JP2017052197A - Method for manufacturing molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a molding in which there is no need to cut off an unnecessary peripheral part after molding.SOLUTION: A method for manufacturing a molding in which a molding 10 of a three-dimensional shape is manufactured from a planar plate-like member 20 including fabric and synthetic resin comprises: a cutting process of forming a planar pre-board 30 having an outer peripheral shape following an outer peripheral shape of the molding 10 by cutting off the plate-like member 20; a fixing process of fixing an outer peripheral end part 31 of the pre-board 30 which is arranged for a molding die 41 having a molding surface 43 following a three-dimensional shape of the molding 10, over the entire periphery; and a molding process of molding the pre-board 30 which is in the state where the outer peripheral end part 31 is fixed into a three-dimensional shape following the molding surface 43.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a method for producing a molded body.

  Conventionally, as a molded body containing fibers and a synthetic resin, for example, the one described in Patent Document 1 is known. In Patent Document 1, a plurality of laminated fiber reinforced sheets are formed into a product shape by sandwiching them between an upper mold and a lower mold, and then a resin molded body is injected by injecting a resin between the upper mold and the lower mold. A method of manufacturing is described.

JP 2008-68553 A

    In Patent Document 1, when the fiber reinforced sheet is formed into a product shape, an unnecessary portion of the outer periphery (a portion not used as a product) may be generated in the formed fiber reinforced sheet. In such a case, it is necessary to cut the unnecessary outer periphery after molding.

  This invention is completed based on the above situations, Comprising: It aims at providing the manufacturing method of the molded object which can suppress the situation where an outer periphery unnecessary part is cut | disconnected after shaping | molding.

  In order to solve the above problems, the present invention is a method for manufacturing a molded body for manufacturing a three-dimensional molded body from a planar plate-shaped member comprising a woven fabric and a synthetic resin, the plate-shaped member being A cutting step of forming a planar preboard having an outer peripheral shape following the outer peripheral shape of the molded body by cutting, and a pre-board disposed in a molding die having a molding surface following the three-dimensional shape of the molded body A fixing step of fixing the outer peripheral end portion over the entire circumference, and a molding step of molding the preboard in a state where the outer peripheral end portion is fixed into a three-dimensional shape following the molding surface.

  According to the present invention, in the cutting step, a flat plate-like member is cut to form a preboard having an outer peripheral shape that follows the outer peripheral shape of the molded body, and thereafter, the outer peripheral end portion extends over the entire periphery. In this state, the preboard is molded into a three-dimensional shape. Thereby, the situation where an outer periphery unnecessary part remains in a molded object can be suppressed. If the outer periphery unnecessary portion is cut after the preboard is formed into a three-dimensional shape, the outer periphery unnecessary portion formed into the three-dimensional shape has higher rigidity than that of a flat shape (two-dimensional shape). In particular, when a woven fabric is included, the rigidity is higher than that including only a synthetic resin. For this reason, workability related to cutting is lowered, and there is a concern that a cutting tool or the like may be deteriorated. In the present invention, it is not necessary to cut an unnecessary outer periphery formed in a three-dimensional shape, and workability can be further improved.

  Further, in the molding step, the preboard is molded into a three-dimensional shape following the molding surface by sucking the preboard to the molding surface through a vacuum suction hole provided in the molding die. be able to. By performing vacuum forming, the pre-board can be formed into a three-dimensional shape all over the entire surface. As a result, it is possible to suppress a situation in which stress is locally applied to the fabric included in the preboard, and it is possible to suppress a situation in which the fabric is wrinkled.

  In the molding step, the peripheral portion of the slit formed in the preboard can be molded into a shape that follows the shape of the protrusion provided on the molding surface, thereby forming a standing wall portion. By molding the standing wall portion, the rigidity of the molded body can be further increased. When the standing wall portion is molded, there is a concern that a stress may act on the top portion or the base portion of the standing wall portion and the fabric may be wrinkled. By forming a slit in the portion that becomes the standing wall portion in advance, the stress can be released and the generation of wrinkles can be suppressed.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the molded object which does not need to cut | disconnect an unnecessary outer periphery after shaping | molding can be provided.

