first step of forming either a step of forming a fiber base material into a developed shape of a product and a step of providing a seam at a bent portion of the fiber base material, and the step of providing a seam. The second step of forming the fiber base material into the developed shape of the product and the step of providing a seam at the bent portion of the fiber base material, and the fiber base in a molding mold corresponding to the shape of the product. It has a third step of feeding a material and bending it along a seam of the bent portion, and forming a base material resin together with the fiber base material into the product shape.
請求項１に記載の発明によれば、本発明の成形方法は、第１工程と第２工程と第３工程とからなり、第１工程及び第２工程のいずれか一方では、繊維基材を製品の展開形状に形成する。つまり、展開形状において、繊維基材の繊維が切断されていない連続的な状態となる。また、第１工程及び第２工程のいずれか他方では、繊維基材における折り曲げ部に縫い目を設ける。したがって、繊維基材の繊維を切断することなく繊維基材を容易に折り曲げることができる。第３工程は、繊維基材を製品の形状に対応した成形型内に繊維基材を投入して折り曲げ部の縫い目に沿って折り曲げて、母材樹脂を繊維基材と共に製品形状に成形する。したがって、繊維基材の繊維の連続性を維持したまま製品が形成されることから、製品の剛性の低下を抑制することができる。 According to the invention of claim 1, the molding method of the present invention comprises a first step, a second step, and a third step, and one of the first step and the second step comprises a fiber base material. Form into the unfolded shape of the product. That is, in the developed shape, the fibers of the fiber base material are in a continuous state in which the fibers are not cut. Further, in either the first step or the second step, a seam is provided at the bent portion of the fiber base material. Therefore, the fiber base material can be easily bent without cutting the fibers of the fiber base material. In the third step, the fiber base material is put into a molding mold corresponding to the shape of the product, bent along the seam of the bent portion, and the base resin is molded into the product shape together with the fiber base material. Therefore, since the product is formed while maintaining the continuity of the fibers of the fiber base material, it is possible to suppress a decrease in the rigidity of the product.
請求項１記載の本発明に係る成形方法は、製品の剛性を低下させることなく成形することができる成形方法を得ることができるという優れた効果を有する。 The molding method according to the present invention according to claim 1 has an excellent effect that a molding method capable of molding without lowering the rigidity of the product can be obtained.
以下、図１〜図６を用いて、本発明に係る成形方法の一実施形態について説明する。 Hereinafter, an embodiment of the molding method according to the present invention will be described with reference to FIGS. 1 to 6.
なお、以下の説明では、各図に示す矢印Ｘを製品前方向、矢印Ｙを製品幅方向一方側（右側）、矢印Ｚを製品上方向として説明する。また、特記なく前後、上下、幅（左右）という語を用いる場合は、製品前後方向の前後、製品上下方向の上下、製品幅方向（左右方向）の幅（左右）を示すものとする。これらの方向は、製品１０の使用状態での方向とは無関係である。また、各図においては、図面を見易くする意図で、一部の符号を省略している場合がある。 In the following description, the arrow X shown in each figure will be described as the product front direction, the arrow Y as the product width direction on one side (right side), and the arrow Z as the product upward direction. In addition, when the terms front-back, top-down, and width (left-right) are used without special mention, they shall indicate front-back in the front-back direction of the product, up-down in the up-down direction of the product, and width (left-right) in the width direction of the product (left-right direction). These directions are independent of the direction in which the product 10 is used. Further, in each drawing, some reference numerals may be omitted for the purpose of making the drawings easier to see.
（繊維基材）
図１に示されるように、繊維基材１２は、一例として、様々な方向に延設された複数の図示しない炭素繊維が織り込まれたシート状の部材とされている。この繊維基材１２は、上側の一面が開放された箱型形状の製品１０（図２参照）を平面状に展開した状態に形成されている。すなわち、繊維基材１２は、底壁部１４と、第１側壁部１６と、第２側壁部１８と、第３側壁部２０と、第４側壁部２２とを有している。底壁部１４は、製品１０（図２参照）の底部を構成する壁部であり、Ｙ方向を長手方向とする矩形状に形成されている。
(Fiber base material)
As shown in FIG. 1, as an example, the fiber base material 12 is a sheet-like member woven with a plurality of carbon fibers (not shown) extending in various directions. The fiber base material 12 is formed in a state in which a box-shaped product 10 (see FIG. 2) having an open upper surface is developed in a plane shape. That is, the fiber base material 12 has a bottom wall portion 14, a first side wall portion 16, a second side wall portion 18, a third side wall portion 20, and a fourth side wall portion 22. The bottom wall portion 14 is a wall portion that constitutes the bottom portion of the product 10 (see FIG. 2), and is formed in a rectangular shape with the Y direction as the longitudinal direction.
