JP6089342B2 - Method and apparatus for molding fiber reinforced composite material - Google Patents

Description

  The present invention relates to a method and apparatus for molding a fiber reinforced composite material using a thermoplastic matrix resin.

  Fiber reinforced composites containing reinforced fibers and thermoplastic matrix resins have high specific strength, high specific modulus, excellent mechanical properties, high functional properties such as weather resistance, chemical resistance, etc. It is attracting attention in the application of automobile materials, building materials, and sports materials, and its demand is increasing year by year.

  In recent years, parts for electrical and electronic equipment such as personal computers, OA equipment, mobile phones, AV equipment, and home appliances, as well as housing parts that house these parts and high-density mounting circuits, have formability, productivity, and economy. Fiber reinforced plastics that excel in quality are frequently used. Carbon fiber reinforced thermoplastic resin composition using carbon fiber as reinforced fiber and nylon, PC or other thermoplastic resin as matrix resin when particularly high mechanical properties, rigidity, mechanical strength, light weight, and conductivity are required (CFRTP) is preferably used because it can flexibly cope with a complicated shape as molded by a conventional injection molding method and can be mass-produced.

  Furthermore, in addition to mechanical characteristics, rigidity, mechanical strength, lightness, and conductivity, such parts and casings of electric / electronic devices are required to have high heat dissipation. Therefore, an attempt has been made to impart such characteristics of the metal material to the fiber reinforced composite material by bonding a metal material having high heat dissipation to a resin material such as a fiber reinforced composite material.

  For joining the resin material and the metal material, for example, a metal foil is placed on the outermost upper layer of the fiber reinforced composite material prepreg and molded by hot pressing, or the metal material is inserted into an injection mold, and carbon fiber A method of performing injection molding using reinforced pellets is known (Patent Document 1).

  In such a method, a molded product obtained by bonding a metal material to a fiber reinforced composite material has a small amount of metal foil protrusion from the molded product and has a good appearance.

JP 2005-285923 A

  However, in the conventional configuration, when the area occupied by the metal material exceeds 10% of the total surface area of the molded product, the pressure applied to the base material and the heat conduction are not uniform during molding. As a result, not only the molded product characteristics such as rigidity and strength are adversely affected, but also the bondability of the metal material to the surface of the molded product is deteriorated. Therefore, the range on the molded product that can impart heat dissipation to the fiber-reinforced composite material with the metal material is extremely limited.

  The present invention can realize a good bonding state between the metal material and the molded product even when the area occupied by the metal material that imparts heat dissipation to the molded product is relatively large compared to the total surface area of the molded product. An object is to provide a forming method.

  The method for molding a fiber reinforced composite material according to the present invention includes a fiber reinforced composite material composed of a reinforced fiber and a matrix resin, and a metal foil disposed in a mold having a cavity-forming surface, The composite material and the metal foil are heated / pressurized / cooled to transfer the unevenness formed on the cavity forming surface to the metal foil, and the molten matrix resin flows into the unevenness transferred to the metal foil. It is made to solidify, and the said fiber reinforced composite material and metal foil are joined.

  The method for molding a fiber reinforced composite material according to the present invention includes a metal foil, and first and second fibers made of reinforcing fiber and matrix resin on the upper and lower surfaces of the metal foil with the metal foil interposed therebetween. By placing the reinforced composite material and clamping, heating, pressurizing, and cooling, a part of the metal foil breaks in the middle of the mold clamping to generate a hole in the metal foil, The matrix resin of the first and second fiber reinforced composite materials melted by heating flows into the holes of the metal foil from both sides of the metal foil, and is solidified and integrated by cooling. .

  According to the present invention, the unevenness formed on the cavity forming surface is transferred to the metal foil, and the molten matrix resin of the fiber reinforced composite material is allowed to flow into the unevenness transferred to the metal foil and then solidified. Even if the area occupied by the metal foil that imparts heat dissipation to the molded product is larger than the total surface area of the molded product, the fiber-reinforced composite material and the metal foil can be firmly bonded.

  According to the present invention, the first and second fiber reinforced composite materials composed of reinforcing fibers and a matrix resin are disposed on the upper and lower surfaces of the metal foil with the metal foil interposed therebetween. When the portion breaks, a hole is generated in a part of the metal foil, and the matrix resin of the first and second fiber reinforced composite materials melted by heating is formed from both sides of the metal foil. The metal reinforced composite material and the metal foil, even if the area occupied by the metal foil that imparts heat dissipation of the molded product is larger than the total surface area of the molded product. Can be firmly joined.

