JP5799522B2 - Manufacturing method of resin molding - Google Patents
Manufacturing method of resin molding Download PDFInfo
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Description
本発明は、成形部品等の成形体を樹脂成形により作製する樹脂成形体の製造方法に関する。 The present invention relates to a method for manufacturing a resin molded body in which a molded body such as a molded part is produced by resin molding.
従来から樹脂を用いた成形体は汎用されているが、その成形方法としては、射出成形による方法が主流となっている。 Conventionally, a molded body using a resin has been widely used, but as a molding method, a method by injection molding has become mainstream.
ところが、射出成形では、大規模な設備と高価な型が必要となるのみならず、成形する際の型温度が高いために、型を成形可能な高温に上昇させたり、成形後の成形品の温度を降下させるために、ある程度の時間を要し、サイクルタイムが長いというのが現状である。 However, injection molding requires not only large-scale equipment and expensive molds, but also because the mold temperature during molding is high, the mold can be raised to a moldable high temperature, In order to lower the temperature, a certain amount of time is required and the cycle time is long.
また、成形に使用する樹脂材料の流通は、一般にチップ材であるため、成形には予めチップ材を溶解しなければならず、そのために溶解炉は不可欠な設備とされている。 Moreover, since the distribution of the resin material used for molding is generally a chip material, the chip material must be melted in advance for molding, and for this reason, a melting furnace is an indispensable facility.
一方、性能面からみると、ポリプロピレンやポリアミドなどの樹脂は、それのみでは強度が低いため、ある程度の強度を持たせるためには、ガラス繊維等などの強化材を用いる必要があるが、ガラス繊維などを混合しようとすると、成形が困難になる。 On the other hand, from the viewpoint of performance, resins such as polypropylene and polyamide have low strength by themselves, and in order to give a certain level of strength, it is necessary to use a reinforcing material such as glass fiber. If it tries to mix etc., shaping | molding will become difficult.
上記のような事情から、例えば自動車のボディ等や航空機などの比較的高い強度が求められる用途には、熱硬化性の炭素繊維強化プラスチック（ＣＦＲＰ）等を用い高温の成形型で成形するといった方法が適用され成形されるに留まっていた。しかしながら、このような繊維強化プラスチックは一般に高価であるため、製造コストが高くなるほか、成形に長時間を要するために少量生産にしか向かないというのが実情である。 Due to the above circumstances, for example, a method in which a thermosetting carbon fiber reinforced plastic (CFRP) or the like is used and molded with a high-temperature mold for applications that require relatively high strength such as an automobile body or an aircraft. Applied and molded. However, since such fiber reinforced plastics are generally expensive, the manufacturing cost is high, and it takes a long time for molding, so that it is suitable only for low-volume production.
このような状況に関連する技術として、植物性繊維と熱可塑性樹脂を含む材料からなる板状体を、加熱炉の内部で吊り下げた状態で搬送しながら加熱し、加熱された板状体を加熱炉の内部に設置された予備成形装置で予備成形した後、本成形する基材成形装置が開示されている（例えば、特許文献１参照）。 As a technology related to such a situation, a plate-like body made of a material containing vegetable fibers and a thermoplastic resin is heated while being transported in a state suspended in a heating furnace, and the heated plate-like body is There is disclosed a base material molding apparatus for performing a main molding after preforming with a preforming apparatus installed inside a heating furnace (see, for example, Patent Document 1).
また、ポリオレフィン系樹脂繊維を混合したマット状の木質系繊維板などを所定温度に加熱軟化させた後、コールドプレス成形して自動車内装用芯材を作製する方法等が開示されている（例えば、特許文献２参照）。 Also disclosed is a method for producing a core material for automobile interior by cold press molding after heating and softening a mat-like wood fiberboard mixed with polyolefin resin fibers to a predetermined temperature (for example, Patent Document 2).
上記従来の熱硬化性の繊維強化プラスチックに比べ、熱可塑性の樹脂材料を用いることにより、低コスト化及びリサイクル化に寄与し、成形サイクルの短縮が期待されるものの、上記した従来の技術による成形方法では、成形体の強度を高めるために繊維材料等を用いた場合に、成形性を良好に維持することができない課題がある。 Compared to the conventional thermosetting fiber reinforced plastic, the use of a thermoplastic resin material contributes to cost reduction and recycling, and is expected to shorten the molding cycle. In the method, when a fiber material or the like is used to increase the strength of the molded body, there is a problem that the moldability cannot be maintained satisfactorily.
本発明は、上記に鑑みなされたものであり、繊維材料を含んで強度を高めた成形体の成形性に優れ、従来に比べて成形時間の短縮が図られた樹脂成形体の製造方法を提供することを目的とし、該目的を達成することを課題とする。 The present invention has been made in view of the above, and provides a method for producing a resin molded body that is excellent in moldability of a molded body that includes a fiber material and has increased strength, and that has a shorter molding time than conventional ones. It is an object to achieve this purpose.
