JP6152373B2 - Method for producing thermoplastic prepreg molded product - Google Patents

Description

  The present invention relates to a method for producing a thermoplastic prepreg molded product by molding a thermoplastic prepreg, and particularly relates to a mold release property for a mold.

  As shown in FIG. 5, by heating and pressurizing a plurality of, for example, five, laminated sheets of thermoplastic prepregs 10 as a set between the upper mold 101 and the lower mold 102 of the mold 100, as shown in FIG. It is generally known to produce a dish-shaped prepreg molded product 1.

Here, when a mold 100 is formed by stacking a plurality of thermoplastic prepregs 10 in which a sheet-like fiber base material is impregnated with a thermoplastic resin as a matrix resin, releasability when removed from the mold 100 Is a problem. Usually, before setting the thermoplastic prepreg 10, the mold 100 is easily released by spraying a release agent on the upper mold 101 and the lower mold 102 of the mold 100 or only on the lower mold 102. ing.
However, among thermoplastic resins, so-called super engineering plastics, which have poor releasability and high melting temperature, are particularly used as matrix resins because of their high adhesive properties such as PEEK (polyether ether ketone) and PEKK (polyether ketone ketone). When used, the thermoplastic prepreg 10 is difficult to be removed from the mold 100, particularly the lower mold 102, after molding, and the molded product or the mold 100 may be damaged if it is forcibly removed.

  In addition, it is possible to use a release paper having a clay coat layer on the side overlapping with the thermoplastic prepreg 10, for example, a paper made of fine paper, kraft paper, glassine paper, and parchment paper using a silicone release agent. What prevents generation | occurrence | production is disclosed (for example, refer patent document 1).

Japanese Patent Laid-Open No. 2007-2217

  However, in the invention described in Patent Document 1, since the thermoplastic prepreg 10 is heated and pressurized while being sandwiched between rolls and is not set in a mold, releasability from the mold is a problem. Not. Super engineering plastics also have heat resistance problems due to their high melting temperature

  Accordingly, an object of the present invention is to provide a method for producing a thermoplastic prepreg molded product that is excellent in releasability from a mold and can prevent quality deterioration.

In order to achieve the above object, the method for producing a thermoplastic prepreg molded product of the present invention comprises stacking a plurality of thermoplastic prepregs (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin. A method for producing a thermoplastic prepreg molded product (1) by molding a product,
A thin metal film (20) is plated on the upper surface of the uppermost thermoplastic prepreg (10a) and the lower surface of the lowermost thermoplastic prepreg (10b) of the thermoplastic prepreg (10) (including vapor deposition and sputtering). ) To form a film,
If there is a remaining thermoplastic prepreg (10c) between the uppermost thermoplastic prepreg (10a) and the lowermost thermoplastic prepreg (10b), the remaining thermoplastic prepreg (10c) is interposed between them. When the remaining thermoplastic prepreg does not exist, the uppermost thermoplastic prepreg (10a) and the lowermost thermoplastic prepreg (10b) are directly overlapped with the thermoplastic prepreg (10). Sanding process that integrates discretely by ultrasonic welding,
A mold forming step in which the integrated thermoplastic prepreg (10) is set in a mold (100) and subjected to heat and pressure treatment;
A pickling step for removing the metal coating (20) formed on the thermoplastic prepreg molded product (1) taken out from the mold (100) after the heat and pressure treatment by washing with acid; To do.
The thermoplastic prepreg (10) referred to here includes so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin.

Further, the method for producing a thermoplastic prepreg molded product of the present invention is obtained by molding a plurality of laminated thermoplastic prepregs (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin. A method for producing a prepreg molded product (1), comprising:
A film forming step of forming a thin metal film (20) on the lower surface of the lowermost thermoplastic prepreg (10b) of the thermoplastic prepreg (10) by plating (including vapor deposition and sputtering); and Sandwiching the remaining thermoplastic prepreg (10c) on the resulting thermoplastic prepreg (10b) and discretely ultrasonically fusing and integrating the thermoplastic prepreg (10), respectively,
A mold forming step in which the integrated thermoplastic prepreg (10) is set in a mold (100) and subjected to heat and pressure treatment;
A pickling step for removing the metal coating (20) formed on the thermoplastic prepreg molded product (1) taken out from the mold (100) after the heat and pressure treatment by washing with acid; To do.
The thermoplastic prepreg (10) referred to here means that a so-called thermoplastic semi-preg obtained by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin is also included.