Sectional side view which shows the shaping | molding apparatus used for the shaping | molding method of Embodiment 1 of this invention Flow chart of the same embodiment Side sectional view of molding apparatus before mold clamping in the same embodiment Side sectional view of the molding apparatus in the middle of mold clamping in the same embodiment Side sectional view of the molding apparatus during mold clamping in the same embodiment The side sectional view which expanded the principal part of metal mold before metal mold clamping in the same embodiment, metal foil, and a fiber reinforced composite material The side sectional view which expanded the principal part of the molding device at the time of mold clamping in the embodiment, metal foil, and a fiber reinforced composite material The sectional side view which expanded the principal part, metal foil, and fiber reinforced composite material of the shaping | molding apparatus before the mold clamping in Embodiment 2 of this invention Side view of the main part of the molding device and the fiber-reinforced composite material during clamping in the same embodiment The sectional side view which expanded the principal part, metal foil, and fiber reinforced composite material of the shaping | molding apparatus before the mold clamping in Embodiment 3 of this invention The side sectional view which expanded the principal part of the molding device at the time of mold clamping in the embodiment, metal foil, and a fiber reinforced composite material The sectional side view which expanded the molding apparatus, metal foil, and fiber reinforced composite material before the mold clamping in Embodiment 4 of this invention The side sectional view which expanded the molding device, metal foil, and fiber reinforced composite material at the time of mold clamping in the embodiment Side sectional view before mold clamping showing a concrete mold shape of the molding apparatus in the same embodiment Side sectional view at the time of mold clamping showing a concrete mold shape of the molding apparatus in the same embodiment The sectional side view which expanded the molding apparatus before metal mold clamping, metal foil, and fiber reinforced composite material in Embodiment 5 of this invention The side sectional view which expanded the molding device, metal foil, and fiber reinforced composite material at the time of mold clamping in the embodiment Side sectional view before mold clamping showing a concrete mold shape of the molding apparatus in the same embodiment Side sectional view at the time of mold clamping showing a concrete mold shape of the molding apparatus in the same embodiment The sectional side view which expanded the molding apparatus before metal mold clamping in Embodiment 6 of this invention, metal foil, and a fiber reinforced composite material The side sectional view which expanded the molding device, metal foil, and fiber reinforced composite material at the time of mold clamping in the embodiment The sectional side view which expanded the molding apparatus before metal mold clamping in Embodiment 7 of this invention, metal foil, and a fiber reinforced composite material The side sectional view which expanded the molding device, metal foil, and fiber reinforced composite material at the time of mold clamping in the embodiment Side sectional view before mold clamping showing a concrete mold shape of the molding apparatus in the same embodiment Side sectional view at the time of mold clamping showing a concrete mold shape of the molding apparatus in the same embodiment

Embodiments of the present invention will be described below with reference to the drawings.
In addition, the same code | symbol may be attached | subjected to the same component and the overlapping description may be abbreviate | omitted.
Further, the drawings schematically show the respective constituent elements mainly for easy understanding. The thickness, length, and the like of each component shown in the drawings are different from actual ones for the convenience of drawing.

The shape, dimensions, and the like of each component shown in the following embodiments are merely examples, and are not particularly limited, and various changes can be made without departing from the effects of the present invention.
(Embodiment 1)
1 to 4A and 4B show Embodiment 1 of the present invention.

FIG. 1 is a side sectional view showing a main part of the molding apparatus.
The molding apparatus includes a movable mold 10 that is a first mold and a fixed mold 11 that is a second mold. The movable mold 10 has a convex cavity forming surface 15a, and forms a molding space for molding a molded product together with the concave cavity forming surface 15b of the fixed mold 11. A cooling circuit 16 and a heating circuit 17 such as an electric heater are provided in the vicinity of the cavity forming surface 15 a inside the movable mold 10. A cooling circuit 16 and a heating circuit 17 are also provided in the vicinity of the cavity forming surface 15 b inside the fixed-side mold 11.