本発明は、繊維材料を含む熱可塑性樹脂のシート状やフィルム状等に加工された板状材料をプレス加工する場合に、厚みがほぼ一定の板状材料について、成形加工後に得られる成形品の樹脂体積が異なる領域毎に、成形加工前の板状材料の該領域の各々に対応する部分の体積を見積もり、該体積に見合う形状を選択する、すなわち成形品のある領域の体積と成形加工前の板状材料の該領域に対応する部分の体積とを等しくすることで、プレス成形する際の成形性が向上するとの知見を得、該知見に基づいて達成されたものである。前記課題を達成するための具体的手段は以下の通りである。 In the present invention, when a plate-like material processed into a sheet or film of a thermoplastic resin containing a fiber material is pressed, a plate-like material having a substantially constant thickness is obtained after molding. For each region with a different resin volume, estimate the volume of the portion corresponding to each of the regions of the plate-like material before molding, and select a shape that matches the volume. The knowledge that the moldability at the time of press molding is improved by making the volume of the portion corresponding to the region of the plate-like material equal is obtained and achieved based on the knowledge. Specific means for achieving the above object are as follows.
上記目的を達成するために、本発明の樹脂成形体の製造方法は、
＜１＞ 繊維材料を含む熱可塑性樹脂の板状材料を、面積の異なる３以上の異形領域からなる形状に裁断する裁断工程と、裁断工程で裁断された板状材料を、熱可塑性樹脂の融点以上の温度にあらかじめ加熱する予備加熱工程と、予備加熱工程で加熱された板状材料を、前記融点未満の温度に保持された成形型にて加圧成形し、前記異形領域の境界に沿って（２以上の）折り曲げ部を有する成形体を成形する加圧成形工程とを設けて構成されたものである。
In order to achieve the above object, the method for producing a resin molded body of the present invention comprises:
<1> A cutting step of cutting a plate-like material of a thermoplastic resin containing a fiber material into a shape composed of three or more deformed regions having different areas, and a melting point of the thermoplastic resin of the plate-like material cut in the cutting step A preheating step for preheating to the above temperature, and a plate-like material heated in the preheating step is pressure-molded with a mold held at a temperature lower than the melting point, along the boundary of the deformed region And a pressure forming step of forming a formed body having a bent portion (two or more).
前記＜１＞に記載の本発明においては、特に２以上の折り曲げ部を有する成形体を成形する場合に、使用する板状材料（繊維材料及び熱可塑性樹脂を含む）を、成形しようとする成形体の各部位に対応させて面積の異なる複数の異形領域からなる形状に裁断することで、成形のための加熱や加圧を付与する前に、成形加工前の板状材料における複数の異形領域の各々において、その各体積を成形後の成形体の前記異形領域に対応する各部位の体積と等しくなるように調節するので、繊維材料を含みながら既存の比較的低い圧力でも、短い成形時間で良好な成形性が得られる。また、あらかじめ被成形物である板状材料を熱可塑性樹脂の融点以上に加熱しておき、これを該融点未満の温度の成形型にて加圧成形を行ない、加圧成形時に加熱を行なわないことで、成形と共に降温するので、成形体の温度降下が速く、成形加工速度が従来法に比べ飛躍的に高められる。これより、量産品の成形に適する。 In the present invention described in the above <1>, a plate-like material (including a fiber material and a thermoplastic resin) to be used is molded particularly when a molded body having two or more bent portions is molded. A plurality of deformed regions in the plate-like material before forming before applying heating or pressurization for forming by cutting into a shape consisting of a plurality of deformed regions having different areas corresponding to each part of the body In each of the above, the volume is adjusted so as to be equal to the volume of each part corresponding to the deformed region of the molded body after molding, so that even in the existing relatively low pressure while containing the fiber material, the molding time is short. Good moldability is obtained. In addition, the plate-like material that is the object to be molded is heated in advance to the melting point or higher of the thermoplastic resin, and this is pressure-molded with a molding die having a temperature lower than the melting point, and is not heated during the pressure molding. Thus, since the temperature is lowered together with the molding, the temperature drop of the molded body is fast, and the molding processing speed is dramatically increased as compared with the conventional method. This makes it suitable for mass-production products.
＜２＞ 前記＜１＞に記載の本発明において、裁断工程は、加圧成形工程で成形される成形体における樹脂体積の異同に基づいて、成形体における樹脂体積の異なる領域の各々に対応する前記異形領域を、前記樹脂体積の異なる各領域の体積と同一の体積となるように形成することによって好ましく行なうことができる。 <2> In the present invention described in <1>, the cutting step corresponds to each of the regions having different resin volumes in the molded body based on the difference in resin volume in the molded body molded in the pressure molding step. The deformed area can be preferably formed by forming the deformed area so as to have the same volume as that of each area having a different resin volume.
加圧成形工程で成形される成形体の各部位を形成する樹脂量からみて、樹脂体積が同じ部位と樹脂体積が異なる部位とに分け、樹脂体積の異同を基準にすると、裁断工程でより容易に異形領域を設定し形成することができる。 In terms of the amount of resin that forms each part of the molded body molded in the pressure molding process, it is easier to cut in the cutting process if the resin volume is divided into parts with the same resin volume and parts with different resin volumes. It is possible to set and form a deformed region.
