JPWO2018139062A1 - Molding method of fiber reinforced resin products - Google Patents

Abstract

A method for molding a fiber reinforced resin product, in which a molded product is molded from a resin sheet containing reinforcing fibers, and a preform product (1) having a main body portion and a collar portion (6), (7) is shaped from the resin sheet. And the preform product (1) with the mold (1) so that the end portions (6A) and (7A) of the collar portions (6) and (7) face the shear edge portions (40) and (41). 10), a pressing step for pressing the preform product (1) with the molding die (10), and the flanges (6) and (7) are cut after the pressing step. A cutting step.

Description

  The present invention relates to a method for molding a fiber reinforced resin product.

  As a method for molding a fiber reinforced resin product having a U-shaped cross section, a method is known in which a preform product having a U-shaped cross section is pressure-molded with a mold having a shear edge structure (for example, Patent Documents). 1). The shear edge structure is provided so that air is smoothly discharged from the cavity when the mold is closed, and the preform product does not substantially flow out of the cavity.

JP 2009-298069 A

  However, when the preform product is shifted from the normal position when the preform product is set in the mold, the preform product may flow out at one shear edge portion and the thin portion may occur at the other shear edge portion. Since preform products generally have low rigidity (shape stability), it is difficult to accurately set them at regular positions of the mold, and this problem becomes more apparent as the size of preform products increases.

  In addition, when the U-shaped section of the molded product is asymmetrical, when the mold is closed, the rising portions on both sides of the preform product receive different pressing forces (shearing forces) from the mold or are pressed at different timings. You will be under pressure. For this reason, even if the preform product is set in the normal position in the mold before the mold is closed, the position is shifted when the mold is closed, and the preform product flows out at one share edge, and the other There is a risk of lacking in the shear edge.

  The present invention was created in order to solve such a problem, and in a molding method of a fiber reinforced resin product including a pressure molding process of a mold having a shear edge structure, a preform on the mold It is an object of the present invention to provide a method for molding a fiber reinforced resin product that can accurately mold a molded product without being affected by the positional deviation of the product.

  In order to solve the above-mentioned problems, the present invention provides a method for molding a fiber reinforced resin product in which a molded product is molded from a resin sheet containing reinforcing fibers, the preform product having a main body portion and a collar portion from the resin sheet. A preforming step for shaping, a setting step for setting the preform product in the molding die so that an end of the flange portion faces a shear edge portion of the molding die, and the preform product is added by the molding die. It comprises a pressure forming step for pressure forming and a cutting step for cutting the flange after the pressure forming step.

  According to the present invention, a molded product can be accurately molded without being affected by the position shift of the preform product on the mold.

Further, the present invention is characterized in that the main body portion is configured to include a portion having a U-shaped section or a V-shaped section.
Furthermore, the present invention is characterized in that the main body portion is configured to include a portion exhibiting a cross-sectional crank shape.

  ADVANTAGE OF THE INVENTION According to this invention, the molded product containing the site | part which exhibits the cross-sectional U-shape or the cross-sectional V shape, and the site | part which exhibits a cross-sectional crank shape can be shape | molded accurately.

  According to the present invention, a molded product can be accurately molded without being affected by the position shift of the preform product on the mold.

It is sectional drawing of the preform goods which concern on this embodiment. (A), (b), (c) is sectional drawing which shows the setting process of this embodiment, a press molding process, and a cutting process, respectively. It is an enlarged view around a share edge part. It is drawing which concerns on a modification, and is a perspective view of the preform product in the molded product which exhibited the cross-sectional crank shape. (A), (b), (c) is sectional drawing which shows the setting process of a modification, a press molding process, and a cutting process, respectively.