  Here, the heating circuit 17 is arranged closer to the cavity forming surfaces 15a and 15b than the cooling circuit 16, but the cooling circuit 16 is arranged closer to the cavity forming surfaces 15a and 15b than the heating circuit 17. May be.

Further, the convex cavity forming surface 15 a and the concave cavity forming surface 15 b may be arranged in either the movable mold 10 or the fixed mold 11, respectively.
The workpiece pressing plate 14 arranged on the fixed mold 11 side is moved to the fixed mold 11 side, and the metal foil 13 and the thermoplastic fiber reinforced composite material 12 are moved between the fixed mold 11 and the fixed mold 11. The fiber reinforced composite material 12 and the metal foil 13 are restrained by being sandwiched. In FIG. 1, the metal foil 13 is disposed on the movable mold 10 side and the fiber reinforced composite material 12 is disposed on the fixed mold 11 side. However, the metal foil 13 is disposed on the fixed mold 11 side. The composite material 12 may be disposed on the movable mold 10 side.

FIG. 2 is a flowchart showing the molding method. Based on this flowchart, the molding steps of FIGS. 3A to 3C will be described in order.
In step S1, as shown in FIG. 3A, the fiber reinforced composite material 12 and the metal foil 13 are conveyed into the mold. At this time, the fiber reinforced composite material 12 and the metal foil 13 are transported between the fixed mold 11 and the workpiece pressing plate 14. An enlarged view of the main part before mold clamping is shown in FIG. 4A.

  As can be seen from this figure, the surface of the cavity forming surface 15a of the movable mold is provided with minute irregularities 19 of several μm to several hundred μm. The fiber reinforced composite material 12 is configured by alternately laminating matrix resins 20 and reinforced fiber fabrics 21. The metal foil 13 has a thickness of about several μm to several hundred μm.

  The cavity forming surface 15a having the minute unevenness 19 may be disposed on either the fixed mold side or the movable mold side, but the metal foil 13 is in contact with the cavity forming surface having the minute unevenness 19. Place on the side.

  In step S2, the workpiece pressing plate 14 moves to the fixed mold 11 side, and the fiber reinforced composite material 12 and the metal foil 13 are sandwiched between the fixed mold 11 and the workpiece pressing plate 14, The fiber reinforced composite material 12 and the metal foil 13 are restrained. A hole 14a through which the cavity forming surface 15a passes in the next step is formed in the workpiece pressing plate 14 in the center.

  In step S3, as shown in FIG. 3B, the mold is closed and temporarily held where the fiber-reinforced composite material 12 and the metal foil 13 come into contact with the cavity forming surface 15a of the movable mold 10, and the fiber-reinforced composite material 12 and the metal The foil 13 is heated to a temperature not lower than the melting temperature of the matrix resin 20 impregnated in the fiber reinforced composite material 12 and not higher than the melting temperature of the reinforced fiber fabric 21. In this example, the movable mold 10 is in contact with the fiber reinforced composite material 12 via the metal foil 13.

  In step S4, the movable mold 10 and the fixed mold 11 are clamped and pressurized to cause the matrix resin 20 of the fiber reinforced composite material 12 to flow into the cavity of the mold, and the flow of the matrix resin 20 is used. The reinforcing fiber fabric 21 is also caused to flow into the mold cavity in synchronization with the matrix resin 20. Here, because the cavity forming surface 15a of the movable mold 10 is provided with the minute irregularities 19, the minute irregularities 19 are transferred to the metal foil 13 by clamping and pressing as shown in FIG. 4B. The molten matrix resin 20 flows into the minute irregularities 19 transferred onto the metal foil 13.

  More specifically, since the minute irregularities 19 are formed on both the first surface 13 u and the second surface 13 d of the metal foil 13 as described above, a part of the molten matrix resin 20 is on the metal foil 13. It flows into the micro unevenness 19 and then the matrix resin is solidified. Since the matrix resin 20 thus solidified has a large contact area with the minute irregularities 19 on the metal foil 13, a large frictional force is generated, and a bonding effect is obtained between the matrix resin 20 and the metal foil 13. . Such an effect is called an anchor effect, and the fiber reinforced composite material and the metal foil can be joined by the anchor effect.

  In step S5, the matrix resin 20 in the fiber reinforced composite material 12 is solidified by the cooling circuit 16 disposed on the cavity forming surface 15b of the fixed side mold 11, and the molded product 18 is molded at a temperature equal to or lower than the solidification temperature of the matrix resin 20. Remove from the mold.

