JP6152373B2 - Method for producing thermoplastic prepreg molded product - Google Patents
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Description
本発明は、熱可塑性プリプレグを型成形して熱可塑性プリプレグ成形品を製造する方法に関し、特に金型に対する離型性に関するものである The present invention relates to a method for producing a thermoplastic prepreg molded product by molding a thermoplastic prepreg, and particularly relates to a mold release property for a mold.
図５に示すように、熱可塑性プリプレグ１０を複数枚、例えば５枚重ねたものを金型１００の上型１０１と下型１０２間にセットとして加熱、加圧することによって、図６に示すような皿状のプリプレグ成形品１を製造することが一般的に知られている。 As shown in FIG. 5, by heating and pressurizing a plurality of, for example, five, laminated sheets of thermoplastic prepregs 10 as a set between the upper mold 101 and the lower mold 102 of the mold 100, as shown in FIG. It is generally known to produce a dish-shaped prepreg molded product 1.
ここで、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に含浸させてなる熱可塑性プリプレグ１０を複数枚重ねたものを金型１００で型成形した場合、金型１００から外すときの離型性が問題になる。通常は、熱可塑性プリプレグ１０をセットする前に金型１００の上型１０１と下型１０２に、あるいは下型１０２だけに離型剤をスプレーで塗布することによって容易に離型させることが行われている。
しかし、熱可塑性樹脂のなかでも、特にＰＥＥＫ（ポリエーテルエーテルケトン）やＰＥＫＫ（ポリエーテルケトンケトン）などといった接着性が高いため離型性が悪くかつ熔融温度の高いいわゆるスーパーエンジニアリングプラスチックをマトリクス樹脂として使用した場合、型成形後に、熱可塑性プリプレグ１０が金型１００、特に下型１０２から外れ難く、無理に外そうとすると成形品や金型１００に損傷が生じる場合もある。
Here, when a mold 100 is formed by stacking a plurality of thermoplastic prepregs 10 in which a sheet-like fiber base material is impregnated with a thermoplastic resin as a matrix resin, releasability when removed from the mold 100 Is a problem. Usually, before setting the thermoplastic prepreg 10, the mold 100 is easily released by spraying a release agent on the upper mold 101 and the lower mold 102 of the mold 100 or only on the lower mold 102. ing.
However, among thermoplastic resins, so-called super engineering plastics, which have poor releasability and high melting temperature, are particularly used as matrix resins because of their high adhesive properties such as PEEK (polyether ether ketone) and PEKK (polyether ketone ketone). When used, the thermoplastic prepreg 10 is difficult to be removed from the mold 100, particularly the lower mold 102, after molding, and the molded product or the mold 100 may be damaged if it is forcibly removed.
なお、熱可塑性プリプレグ１０と重なり合う側にクレーコート層を有する離型紙、例えばシリコーン系の離型剤が用いられた上質紙，クラフト紙，グラシン紙，パーチメント紙からなるものを使用することでしわの発生を防止するものが開示されている（例えば、特許文献１参照）。 In addition, it is possible to use a release paper having a clay coat layer on the side overlapping with the thermoplastic prepreg 10, for example, a paper made of fine paper, kraft paper, glassine paper, and parchment paper using a silicone release agent. What prevents generation | occurrence | production is disclosed (for example, refer patent document 1).
しかしながら、特許文献１に記載の発明は、熱可塑性プリプレグ１０をロール間で挟みながら加熱及び加圧処理を施すものであり金型にセットするものではないので、金型からの離型性は問題とならない。またスーパーエンジニアリングプラスチックは溶融温度が高いため耐熱性の問題もある However, in the invention described in Patent Document 1, since the thermoplastic prepreg 10 is heated and pressurized while being sandwiched between rolls and is not set in a mold, releasability from the mold is a problem. Not. Super engineering plastics also have heat resistance problems due to their high melting temperature
そこで、本発明の目的とするところは、金型からの離型性に優れ品質劣化を防止しうる熱可塑性プリプレグ成形品の製造方法を提供することにある。 Accordingly, an object of the present invention is to provide a method for producing a thermoplastic prepreg molded product that is excellent in releasability from a mold and can prevent quality deterioration.