＜３＞ 前記＜１＞又は前記＜２＞に記載の本発明において、裁断工程は、加圧成形工程で成形される成形体における、加圧成形工程での加圧の方向と交差する面を基準として成形体を複数の領域に分割し、分割された各領域に対応する前記異形領域を、分割された前記領域の各々の体積と同一の体積となるように形成するによって好ましく行なうことができる。 <3> In the present invention described in the above <1> or <2>, the cutting step includes a surface that intersects the direction of pressurization in the press molding step in the molded body molded in the press molding step. The molded body can be divided into a plurality of regions as a reference, and the deformed regions corresponding to the divided regions can be preferably formed so as to have the same volume as each of the divided regions. .
加圧成形の際に熱可塑性樹脂は同一平面内を容易に広がるが屈曲のある加圧の方向（例えば高さ方向）には広がり難いため、加圧成形工程で成形される成形体における加圧の方向と交差する面、例えば加圧の方向を成形体の高さ方向として捉えた場合、成形体の例えば最も高い位置の平面と最も低い位置の平面とこれらの中間に位置する平面とを基準として成形体を複数の領域に分割（具体的には、例えば最も高い位置の平面と最も低い位置の平面とこれら両者と連結し両者と直交する平面とからなる３面に分割）し、分割された面毎に樹脂体積が成形前後で等しくなるように異形領域を設定し形成することで、既存の比較的低い圧力で短い成形時間にて、より良好な成形性が得られる。 During pressure molding, the thermoplastic resin easily spreads in the same plane, but does not easily spread in the direction of pressure with bending (for example, the height direction). When the plane that intersects the direction of, for example, the direction of pressurization, is taken as the height direction of the molded body, for example, the plane of the highest position, the plane of the lowest position, and the plane positioned between them The molded body is divided into a plurality of regions (specifically, for example, divided into three planes composed of the highest plane, the lowest plane, and a plane perpendicular to both). By forming the deformed region so that the resin volume is equal before and after molding for each surface, better moldability can be obtained with a relatively low pressure and a short molding time.
＜４＞ 前記＜１＞〜前記＜３＞のいずれか１つに記載の本発明においては、裁断工程を複数回繰り返すことにより、面積の異なる複数の異形領域からなる形状に裁断された板状材料を複数作製し、作製された複数の板状材料を予備加熱工程で加熱後、これを加圧成形工程で単一の成形型に配して加圧成形し、単一の成形体を成形する態様が好ましい。 <4> In the present invention described in any one of the above items <1> to <3>, a plate shape cut into a shape composed of a plurality of deformed regions having different areas by repeating the cutting step a plurality of times. A plurality of materials are produced, and the produced plate-like materials are heated in a preheating process, and then placed in a single mold in a pressure molding process and then pressure molded to form a single molded body. This embodiment is preferable.
このように成形体の各部位に対応させて所望の形状に作製された複数の板状材料を単一の成形型に配置することで、一般に流通する所定サイズ（例えば３００ｍｍ〜５００ｍｍの正方形状）のシート状等の板状材料を用いて、例えば自動車のボディなどの大サイズの成形体を容易に成形することが可能である。 By arranging a plurality of plate-like materials produced in a desired shape corresponding to each part of the molded body in this manner in a single molding die, a predetermined size generally distributed (for example, a square shape of 300 mm to 500 mm) It is possible to easily form a large-sized molded body such as a body of an automobile, for example, using a sheet-like material such as a sheet.
＜５＞ 前記＜１＞〜前記＜４＞のいずれか１つに記載の本発明では、加圧成形工程において、成形型を、熱可塑性樹脂の融点−（５０〜１５０℃）の範囲の温度に保持して加圧成形を行なう場合が好ましい。 <5> In the present invention according to any one of <1> to <4>, in the pressure molding step, the mold is set to a temperature in the range of the melting point of the thermoplastic resin— (50 to 150 ° C.). It is preferable that the pressure molding is performed while being held.
本発明では、予備加熱工程で一旦熱可塑性樹脂が溶融するような温度にまで加熱されるため、成形時には成形と同時に降温するようにすることで、成形後に成形体を冷却する必要がなく、降温に要する時間の短縮が図れる。 In the present invention, since the thermoplastic resin is once heated to a temperature at which the thermoplastic resin melts in the preheating step, it is not necessary to cool the molded body after molding by lowering the temperature simultaneously with the molding. Can be shortened.
＜６＞ 前記＜１＞〜前記＜５＞のいずれか１つに記載の本発明においては、熱可塑性樹脂と共に含有される繊維材料として、ガラス繊維及び／又はカーボン繊維を好適に用いることができる。 <6> In the present invention according to any one of <1> to <5>, glass fiber and / or carbon fiber can be suitably used as the fiber material contained together with the thermoplastic resin. .
ガラス繊維やカーボン繊維を用いても、所望とする成形性を維持しながら、樹脂成形体の強度もより高めることが可能である。 Even if glass fiber or carbon fiber is used, it is possible to further increase the strength of the resin molding while maintaining the desired moldability.