The perspective view which shows the molded article which concerns on Embodiment 1 of this invention. Front view showing a plate-like member Front view showing the cutting process Plan view showing the fixing process Sectional drawing which shows a fixing process (corresponding to the figure cut | disconnected by the VV line of FIG. 4) Sectional view showing the molding process The perspective view which shows a part of molded article which concerns on Embodiment 2 of this invention. Sectional drawing which shows the formation process which concerns on Embodiment 2 (corresponding to the figure cut | disconnected by the VIII-VIII line of FIG. 7) The perspective view which shows the pre board which concerns on Embodiment 3 of this invention. The perspective view which shows the molded article which concerns on Embodiment 3. The perspective view which shows the pre board which concerns on Embodiment 4 of this invention. The perspective view which shows the molded product which concerns on Embodiment 4. The perspective view which shows the pre board which concerns on Embodiment 5 of this invention. The perspective view which shows the molded product which concerns on Embodiment 5. Schematic which shows the fiber direction of the molded article which concerns on Embodiment 5. FIG.

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. In this embodiment, what constitutes a backboard in a vehicle seat is exemplified as a molded body. FIG. 1 is a perspective view of the molded body 10 viewed from the vehicle rear side. The molded body 10 has a long longitudinal shape in the vehicle vertical direction, and mainly constitutes the back surface (design surface) of the vehicle seat. As shown in FIG. 1, the molded body 10 is formed, for example, from the main wall portion 11 constituting the rear surface of the molded body 10 and the side end portions of the main wall portion 11 in the vehicle width direction to the front of the vehicle. And a pair of side wall portions 12 (standing wall portions) that rises toward the vehicle, and has a curved shape (three-dimensional shape) recessed toward the rear of the vehicle. In addition, a backboard is comprised by laminating | stacking the some molded object 10, for example, and hardening with a thermosetting resin.

  The molded body 10 is manufactured, for example, by molding (shaping) a planar plate-like member 20 (see FIG. 2) configured by impregnating a fabric with a thermoplastic resin so as to follow a product shape. . Examples of the fibers (reinforcing fibers) constituting the woven fabric of the molded body 10 include carbon fibers, glass fibers, and aramid fibers. Moreover, as a thermoplastic resin (binder resin) which comprises the molded object 10, a thermoplastic emulsion can be illustrated, for example. In addition, the material of the fiber and thermoplastic resin which comprise the molded object 10 is not limited to what was mentioned above, It can change suitably.

  In the present embodiment, the plate-like member 20 shown in FIG. 2 is formed into a pre-board 30 (see FIG. 3, details will be described later), and then the pre-board 30 that is a pre-formed body is formed into the formed body 10 (this Molded body). Next, the shaping | molding apparatus 40 for manufacturing the molded object 10 is demonstrated. As shown in FIG. 5, the molding apparatus 40 includes a molding die 41 and a plurality of fixing members 51 that fix the preboard 30 to the molding die 41. As shown in FIG. 5, the molding die 41 includes a recess 42 having a molding surface 43 that follows the product shape of the molded body 10. A plurality of vacuum suction holes 43 </ b> A are formed on the molding surface 43 of the molding die 41. A pneumatic supply device (not shown) such as a pump is connected to the plurality of vacuum suction holes 43A.

  With this configuration, it is possible to apply a negative pressure (vacuum evacuation) to the preboard 30 via each vacuum suction hole 43A by operating the air pressure supply device in a state where the preboard 30 is set in the molding die 41. It has become. The recess 42 has a shape that is slightly smaller than the preboard 30 in plan view. As the fixing member 51, for example, a clamp or the like can be used. A plurality of fixing members 51 are arranged along the outer peripheral portion of the recess 42 in the upper surface of the mold 41. Further, the plurality of fixing members 51 are arranged over the entire circumference of the outer peripheral portion of the recess 42. Thereby, the outer peripheral end portion 31 of the preboard 30 can be fixed over the entire periphery by the plurality of fixing members 51.