上記の目的を達成するために、本発明の熱可塑性プリプレグ成形品の製造方法は、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に含浸させてなる熱可塑性プリプレグ（１０）を複数枚重ねたものを型成形して熱可塑性プリプレグ成形品（１）を製造する方法であって、
前記熱可塑性プリプレグ（１０）のうち最も上段になる熱可塑性プリプレグ（１０ａ）の上面及び最も下段になる熱可塑性プリプレグ（１０ｂ）の下面に薄い金属被膜（２０）をメッキ（蒸着，スパッタリングも含まれる）によって形成する被膜形成工程と、
前記最も上段になる熱可塑性プリプレグ（１０ａ）と最も下段になる熱可塑性プリプレグ（１０ｂ）の間に残りの熱可塑性プリプレグ（１０ｃ）が存在する場合にはその残りの熱可塑性プリプレグ（１０ｃ）を間に重ね、残りの熱可塑性プリプレグが存在しない場合には前記最も上段になる熱可塑性プリプレグ（１０ａ）と最も下段になる熱可塑性プリプレグ（１０ｂ）を直接重ねるとともに前記熱可塑性プリプレグ（１０）に対してそれぞれ離散的に超音波融着して一体化するサンド工程と、
前記一体化された熱可塑性プリプレグ（１０）を金型（１００）にセットして加熱加圧処理を施す型成形工程と、
前記加熱加圧処理後に前記金型（１００）から取り出された熱可塑性プリプレグ成形品（１）に形成された金属被膜（２０）を酸で洗い流して除去する酸洗い工程を、備えることを特徴にする。
なお、ここでいう熱可塑性プリプレグ（１０）には、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に半含浸させてなる、いわゆるセミプレグも含まれることを意味する。
In order to achieve the above object, the method for producing a thermoplastic prepreg molded product of the present invention comprises stacking a plurality of thermoplastic prepregs (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin. A method for producing a thermoplastic prepreg molded product (1) by molding a product,
A thin metal film (20) is plated on the upper surface of the uppermost thermoplastic prepreg (10a) and the lower surface of the lowermost thermoplastic prepreg (10b) of the thermoplastic prepreg (10) (including vapor deposition and sputtering). ) To form a film,
If there is a remaining thermoplastic prepreg (10c) between the uppermost thermoplastic prepreg (10a) and the lowermost thermoplastic prepreg (10b), the remaining thermoplastic prepreg (10c) is interposed between them. When the remaining thermoplastic prepreg does not exist, the uppermost thermoplastic prepreg (10a) and the lowermost thermoplastic prepreg (10b) are directly overlapped with the thermoplastic prepreg (10). Sanding process that integrates discretely by ultrasonic welding,
A mold forming step in which the integrated thermoplastic prepreg (10) is set in a mold (100) and subjected to heat and pressure treatment;
A pickling step for removing the metal coating (20) formed on the thermoplastic prepreg molded product (1) taken out from the mold (100) after the heat and pressure treatment by washing with acid; To do.
The thermoplastic prepreg (10) referred to here includes so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin.
また本発明の熱可塑性プリプレグ成形品の製造方法は、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に含浸させてなる熱可塑性プリプレグ（１０）を複数枚重ねたものを型成形して熱可塑性プリプレグ成形品（１）を製造する方法であって、
前記熱可塑性プリプレグ（１０）のうち最も下段になる熱可塑性プリプレグ（１０ｂ）の下面に薄い金属被膜（２０）をメッキ（蒸着，スパッタリングも含まれる）によって形成する被膜形成工程と、前記最も下段になる熱可塑性プリプレグ（１０ｂ）の上に残りの熱可塑性プリプレグ（１０ｃ）を重ねるとともに前記熱可塑性プリプレグ（１０）に対してそれぞれ離散的に超音波融着して一体化するサンド工程と、
前記一体化された熱可塑性プリプレグ（１０）を金型（１００）にセットして加熱加圧処理を施す型成形工程と、
前記加熱加圧処理後に前記金型（１００）から取り出された熱可塑性プリプレグ成形品（１）に形成された金属被膜（２０）を酸で洗い流して除去する酸洗い工程を、備えることを特徴にする。
なお、ここでいう熱可塑性プリプレグ（１０）には、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に半含浸させてなる、いわゆる熱可塑性セミプレグも含まれることを意味する。
Further, the method for producing a thermoplastic prepreg molded product of the present invention is obtained by molding a plurality of laminated thermoplastic prepregs (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin. A method for producing a prepreg molded product (1), comprising:
A film forming step of forming a thin metal film (20) on the lower surface of the lowermost thermoplastic prepreg (10b) of the thermoplastic prepreg (10) by plating (including vapor deposition and sputtering); and Sandwiching the remaining thermoplastic prepreg (10c) on the resulting thermoplastic prepreg (10b) and discretely ultrasonically fusing and integrating the thermoplastic prepreg (10), respectively,
A mold forming step in which the integrated thermoplastic prepreg (10) is set in a mold (100) and subjected to heat and pressure treatment;
A pickling step for removing the metal coating (20) formed on the thermoplastic prepreg molded product (1) taken out from the mold (100) after the heat and pressure treatment by washing with acid; To do.