第１側壁部１６は、底壁部１４の前方側に設けられており、底壁部１４と同様にＹ方向を長手方向とする矩形状に形成されている。第１側壁部１６と底壁部１４とは、後述する折り曲げ部２４を挟んでＸ方向に隣接されている。なお、第１側壁部１６のＹ方向の端部１６Ａ、１６Ｂには、それぞれ接合片２８が一体的に形成されている。この接合片２８は、後述する折り曲げ部３０を挟んで第１側壁部１６とＹ方向にて隣接されている。 The first side wall portion 16 is provided on the front side of the bottom wall portion 14, and is formed in a rectangular shape with the Y direction as the longitudinal direction like the bottom wall portion 14. The first side wall portion 16 and the bottom wall portion 14 are adjacent to each other in the X direction with the bent portion 24 described later interposed therebetween. The joint pieces 28 are integrally formed at the ends 16A and 16B of the first side wall portion 16 in the Y direction. The joint piece 28 is adjacent to the first side wall portion 16 in the Y direction with the bent portion 30 described later interposed therebetween.
第２側壁部１８は、製品１０にて第１側壁部１６と前後方向にて対向して設けられている（図２参照）。すなわち、第２側壁部１８は、底壁部１４の後方側に設けられており、底壁部１４と略同様にＹ方向を長手方向とする形状にいる。第２側壁部１８と底壁部１４とは、後述する折り曲げ部３２を挟んでＸ方向に隣接されている。なお、第２側壁部１８のＹ方向の端部１８Ａ、１８Ｂには、第１側壁部１６と同様に、それぞれ接合片３６が一体的に形成されている。この接合片３６は、後述する折り曲げ部３８を挟んで第２側壁部１８とＹ方向にて隣接されている。 The second side wall portion 18 is provided in the product 10 so as to face the first side wall portion 16 in the front-rear direction (see FIG. 2). That is, the second side wall portion 18 is provided on the rear side of the bottom wall portion 14, and has a shape in which the Y direction is the longitudinal direction substantially like the bottom wall portion 14. The second side wall portion 18 and the bottom wall portion 14 are adjacent to each other in the X direction with the bent portion 32 described later interposed therebetween. Similar to the first side wall portion 16, joint pieces 36 are integrally formed at the ends 18A and 18B of the second side wall portion 18 in the Y direction. The joint piece 36 is adjacent to the second side wall portion 18 in the Y direction with the bent portion 38 described later interposed therebetween.
第３側壁部２０は、底壁部１４の右側に設けられており、略方形状に形成されている。第３側壁部２０と底壁部１４とは、後述する折り曲げ部４０を挟んでＹ方向に隣接されている。なお、第３側壁部２０は、一例として、Ｙ方向の寸法が第１側壁部１６及び第２側壁部１８のＸ方向の寸法と略同一に設定されている。 The third side wall portion 20 is provided on the right side of the bottom wall portion 14, and is formed in a substantially rectangular shape. The third side wall portion 20 and the bottom wall portion 14 are adjacent to each other in the Y direction with the bent portion 40 described later interposed therebetween. As an example, the dimensions of the third side wall portion 20 in the Y direction are set to be substantially the same as the dimensions of the first side wall portion 16 and the second side wall portion 18 in the X direction.