本発明によれば、繊維材料を含んで強度を高めた成形体の成形性に優れ、従来に比べて成形時間の短縮が図られた樹脂成形体の製造方法を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the resin molding which was excellent in the moldability of the molded object which included the fiber material and improved the intensity | strength, and shortened molding time compared with the past can be provided.
以下、図面を参照して、本発明の樹脂成形体の製造方法の実施形態について詳細に説明する。なお、下記の実施形態において、繊維材料を含む熱可塑性樹脂の板状材料として、炭素繊維を含むポリアミド樹脂のシート材を用いて成形する場合を中心に説明する。但し、本発明においては下記の実施形態に制限されるものではない。 Hereinafter, an embodiment of a method for producing a resin molded body of the present invention will be described in detail with reference to the drawings. In the following embodiment, a case where molding is performed using a sheet material of a polyamide resin containing carbon fibers as a plate-like material of a thermoplastic resin containing a fiber material will be mainly described. However, the present invention is not limited to the following embodiment.
本発明の樹脂成形体の製造方法の実施形態を図１〜図２を参照して説明する。本実施形態は、炭素繊維を含むポリアミド樹脂のシート材を用意し、これを３つの異形領域からなる形状に裁断したものを用いて成形を行なう構成としたものである。 An embodiment of a method for producing a resin molded body of the present invention will be described with reference to FIGS. In the present embodiment, a polyamide resin sheet material containing carbon fibers is prepared, and the sheet is cut into a shape composed of three deformed regions, and molding is performed.
図１（Ａ）に示すように、まず所望サイズとして３００ｍｍ×３００ｍｍ×厚み５ｍｍサイズの炭素繊維を含むポリアミド樹脂シート１０を用意する。シート形態のポリアミド樹脂は、一般に流通されているものがあり、容易に市販のものを入手可能である。 As shown in FIG. 1A, first, a polyamide resin sheet 10 containing carbon fibers having a size of 300 mm × 300 mm × thickness 5 mm is prepared as a desired size. Some sheet-form polyamide resins are generally available, and commercially available ones are readily available.
本発明においては、シート材のマトリックスとして、ポリアミド樹脂であるナイロンなどを用いることができる。また、シート材のマトリックスの例としては、熱可塑性樹脂であれば特に制限されるものではなく、ポリアミド樹脂のほか、ポリオレフィン（例えば、高密度ポリエチレン、ポリプロピレン等）、スチレン系樹脂（例えば、ポリスチレン、スチレン・アクリロニトリル共重合体、スチレン・ブタジエン・アクリロニトリル共重合体等）、（メタ）アクリル系樹脂（例えばポリメチルメタクリレート等）、ポリウレタン系樹脂、ビニル系樹脂（例えば、ポリ塩化ビニリデン、ポリビニルアルコール等）などを挙げることができる。
なお、本発明の製造方法における成形性を大きく損なわない範囲であれば、熱硬化性の樹脂が含有されていてもよい。
In the present invention, nylon, which is a polyamide resin, can be used as the matrix of the sheet material. Further, examples of the matrix of the sheet material are not particularly limited as long as they are thermoplastic resins. In addition to polyamide resins, polyolefins (for example, high density polyethylene, polypropylene, etc.), styrene resins (for example, polystyrene, Styrene / acrylonitrile copolymer, styrene / butadiene / acrylonitrile copolymer, etc.), (meth) acrylic resin (for example, polymethyl methacrylate), polyurethane resin, vinyl resin (for example, polyvinylidene chloride, polyvinyl alcohol, etc.) And so on.
Note that a thermosetting resin may be contained as long as the moldability in the production method of the present invention is not significantly impaired.
また、シート材には、成形体の外力に対する強度を高める観点から、強化繊維として炭素繊維が含有されている。繊維材料の例としては、炭素繊維のほか、ガラス繊維などの無機繊維や無機フィラー等を含有することができる。 In addition, the sheet material contains carbon fibers as reinforcing fibers from the viewpoint of increasing the strength against external force of the molded body. As an example of the fiber material, in addition to carbon fibers, inorganic fibers such as glass fibers, inorganic fillers, and the like can be contained.
炭素繊維などの繊維材料の含有比率は、特に制限されるものではなく、所望とする成形体の強度に合わせて選択することができる。繊維材料の具体的な含有比率としては、成形体の強度の観点から、シート材のマトリックス（熱可塑性樹脂）に対して、５質量％以上７０質量％以下の範囲であることが好ましく、２０質量％以上５０質量％以下の範囲であることがより好ましい。 The content ratio of the fiber material such as carbon fiber is not particularly limited, and can be selected according to the desired strength of the molded body. The specific content ratio of the fiber material is preferably in the range of 5% by mass to 70% by mass with respect to the matrix (thermoplastic resin) of the sheet material from the viewpoint of the strength of the molded body, and is 20% by mass. More preferably, it is in the range of not less than 50% and not more than 50% by mass.