The thermoplastic prepreg (10) referred to here means that a so-called thermoplastic semi-preg obtained by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin is also included.
また本発明の熱可塑性プリプレグ成形品の製造方法は、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に含浸させてなる熱可塑性プリプレグ（１０）を型成形して熱可塑性プリプレグ成形品（１）を製造する方法であって、
前記熱可塑性プリプレグ（１０）の上面及び下面、あるいは下面だけに薄い金属被膜（２０）をメッキ（蒸着，スパッタリングも含まれる）によって形成する被膜形成工程と、
前記熱可塑性プリプレグ（１０）を金型（１００）にセットして加熱加圧処理を施す型成形工程と、
前記加熱加圧処理後に前記金型（１００）から取り出された熱可塑性プリプレグ成形品（１）に形成された金属被膜（２０）を酸で洗い流して除去する酸洗い工程を、備えることを特徴にする。
なお、ここでいう熱可塑性プリプレグ（１０）には、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に半含浸させてなる、いわゆる熱可塑性セミプレグも含まれることを意味する。
Moreover, the manufacturing method of the thermoplastic prepreg molded product of the present invention comprises molding a thermoplastic prepreg (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin, and molding the thermoplastic prepreg molded product (1). A method of manufacturing
A film forming step of forming a thin metal film (20) on the upper surface and lower surface of the thermoplastic prepreg (10) or only the lower surface by plating (including vapor deposition and sputtering);
A mold forming step in which the thermoplastic prepreg (10) is set in a mold (100) and subjected to heat and pressure treatment;
A pickling step for removing the metal coating (20) formed on the thermoplastic prepreg molded product (1) taken out from the mold (100) after the heat and pressure treatment by washing with acid; To do.
The thermoplastic prepreg (10) referred to here means that a so-called thermoplastic semi-preg obtained by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin is also included.
また本発明は、前記金属被膜（２０）は、ニッケル，アルミ，銅、金、銀、チタンのうちいずれか一つで形成されてなり酸に溶ける性質を持つ金属であることを特徴とする。 Further, the present invention is characterized in that the metal coating (20) is formed of any one of nickel, aluminum, copper, gold, silver and titanium and has a property of being dissolved in an acid.
また本発明は、前記熱可塑性樹脂は、ＰＥＥＫ（ポリエーテルエーテルケトン）又はＰＥＫＫ（ポリエーテルケトンケトン）等の接着性が高く、離型しにくい性質をもち、かつ熔融温度の高い熱可塑性樹脂であることを特徴とする。 In the present invention, the thermoplastic resin is a thermoplastic resin having a high adhesion property such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone), having a property of being difficult to release, and having a high melting temperature. It is characterized by being.
なお、括弧内の記号は、図面および後述する発明を実施するための形態に記載された対応要素または対応事項を示す。 Note that symbols in parentheses indicate corresponding elements or corresponding matters described in the drawings and modes for carrying out the invention described later.
本発明の熱可塑性プリプレグ成形品の製造方法によれば、複数枚重ねられたプリプレグの上面及び下面にメッキ（蒸着，スパッタリングも含まれる）で金属被膜が形成されたものを金型にセットして加熱加圧による型成形を行うので、金属同士の接触により金型からプリプレグを容易に取り出すことができる。特に、接着性の高い樹脂、例えば、ＰＥＥＫ（ポリエーテルエーテルケトン）又はＰＥＫＫ（ポリエーテルケトンケトン）をマトリクス樹脂としてシート状繊維基材に含浸させてなるプリプレグが金型に対して直接接触しないため離型が簡単である。 According to the method for producing a thermoplastic prepreg molded product of the present invention, a plurality of stacked prepregs each having a metal film formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of the prepreg are set in a mold. Since the mold is formed by heating and pressing, the prepreg can be easily taken out from the mold by contact between the metals. In particular, a prepreg formed by impregnating a sheet-like fiber base material with a highly adhesive resin such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as a matrix resin does not directly contact the mold. Easy to release.