第４側壁部２２は、製品１０にて第３側壁部２０と左右方向にて対向して設けられている（図２参照）。すなわち、第４側壁部２２は、底壁部１４の左側に設けられており、第３側壁部２０と同様に、略方形状に形成されている。第４側壁部２２と底壁部１４とは、後述する折り曲げ部４５を挟んでＹ方向に隣接されている。なお、第４側壁部２２は、一例として、Ｙ方向の寸法が第１側壁部１６及び第２側壁部１８のＸ方向の寸法と略同一に設定されている。 The fourth side wall portion 22 is provided in the product 10 so as to face the third side wall portion 20 in the left-right direction (see FIG. 2). That is, the fourth side wall portion 22 is provided on the left side of the bottom wall portion 14, and is formed in a substantially rectangular shape like the third side wall portion 20. The fourth side wall portion 22 and the bottom wall portion 14 are adjacent to each other in the Y direction with the bent portion 45 described later interposed therebetween. As an example, the dimensions of the fourth side wall portion 22 in the Y direction are set to be substantially the same as the dimensions of the first side wall portion 16 and the second side wall portion 18 in the X direction.
上述の折り曲げ部２４、３０、３２、３８、４０、４５、４５は、それぞれ略直線状に形成されていると共に図示しない縫い目が設けられている。この縫い目は、折り曲げ部２４、３０、３２、３８、４０、４５の延設方向に沿ってそれぞれ設けられている。 The bent portions 24, 30, 32, 38, 40, 45, and 45 are each formed in a substantially linear shape and are provided with seams (not shown). The seams are provided along the extending directions of the bent portions 24, 30, 32, 38, 40, and 45, respectively.
次に、製品１０の成形方法について説明する。 Next, the molding method of the product 10 will be described.
（第１工程）
シート状の繊維基材１２は、製品１０の展開形状に形成されたトムソン刃を有する打ち抜き型（いずれも不図示）によって打ち抜かれることで、製品１０の展開形状に形成される。なお、この工程が請求項１に記載の「第１工程」に相当する。
(First step)
The sheet-shaped fiber base material 12 is formed into the developed shape of the product 10 by punching with a punching die having a Thomson blade (all not shown) formed in the developed shape of the product 10. This step corresponds to the "first step" according to claim 1.
（第２工程）
製品１０の展開形状に打ち抜かれた繊維基材１２は、折り曲げ部２４、３０、３２、３８、４０、４５に縫い目が設けられる。これにより、底壁部１４に対して第１側壁部１６、第２側壁部１８、第３側壁部２０及び第４側壁部２２が底壁部１４と一体のまま折り曲り易くなる。同様に、接合片２８、３６がそれぞれ第１側壁部１６又は第２側壁部１８と一体のまま折り曲げ易くなる。なお、この工程が請求項１に記載の「第２工程」に相当する。また、接合片２８、３６が折り曲げられた状態では、それぞれ第３側壁部２０、第４側壁部２０の内側面に当接するように折り曲げられる（図２参照）。
(Second step)
The fiber base material 12 punched into the developed shape of the product 10 is provided with seams at the bent portions 24, 30, 32, 38, 40, and 45. As a result, the first side wall portion 16, the second side wall portion 18, the third side wall portion 20, and the fourth side wall portion 22 can be easily bent with respect to the bottom wall portion 14 while being integrated with the bottom wall portion 14. Similarly, the joint pieces 28 and 36 can be easily bent while being integrated with the first side wall portion 16 or the second side wall portion 18, respectively. This step corresponds to the "second step" according to claim 1. Further, when the joint pieces 28 and 36 are bent, they are bent so as to abut on the inner side surfaces of the third side wall portion 20 and the fourth side wall portion 20, respectively (see FIG. 2).
（第３工程）
図３に示されるように、製品１０の形状に対応した成形型４２における雌型４２Ａ内に第２工程にて縫い目が設けられた繊維基材１２を投入する。この際に、雌型４２Ａの型内の形状に沿って繊維基材１２を折り曲げ部２４、３０、３２、３８、４０、４５の縫い目に沿って折り曲げることで、雌型４２Ａ内に沿うように繊維基材１２が投入される。
(Third step)
As shown in FIG. 3, the fiber base material 12 provided with the seam in the second step is put into the female mold 42A in the molding mold 42 corresponding to the shape of the product 10. At this time, the fiber base material 12 is bent along the seams of the bent portions 24, 30, 32, 38, 40, and 45 along the shape inside the female mold 42A so as to follow the inside of the female mold 42A. The fiber base material 12 is charged.