  The present invention relates to a method for molding a reinforced fiber resin product, in which a molded product having a U-shaped cross section is molded from a resin sheet containing reinforcing fibers. The resin sheet is a flat plate member made of a composite material composed of reinforcing fibers such as glass fibers and carbon fibers and a thermoplastic resin or a thermosetting resin. The thermoplastic resin sheet is solidified at room temperature, and is softened by being heated to a predetermined temperature, and can be processed such as press molding. A thermosetting resin sheet is easily deformable at room temperature, and is cured by heating and pressing at a predetermined temperature. Thereby, a product having a desired shape is formed.

  1 and 2, the molding method of the present invention includes a preform process for shaping a cross-sectional hat-shaped preform product 1 having a pair of flanges 6 and 7 from a laminate in which a plurality of resin sheets are laminated. The setting process of setting the preform product 1 in the mold 10 so that the end portions 6A, 7A of the flanges 6, 7 face the shear edge portions 40, 41 of the mold 10, and the preform product 1 in the mold 10 And a cutting step of cutting the flange portions 6 and 7 so as to have a U-shaped cross section after the pressure forming step.

"Preform process"
The preform product 1 shaped in the preform process is heated and pressed in a subsequent pressure molding process. Therefore, the preform 1 may have any shape that can be satisfactorily set on the mold 10, and a known pressing method or the like can be applied as a shaping method. As shown in FIG. 1, the preform product 1 includes a U-shaped portion 5 composed of a bottom portion 2 and a pair of rising portions 3 and 4 rising from both sides of the bottom portion 2, and end portions of the rising portions 3 and 4. And flanges 6 and 7 extending substantially orthogonally to the outside.

  In the present embodiment, the bottom portion 2 and the rising portions 3 and 4 each extend in a substantially planar shape. Further, the rising portions 3 and 4 are each formed in an inclined shape so that the distance between the rising portions 3 and 4 increases as they rise from the bottom portion 2. Further, the one rising portion 3 and the other rising portion 4 are formed so as to have different lengths.

"Set process"
In FIG. 2, the mold 10 includes an upper mold (female) first mold 11 and a lower (male) second mold 12. The first mold 11 is composed of, for example, a movable mold that moves in the pressing direction, and the second mold 12 is composed of a fixed mold. Of course, both may be movable. The first mold 11 includes a bottom cavity surface 13 for heating and pressurizing the bottom portion 2 of the preform 1, rising portion cavity surfaces 14 and 15 for heating and pressurizing rising portions 3 and 4, and rising portion cavity surfaces 14 and 15, respectively. The flange portions 16 and 17 extend outward from the respective end portions and heat and press the flange portions 6 and 7. Further, the first molding die 11 has shear edge surfaces 18 and 19 extending in the mold opening direction of the first molding die 11 from the respective end portions of the flange cavity surfaces 16 and 17, and base portions of the shear edge surfaces 18 and 19. The mold matching surfaces 20 and 21 each extend outward. The second mold 12 has a bottom cavity surface 23, rising cavity surfaces 24, 25, flange cavity surfaces 26, 27, shear edge surfaces 28, so as to face each surface of the first mold 11. 29 and mold matching surfaces 30 and 31.

  One shear edge portion 40 is configured by the shear edge surface 18 of the first mold 11 and the shear edge surface 28 of the second mold 12. As shown in FIG. 3 in an enlarged manner, the shear edge portion 40 is formed so that the distance L between the shear edge surface 18 and the shear edge surface 28 increases as the distance from the cavity increases, and both surfaces slide. As a result, the volume of the cavity changes. In FIG. 3, the interval L is exaggerated. The shear edge surface 19 of the first mold 11 and the shear edge surface 29 of the second mold 12 constitute the other shear edge portion 41. The shear edge portion 41 is also formed so that the distance L between the shear edge surface 19 and the shear edge surface 29 increases as the distance from the cavity increases. The share edge portions 40 and 41 are provided so that air is smoothly discharged from the cavity when the mold is closed, and the preform product 1 does not substantially flow out of the cavity. The share edge portions 40 and 41 are generally referred to as a share edge structure and are also referred to as a chopping structure.