しかも、メッキ（蒸着，スパッタリングも含まれる）により形成される金属被膜は薄いものであるので、延性が高く、変形しやすく金型でプレスしたときでも形状に倣い易い。さらに、上下に重ねられた熱可塑性プリプレグは金属被膜が形成されたものも含めて離散的に超音波融着により接着することにより一体化されているので、重ねられたものを容易にかつ強固に仮止めすることができ、金型成形時に位置ズレすることもない。
さらに、メッキ（蒸着，スパッタリングも含まれる）でつけられた金属被膜は、酸洗いによって除去されるので表面がきれいな熱可塑性プリプレグ成形品が提供される。
Moreover, since the metal film formed by plating (including vapor deposition and sputtering) is thin, it has high ductility, is easily deformed, and easily follows the shape even when pressed with a mold. Furthermore, since the thermoplastic prepregs stacked one above the other are integrated by discrete ultrasonic bonding, including those with metal coatings, the stacked ones can be easily and firmly Temporary fixing is possible, and there is no positional displacement during mold forming.
Furthermore, since the metal film applied by plating (including vapor deposition and sputtering) is removed by pickling, a thermoplastic prepreg molded product having a clean surface is provided.
また、重ねられた熱可塑性プリプレグの下面だけに金属被膜を形成するだけでも離型性は向上するし、複数の熱可塑性プリプレグからなるものではなく単体（１枚）の熱可塑性プリプレグを型成形する場合に、その単体の熱可塑性プリプレグの上面及び下面、あるいは下面だけに金属被膜を形成するものであっても離型性は向上する。 Further, the mold release property can be improved by forming a metal film only on the lower surface of the stacked thermoplastic prepregs, and a single thermoplastic prepreg is molded instead of a plurality of thermoplastic prepregs. In this case, even if the metal film is formed only on the upper and lower surfaces or only the lower surface of the single thermoplastic prepreg, the releasability is improved.
また、本発明では、金属被膜として、ニッケル，アルミ，銅、金、チタンといった金属を使用したので、強度性及び加工性に優れる。 Moreover, in this invention, since metals, such as nickel, aluminum, copper, gold | metal | money, and titanium, were used as a metal film, it is excellent in intensity | strength and workability.
なお、本発明の熱可塑性プリプレグ成形品の製造方法のように、熱可塑性プリプレグの上面や下面にメッキ（蒸着，スパッタリングも含まれる）によって金属被膜を形成したものを金型にセットして型成形した後、金属被膜を酸洗いで除去することによって、金型からの離型性を向上させて成形品の品質劣化を防止するようにした点は、上述した特許文献１には全く記載されていない。 In addition, as in the method for producing a thermoplastic prepreg molded product of the present invention, a metal film formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of the thermoplastic prepreg is set in a mold and molded. After that, the above-described Patent Document 1 completely describes that the metal film is removed by pickling to improve the mold releasability from the mold and prevent the quality deterioration of the molded product. Absent.
図面を参照して本発明の実施形態に係る熱可塑性プリプレグ成形品の製造方法について説明する。
本実施形態では、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に含浸させてなる熱可塑性プリプレグ１０を複数枚（Ｎ枚、ここでは５枚とした）、重ねたものを図５で示したような金型１００を使用することで型成形して、図６で示したような熱可塑性プリプレグ成形品１を製造するものである。ここでは、熱可塑性樹脂のなかでも、特にＰＥＥＫ（ポリエーテルエーテルケトン）やＰＥＫＫ（ポリエーテルケトンケトン）などといった接着性が高いため離型性が悪く、かつ溶融温度か高い、いわゆるスーパーエンジニアリングプラスチックをマトリクス樹脂として使用した熱可塑性プリプレグ１０を重ねている。
なお、本実施形態でいう熱可塑性プリプレグ１０には、熱可塑性樹脂をマトリクス樹脂としてシート状繊維基材に半含浸させてなる、いわゆるセミプレグも含まれる。
A method for producing a thermoplastic prepreg molded product according to an embodiment of the present invention will be described with reference to the drawings.
In the present embodiment, a plurality of (N, here, 5) thermoplastic prepregs 10 obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin are shown in FIG. Molding is performed by using such a mold 100, and the thermoplastic prepreg molded product 1 as shown in FIG. 6 is manufactured. Here, among the thermoplastic resins, a so-called super engineering plastic having a high releasability due to high adhesiveness such as PEEK (polyetheretherketone) and PEKK (polyetherketoneketone) and having a high melting temperature is used. A thermoplastic prepreg 10 used as a matrix resin is stacked.
The thermoplastic prepreg 10 referred to in the present embodiment also includes a so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin.