Moreover, the manufacturing method of the thermoplastic prepreg molded product of the present invention comprises molding a thermoplastic prepreg (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin, and molding the thermoplastic prepreg molded product (1). A method of manufacturing
A film forming step of forming a thin metal film (20) on the upper surface and lower surface of the thermoplastic prepreg (10) or only the lower surface by plating (including vapor deposition and sputtering);
A mold forming step in which the thermoplastic prepreg (10) is set in a mold (100) and subjected to heat and pressure treatment;
A pickling step for removing the metal coating (20) formed on the thermoplastic prepreg molded product (1) taken out from the mold (100) after the heat and pressure treatment by washing with acid; To do.
The thermoplastic prepreg (10) referred to here means that a so-called thermoplastic semi-preg obtained by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin is also included.

  Further, the present invention is characterized in that the metal coating (20) is formed of any one of nickel, aluminum, copper, gold, silver and titanium and has a property of being dissolved in an acid.

  In the present invention, the thermoplastic resin is a thermoplastic resin having a high adhesion property such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone), having a property of being difficult to release, and having a high melting temperature. It is characterized by being.

  Note that symbols in parentheses indicate corresponding elements or corresponding matters described in the drawings and modes for carrying out the invention described later.

  According to the method for producing a thermoplastic prepreg molded product of the present invention, a plurality of stacked prepregs each having a metal film formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of the prepreg are set in a mold. Since the mold is formed by heating and pressing, the prepreg can be easily taken out from the mold by contact between the metals. In particular, a prepreg formed by impregnating a sheet-like fiber base material with a highly adhesive resin such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as a matrix resin does not directly contact the mold. Easy to release.

Moreover, since the metal film formed by plating (including vapor deposition and sputtering) is thin, it has high ductility, is easily deformed, and easily follows the shape even when pressed with a mold. Furthermore, since the thermoplastic prepregs stacked one above the other are integrated by discrete ultrasonic bonding, including those with metal coatings, the stacked ones can be easily and firmly Temporary fixing is possible, and there is no positional displacement during mold forming.
Furthermore, since the metal film applied by plating (including vapor deposition and sputtering) is removed by pickling, a thermoplastic prepreg molded product having a clean surface is provided.

  Further, the mold release property can be improved by forming a metal film only on the lower surface of the stacked thermoplastic prepregs, and a single thermoplastic prepreg is molded instead of a plurality of thermoplastic prepregs. In this case, even if the metal film is formed only on the upper and lower surfaces or only the lower surface of the single thermoplastic prepreg, the releasability is improved.

  Moreover, in this invention, since metals, such as nickel, aluminum, copper, gold | metal | money, and titanium, were used as a metal film, it is excellent in intensity | strength and workability.

  In addition, as in the method for producing a thermoplastic prepreg molded product of the present invention, a metal film formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of the thermoplastic prepreg is set in a mold and molded. After that, the above-described Patent Document 1 completely describes that the metal film is removed by pickling to improve the mold releasability from the mold and prevent the quality deterioration of the molded product. Absent.

It is sectional drawing which shows the state in which the metal film was formed in the thermoplastic prepreg at the film formation process in the manufacturing method of the thermoplastic prepreg molded product which concerns on embodiment of this invention. It is sectional drawing which shows the state by which the thermoplastic prepreg was piled up and integrated by the sand process in the manufacturing method of the thermoplastic prepreg molded product which concerns on embodiment of this invention. It is a top view which shows the state by which the thermoplastic prepreg was integrated by the ultrasonic fusion | bonding at the sand process in the manufacturing method of the thermoplastic prepreg molded product which concerns on embodiment of this invention. It is sectional drawing which shows the state in which the prepreg was immersed in the acid solution at the pickling process in the manufacturing method of the thermoplastic prepreg molded product which concerns on embodiment of this invention. It is sectional drawing which shows the manufacturing method of the thermoplastic prepreg molded product which concerns on a prior art example. It is sectional drawing which shows the manufactured thermoplastic prepreg molded product.

A method for producing a thermoplastic prepreg molded product according to an embodiment of the present invention will be described with reference to the drawings.
In the present embodiment, a plurality of (N, here, 5) thermoplastic prepregs 10 obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin are shown in FIG. Molding is performed by using such a mold 100, and the thermoplastic prepreg molded product 1 as shown in FIG. 6 is manufactured. Here, among the thermoplastic resins, a so-called super engineering plastic having a high releasability due to high adhesiveness such as PEEK (polyetheretherketone) and PEKK (polyetherketoneketone) and having a high melting temperature is used. A thermoplastic prepreg 10 used as a matrix resin is stacked.
The thermoplastic prepreg 10 referred to in the present embodiment also includes a so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin.