In step S6, the movable mold 10 and the fixed mold 11 are opened, and the molded product 18 attached to the convex cavity forming surface 15a of the movable mold 10 is taken out from the mold.
According to such a configuration, the thermoplastic fiber reinforced composite material 12 and the metal foil 13 are heated in the mold, the matrix resin 20 is remelted, and simultaneously compressed, so that the matrix resin 20 is placed in the cavity of the mold. By flowing the metal foil 13 and the matrix resin 20 by the anchor effect, a molded product 18 in which the metal foil 13 is bonded to the entire surface of one side of the fiber reinforced composite material 12 made of continuous fibers can be obtained.

  In addition, it is confirmed that, when the surface of the cavity forming surface 15a is molded by the same method without applying the micro unevenness 19, the bonding effect is not obtained between the fiber reinforced composite material and the metal foil, and it is easily peeled off. ing. It was confirmed that by applying the minute unevenness 19 on the surface of the cavity forming surface 15a, a sufficient bonding effect was obtained between the fiber reinforced composite material and the metal foil, and it was not easily peeled off.

(Embodiment 2)
5A and 5B show Embodiment 2 of the present invention.
In the first embodiment, the minute irregularities 19 are formed on the cavity forming surface 15a. However, in the second embodiment, as shown in FIG. 5A, the minute irregularities 19 are not formed on the cavity forming surface 15a. Further, in the second embodiment, holes 22 are formed in the metal foil 13 in advance. In the case where the hole 22 of the metal foil 13 is formed in advance, for example, in the case of a deep dish-shaped molded product having a square bottom surface, the vicinity of the corners 15c (see FIG. 1) at the four corners of the rectangular bottom surface, or On the molded product, the metal foil 13 is generated in advance at a site where the metal foil 13 is easily peeled off from the fiber reinforced composite material.

  As for the hole 22, it is desirable to arrange a plurality of holes 22 of about several mm in the portion corresponding to the flat portion of the molded product. The shape, size, and arrangement of the holes 22 are appropriately handled according to the shape of the molded product. The configuration and the molding method other than the presence or absence of the minute unevenness 19 on the cavity forming surface 15a are the same as those in the first embodiment.

FIG. 5B shows a side sectional view of the molding apparatus during mold clamping.
According to such a configuration, the metal foil 13 in which the holes 22 are formed is used, and a part of the molten matrix resin 20 flows into the holes 22 on the metal foil 13 and is solidified by cooling and solidifying. Since the matrix resin 20 fixes the metal foil 13 having the holes 22 by the frictional force of the portion in contact with the wall surface 22a of the holes 22, the bonding effect between the fiber reinforced composite material 12 and the metal foil 13 can be obtained. .

The metal foil 13 may be disposed on either the cavity forming surface 15a side of the movable mold or the cavity forming surface 15b side of the fixed mold.
Further, molding may be performed by the method shown in the second embodiment using the cavity forming surface 15a having the minute irregularities 19 shown in the first embodiment.

  In the second embodiment, the hole 22 penetrates from the second surface 13d which is the lower surface of the metal foil 13 to the first surface 13u which is the upper surface. However, the hole 22 penetrates the first surface 13u of the metal foil 13. If not, it was effective.

(Embodiment 3)
6A and 6B show Embodiment 3 of the present invention.
In the second embodiment, the cavity forming surface 15a at a position corresponding to the hole 22 of the metal foil 13 is flat. However, in the third embodiment, as shown in FIG. Corresponding to the position, a recess 23 is formed in the cavity forming surface 15a. The length L1 of the recess 23 is greater than the length L2 of the hole 22.

  The configuration and the forming method other than the presence or absence of the holes 22 in the metal foil 13, the presence or absence of minute irregularities on the cavity forming surface 15 a, and the recesses 23 are the same as those in the first embodiment. The shape of the hole 22 in the metal foil 13 is the same as that in the second embodiment.