この熱可塑性プリプレグ成形品の製造方法は、以下に説明するように、被膜形成工程と、サンド工程と、型成形工程と、酸洗い工程を備えている。 As described below, the method for producing a thermoplastic prepreg molded product includes a film forming step, a sanding step, a mold forming step, and a pickling step.
（被膜形成工程）
最初に行われる被膜形成工程では、図１に示すように、５枚の熱可塑性プリプレグ１０のうち最も上段になる熱可塑性プリプレグ１０ａの上面に薄い金属被膜２０が蒸着によるメッキで形成されるともに、図示は省略するが、最も下段になる熱可塑性プリプレグ１０ｂの下面にも薄い金属被膜２０が蒸着によるメッキで形成される。
金属被膜２０としては、様々ものが考えられるが、ここでは、強度性及び加工性に優れるニッケル，アルミ，銅、金、チタンなどといった金属のうちニッケルを使用した。
(Film formation process)
In the first film formation step, as shown in FIG. 1, a thin metal film 20 is formed on the upper surface of the uppermost thermoplastic prepreg 10a among the five thermoplastic prepregs 10 by plating, Although illustration is omitted, a thin metal film 20 is also formed on the lower surface of the lowermost thermoplastic prepreg 10b by plating by vapor deposition.
Various metal coatings 20 are conceivable. Here, nickel is used among metals such as nickel, aluminum, copper, gold, and titanium which are excellent in strength and workability.
また、金属被膜２０を形成するメッキとしては、真空蒸着に類するものとしてスパッタリングによって薄膜を形成したり、その他の電気メッキ（メッキする金属を電気化学的に析出させるもの）や無電解メッキ（メッキする金属を含む溶液中にプリプレグを浸けて金属を化学的に還元析出させるもの）や化成処理（化学的な処理によって金属表面に安定な化合物を生成させるもの）などによって薄膜を形成するようにしてもよい。 As the plating for forming the metal coating 20, a thin film is formed by sputtering as a method similar to vacuum deposition, or other electroplating (a method for electrochemically depositing a metal to be plated) or electroless plating (plating). It is possible to form a thin film by immersing a prepreg in a solution containing metal to chemically reduce and precipitate the metal) or chemical conversion treatment (to produce a stable compound on the metal surface by chemical treatment). Good.
（サンド工程）
次に行われるサンド工程では、図２に示すように、金属被膜２０が上面に形成された最も上段になる熱可塑性プリプレグ１０ａと金属被膜２０が下面に形成された最も下段になる熱可塑性プリプレグ１０ｂの間に３枚の熱可塑性プリプレグ１０ｃを挟むようにして５枚の熱可塑性プリプレグ１０を重ねるとともに、図３に示すように、超音波融着で５枚の熱可塑性プリプレグ１０を一体化させることで金型１００にセットする前に仮止めする。
(Sand process)
In the next sanding process, as shown in FIG. 2, the uppermost thermoplastic prepreg 10a with the metal coating 20 formed on the upper surface and the lowermost thermoplastic prepreg 10b with the metal coating 20 formed on the lower surface. 5 thermoplastic prepregs 10 are stacked so that three thermoplastic prepregs 10c are sandwiched between them, and the five thermoplastic prepregs 10 are integrated by ultrasonic welding as shown in FIG. Temporarily fix before setting to the mold 100.
超音波融着は、超音波熱融着又は超音波溶着とも呼ばれ、微細な超音波振動と加圧力によって熱可塑性プリプレグ１０を構成する熱可塑性樹脂（ここでは、ＰＥＥＫ（ポリエーテルエーテルケトン）やＰＥＫＫ（ポリエーテルケトンケトン））を瞬時に溶融して接合するもので、複数の超音波融着点１５が離散的に形成されている。 The ultrasonic fusion is also called ultrasonic thermal fusion or ultrasonic welding, and is a thermoplastic resin (here, PEEK (polyetheretherketone)) or the like that constitutes the thermoplastic prepreg 10 by fine ultrasonic vibration and pressure. PEKK (polyetherketoneketone) is instantaneously melted and joined, and a plurality of ultrasonic fusion points 15 are discretely formed.
（型成形工程）
次に行われる型成形工程では、超音波融着によって一体化された５枚の熱可塑性プリプレグ１０を、図５で示したような金型１００の上型１０１と下型１０２の間にセットした後、下型１０２に対して上型１０１を押し込み加熱加圧処理を施す。
(Molding process)
In the next molding process, five thermoplastic prepregs 10 integrated by ultrasonic fusion were set between the upper mold 101 and the lower mold 102 of the mold 100 as shown in FIG. Thereafter, the upper mold 101 is pushed into the lower mold 102 and subjected to heat and pressure treatment.