  Next, the manufacturing method of the molded object 10 is demonstrated. The manufacturing method of the molded body 10 of the present embodiment includes a cutting step for cutting the plate-like member 20 to form the preboard 30, a fixing step for fixing the planar preboard 30 to the molding die 41, and the preboard 30. And a vacuum forming process for forming a three-dimensional shape.

(Cutting process)
In the cutting step, the plate-like member 20 shown in FIG. 2 is fixed to a mounting table (not shown), and as shown in FIG. 3, for example, a plate is used by using laser light L1 emitted from the laser light emitting device 61. The shaped member 20 is cut. Thereby, the pre-board 30 is shape | molded. Here, the shape of the pre-board 30 is a flat shape, and the outer peripheral shape thereof follows the outer peripheral shape of the molded body 10. The shape of the pre-board 30 is determined based on the elongation rate of the fabric constituting the pre-board 30 and the three-dimensional shape of the molded body 10 (surface shape of the molding surface 43), and is determined using, for example, CAE analysis. Can do.

(Fixing process)
Next, as shown in FIGS. 4 and 5, the preboard 30 is placed on the mold 41. Specifically, as shown in FIG. 5, the concave portion 42 of the mold 41 is covered with the preboard 30. Thereafter, the outer peripheral end 31 of the preboard 30 is fixed to the molding die 41 over the entire circumference using a plurality of fixing members 51. Subsequently, a film 52 (bagging film) is disposed so as to cover the preboard 30 from above. Further, the entire periphery of the film 52 and the molding die 41 are sealed with a sealing material 53. As shown in FIG. 5, the film 52 may be fixed together with the preboard 30 by a fixing member 51, or may be fixed separately from the preboard 30.

(Molding process)
Next, an air pressure supply device (not shown) is driven to decompress the inside of the concave portion 42 sealed by the film 52 through the vacuum suction hole 43 </ b> A of the mold 41. At the same time (or after the pressure is reduced), the preboard 30 is heated using a heating device (not shown) (for example, a heater provided in the mold 41). As a result, as shown in FIG. 6, the softened pre-board 30 is sucked by the molding surface 43 and molded into a three-dimensional shape following the shape of the molding surface 43. Thereafter, while the suction of the preboard 30 through the vacuum suction hole 43A is maintained, the heating device is stopped, and after cooling the preboard 30, the suction through the vacuum suction hole 43A is stopped. Thereby, the molded object 10 is completed. In addition, after the preboard 30 is heated, the inside of the recess 42 may be decompressed.

  Note that the preboard 30 has a certain degree of elasticity, and in the process in which the preboard 30 is deformed into the shape of the molding surface 43, the fabric constituting the preboard 30 is partially due to the uneven shape of the molding surface 43. Extends and contracts. In addition, the fabric constituting the preboard 30 has, for example, the lowest stretchability in the fiber direction (warp direction and weft direction), and the stretchability becomes higher as it goes to the direction of 45 degrees with respect to the fiber direction. The

  Next, the effect of this embodiment will be described. According to this embodiment, by cutting the planar plate-like member 20 in the cutting step, the preboard 30 having an outer peripheral shape that follows the outer peripheral shape of the molded body 10 is formed, and thereafter, the outer peripheral end portion 31 thereof. Is fixed over the entire circumference, and the preboard 30 is formed into a three-dimensional shape. Thereby, the situation where an outer periphery unnecessary part remains in the molded object 10 can be suppressed.

  If the pre-board 30 is formed into a three-dimensional shape and then the outer peripheral unnecessary portion is cut, the outer peripheral unnecessary portion formed into the three-dimensional shape has higher rigidity than that of a flat shape (two-dimensional shape). In particular, when a woven fabric is included, the rigidity is higher than that including only a synthetic resin. For this reason, workability related to cutting is lowered, and when a cutting tool is used, there is a concern that the cutting tool may be deteriorated. In this embodiment, it is not necessary to cut the outer periphery unnecessary part of a three-dimensional shape, and workability can be further enhanced.