図４に示されるように、成形型４２における雌型４２Ａ内に繊維基材１２を投入した後、雄型４２Ｂと雌型４２Ａとを型締めし、雌型４２Ａと雄型４２Ｂとの間の空間にゲート４２ＢＡから母材樹脂４８及び硬化剤５０が射出される。これにより、予め雌型４２Ａ内に投入されていた繊維基材１２に母材樹脂４８が部分的に含浸される。 As shown in FIG. 4, after the fiber base material 12 is put into the female mold 42A of the molding mold 42, the male mold 42B and the female mold 42A are molded, and between the female mold 42A and the male mold 42B. The base resin 48 and the curing agent 50 are injected into the space from the gate 42BA. As a result, the base material resin 48 is partially impregnated into the fiber base material 12 that has been previously charged into the female mold 42A.
図５に示されるように、母材樹脂４８及び硬化剤５０が成形型４２内に射出された後、雄型４２Ｂを雌型４２Ａ側へさらに移動させることで、成形型４２内の母材樹脂４８を繊維基材１２全体に含浸させると共に、製品１０の形状にて硬化が促進される。これにより、繊維基材１２及び母材樹脂４８が製品１０の形状に成形される。なお、この工程が請求項１に記載の「第３工程」に相当する。 As shown in FIG. 5, after the base material resin 48 and the curing agent 50 are injected into the mold 42, the male mold 42B is further moved to the female mold 42A side, so that the base material resin in the mold 42 is further moved. The entire fiber base material 12 is impregnated with 48, and curing is promoted in the shape of the product 10. As a result, the fiber base material 12 and the base material resin 48 are formed into the shape of the product 10. This step corresponds to the "third step" according to claim 1.
図６に示されるように、成形型４２を開くことで、第３工程にて製品１０の形状に形成された繊維基材１２及び母材樹脂４８を成形型４２内から取り出すことができる。 As shown in FIG. 6, by opening the molding die 42, the fiber base material 12 and the base material resin 48 formed in the shape of the product 10 in the third step can be taken out from the molding die 42.
（作用・効果）
次に、本実施形態の作用並びに効果を説明する。
(Action / effect)
Next, the action and effect of this embodiment will be described.
本実施形態では、第１工程と第２工程と第３工程とからなり、第１工程は、図１に示されるように、繊維基材１２を製品１０（図２参照）の展開形状に形成する。つまり、展開形状において、繊維基材１２の繊維が切断されていない連続的な状態となる。第２工程は、繊維基材１２における折り曲げ部２４、３０、３２、３８、４０、４５に縫い目を設ける。したがって、繊維基材１２の繊維を切断することなく繊維基材１２を容易に折り曲げることができる。つまり、繊維基材１２を容易に成形型４２内にセットすることができる。また、第３工程は、図３に示されるように、繊維基材１２を製品１０の形状に対応した成形型４２内に繊維基材１２を投入して折り曲げ部２４、３０、３２、３８、４０、４５の縫い目に沿って折り曲げて、図４、図５に示されるように、母材樹脂４８を繊維基材１２と共に製品形状に成形する。したがって、繊維基材１２の繊維の連続性を維持したまま製品が形成されることから、製品１０の剛性の低下を抑制することができる。つまり、本実施形態の成形方法では、製品１０の剛性を低下させることなく成形することができる。 In the present embodiment, the first step, the second step, and the third step are composed, and in the first step, the fiber base material 12 is formed into the developed shape of the product 10 (see FIG. 2) as shown in FIG. To do. That is, in the developed shape, the fibers of the fiber base material 12 are in a continuous state in which they are not cut. In the second step, seams are provided at the bent portions 24, 30, 32, 38, 40, and 45 of the fiber base material 12. Therefore, the fiber base material 12 can be easily bent without cutting the fibers of the fiber base material 12. That is, the fiber base material 12 can be easily set in the molding die 42. Further, in the third step, as shown in FIG. 3, the fiber base material 12 is put into the molding die 42 corresponding to the shape of the product 10, and the bent parts 24, 30, 32, 38, It is bent along the seams of 40 and 45, and the base material resin 48 is formed into a product shape together with the fiber base material 12 as shown in FIGS. 4 and 5. Therefore, since the product is formed while maintaining the continuity of the fibers of the fiber base material 12, it is possible to suppress a decrease in the rigidity of the product 10. That is, in the molding method of the present embodiment, the product 10 can be molded without reducing the rigidity.