（酸洗い工程）
そして、酸洗い工程では、加熱加圧処理後に金型１００から取り出された熱可塑性プリプレグ成形品１を冷却した後に、酸溶液３０が満たされた容器５０に浸漬させ、一定時間が経過すると熱可塑性プリプレグ成形品１を容器５０から引き上げるようにして、熱可塑性プリプレグ成形品１に形成された金属被膜２０を酸で洗い流して除去する。
酸としては、特に限定されるわけではなく、通常、塩酸や硫酸が使用されるがここでは、塩酸を使用した。
(Pickling process)
In the pickling step, after the thermoplastic prepreg molded product 1 taken out from the mold 100 after the heat and pressure treatment is cooled, it is immersed in a container 50 filled with the acid solution 30, and after a certain time has passed, the thermoplasticity is reached. As the prepreg molded product 1 is pulled up from the container 50, the metal coating 20 formed on the thermoplastic prepreg molded product 1 is washed away with acid and removed.
The acid is not particularly limited, and hydrochloric acid and sulfuric acid are usually used. In this case, hydrochloric acid was used.
特にＰＥＥＫ（ポリエーテルエーテルケトン）やＰＥＫＫ（ポリエーテルケトンケトン）などといった接着性が高く溶融温度が高いいわゆるスーパーエンジニアリングプラスチックは、酸に対する耐性が強く、酸洗いによりその特性が変化することがないので、酸洗い後の表面をきれいに仕上げることができる。 In particular, super engineering plastics such as PEEK (polyetheretherketone) and PEKK (polyetherketoneketone) that have high adhesion and high melting temperature are highly resistant to acid, and their properties are not changed by pickling. The surface after pickling can be finished cleanly.
以上のように、被膜形成工程と、サンド工程と、型成形工程と、酸洗い工程をこの順で行い工程が終了すると、図６に示すような、熱可塑性プリプレグ成形品１が完成する。 As described above, when the film forming process, the sanding process, the mold forming process, and the pickling process are performed in this order and the process is completed, the thermoplastic prepreg molded product 1 as shown in FIG. 6 is completed.
このような熱可塑性プリプレグ成形品の製造方法によれば、複数枚重ねられた熱可塑性プリプレグ１０の上面及び下面にメッキ（蒸着，スパッタリングも含まれる）で金属被膜２０が形成されたものを金型１００にセットして加熱加圧による型成形を行うので、金属同士の接触により金型１００から熱可塑性プリプレグ成形品１を容易に取り出すことができる。特に、接着性の高い樹脂、例えば、ＰＥＥＫ（ポリエーテルエーテルケトン）又はＰＥＫＫ（ポリエーテルケトンケトン）をマトリクス樹脂としてシート状繊維基材に含浸させてなる熱可塑性プリプレグ１０が金型１００に対して直接接触しないため離型が簡単である。 According to such a method for manufacturing a thermoplastic prepreg molded product, a mold in which a metal coating 20 is formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of a plurality of stacked thermoplastic prepregs 10 is molded. Since the molding is performed by heating and pressurizing after setting to 100, the thermoplastic prepreg molded product 1 can be easily taken out from the mold 100 by contact between metals. In particular, a thermoplastic prepreg 10 obtained by impregnating a sheet-like fiber base material with a highly adhesive resin, for example, PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as a matrix resin is used for the mold 100. Release is easy because there is no direct contact.
しかも、メッキ（蒸着，スパッタリングも含まれる）により形成される金属被膜２０は薄いものであるので、延性がよく、変形しやすく金型１００でプレスしたときでも形状に倣い易い。さらに、上下に重ねられた熱可塑性プリプレグ１０は金属被膜２０が形成されたものも含めて離散的に超音波融着により一体化されているので、重ねられたものを容易にかつ強固に仮止めすることができ、金型成形時に位置ズレすることもない。
さらに、メッキ（蒸着，スパッタリングも含まれる）された金属被膜２０は、酸洗いによって簡単に除去されるので表面がきれいな熱可塑性プリプレグ成形品１が提供される。
Moreover, since the metal film 20 formed by plating (including vapor deposition and sputtering) is thin, it has good ductility, is easily deformed, and easily follows the shape even when pressed with the mold 100. Furthermore, since the thermoplastic prepreg 10 stacked up and down is integrated discretely by ultrasonic fusion including the one on which the metal coating 20 is formed, the stacked one can be easily and firmly temporarily fixed. And there is no misalignment during mold forming.