  In addition, when the outer periphery unnecessary portion of the three-dimensional shape is cut, the outer periphery unnecessary portion that is cut is difficult to be continuous and tends to be fine fragments. In the present embodiment, since the planar plate-like member 20 is cut, the unnecessary portion of the cut outer periphery becomes relatively large, and the processing can be easily performed. Further, in the case of cutting a planar plate-like member, the laser scanning and the shape of the cutting tool can be made simpler, and a simpler configuration can be obtained.

  Conventionally, a method of molding is known in which only one end of the preboard is fixed and pressed against the molding surface for each part from one end side to the other end side. In such a method, the molding error of each part in the pre-board accumulates on the other end side, and the outer peripheral unnecessary part on the other end side tends to be excessive. In this embodiment, since it shape | molds in the state which fixed the outer peripheral edge part of the preboard 30 over the perimeter, the situation where an outer periphery unnecessary part arises can be suppressed.

  In the molding step, the preboard 30 can be molded into a three-dimensional shape following the molding surface 43 by sucking the preboard 30 to the molding surface 43 through the vacuum suction holes 43 </ b> A provided in the molding die 41. . By performing vacuum forming, the pre-board 30 can be formed into a three-dimensional shape all over the entire surface. As a result, a situation in which stress is locally applied to the fabric included in the preboard 30 can be suppressed, and a situation in which the fabric is wrinkled can be suppressed. In general, when the three-dimensional shape of a molded product becomes complicated, there is a higher possibility that wrinkles will occur, and molding is often difficult from the viewpoint of design. In other words, in the manufacturing method of the present embodiment, a situation in which wrinkles are generated can be suppressed, so that a more complicated three-dimensional shape can be formed.

<Embodiment 2>
Next, a second embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 7, the molded body 110 of the present embodiment includes two wall portions 111 and 112 having different extending directions, and a standing wall portion 113 (connection rib) that connects both the wall portions 111 and 112. Yes. In order to form the standing wall portion 113, first, as shown in FIG. 8, a slit 131 is previously formed in the preboard 130 (two-dot chain line in FIG. 8). Such a slit 131 may be formed at the same time when the outer peripheral shape of the preboard 130 is formed in the cutting step. Thereafter, in the molding step, the peripheral portion of the slit 131 is pressed by the projection 145 provided on the molding surface 143 of the molding die 141 and partially stretched. Accordingly, the peripheral portion of the slit 131 is formed into a shape that follows the shape of the protruding portion 145, and becomes the standing wall portion 113. In FIG. 8, reference numeral 131A is given to the slit 131 after molding.

  By providing such a standing wall portion 113, the rigidity of the molded body 110 can be further increased. Moreover, when shape | molding the standing wall part 113, stress acts on the top part, base part, etc. of the standing wall part 113, and there exists a concern about the situation where a wrinkle arises in a textile fabric. By forming the slit 131 in advance in the portion that becomes the standing wall 113, the stress can be released and the generation of wrinkles can be suppressed. Further, as shown in FIG. 8, in the molding process, molding may be performed in a state in which a portion that becomes the top of the standing wall portion 113 and a peripheral portion of the standing wall portion 113 are fixed by fixing members 151 and 152. In this way, it is possible to suppress the occurrence of wrinkles near the standing wall portion 113.

<Embodiment 3>
Next, a third embodiment of the present invention will be described with reference to FIGS. In the present embodiment, as shown in FIG. 9, slits 231 are formed at the peripheral end portion of the preboard 230, and in the molding process, the peripheral portions of the slits 231 are overlapped to form the overlapping portion 232. By forming the slits 231, it is possible to release stress when the preboard 230 is formed into the three-dimensional shaped molded body 210, and it is possible to suppress the occurrence of wrinkles. Moreover, the rigidity of the molded object 210 can be made higher by making the peripheral part of the slit 231 into the overlapping part 232.