  FIG. 6B shows a cross-sectional side view of the molding apparatus during mold clamping. According to such a configuration, part of the molten matrix resin 20 flows into the holes 22 on the metal foil 13, and the matrix resin 20 that has passed through the holes 22 is filled into the recesses 23 on the surface of the cavity forming surface 15a. Thereafter, the matrix resin 20 solidified by cooling takes a shape in which the metal foil 13 having the holes 22 is sandwiched from both sides, and the fiber-reinforced composite material 12 is engaged with the first surface 13u that is the upper surface of the metal foil 13. Therefore, the metal foil 13 becomes difficult to peel off, and the bonding effect between the fiber reinforced composite material 12 and the metal foil 13 is obtained.

In addition, molding may be performed by the method shown in the third embodiment using the cavity forming surface 15a having the minute unevenness 19 shown in the first embodiment.
The metal foil 13 may be disposed on either the cavity forming surface 15a side of the movable mold or the cavity forming surface 15b side of the fixed mold.

(Embodiment 4)
7A to 7D show Embodiment 4 of the present invention.
In the second embodiment, the metal foil 13 having the holes 22 already formed before clamping is used. However, in the fourth embodiment, the metal foil 13 has the holes 22 as shown in FIG. 7A. What is not formed is used.

FIG. 7A is a side sectional view of the molding apparatus according to Embodiment 4 before clamping, and FIG. 7B is a side sectional view of the molding apparatus during clamping.
It is assumed that the minute unevenness 19 is not provided on the cavity forming surface 15a. The metal foil 13 may be disposed on either the cavity forming surface 15a side of the movable mold or the cavity forming surface 15b side of the fixed mold.

  Holes 22 are generated during mold clamping by intentionally breaking the metal foil 13 during mold clamping. Examples of the method for generating the holes 22 by fracture include giving the molded product a shape in which the metal foil is greatly elongated, and giving a sharp shape with a small R.

  The configuration and the molding method are the same as those in the first and second embodiments except that the metal foil 13 is broken during the mold clamping to generate the holes 22 and the minute unevenness 19 is present on the cavity forming surface 15a.

7C and 7D show a specific example in which the hole 22 is generated during mold clamping.
Although the hole 22 is not formed in the metal foil 13 before mold clamping as shown in FIG. 7C, for example, in the case of a deep dish-shaped molded article having a rectangular bottom surface, by clamping the mold, The tension is applied to the portion of the metal foil 13 located at the top 15c of the corners of the four corners, and the hole 22 is easily formed by breaking the metal foil 13 in the vicinity of the top 15c as shown in FIG. 7D. be able to.

  According to such a configuration, a part of the molten matrix resin 20 flows into the holes 22 generated when a part of the metal foil 13 is broken during mold clamping, and is solidified after cooling, thereby solidifying the matrix resin 20. Since the metal foil 13 having the hole 22 is fixed by the frictional force of the portion in contact with the wall surface of the hole 22, the bonding effect between the fiber reinforced composite material 12 and the metal foil 13 is obtained.

Further, molding may be performed by the method shown in the fourth embodiment using the cavity forming surface 15a having the minute unevenness 19 shown in the first embodiment.
(Embodiment 5)
8A to 8D show Embodiment 5 of the present invention.

  In the fourth embodiment, the cavity forming surface 15a at the position corresponding to the hole 22 formed in the subsequent process is flat, but in this fifth embodiment, as shown in FIG. 8A, the recess 23 is formed in the cavity forming surface 15a. Is formed. The length L1 of the recess 23 is larger than the length L2 of the hole 22 formed at the time of mold clamping.

FIG. 8A is a side sectional view of the molding apparatus in Embodiment 5 before clamping, and FIG. 8B is a side sectional view of the molding apparatus in Embodiment 5 when clamping.
The metal foil 13 used here does not have the hole 22 in a state before mold clamping, but the hole 22 is formed when a part of the metal foil 13 is broken during mold clamping. A recess 23 is formed in a portion of the surface of the cavity forming surface 15a that comes into contact with the hole 22 generated by the fracture of the metal foil 13. Further, it is assumed that the minute unevenness 19 seen in the first embodiment is not applied to the cavity forming surface 15a.

  According to such a configuration, when the metal foil 13 is broken during the mold clamping, a part of the molten matrix resin 20 flows into the generated hole 22 on the metal foil 13 and passes through the hole 22. It fills in the recessed part 23 of the surface of the formation surface 15a. Thereafter, the matrix resin 20 solidified by cooling takes the shape in which the metal foil 13 having the holes 22 is sandwiched from both sides, and the bonding effect between the fiber reinforced composite material 12 and the metal foil 13 is obtained.