Furthermore, since the plated metal film 20 (including vapor deposition and sputtering) is easily removed by pickling, the thermoplastic prepreg molded article 1 having a clean surface is provided.
また、熱可塑性樹脂のなかでも、特にＰＥＥＫ（ポリエーテルエーテルケトン）やＰＥＫＫ（ポリエーテルケトンケトン）などといった接着性が高く熔融温度の高いいわゆるスーパーエンジニアリングプラスチックをマトリクス樹脂として使用した場合について説明したが、熱可塑性樹脂として、ＰＡ（ナイロン），ＰＰＳ（ポリフェニレンサルファイド），ＰＥＩ（ポリエーテルイミド），ＰＣ（ポリカーボネート），ＰＡＩ（ポリアミドイミド），ＴＰＩ（熱可塑性ポリイミド），ＰＥＳ，ＰＳＵ，ＬＣＰ，ＰＡＲ，ＰＴＦＥ，ＦＥＰ，ＰＦＡ，ＰＣＴＦＥ，ＥＴＦＥ，ＥＣＴＦＥ，ＰＶＤＦ，ＰＶＦ，ＰＥＴ（ポリエーテルテフタレート）などをマトリクス樹脂としてシート状繊維基材に含浸させてなる熱可塑性プリプレグ１０から成形品を製造する場合にも同様に適用することができる。 In addition, among the thermoplastic resins, the case where so-called super engineering plastics such as PEEK (polyetheretherketone) and PEKK (polyetherketoneketone) having high adhesiveness and high melting temperature are used as the matrix resin has been described. As thermoplastic resins, PA (nylon), PPS (polyphenylene sulfide), PEI (polyetherimide), PC (polycarbonate), PAI (polyamideimide), TPI (thermoplastic polyimide), PES, PSU, LCP, PAR, It consists of a thermoplastic prepreg 10 made by impregnating a sheet-like fiber base material with PTFE, FEP, PFA, PCTFE, ETFE, ECTFE, PVDF, PVF, PET (polyether terephthalate) as a matrix resin. It can be similarly applied to the case of producing a goods.
また、本実施形態では、熱可塑性プリプレグ１０の上面及び下面にメッキ（蒸着，スパッタリングも含まれる）で金属被膜２０を形成して金型１００に対する離型性が悪くなることを防止したが、特に金型１００の下型１０２からの離型性を考慮して、最も下段になる熱可塑性プリプレグ１０ｂの下面だけにメッキ（蒸着，スパッタリングも含まれる）を施して金属被膜２０を形成するようにしてもよい。
また、複数枚（５枚）重ねられた熱可塑性プリプレグ１０を金型１００でプレスするようにしたが、熱可塑性プリプレグ１０を１枚（単体）のものに対してその上面及び下面、あるいは下面だけに薄い金属被膜２０をメッキ（蒸着，スパッタリングも含まれる）によって形成したものを金型１００にセットとして型成形し、その後、金属被膜２０を酸洗いして熱可塑性プリプレグ成形品１が完成するようにしてもよい。
Further, in this embodiment, the metal coating 20 is formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of the thermoplastic prepreg 10 to prevent the mold releasability from being deteriorated. In consideration of releasability from the lower mold 102 of the mold 100, only the lower surface of the lowermost thermoplastic prepreg 10b is plated (including vapor deposition and sputtering) to form the metal coating 20. Also good.
Further, a plurality of (five) sheets of the thermoplastic prepreg 10 are pressed by the mold 100, but only the upper surface and the lower surface, or the lower surface of the thermoplastic prepreg 10 with respect to one (single unit). A thin metal film 20 formed by plating (including vapor deposition and sputtering) is molded into a mold 100 as a set, and then the metal film 20 is pickled to complete the thermoplastic prepreg molded product 1. It may be.