<Embodiment 4>
Next, a fourth embodiment of the present invention will be described with reference to FIGS. In the present embodiment, as shown in FIG. 11, a through hole 331 is formed in the inner portion of the preboard 330, and the peripheral portion of the through hole 331 is bulged in the molding step to form a bulged portion 311 ( (See FIG. 12). By forming the through-hole 331 at a location where the bulging portion 311 is formed, stress at the time of molding the bulging portion 311 can be released, and a situation in which wrinkles occur in the molded body 310 can be suppressed.

<Embodiment 5>
Next, a fifth embodiment of the present invention will be described with reference to FIGS. In this embodiment, as shown in FIG. 13, a V-shaped cutout 431 is formed at the outer peripheral end of the preboard 430, and the inner surfaces 431A and 431A of the cutout 431 are brought into contact with each other in the molding process. To form the bulging portion 411 (see FIG. 14). If it does in this way, as shown in FIG. 15, in the bulging part 411 of the molded object 410, the direction of a fiber can be changed for every surface. In the molded body 410, the tensile strength in the direction along the fiber direction becomes higher. In the present embodiment, since the fiber direction can be set for each surface, the tensile strength in a predetermined direction can be increased.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.
(1) In the above embodiment, the method of forming the preboard into a three-dimensional shape by vacuum forming using the vacuum suction hole 43A is exemplified, but the present invention is not limited to this. For example, the preboard may be formed into a three-dimensional shape by press forming with a pair of forming dies.
(2) In the above-described embodiment, as the molded body, the back board is exemplified, but the present invention is not limited to this. The usage of the molded body is not limited to those exemplified in the above embodiment, and can be appropriately changed. Moreover, the shape of a preboard and a molded object is not limited to what was illustrated by the said embodiment, It can change suitably.
(3) The formation location of the vacuum suction hole 43A is not limited to that shown in FIG.
(4) In the molding step of the above embodiment, a portion other than the outer peripheral end of the preboard may be fixed with a fixing member.
(5) In the said embodiment, although the method of cut | disconnecting the plate-shaped member 20 using a laser beam was illustrated, it is not limited to this. For example, the plate-like member 20 may be cut using a Thomson blade or the like.
(6) You may perform combining the method of forming the standing wall part, slit, through-hole, notch part, etc. which were illustrated in the said embodiment, respectively.
(7) In the said embodiment, although the thermoplastic resin was illustrated as a synthetic resin which comprises the plate-shaped member 20, it is not limited to this. A thermosetting resin may be used as the synthetic resin constituting the plate member 20.

10, 110, 210, 310, 410 ... molded body, 20 ... plate-like member, 30, 130, 230, 330, 430 ... preboard, 31 ... outer peripheral edge of preboard, 41, 141 ... molding die, 43, 143 ... Molding surface, 43A ... vacuum suction hole, 113 ... standing wall, 131 ... slit, 145 ... projection

Claims (3)

A method for producing a molded body for producing a three-dimensional shaped molded body from a planar plate-shaped member comprising a woven fabric and a synthetic resin,
A cutting step of forming a planar preboard having an outer peripheral shape that follows the outer peripheral shape of the molded body by cutting the plate-like member,
A fixing step of fixing the outer peripheral end of the preboard disposed on a molding die having a molding surface following the three-dimensional shape of the molded body, over the entire circumference;
A forming step of forming the preboard in a state where the outer peripheral end portion is fixed into a three-dimensional shape following the forming surface, and a method for manufacturing a formed body. In the molding step,
2. The molded body according to claim 1, wherein the preboard is molded into a three-dimensional shape following the molding surface by sucking the preboard through the vacuum suction hole provided in the molding die. Method. In the molding step,
The manufacturing method of the molded object of Claim 1 or Claim 2 which shape | molds the peripheral part of the slit formed in the said preboard in the shape which follows the shape of the projection part provided in the said molding surface, and makes it a standing wall part.

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