シート材のサイズについては、特に制限されるものではなく、成形体のサイズに合わせて適宜選択すればよい。例えば、成形体の１つの領域を３００ｍｍ〜５００ｍｍの正方領域で捉えてもよく、この場合には、シート材は３００ｍｍ〜５００ｍｍのサイズの正方形であることが好ましい。また、成形体のサイズが流通に適したシートサイズに比べて大きい場合、流通に適したサイズのシートを複数枚使用し、後述するように各シート材について面積の異なる複数の異形領域からなる形状に裁断することにより、成形体の成形が可能である。 The size of the sheet material is not particularly limited, and may be appropriately selected according to the size of the molded body. For example, one area of the molded body may be captured as a square area of 300 mm to 500 mm. In this case, the sheet material is preferably a square having a size of 300 mm to 500 mm. In addition, when the size of the molded body is larger than the sheet size suitable for distribution, a plurality of sheets having a size suitable for distribution are used, and a shape composed of a plurality of deformed regions having different areas for each sheet material as will be described later It is possible to mold the molded body by cutting into pieces.
また、シート材の厚みも、特に制限されるものではなく、成形しようとする成形体の各部位の厚み、あるいは該部位を占める体積にあわせて選択すればよい。 The thickness of the sheet material is not particularly limited, and may be selected according to the thickness of each part of the molded body to be molded or the volume occupying the part.
次に、図１（Ｂ）に示すように、図１（Ａ）の正方形のシート材を、３つの異形領域２０Ａ、２０Ｂ、２０Ｃが連なった単一形状に裁断加工する（裁断工程）。本実施形態では、プレス成形により最終的に図２（Ａ）に示す３面（厚み＝２ｍｍ）からなる成形体５０を成形するが、成形前に裁断加工して得られた形状２０中の異形領域２０Ａ、２０Ｂ、２０Ｃはそれぞれ、成形体５０を構成する面５０Ａ、面５０Ｂ、面５０Ｃに対応するように加工されている。 Next, as shown in FIG. 1B, the square sheet material of FIG. 1A is cut into a single shape in which three deformed regions 20A, 20B, and 20C are connected (cutting step). In the present embodiment, a molded body 50 having three surfaces (thickness = 2 mm) as shown in FIG. 2A is finally formed by press molding, but an irregular shape in the shape 20 obtained by cutting before molding. The regions 20A, 20B, and 20C are processed so as to correspond to the surface 50A, the surface 50B, and the surface 50C constituting the molded body 50, respectively.
具体的には、異形領域２０Ａ、２０Ｂ、２０Ｃの各領域における体積は、下記のように表されるが、
・異形領域２０Ａの体積＝領域２０Ａの面積×５ｍｍ（シート材の厚み）
・異形領域２０Ｂの体積＝領域２０Ｂの面積×５ｍｍ（シート材の厚み）
・異形領域２０Ｃの体積＝領域２０Ｃの面積×５ｍｍ（シート材の厚み）
この各体積が、成形体５０の面５０Ａ、面５０Ｂ、面５０Ｃにおける体積、すなわち、
・面５０Ａの体積＝成形後の領域３０Ａの面積×２ｍｍ（成形体の厚み）
・面５０Ｂの体積＝成形後の領域３０Ｂの面積×２ｍｍ（成形体の厚み）
・面５０Ｃの体積＝成形後の領域３０Ｃの面積×２ｍｍ（成形体の厚み）
とそれぞれ等しくなるように加工する。
Specifically, the volume in each region of the deformed regions 20A, 20B, 20C is expressed as follows,
・ Volume of deformed region 20A = area of region 20A × 5 mm (thickness of sheet material)
・ Volume of deformed region 20B = area of region 20B × 5 mm (sheet material thickness)
・ Volume of deformed region 20C = area of region 20C × 5 mm (sheet material thickness)
These volumes are the volumes at the surface 50A, the surface 50B, and the surface 50C of the molded body 50, that is,
-Volume of surface 50A = area of region 30A after molding x 2 mm (thickness of molded body)
-Volume of surface 50B = area of the region 30B after molding × 2 mm (thickness of the molded body)
-Volume of surface 50C = area of region 30C after molding × 2 mm (thickness of molded body)
Are processed to be equal to each other.
このように、本実施形態では、最終的に得ようとする成形体５０の各部位（面５０Ａ、面５０Ｂ、面５０Ｃ）にあわせて、該部位の各々の体積と同一の体積となる形状になるように異形領域２０Ａ、２０Ｂ、２０Ｃを形成している。
本実施形態では、図１（Ｂ）に示すように、３つの異形領域を１つの正方形と２つの異なる台形とに形成しているが、これらの形状自体は、特に制限されるものではなく、加圧した際に樹脂が流れやすい等の場合に応じて選択することができる。例えば図１（Ｂ）のように、３つの異形領域のうち隣接の２領域の境界が折り曲げ部となるように該境界となる辺を共有する形状に形成されると、取り扱いの点で有利である。また更には、成形される成形体の厚みよりも厚いシート材を用い、各異形領域（本実施形態では２０Ａ、２０Ｂ、２０Ｃの領域）の面積が、各異形領域に対応する成形体の各領域の面積より５０〜９０％の範囲で小さく形成されている態様が好ましい。
Thus, in this embodiment, according to each part (surface 50A, surface 50B, surface 50C) of the molded body 50 to be finally obtained, a shape having the same volume as the volume of each part is obtained. The deformed regions 20A, 20B, and 20C are formed so as to be.