  With respect to the mold 10 having the above configuration, in the setting process, as shown in FIG. 2A, the end portions 6A and 7A of the flange portions 6 and 7 are in the shared edge portions 40 and 41, respectively, in the mold open state. Then, the preform product 1 is set (placed) on the second mold 12 so as to face. More specifically, the bottom cavity surface 23 and the rising portion cavity surfaces 24 and 25 are in contact with the bottom portion 2 and the rising portions 3 and 4 of the preform 1, and the flange portion cavity surfaces 26 and 27 and the flange portion 6 are in contact with each other. , 7 are in contact with each other. Further, the end portion 6A of the flange portion 6 and the shear edge surface 28 and the end portion 7A of the flange portion 7 and the shear edge surface 29 are in contact with each other or are opposed to each other with a slight gap.

"Pressure forming process"
As shown in FIG. 2B, in the pressure molding process, the first mold 11 is closed and the preform 1 is heated by the first mold 11 and the second mold 12 while being heated. Molded. As a heating means, the aspect which heats the preform 1 with the heating means incorporated in the 1st shaping | molding die 11 and the 2nd shaping | molding die 12 may be sufficient, and the heat source provided separately from the shaping | molding die 10 may be used. An embodiment in which the preform product 1 is heated in advance and then the preform product 1 is placed on the second mold 12 may be employed. Further, a sealing material 35 may be interposed between the mold matching surfaces 20 and 30 and between the mold matching surfaces 21 and 31, and a gap 36 formed between the surfaces may be evacuated.

"Cutting process"
The molded product that has been pressure-molded in the pressure-molding step is taken out from the mold 10 and, as shown in FIG. 2 (c), the flanges 6 and 7 are cut by a cutting device (not shown). . Thereby, the molded product 50 provided with the U-shaped part 5 comprised by the bottom part 2 and a pair of standing part 3 and 4 is obtained.

According to the molding method including the above steps, in the setting step, the bottom cavity surface 23 and the rising portion cavity surfaces 24 and 25 are brought into contact with the bottom portion 2 and the rising portions 3 and 4 of the preform 1, respectively. By bringing the partial cavity surfaces 26 and 27 and the flange portions 6 and 7 into contact with each other, the preform product 1 can be placed on the second mold 12 with high accuracy.
If the preform product 1 is placed on the second mold 12 in a setting step, or if the preform product 1 is misaligned when the first mold 11 is closed, one of the collars A part of the end portion 6A (for example, the flange portion 6) may flow out of the shear edge portion 40, and the other flange portion 7 may be in a thin state. However, since the collar parts 6 and 7 are cut | disconnected by a cutting process, the molded article 50 provided with the U-shaped part 5 which is a fixed final shape can be obtained.

  The preferred embodiments of the present invention have been described above. The present invention is not limited to that described in the drawings, and various design changes can be made without departing from the spirit of the present invention.

"Modifications of molded products"
With reference to FIG. 4 and FIG. 5, the example which changed the shape of the molded article is demonstrated. The main body of the molded product 50 (FIG. 2 (c)) described with reference to FIGS. 1 and 2 has a U-shaped portion 5 (FIG. 1), that is, a U-shaped cross section. The main body 62 of the molded product 60 according to the modification has a crank shape in cross section.

  Also in this modification, the molding method of the molded product 60 includes a preform process for shaping a preform product 61 having a main body 62 and a pair of flanges 63 and 64 from a resin sheet, A setting step for setting the preform product 61 on the molding die 70 so that the end portions 63A, 64A face the shear edge portion 40 of the molding die 70, and a pressure molding step for pressure-molding the preform product 61 with the molding die 70 And a cutting step of cutting the flange portions 63 and 64 after the pressure molding step.

"Preform process"
As shown in FIG. 4, a preform product 61 shaped in the preforming process includes a base surface portion 65 extending in a substantially planar shape and a pair of rising portions 66 extending in opposite directions substantially orthogonal to both ends of the base surface portion 65. , 67, and flange portions 63, 64 extending outward from the end portions of the rising portions 66, 67.