また、一つの繊維基材１２から製品１０を成形することから、複数の繊維基材１２を設けてそれぞれの繊維基材１２同士を接合する工程が不要となる。つまり、構成部材を削減できるので、コストを低減することができると共に、工数も削減することができる。 Further, since the product 10 is molded from one fiber base material 12, the step of providing a plurality of fiber base materials 12 and joining the respective fiber base materials 12 to each other becomes unnecessary. That is, since the number of constituent members can be reduced, the cost can be reduced and the man-hours can be reduced.
なお、本実施形態では、繊維基材１２が炭素繊維が織り込まれた構成とされているが、これに限らず、ガラス繊維等その他の繊維により構成されてもよい。 In the present embodiment, the fiber base material 12 is configured to be woven with carbon fibers, but the present invention is not limited to this, and may be composed of other fibers such as glass fibers.
また、第一工程が繊維基材１２を製品１０（図２参照）の展開形状に形成し、第二工程が繊維基材１２における折り曲げ部２４、３０、３２、３８、４０、４５に縫い目を設ける工程とされているが、これに限らず、第一工程が繊維基材１２における折り曲げ部２４、３０、３２、３８、４０、４５に縫い目を設ける工程とし、第二工程が繊維基材１２を製品１０の展開形状に形成する工程としてもよい。 Further, in the first step, the fiber base material 12 is formed into the developed shape of the product 10 (see FIG. 2), and in the second step, seams are made on the bent portions 24, 30, 32, 38, 40, 45 of the fiber base material 12. The step is not limited to this, but the first step is a step of providing seams on the bent portions 24, 30, 32, 38, 40, 45 of the fiber base material 12, and the second step is the fiber base material 12. May be a step of forming the developed shape of the product 10.
以上、本発明の実施形態について説明したが、本発明は、上記に限定されるものでなく、その主旨を逸脱しない範囲内において上記以外にも種々変形して実施することが可能であることは勿論である。 Although the embodiments of the present invention have been described above, the present invention is not limited to the above, and it is possible to carry out various modifications other than the above within a range not deviating from the gist thereof. Of course.
１０ 製品
１２ 繊維基材
２４ 折り曲げ部
３０ 折り曲げ部
３２ 折り曲げ部
３８ 折り曲げ部
４０ 折り曲げ部
４２ 成形型
４５ 折り曲げ部
４８ 母材樹脂
10 Product 12 Fiber base material 24 Bending part 30 Bending part 32 Bending part 38 Bending part 40 Bending part 42 Molding mold 45 Bending part 48 Base material resin
Claims (1)
前記繊維基材を製品の展開形状に形成する工程及び前記繊維基材における折り曲げ部に縫い目を設ける工程のいずれか他方をとる第２工程と、
前記製品の形状に対応した成形型内に前記繊維基材を投入して前記折り曲げ部の縫い目に沿って折り曲げると共に、母材樹脂を前記繊維基材と共に前記製品形状に成形する第３工程と、
を有する成形方法。 The first step of forming the fiber base material into the developed shape of the product and the step of providing a seam at the bent portion of the fiber base material, and the first step.
A second step of forming the fiber base material into the developed shape of the product and a step of providing a seam at the bent portion of the fiber base material, whichever is the other.
A third step of putting the fiber base material into a molding mold corresponding to the shape of the product, bending the fiber base material along the seam of the bent portion, and molding the base resin together with the fiber base material into the product shape.
Molding method having.
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|---|---|---|---|---|
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| JP2016182776A (en) * | 2015-03-26 | 2016-10-20 | 本田技研工業株式会社 | RTM molding method |
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| JPS4930452A (en) * | 1972-07-19 | 1974-03-18 | ||
| JPH04232008A (en) * | 1990-05-29 | 1992-08-20 | United Technol Corp <Utc> | Manufacture of conductive composite material product |
| JP2004506799A (en) * | 2000-08-22 | 2004-03-04 | サイテク・テクノロジー・コーポレーシヨン | Flexible polymer elements as toughening agents in prepregs |
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| JP2016182776A (en) * | 2015-03-26 | 2016-10-20 | 本田技研工業株式会社 | RTM molding method |
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