  As described below, the method for producing a thermoplastic prepreg molded product includes a film forming step, a sanding step, a mold forming step, and a pickling step.

(Film formation process)
In the first film formation step, as shown in FIG. 1, a thin metal film 20 is formed on the upper surface of the uppermost thermoplastic prepreg 10a among the five thermoplastic prepregs 10 by plating, Although illustration is omitted, a thin metal film 20 is also formed on the lower surface of the lowermost thermoplastic prepreg 10b by plating by vapor deposition.
Various metal coatings 20 are conceivable. Here, nickel is used among metals such as nickel, aluminum, copper, gold, and titanium which are excellent in strength and workability.

  As the plating for forming the metal coating 20, a thin film is formed by sputtering as a method similar to vacuum deposition, or other electroplating (a method for electrochemically depositing a metal to be plated) or electroless plating (plating). It is possible to form a thin film by immersing a prepreg in a solution containing metal to chemically reduce and precipitate the metal) or chemical conversion treatment (to produce a stable compound on the metal surface by chemical treatment). Good.

(Sand process)
In the next sanding process, as shown in FIG. 2, the uppermost thermoplastic prepreg 10a with the metal coating 20 formed on the upper surface and the lowermost thermoplastic prepreg 10b with the metal coating 20 formed on the lower surface. 5 thermoplastic prepregs 10 are stacked so that three thermoplastic prepregs 10c are sandwiched between them, and the five thermoplastic prepregs 10 are integrated by ultrasonic welding as shown in FIG. Temporarily fix before setting to the mold 100.

  The ultrasonic fusion is also called ultrasonic thermal fusion or ultrasonic welding, and is a thermoplastic resin (here, PEEK (polyetheretherketone)) or the like that constitutes the thermoplastic prepreg 10 by fine ultrasonic vibration and pressure. PEKK (polyetherketoneketone) is instantaneously melted and joined, and a plurality of ultrasonic fusion points 15 are discretely formed.

(Molding process)
In the next molding process, five thermoplastic prepregs 10 integrated by ultrasonic fusion were set between the upper mold 101 and the lower mold 102 of the mold 100 as shown in FIG. Thereafter, the upper mold 101 is pushed into the lower mold 102 and subjected to heat and pressure treatment.

(Pickling process)
In the pickling step, after the thermoplastic prepreg molded product 1 taken out from the mold 100 after the heat and pressure treatment is cooled, it is immersed in a container 50 filled with the acid solution 30, and after a certain time has passed, the thermoplasticity is reached. As the prepreg molded product 1 is pulled up from the container 50, the metal coating 20 formed on the thermoplastic prepreg molded product 1 is washed away with acid and removed.
The acid is not particularly limited, and hydrochloric acid and sulfuric acid are usually used. In this case, hydrochloric acid was used.

  In particular, super engineering plastics such as PEEK (polyetheretherketone) and PEKK (polyetherketoneketone) that have high adhesion and high melting temperature are highly resistant to acid, and their properties are not changed by pickling. The surface after pickling can be finished cleanly.

  As described above, when the film forming process, the sanding process, the mold forming process, and the pickling process are performed in this order and the process is completed, the thermoplastic prepreg molded product 1 as shown in FIG. 6 is completed.

  According to such a method for manufacturing a thermoplastic prepreg molded product, a mold in which a metal coating 20 is formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of a plurality of stacked thermoplastic prepregs 10 is molded. Since the molding is performed by heating and pressurizing after setting to 100, the thermoplastic prepreg molded product 1 can be easily taken out from the mold 100 by contact between metals. In particular, a thermoplastic prepreg 10 obtained by impregnating a sheet-like fiber base material with a highly adhesive resin, for example, PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as a matrix resin is used for the mold 100. Release is easy because there is no direct contact.

Moreover, since the metal film 20 formed by plating (including vapor deposition and sputtering) is thin, it has good ductility, is easily deformed, and easily follows the shape even when pressed with the mold 100. Furthermore, since the thermoplastic prepreg 10 stacked up and down is integrated discretely by ultrasonic fusion including the one on which the metal coating 20 is formed, the stacked one can be easily and firmly temporarily fixed. And there is no misalignment during mold forming.
Furthermore, since the plated metal film 20 (including vapor deposition and sputtering) is easily removed by pickling, the thermoplastic prepreg molded article 1 having a clean surface is provided.

