Method for producing resin molded body and press molding apparatus

Patent metadata

Field	Value
Publication number	US-2016354967-A1
Application number	US-201615164517-A
Country	US
Kind code	A1
Filing date	May 25, 2016
Priority date	Jun 4, 2015
Publication date	Dec 8, 2016
Grant date	—

Abstract

A method for producing a three-dimensional fiber-reinforced resin molded body by press-molding a heated and softened plate-like molding matrix using a mold, the method sequentially including: setting the matrix on a lower mold including a pad and mold main bodies by mounting a central portion of the matrix on the pad and supporting at least one end side of the matrix by at least one support protruding upward from a molding surface of at least one of the mold main bodies; bringing an upper mold and the lower mold close together to sandwich the central portion of the matrix by the pad and the upper mold; bringing the upper and lower molds still closer together to reduce the protrusion amount of the at least one support; and pressing the matrix by using the lower and upper molds to form the molded body.

First claim

1 . A method for producing a fiber-reinforced resin molded body in which a fiber-reinforced resin molded body having a three-dimensional shape is produced by press-molding a heated and softened plate-like molding matrix using a mold,
the method sequentially comprising: (A) a step that sets the plate-like molding matrix on a lower mold including a pad in a central portion and mold main bodies on both sides of the pad by mounting a central portion of the plate-like molding matrix on the pad and causing at least one of both end sides of the plate-like molding matrix to be supported by at least one support protruding upward from a molding surface of at least one of the mold main bodies; (B) a step that brings an upper mold and the lower mold close together to cause the central portion of the plate-like molding matrix to be sandwiched by the pad and the upper mold; (C) a step that brings the upper mold and the lower mold still closer together to reduce the amount of protrusion of the at least one support; and (D) a step that presses the plate-like molding matrix by using the lower mold and the upper mold to form the fiber-reinforced resin molded body.

2 . The method for producing a fiber-reinforced resin molded body according to claim 1 , wherein
in the step (A), at least one end of the plate-like molding matrix in an area supported by the at least one support is located on an outside of at least one shear edge provided in at least one of the mold main bodies, and in the step (C), the amount of protrusion of the at least one support is reduced to bring the at least one end of the plate-like molding matrix down to an inside of the at least one shear edge.

3 . The method for producing a fiber-reinforced resin molded body according to claim 1 , wherein
the plate-like molding matrix is made of a fiber-reinforced resin in which reinforcing fibers oriented in one direction are impregnated with a matrix resin, and in the step (A), a central portion in a direction crossing the one direction is mounted on the pad and at least one of the both end sides in the direction crossing the one direction is caused to be supported by the at least one support.

4 . The method for producing a fiber-reinforced resin molded body according to claim 2 , wherein
the plate-like molding matrix is made of a fiber-reinforced resin in which reinforcing fibers oriented in one direction are impregnated with a matrix resin, and in the step (A), a central portion in a direction crossing the one direction is mounted on the pad and at least one of the both end sides in the direction crossing the one direction is caused to be supported by the at least one support.

5 . The method for producing a fiber-reinforced resin molded body according to claim 1 , wherein
in the step (D), the pressing is performed after the at least one support recedes to the molding surface of at least one of the mold main bodies.

6 . The method for producing a fiber-reinforced resin molded body according to claim 2 , wherein
in the step (D), the pressing is performed after the at least one support recedes to the molding surface of at least one of the mold main bodies.

7 . The method for producing a fiber-reinforced resin molded body according to claim 1 , wherein
in the step (A), an upper surface of the pad and an upper surface of the at least one support are located above the molding surfaces of the mold main bodies, the plate-like molding matrix is set on the pad and the at least one support while an area of the plate-like molding matrix between a portion mounted on the pad and a portion caused to be supported by the at least one support is supported by at least one conveyance tool, and then the at least one conveyance tool is pulled out from a space between the pad and the at least one support.

8 . The method for producing a fiber-reinforced resin molded body according to claim 2 , wherein
in the step (A), an upper surface of the pad and an upper surface of the at least one support are located above the molding surfaces of the mold main bodies, the plate-like molding matrix is set on the pad and the at least one support while an area of the plate-like molding matrix between a portion mounted on the pad and a portion caused to be supported by the at least one support is supported by at least one conveyance tool, and then the at least one conveyance tool is pulled out from a space between the pad and the at least one support.

9 . A press molding apparatus for producing a fiber-reinforced resin molded body having a three-dimensional shape by press-molding a heated and softened plate-like molding matrix using a mold,
the press molding apparatus comprising: a pad that is disposed in a central portion in one direction of a lower mold and to which a load is applied upward; mold main bodies that are disposed on both sides in the one direction of the lower mold across the pad and have molding surfaces in positions below an upper surface of the pad; and at least one support that protrudes upward from at least one of the molding surfaces of the mold main bodies and of which the amount of protrusion decreases as an upper mold and the lower mold come closer together.

10 . The press molding apparatus according to claim 9 , wherein
when the upper mold and the lower mold come close together, at least one part to be pushed that is coupled to the at least one support of the lower mold is pushed by at least one pushing part that is provided in the upper mold and thereby the amount of protrusion of the at least one support decreases.

11 . The press molding apparatus according to claim 10 , wherein a distance between the at least one pushing part of the upper mold and the at least one part to be pushed of the lower mold is shorter than a distance between the pad and the upper mold.

12 . The press molding apparatus according to claim 10 , further comprising at least one elastic part that applies a load to the at least one pushing part of the upper mold downward.

13 . The press molding apparatus according to claim 11 , further comprising at least one elastic part that applies a load to the at least one pushing part of the upper mold downward.

14 . The press molding apparatus according to claim 9 , wherein an upper surface of the at least one support is a curved surface protruding upward.

15 . The press molding apparatus according to claim 10 , wherein an upper surface of the at least one support is a curved surface protruding upward.

Assignees

• Fuji Heavy Ind Ltd
• Toa Ind Co Ltd

Inventors

• Ono Tsubasa
• Yoshizawa Satoshi
• Iwanuma Tadashi

Classifications

• B29K2105/06

  containing reinforcements, fillers or inserts · CPC title

• B29C51/087 Primary

  with at least one of the mould parts comprising independently movable sections (B29C51/32 and B29C51/34 take precedence) · CPC title

• B29C51/30

  Moulds · CPC title

• B29C51/085

  with at least one of the shaping surfaces being made of resilien material, e.g. rubber · CPC title

• B29C51/082 Primary

  by shaping between complementary mould parts · CPC title