In this embodiment, as shown in FIG. 1 (B), three deformed regions are formed into one square and two different trapezoids, but these shapes are not particularly limited, It can be selected according to the case where the resin is easy to flow when pressurized. For example, as shown in FIG. 1 (B), it is advantageous in terms of handling if it is formed in a shape that shares the boundary side so that the boundary between two adjacent regions among the three deformed regions becomes a bent portion. is there. Still further, a sheet material that is thicker than the thickness of the molded body to be molded is used, and the area of each deformed area (in the present embodiment, the area of 20A, 20B, and 20C) is each area of the molded body corresponding to each deformed area. The aspect formed smaller in the range of 50 to 90% than the area of is preferable.
ここで、成形後の領域３０Ａ、３０Ｂ、３０Ｃはそれぞれ、図２（Ａ）に示す成形体５０の成形時の加圧方向（図２中の矢印で示される高さ方向）において、最も高い位置の平面５０Ａと、最も低い位置の平面５０Ｃと、平面５０Ａと平面５０Ｃとの間に屈曲部を有して繋がり両平面と直交する平面５０Ｂとからなる３平面に対応している。平面５０Ａ、５０Ｂ、５０Ｃの各面内では、樹脂は加圧時に面方向に流れて広がるため良好に成形が進行するが、屈曲部を介した平面５０Ａと平面５０Ｂとの間、又は平面５０Ｂと平面５０Ｃとの間は、樹脂は屈曲部を超えて流れにくく、平面間での樹脂の広がりは期待できない。そのため、本実施形態のように、成形時の加圧の方向（すなわち成形体の高さ方向）において最も高い位置の平面と最も低い位置の平面とを基準に３つの領域に分割し、成形前のシート材の異形領域を形成するようにすることで成形性を向上させることができる。 Here, the regions 30A, 30B, and 30C after molding are the highest positions in the pressing direction (the height direction indicated by the arrow in FIG. 2) during molding of the molded body 50 shown in FIG. The flat surface 50A, the lowest flat surface 50C, and a flat surface 50B that has a bent portion between the flat surface 50A and the flat surface 50C and is orthogonal to the two flat surfaces correspond to the three flat surfaces. In each of the planes 50A, 50B, and 50C, the resin flows and spreads in the plane direction when pressed, so that the molding proceeds well. However, between the plane 50A and the plane 50B via the bent portion, or between the plane 50B and the plane 50B, Between the flat surfaces 50C, the resin hardly flows beyond the bent portion, and the spread of the resin between the flat surfaces cannot be expected. For this reason, as in the present embodiment, in the direction of pressurization during molding (that is, the height direction of the molded body), the plane is divided into three regions based on the highest plane and the lowest plane, before molding. Formability can be improved by forming a deformed region of the sheet material.
次いで、上記のように裁断された板状材料を加圧成形前にあらかじめ、熱可塑性樹脂の融点以上の温度に予備加熱する（予備加熱工程）。本実施形態では、ポリアミド樹脂の融点以上の温度に加熱されている。 Next, the plate-like material cut as described above is preheated to a temperature equal to or higher than the melting point of the thermoplastic resin in advance before pressure molding (preheating step). In this embodiment, it is heated to a temperature equal to or higher than the melting point of the polyamide resin.
予備加熱は、例えば、加熱炉や、熱板、ヒートロール、各種ヒータなどを用いて行なうことができる。中でも、シート材の昇温速度が速く、複数枚を並行して加熱できる等の観点から、加熱炉による加熱が好ましい。 Preheating can be performed using, for example, a heating furnace, a hot plate, a heat roll, or various heaters. Among these, heating by a heating furnace is preferable from the viewpoint that the heating rate of the sheet material is fast and a plurality of sheets can be heated in parallel.
予備加熱は、使用する熱可塑性樹脂が溶融し、後述の成形型に配されてプレスされた際に流動する時間帯が得られるだけの溶融状態が得られるように行なわれる。このとき、シート材は、炭素繊維を含有しているため、シート形状が保持されている。 The preheating is performed so that the thermoplastic resin to be used is melted and a melted state is obtained in which a time zone is obtained in which the thermoplastic resin used flows when the resin is placed in a mold described later and pressed. At this time, since the sheet material contains carbon fibers, the sheet shape is maintained.
予備加熱する際の具体的な温度範囲としては、樹脂の融点で異なるが、１８０℃以上２７０℃以下の範囲に調節される態様が好適である。この範囲に加熱されると、成形時に加熱せずとも安定的に成形が行なえる。 A specific temperature range for the preheating is preferably adjusted to a range of 180 ° C. or higher and 270 ° C. or lower, although it varies depending on the melting point of the resin. When heated to this range, molding can be performed stably without heating during molding.