  In addition, among the thermoplastic resins, the case where so-called super engineering plastics such as PEEK (polyetheretherketone) and PEKK (polyetherketoneketone) having high adhesiveness and high melting temperature are used as the matrix resin has been described. As thermoplastic resins, PA (nylon), PPS (polyphenylene sulfide), PEI (polyetherimide), PC (polycarbonate), PAI (polyamideimide), TPI (thermoplastic polyimide), PES, PSU, LCP, PAR, It consists of a thermoplastic prepreg 10 made by impregnating a sheet-like fiber base material with PTFE, FEP, PFA, PCTFE, ETFE, ECTFE, PVDF, PVF, PET (polyether terephthalate) as a matrix resin. It can be similarly applied to the case of producing a goods.

Further, in this embodiment, the metal coating 20 is formed by plating (including vapor deposition and sputtering) on the upper and lower surfaces of the thermoplastic prepreg 10 to prevent the mold releasability from being deteriorated. In consideration of releasability from the lower mold 102 of the mold 100, only the lower surface of the lowermost thermoplastic prepreg 10b is plated (including vapor deposition and sputtering) to form the metal coating 20. Also good.
Further, a plurality of (five) sheets of the thermoplastic prepreg 10 are pressed by the mold 100, but only the upper surface and the lower surface, or the lower surface of the thermoplastic prepreg 10 with respect to one (single unit). A thin metal film 20 formed by plating (including vapor deposition and sputtering) is molded into a mold 100 as a set, and then the metal film 20 is pickled to complete the thermoplastic prepreg molded product 1. It may be.

DESCRIPTION OF SYMBOLS 1 Thermoplastic prepreg molded product 10 Thermoplastic prepreg 10a The uppermost thermoplastic prepreg 10b The lowermost thermoplastic prepreg 10c The thermoplastic prepreg located in the middle 15 Ultrasonic fusion point 20 Metal coating 30 Acid solution 50 Container 100 Gold Mold 101 Upper mold 102 Lower mold

Claims (5)

A method for producing a thermoplastic prepreg molded product by molding a plurality of laminated thermoplastic prepregs obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
A film forming step of forming a thin metal film by plating on the upper surface of the uppermost thermoplastic prepreg and the lower surface of the lowermost thermoplastic prepreg among the thermoplastic prepregs ;
The most If the remaining thermoplastic prepreg exists between becomes the upper thermoplastic prepreg of the most become lower thermoplastic prepregs stacked between the remainder of the thermoplastic prepreg, in the absence of the remaining thermoplastic prepreg Is a sand process in which the uppermost thermoplastic prepreg and the lowermost thermoplastic prepreg are directly stacked and discretely ultrasonically fused and integrated with the thermoplastic prepreg , respectively.
A mold forming step in which the integrated thermoplastic prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a thermoplastic prepreg molded article, comprising a pickling step of washing away a metal film formed on the thermoplastic prepreg molded article taken out of the mold after the heating and pressing treatment with an acid. . A method for producing a thermoplastic prepreg molded product by molding a plurality of laminated thermoplastic prepregs obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
A film forming step of forming a thin metal film by plating on the lower surface of the thermoplastic prepreg at the bottom of the thermoplastic prepreg;
A sand process for superimposing the remaining thermoplastic prepreg on the lowermost thermoplastic prepreg and discretely ultrasonically bonding the thermoplastic prepreg to the thermoplastic prepreg, and the integrated thermoplastic; A mold forming process in which a prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a thermoplastic prepreg molded article, comprising a pickling step of washing away a metal film formed on the thermoplastic prepreg molded article taken out of the mold after the heating and pressing treatment with an acid. . A method for producing a thermoplastic prepreg molded product by molding a thermoplastic prepreg obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
A film forming step of forming a thin metal film on the upper and lower surfaces of the thermoplastic prepreg, or only on the lower surface by plating; and
A mold forming step in which the thermoplastic prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a thermoplastic prepreg molded article, comprising a pickling step of washing away a metal film formed on the thermoplastic prepreg molded article taken out of the mold after the heating and pressing treatment with an acid. .   The thermoplastic metal prepreg molded product according to any one of claims 1 to 3, wherein the metal coating is formed of any one of nickel, aluminum, copper, gold, and titanium. Production method.   The method for producing a thermoplastic prepreg molded product according to any one of claims 1 to 4, wherein the thermoplastic resin is PEEK (polyetheretherketone) or PEKK (polyetherketoneketone). .