Molding device and molded article manufacturing method

Patent metadata

Field	Value
Publication number	US-11298896-B2
Application number	US-201916382598-A
Country	US
Kind code	B2
Filing date	Apr 12, 2019
Priority date	Jun 4, 2018
Publication date	Apr 12, 2022
Grant date	Apr 12, 2022

Abstract

A pressing member is configured to press a portion-to-be-pressed of a continuous-fiber sheet against a recessed surface of a first mold in a state where the continuous-fiber sheet is placed between the first mold and a second mold. A pulling member is configured to bring the continuous-fiber sheet into close contact with the main surface and the recessed surface by pulling a portion of the continuous-fiber sheet located on an outer peripheral side of the portion-to-be-pressed after the pressing member presses the portion-to-be-pressed against the recessed surface.

First claim

What is claimed is:

1. A molding device comprising:
a first mold; and
a second mold, wherein:
the molding device is configured to shape a continuous-fiber sheet configured to be placed between the first mold and the second mold;
the first mold and the second mold face each other;
at least one of the first mold and the second mold is configured to be movable in a separating direction, in which the first mold and the second mold are separated relatively farther away from each other, and in an approaching direction, in which the first mold and the second mold are brought relatively closer to each other;
the first mold includes a placing surface on which the continuous-fiber sheet is configured to be placed between the first mold and the second mold;
the placing surface includes a main surface and at least one recessed surface that is connected to the main surface and that is located farther away from the second mold than the main surface;
the second mold includes at least one pressing member configured to press the continuous-fiber sheet which is configured to be placed on the placing surface against the recessed surface, and a pulling member configured to pull the continuous-fiber sheet;
the pressing member is configured to press a portion-to-be-pressed of the continuous-fiber sheet against the recessed surface in a state where the continuous-fiber sheet is placed between the first mold and the second mold; and
the pulling member includes a contact member having a base and a protrusion extending vertically downward from the base, and is configured to bring the continuous-fiber sheet into close contact with the main surface by pulling a portion of the continuous-fiber sheet located on an outer peripheral side of the portion-to-be-pressed after the pressing member presses the portion-to-be-pressed against the recessed surface,
wherein the continuous-fiber sheet which is configured to be placed on the placing surface includes an outer peripheral portion that projects outward from an outer peripheral edge portion of the placing surface, and the pulling member is configured to bring the continuous-fiber sheet into close contact with the main surface by pulling the outer peripheral portion.

2. The molding device according to claim 1 , further comprising a third mold, wherein:
the first mold includes a peripheral surface that is connected to the outer peripheral edge portion of the placing surface and extends in a direction away from the second mold;
the pulling member is configured to bring the continuous-fiber sheet into close contact with the main surface by moving the outer peripheral portion in the approaching direction and shaping the outer peripheral portion so as to fit the peripheral surface; and
the third mold is configured to press against the peripheral surface, an outer edge of the outer peripheral portion, that has been shaped by the pulling member, so as to fit the peripheral surface.

3. The molding device according to claim 2 , further comprising a supply device, wherein:
the molding device is configured such that a cavity to house the continuous-fiber sheet is formed, as the first mold, the second mold, and the third mold are moved closer to one another; and
the supply device is configured to supply resin into the cavity.

4. The molding device according to claim 1 , wherein:
the placing surface includes a first recessed surface and a second recessed surface that is located closer to an outer peripheral edge portion of the placing surface than the first recessed surface;
the second mold includes a first pressing member and a second pressing member;
the portion-to-be-pressed of the continuous-fiber sheet includes a first portion-to-be-pressed and a second portion-to-be-pressed;
the first pressing member is configured to press the first portion-to-be-pressed of the continuous-fiber sheet against the first recessed surface;
the second pressing member is configured to press the second portion-to-be-pressed of the continuous-fiber sheet against the second recessed surface;
the second pressing member is configured to press the second portion-to-be-pressed against the second recessed surface after the first pressing member presses the first portion-to-be-pressed against the first recessed surface; and
the pulling member is configured to pull a portion of the continuous-fiber sheet located on an outer peripheral side of the second portion-to-be-pressed after the second pressing member presses the second portion-to-be-pressed against the second recessed surface.

5. A molded article manufacturing method comprising:
preparing a first mold and a second mold placed so as to face each other;
placing a continuous-fiber sheet between the first mold and the second mold; and
processing the continuous-fiber sheet by the first mold and the second mold, wherein:
at least one of the first mold and the second mold is configured to be movable in a separating direction, in which the first mold and the second mold are separated relatively farther away from each other, and in an approaching direction, in which the first mold and the second mold are brought relatively closer to each other;
the first mold includes a placing surface on which the continuous-fiber sheet is configured to be placed between the first mold and the second mold;
the placing surface includes a main surface and at least one recessed surface that is connected to the main surface and is located farther away from the second mold than the main surface; and
processing the continuous-fiber sheet includes pressing a portion-to-be-pressed of the continuous-fiber sheet against the recessed surface, and after pressing the portion-to-be-pressed against the recessed surface, bringing the continuous-fiber sheet into close contact with the main surface by pulling a portion of the continuous-fiber sheet located on an outer peripheral side of the portion-to-be-pressed,
wherein the continuous-fiber sheet which is configured to be placed on the placing surface includes an outer peripheral portion that projects outward from an outer peripheral edge portion of the placing surface, and the bringing of the continuous-fiber sheet into close contact with the main surface included in the processing includes bringing the continuous-fiber sheet into close contact with the main surface by pulling the outer peripheral portion with a pulling member including a contact member having a base and a protrusion extending vertically downward from the base.

6. The molded article manufacturing method according to claim 5 , further comprising pressing an outer edge of the outer peripheral portion that has been shaped so as to fit a peripheral surface of the first mold, against the peripheral surface by a third mold, wherein:
the peripheral surface of the first mold is connected to the outer peripheral edge portion of the placing surface and extends in a direction away from the second mold; and
the bringing of the continuous-fiber sheet into close contact with the main surface included in the processing includes bringing the continuous-fiber sheet into close contact with the main surface by moving the outer peripheral portion in the approaching direction and shaping the outer peripheral portion so as to fit the peripheral surface.

7. The molded article manufacturing method according to claim 6 , further comprising forming a cavity to house the continuous-fiber sheet by moving the first mold, the second mold, and the third mold closer to one another, and then supplying resin into the cavity.

8. The molded article manufacturing method according to claim 5 , wherein:
the portion-to-be-pressed of the continuous-fiber sheet includes a first portion-to-be-pressed and a second portion-to-be-pressed;
the placing su

Assignees

• Toyota Motor Co Ltd

Inventors

• Ueno Yasuhiro
• Ishikawa Shotaro
• Asai Masataka

Classifications

• B29C70/543 Primary

  Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08) · CPC title

• B29C45/14262 Primary

  Clamping or tensioning means for the insert · CPC title

• B29C70/461

  Rigid movable compressing mould parts acting independently from opening or closing action of the main mould · CPC title

• B29C70/46

  using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs · CPC title

• B29D99/001

  Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings (articles with hollow walls B29D24/00) · CPC title