そして、シート材の予備加熱を行なった後、予備加熱されたシート材を、熱可塑性樹脂の融点未満の温度に保持された成形型に配してプレス成形する（加圧成形工程）。本実施形態では、ポリアミド樹脂の融点未満の温度、具体的には１００℃に加熱、保持されるようになっている。 Then, after preheating the sheet material, the preheated sheet material is placed in a mold held at a temperature lower than the melting point of the thermoplastic resin and press-molded (pressure molding process). In this embodiment, it is heated and held at a temperature lower than the melting point of the polyamide resin, specifically at 100 ° C.
予備加熱工程で一旦融点以上の高温で加熱された後、融点に満たない成形型に配してプレス成形されると、急冷されながら成形され、成形終了時には比較的温度の低くなった成形体が得られる。そのため、成形体の降温を待つことなく、次の成形加工に移ることが可能である。これより、成形サイクルの時間短縮が図られる。 After being heated at a high temperature above the melting point once in the preheating step, when placed in a mold that does not meet the melting point and press-molded, it is molded while being rapidly cooled, and a molded body having a relatively low temperature at the end of molding is formed. can get. Therefore, it is possible to move to the next molding process without waiting for the temperature of the molded body to drop. Thus, the molding cycle time can be shortened.
成形型の加熱は、溶融状態のシート材が成形型との間で熱交換しながら成形される間、あくまでもシート材の降温速度を緩和してプレス時の流動時間を稼ぐために与えられるものであり、シート材を溶融するための加熱とは異なる。そのため、成形型に対する加熱は、熱可塑性樹脂の融点−（５０〜１５０℃）の範囲の温度に調整されるのが好ましく、更には１００℃±２０℃の範囲に調節されるのが好ましい。 The heating of the mold is given only to ease the temperature drop rate of the sheet material and increase the flow time during pressing while the molten sheet material is molded while exchanging heat with the mold. Yes, this is different from heating to melt the sheet material. Therefore, the heating for the mold is preferably adjusted to a temperature in the range of the melting point of the thermoplastic resin— (50 to 150 ° C.), and more preferably adjusted to a range of 100 ° C. ± 20 ° C.
加圧成形する際の圧力としては、特に制限されるものではないが、５００〜６０００ＭＰａが好ましく、４０００〜６０００ＭＰａがより好ましい。圧力が前記範囲内であることで、比較的低い圧力としながら、短い成形時間で良好な成形性が得られる。 Although it does not restrict | limit especially as a pressure at the time of press-molding, 500-6000 MPa is preferable and 4000-6000 MPa is more preferable. When the pressure is within the above range, good moldability can be obtained in a short molding time while maintaining a relatively low pressure.
以上のようにして、本実施形態では、図２（Ａ）に示すように、２つの折り曲げ部を有する成形体が成形される。 As described above, in this embodiment, as shown in FIG. 2A, a molded body having two bent portions is formed.
本発明では、上記のように成形した場合、プレス時に樹脂が流動して成形が進行するが樹脂中に含まれる炭素繊維等の繊維材料は流動し難いため、炭素繊維等の繊維材料は成形前の、複数の異形領域が形成された形状の端部近傍に偏在して残りやすい。そのため、成形体に該形状に沿って線状の痕跡が残り、この線状の痕跡の有無から、本発明の樹脂成形体の製造方法による成形であるか否かの確認が可能である。 In the present invention, when molded as described above, the resin flows during molding and the molding proceeds, but the fiber material such as carbon fiber contained in the resin is difficult to flow. However, it tends to remain unevenly in the vicinity of the end of the shape in which a plurality of irregular regions are formed. Therefore, linear traces remain along the shape on the molded body, and it is possible to confirm whether or not the molding is performed by the method for producing a resin molded body of the present invention based on the presence or absence of the linear traces.
そして、この成形体を図２（Ｂ）のように２つ成形し、図２（Ｃ）に示すように、一方の平面５０Ａと他方の平面５０Ｃとをそれぞれ組み合わせて互いに接着することにより、部品を作製することができる。 Then, two molded bodies are molded as shown in FIG. 2 (B), and as shown in FIG. 2 (C), one plane 50A and the other plane 50C are combined and bonded to each other. Can be produced.