"Set process"
In FIG. 5, the mold 70 includes an upper first mold 71 and a lower second mold 72. For example, the first mold 71 is a movable mold that moves in the pressing direction, and the second mold 72 is a fixed mold. Of course, both may be movable. The first mold 71 includes a base surface portion cavity surface 73 that heats and presses the base surface portion 65 of the preform 61, rising portion cavity surfaces 74 and 75 that heat and press the rising portions 66 and 67, and a rising portion cavity surface 74. , 75 extending outward from each end of the flange 75 and 77, and flange portions 76, 77 that heat and press the flanges 63, 64. The flange cavity surfaces 76 and 77 are formed horizontally, the base surface cavity surface 73 is inclined with respect to the horizontal direction, and the rising cavity surfaces 74 and 75 are formed inclined with respect to the vertical direction. Yes.

  Further, the first molding die 71 has shear edge surfaces 78 and 79 extending in the mold opening direction of the first molding die 71 from the respective end portions of the flange cavity surfaces 76 and 77, and bases of the shear edge surfaces 78 and 79. The mold matching surfaces 80 and 81 each extend outward. The second molding die 72 has a base surface cavity surface 83, rising portion cavity surfaces 84 and 85, flange cavity surfaces 86 and 87, and a shear edge surface 88 so as to face each surface of the first molding die 71. , 89 and mold matching surfaces 90, 91.

  The shear edge surface 78 and the shear edge surface 88 constitute one shear edge portion 40, and the shear edge surface 79 and the shear edge surface 89 constitute the other shear edge portion 41. The share edge portions 40 and 41 are provided so that air is smoothly discharged from the cavity when the mold is closed, and the preform product 61 does not substantially flow out of the cavity.

  With respect to the mold 70 having the above configuration, in the setting process, as shown in FIG. 5A, the end portions 63A and 64A of the flange portions 63 and 64 are respectively connected to the shear edge portions 40 and 41 in the mold open state. Then, the preform 61 is set (placed) on the second mold 72 so as to face. More specifically, the base surface portion cavity surface 83, the rising portion cavity surfaces 84 and 85, and the base surface portion 65 and the rising portions 66 and 67 of the preform 61 are in contact with each other, and the flange portion cavity surfaces 86 and 87, The parts 63 and 64 are in contact with each other. Further, the end portion 63A of the flange portion 63 and the shear edge surface 88 and the end portion 64A of the flange portion 64 and the shear edge surface 89 are in contact with each other with a slight gap therebetween.

"Pressure forming process"
As shown in FIG. 5B, in the pressure molding process, the first molding die 71 is closed and the preform product 61 is heated, and the first molding die 71 and the second molding die 72 are pressed. Molded. As a heating means, the aspect which heats the preform 61 with the heating means incorporated in the 1st shaping | molding die 71 and the 2nd shaping | molding die 72 may be sufficient, and the heat source provided separately from the shaping | molding die 70 may be used. An embodiment in which the preform product 61 is preliminarily heated and then the preform product 61 is placed on the second mold 72 may be employed. Further, a sealing material 92 may be interposed between the mold matching surfaces 80 and 90 and between the mold matching surfaces 81 and 91, and the gap 93 formed between the surfaces may be evacuated.

"Cutting process"
The molded product that has been pressure-molded in the pressure-molding step is taken out of the mold 70, and then the collars 63 and 64 are cut by a cutting device (not shown) as shown in FIG. 5C. . Thereby, the molded product 60 provided with the crank shape part 68 is obtained.