8C and 8D show a specific example in which the hole 22 is generated during mold clamping.
Although the hole 22 is not formed in the metal foil 13 before mold clamping as shown in FIG. 8C, the metal foil that comes into contact with the top 15c of the corner of the cavity forming surface 15a of the movable mold by clamping the mold. A tension of a magnitude that breaks a part of the metal foil 13 acts on the specific portion 13, and the metal foil 13 is broken at the specific portion to form a hole 22 as shown in FIG. 8D.

Here, the metal foil 13 is disposed on the cavity forming surface 15a side of the movable mold, but the metal foil 13 may be disposed on the cavity forming surface 15b side of the fixed mold.
A part of the metal foil 13 is broken during the mold clamping to generate the hole 22, and the presence / absence of the minute unevenness 19 on the cavity forming surface 15a and the configuration and the forming method other than the recessed portion 23 are the same as those in the first embodiment. is there. The method for generating the holes 22 in the metal foil 13 is the same as in the fourth embodiment.

In addition, molding may be performed by the method shown in the fifth embodiment using the cavity forming surface 15a having the minute unevenness 19 shown in the first embodiment.
(Embodiment 6)
9A and 9B show Embodiment 6 of the present invention.

  In the second embodiment, the metal foil 13 having the holes 22 is disposed between the fiber reinforced composite material 12 and the cavity forming surface 15a. However, in the sixth embodiment, the metal foil 13 is provided between the cavity forming surfaces 15a and 15b. The first and second fiber reinforced composite materials 12a and 12b are disposed, and the metal foil 13 having the holes 22 is disposed between the first and second fiber reinforced composite materials 12a and 12b.

9A is a side cross-sectional view of the molding apparatus in Embodiment 6 before clamping, and FIG. 9B is a side sectional view of the molding apparatus in Embodiment 5 during clamping.
The metal foil 13 in a state before clamping is not in contact with either the cavity forming surface 15a side or the cavity forming surface 15b side of the fixed mold. Furthermore, the minute unevenness 19 is not applied to the cavity forming surface 15a. The configuration and the forming method other than the presence / absence of the hole 22 in the metal foil 13, the location of the metal foil, and the presence / absence of the minute unevenness 19 in the cavity forming surface 15a are the same as those in the first and second embodiments.

  According to such a configuration, as shown in FIG. 9B, at the time of clamping, a part of the matrix resin 20 of the first and second fiber reinforced composite materials 12a and 12b melted by heating is transferred to the hole 22 of the metal foil 13 in the metal. It flows from both sides of the foil 13 and merges. Thereafter, since the matrix resin 20 of the first and second fiber reinforced composite materials 12a and 12b solidified by cooling is fixed by the shape connected by the holes 22, the first and second fiber reinforced composite materials 12a and 12b and the metal A bonding effect with the foil 13 is obtained.

In addition, molding may be performed by the method shown in the sixth embodiment using the cavity forming surface 15a having the minute unevenness 19 shown in the first embodiment.
(Embodiment 7)
10A and 10B show Embodiment 7 of the present invention.

  In the sixth embodiment, the metal foil 13 in which the holes 22 are formed in advance is arranged between the first and second fiber reinforced composite materials 12a and 12b. In the seventh embodiment, the state before the mold clamping is illustrated in FIG. As shown to 10A, the metal foil 13 in which the hole 22 is not formed is arrange | positioned between the 1st, 2nd fiber reinforced composite materials 12a and 12b. Further, the metal foil 13 does not contact either the cavity forming surface 15a side of the movable mold or the cavity forming surface 15b side of the fixed mold. Furthermore, the minute unevenness 19 is not applied to the cavity forming surface 15a.

The metal foil 13 used here does not have the hole 22 at first, but the hole 22 is formed by partly breaking the metal foil 13 during the mold clamping.
The configuration and the molding method other than the metal foil 13 being partially broken during mold clamping to generate the holes 22 and the location of the metal foil 13 and the presence or absence of the minute irregularities 19 on the cavity forming surface 15a are described in the embodiment. Same as 1. The method for breaking a part of the metal foil 13 during mold clamping is the same as in the fourth embodiment.