上記実施形態では、単一のシート材を用いて成形体とする場合を中心に説明したが、さらに体格の大きい成形体を成形する場合には、複数のシート材を用いて上記と同様の工程を経て作製することが可能である。具体的には、
まず、繊維材料を含む熱可塑性樹脂の複数のシート材（例えば３００ｍｍ〜５００ｍｍの正方形のシート材）を用意し、その各々について、上記と同様の裁断工程を実施する。すなわち、複数あるシート材の枚数だけ裁断工程を繰り返す。このとき、成形後の成形体を想定し、１つのシート材に入る成形体の部分を１つの成形エリアとして決定し、成形体全体について複数の成形エリアを決定する。各成形エリアは、１つのシート材が成形を担う。そして、各成形エリアの中を、上記実施形態と同様に樹脂体積の異同や成形時の加圧の方向における位置関係などに基づいて複数の領域に分割し、各シート材に前記分割された各領域に対応する異形領域を、分割された各領域の体積と同一の体積となるように形成する。そして、複数の異形領域が形成された各シート材をそれぞれ予備加熱し、予備加熱された複数のシート材を、単一の成形型の対応する位置に配置し、一度にプレス成形する。このようにすることで、隣接するシート材同士が互いに連結して一体化し、単一のシート材に比べて体格の大きい成形体が容易に作製される。
In the said embodiment, although demonstrated centering on the case where it is set as a molded object using a single sheet material, when shape | molding a molded object with a larger physique, the process similar to the above using several sheet | seat material It is possible to produce through this. In particular,
First, a plurality of sheet materials (for example, a 300 mm to 500 mm square sheet material) of a thermoplastic resin containing a fiber material are prepared, and a cutting process similar to the above is performed on each of the sheet materials. That is, the cutting process is repeated as many as the number of sheets. At this time, assuming a molded body after molding, a portion of the molded body entering one sheet material is determined as one molding area, and a plurality of molding areas are determined for the entire molded body. In each forming area, one sheet material is responsible for forming. And, in each molding area, as in the above embodiment, it is divided into a plurality of regions based on the difference in resin volume and the positional relationship in the direction of pressurization at the time of molding, and each of the divided sheet materials The deformed region corresponding to the region is formed to have the same volume as the volume of each divided region. Then, each sheet material on which a plurality of deformed regions are formed is preheated, and the plurality of preheated sheet materials are arranged at corresponding positions of a single mold and press-molded at a time. By doing in this way, adjacent sheet materials are connected and integrated with each other, and a compact having a larger physique than a single sheet material is easily produced.
本発明においては、上記のように、既存の低いプレス圧を維持しながら、繊維材料を含む熱可塑性樹脂の板状材料を用いて低コスト化及び成形時間の短縮化が図れ、量産品の成形に適すると共に、リサイクル性も具備した成形加工システムを構築することができる。 In the present invention, as described above, while maintaining the existing low press pressure, it is possible to reduce the cost and shorten the molding time by using a thermoplastic resin plate-like material containing a fiber material, and to mold a mass-produced product. It is possible to construct a molding processing system that is suitable for the above and also has recyclability.
１０・・・炭素繊維を含むポリアミド樹脂のシート材
２０・・・面積の異なる複数の異形領域からなる形状に裁断されたシート材
２０Ａ，２０Ｂ，２０Ｃ・・・異形領域
３０・・・プレス成形後のシート材
３０Ａ・・・異形領域２０Ａに対応する成形後の領域
３０Ｂ・・・異形領域２０Ｂに対応する成形後の領域
３０Ｃ・・・異形領域２０Ｃに対応する成形後の領域
５０・・・成形体
10 ... Polyamide resin sheet material 20 containing carbon fibers 20 ... Sheet materials 20A, 20B, 20C cut into a shape composed of a plurality of deformed regions having different areas ... Deformed region 30 ... After press molding The sheet material 30A of the molding 30B corresponding to the deformed area 20A ... The molded area 30C corresponding to the deformed area 20B ... The molded area 50 corresponding to the deformed area 20C ... body
Claims (4)
裁断された板状材料を、前記熱可塑性樹脂の融点以上の温度であって１８０℃以上２７０℃以下の範囲にあらかじめ加熱する予備加熱工程と、
加熱された前記板状材料を、前記融点−（５０〜１５０℃）の範囲の温度に保持された成形型にて加圧成形し、前記異形領域の境界に沿って折り曲げ部を有する成形体を成形する加圧成形工程と、
を有し、
前記裁断工程は、前記加圧成形工程で成形される成形体における樹脂体積の異同に基づいて、前記成形体における樹脂体積の異なる領域の各々に対応する前記異形領域を、前記樹脂体積の異なる各領域の体積と同一の体積となるように形成する樹脂成形体の製造方法。 A cutting step of cutting a thermoplastic resin plate-like material containing a fiber material into a shape composed of three or more deformed regions having different areas;
A preheating step of preliminarily heating the cut plate-like material to a temperature not lower than the melting point of the thermoplastic resin and not lower than 180 ° C. and not higher than 270 ° C . ;
The heated plate-like material is pressure-molded with a molding die maintained at a temperature in the range of the melting point − (50 to 150 ° C.), and a molded body having a bent portion along the boundary of the deformed region. A pressure molding process for molding;
Have
In the cutting step, based on the difference in resin volume in the molded body molded in the pressure molding step, the deformed region corresponding to each of the regions having different resin volumes in the molded body is changed to each of the different resin volumes. The manufacturing method of the resin molding formed so that it may become the volume same as the volume of an area | region.
前記加圧成形工程は、前記予備加熱工程で加熱された前記複数の板状材料を単一の成形型に配して加圧成形し、単一の成形体を成形する請求項１又は請求項２に記載の樹脂成形体の製造方法。 The cutting process is repeated a plurality of times to produce a plurality of the plate-like materials cut into a shape composed of a plurality of deformed regions having different areas,
The said press molding process arrange | positions the said several plate-shaped material heated by the said preheating process to a single shaping | molding die, press-molds, and shape | molds a single molded object. The manufacturing method of the resin molding of 2.
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| JP5167953B2 (en) * | 2008-05-27 | 2013-03-21 | 東レ株式会社 | Laminated substrate, fiber reinforced plastic, and production method thereof |
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