According to the molding method including the above steps, in the setting step, the base surface portion cavity surface 83 and the rising portion cavity surfaces 84 and 85 are brought into contact with the base surface portion 65 and the rising portions 66 and 67 of the preform 61, respectively. The preform product 61 can be placed on the second mold 72 with high accuracy by bringing the flange cavity surfaces 86 and 87 into contact with the flange portions 63 and 64, respectively.
If the preform product 61 is placed on the second molding die 72 while being displaced in the setting step, or if the preform product 61 is misaligned when the first molding die 71 is closed, one of the collars A part of the end portion 63A (for example, the flange portion 63) may flow out of the shear edge portion 40 and the other flange portion 64 may be in a thin state. However, since the collar portions 63 and 64 are cut in the cutting step, the molded product 60 including the crank shape portion 68 having a certain final shape can be obtained.

  The molded product 50 including the U-shaped portion 5 and the molded product 60 including the crank-shaped portion 68 have been described above. However, the molded product may include a portion where the main body portion has a V-shape. The crank shape portion 68 may have a substantially Z shape or a substantially S shape.

DESCRIPTION OF SYMBOLS 1 Preform product 2 Bottom part 3, 4 Stand-up part 5 U-shaped part 6,7 ridge part 10 Mold 11 First mold 12 Second mold 40, 41 Shear edge part 50, 60 Mold 61 61 Preform 62 Main body parts 63, 64 Fence part 65 Base surface parts 66, 67 Rising part 68 Crank shape part 70 Mold 71 First mold 72 Second mold

[0002]
is there.
[0006]
The present invention was created in order to solve such a problem, and in a molding method of a fiber reinforced resin product including a pressure molding process of a mold having a shear edge structure, a preform on the mold It is an object of the present invention to provide a method for molding a fiber reinforced resin product that can accurately mold a molded product without being affected by the positional deviation of the product.
Means for Solving the Problems [0007]
In order to solve the above-mentioned problems, the present invention provides a method for molding a fiber reinforced resin product in which a molded product is molded from a resin sheet containing reinforcing fibers, the preform product having a main body portion and a collar portion from the resin sheet. A preforming step for shaping, and a setting step for setting the preform product in the molding die so that the end of the flange portion contacts the shear edge surface of the molding die or faces with a slight gap. And a pressure molding step for pressure molding the preform product with the molding die, and a cutting step for cutting the flange after the pressure molding step.
[0008]
According to the present invention, a molded product can be accurately molded without being affected by the position shift of the preform product on the mold.
[0009]
Further, the present invention is characterized in that the main body portion is configured to include a portion having a U-shaped section or a V-shaped section.
Furthermore, the present invention is characterized in that the main body portion is configured to include a portion exhibiting a cross-sectional crank shape.
[0010]
ADVANTAGE OF THE INVENTION According to this invention, the molded product containing the site | part which exhibits the cross-sectional U-shape or the cross-sectional V shape, and the site | part which exhibits a cross-sectional crank shape can be shape | molded accurately.
Effects of the Invention [0011]
According to the present invention, a molded product can be accurately molded without being affected by the position shift of the preform product on the mold.
BRIEF DESCRIPTION OF THE DRAWINGS [0012]
FIG. 1 is a cross-sectional view of a preform product according to this embodiment.
[FIG. 2] (a), (b), and (c) are the setting process and pressure molding of this embodiment, respectively.

Claims (3)

A method for molding a fiber-reinforced resin product, in which a molded product is molded from a resin sheet containing reinforcing fibers,
A preform process for shaping a preform product having a main body part and a collar part from the resin sheet;
A setting step of setting the preform product in the mold so that an end of the collar part faces a shear edge part of the mold;
A pressure molding step of pressure molding the preform product with the mold;
A cutting step of cutting the flange after the pressure molding step;
A method for molding a fiber reinforced resin product, comprising:   The method for molding a fiber reinforced resin product according to claim 1, wherein the main body portion includes a portion having a U-shaped cross section or a V-shaped cross section.   The method for molding a fiber-reinforced resin product according to claim 1, wherein the main body portion includes a portion exhibiting a crank shape in cross section.

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