10C and 10D show a specific example in which the hole 22 is generated during mold clamping.
Although the hole 22 is not formed in the metal foil 13 before mold clamping as shown in FIG. 10C, the metal corresponding to the corner top 15c of the cavity forming surface 15a of the movable mold is obtained by clamping the mold. Tensile force that breaks a part of the metal foil 13 acts on a specific portion of the foil 13, and the metal foil 13 is broken at the specific portion to form a hole 22 as shown in FIG. 10D. . The molten matrix resin 20 of the first and second fiber-reinforced composite materials 12a and 12b flows into the holes 22 and is cooled, whereby the matrix resin 20 of the first fiber-reinforced composite material 12a and the second Since the matrix resin 20 of the fiber reinforced composite material 12b is integrated and solidified inside the hole 22, a bonding effect between the first and second fiber reinforced composite materials 12a and 12b and the metal foil 13 is obtained.

  According to such a configuration, the metal foil 13 is broken during the mold clamping, so that a part of the molten matrix resin 20 is generated in the hole 22 on the metal foil 13 in the hole 22 on the metal foil 13. Flows in from both sides and merges. Thereafter, since the matrix resin 20 of the first and second fiber reinforced composite materials 12a and 12b solidified by cooling is fixed by the shape connected by the holes 22, the first and second fiber reinforced composite materials 12a and 12b and the metal A bonding effect with the foil 13 is obtained.

In addition, molding may be performed by the method shown in the sixth embodiment using the cavity forming surface 15a having the minute unevenness 19 shown in the first embodiment.
The metal foil of each of the above embodiments is a foil having a melting point and a thermal conductivity that are both higher than that of the matrix resin in the fiber reinforced composite material. Specifically, an aluminum foil, a copper foil, or the like can be used.

  In each of the above embodiments, the metal foil has been described. However, this may be a polymer foil having a melting point and thermal conductivity higher than those of the fiber-reinforced composite material. Specifically, a high heat conductive foil such as a heat conductive graphite sheet may be used.

  The present invention is useful for various molded products that require both high mechanical properties, rigidity, mechanical strength, light weight, and heat dissipation.

DESCRIPTION OF SYMBOLS 10 Movable side metal mold | die 11 Fixed side metal mold | die 12 Fiber reinforced composite material 12a, 12b 1st, 2nd fiber reinforced composite material 13 Metal foil 13a Concavity and convexity transcribe | transferred to the metal foil 13 14 Workpiece material pressing plate 15a Movable side metal mold | die Cavity forming surface 15b Cavity forming surface 15c of fixed side mold 15c Corner top part 15d of cavity forming surface 15a Plane part of cavity forming surface 15a 16 Cooling circuit 17 Heating circuit 18 Molded product 19 Micro unevenness 20 Matrix resin 21 Reinforced fiber fabric 22 Hole 23 Recess

Claims (3)

A fiber reinforced composite material composed of reinforced fibers and a matrix resin, and a metal foil are arranged in a mold having a cavity forming surface, and the fiber reinforced composite material and the metal foil are heated, pressurized, and pressed in the mold. Cool down
The unevenness formed on the cavity forming surface is transferred to the metal foil, the molten matrix resin is allowed to flow into the unevenness transferred to the metal foil, and then solidified, so that the fiber-reinforced composite material and the metal A method for forming a fiber-reinforced composite material for joining foils. A metal foil and first and second fiber reinforced composite materials composed of reinforcing fibers and a matrix resin are disposed on the upper and lower surfaces of the metal foil with the metal foil sandwiched in the mold, and the mold is clamped and heated and heated. By pressure and cooling,
The metal resin of the first and second fiber reinforced composite materials melted by the heating is generated in the part of the metal foil by part of the metal foil being broken during the mold clamping, A method for forming a fiber-reinforced composite material, which flows from both sides of a metal foil into the hole of the metal foil and solidifies and integrates by cooling. Molding in which fiber reinforced composite material composed of reinforced fiber and matrix resin and metal foil are placed in a mold having a cavity forming surface, and the fiber reinforced composite material and metal foil are heated, pressurized and cooled in the mold. A device,
An apparatus for molding a fiber-reinforced composite material, wherein unevenness having a shape to be transferred to the metal foil is formed on a cavity forming surface on the metal foil side of the mold.