１ 熱可塑性プリプレグ成形品
１０ 熱可塑性プリプレグ
１０ａ 最も上段になる熱可塑性プリプレグ
１０ｂ 最も下段になる熱可塑性プリプレグ
１０ｃ 中間に位置する熱可塑性プリプレグ
１５ 超音波融着点
２０ 金属被膜
３０ 酸溶液
５０ 容器
１００ 金型
１０１ 上型
１０２ 下型
DESCRIPTION OF SYMBOLS 1 Thermoplastic prepreg molded product 10 Thermoplastic prepreg 10a The uppermost thermoplastic prepreg 10b The lowermost thermoplastic prepreg 10c The thermoplastic prepreg located in the middle 15 Ultrasonic fusion point 20 Metal coating 30 Acid solution 50 Container 100 Gold Mold 101 Upper mold 102 Lower mold
Claims (5)
前記熱可塑性プリプレグのうち最も上段になる熱可塑性プリプレグの上面及び最も下段になる熱可塑性プリプレグの下面に薄い金属被膜をメッキによって形成する被膜形成工程と、
前記最も上段になる熱可塑性プリプレグと最も下段になる熱可塑性プリプレグの間に残りの熱可塑性プリプレグが存在する場合はその残りの熱可塑性プリプレグを間に重ね、残りの熱可塑性プリプレグが存在しない場合には前記最も上段になる熱可塑性プリプレグと最も下段になる熱可塑性プリプレグを直接重ねるとともに前記熱可塑性プリプレグに対してそれぞれ離散的に超音波融着して一体化するサンド工程と、
前記一体化された熱可塑性プリプレグを金型にセットして加熱加圧処理を施す型成形工程と、
前記加熱加圧処理後に前記金型から取り出された熱可塑性プリプレグ成形品に形成された金属被膜を酸で洗い流して除去する酸洗い工程を、備えることを特徴にする熱可塑性プリプレグ成形品の製造方法。 A method for producing a thermoplastic prepreg molded product by molding a plurality of laminated thermoplastic prepregs obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
A film forming step of forming a thin metal film by plating on the upper surface of the uppermost thermoplastic prepreg and the lower surface of the lowermost thermoplastic prepreg among the thermoplastic prepregs ;
The most If the remaining thermoplastic prepreg exists between becomes the upper thermoplastic prepreg of the most become lower thermoplastic prepregs stacked between the remainder of the thermoplastic prepreg, in the absence of the remaining thermoplastic prepreg Is a sand process in which the uppermost thermoplastic prepreg and the lowermost thermoplastic prepreg are directly stacked and discretely ultrasonically fused and integrated with the thermoplastic prepreg , respectively.
A mold forming step in which the integrated thermoplastic prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a thermoplastic prepreg molded article, comprising a pickling step of washing away a metal film formed on the thermoplastic prepreg molded article taken out of the mold after the heating and pressing treatment with an acid. .
前記熱可塑性プリプレグのうち最も下段になる熱可塑性プリプレグの下面に薄い金属被膜をメッキによって形成する被膜形成工程と、
前記最も下段になる熱可塑性プリプレグの上に残りの熱可塑性プリプレグを重ねるとともに前記熱可塑性プリプレグに対してそれぞれ離散的に超音波融着して一体化するサンド工程と、前記一体化された熱可塑性プリプレグを金型にセットして加熱加圧処理を施す型成形工程と、
前記加熱加圧処理後に前記金型から取り出された熱可塑性プリプレグ成形品に形成された金属被膜を酸で洗い流して除去する酸洗い工程を、備えることを特徴にする熱可塑性プリプレグ成形品の製造方法。 A method for producing a thermoplastic prepreg molded product by molding a plurality of laminated thermoplastic prepregs obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
A film forming step of forming a thin metal film by plating on the lower surface of the thermoplastic prepreg at the bottom of the thermoplastic prepreg;
A sand process for superimposing the remaining thermoplastic prepreg on the lowermost thermoplastic prepreg and discretely ultrasonically bonding the thermoplastic prepreg to the thermoplastic prepreg, and the integrated thermoplastic; A mold forming process in which a prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a thermoplastic prepreg molded article, comprising a pickling step of washing away a metal film formed on the thermoplastic prepreg molded article taken out of the mold after the heating and pressing treatment with an acid. .
前記熱可塑性プリプレグの上面及び下面、あるいは下面だけに薄い金属被膜をメッキによって形成する被膜形成工程と、
前記熱可塑性プリプレグを金型にセットして加熱加圧処理を施す型成形工程と、
前記加熱加圧処理後に前記金型から取り出された熱可塑性プリプレグ成形品に形成された金属被膜を酸で洗い流して除去する酸洗い工程を、備えることを特徴にする熱可塑性プリプレグ成形品の製造方法。 A method for producing a thermoplastic prepreg molded product by molding a thermoplastic prepreg obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
A film forming step of forming a thin metal film on the upper and lower surfaces of the thermoplastic prepreg, or only on the lower surface by plating; and
A mold forming step in which the thermoplastic prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a thermoplastic prepreg molded article, comprising a pickling step of washing away a metal film formed on the thermoplastic prepreg molded article taken out of the mold after the heating and pressing treatment with an acid. .
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