JP6786282B2 - A pair of roll molding dies, molding equipment and manufacturing method of molded products - Google Patents

Description

The present invention relates to a pair of roll molding dies, a molding apparatus and a method for manufacturing a molded product. In particular, the present invention relates to a pair of roll molding dies, a molding apparatus, and a method for manufacturing a molded product, which are used for molding a sheet-like material such as a continuous fiber reinforced thermoplastic resin sheet into a desired shape.

Conventionally, when a sheet-shaped material such as a continuous fiber-reinforced thermoplastic resin sheet is molded into a desired shape, stamping molding is performed by charging the heated sheet-shaped material into a mold and then pressurizing the molded product. The method is used.
The stamping molding method is an excellent technique depending on the shape of the molded product, but is not suitable for molding a long product or an undercut molded product.
On the other hand, as a molding method for a long product or an undercut molded product, Patent Document 1 states that a fiber-reinforced thermoplastic resin sheet before molding is heated only on both local regions that are processed as bent portions during molding. A fiber-reinforced heat characterized by continuously processing a heating step of preheating by an apparatus and a molding step of processing and molding both side regions of the fiber-reinforced thermoplastic resin sheet after the heating step by a roll forming apparatus. A method for molding a thermoplastic resin sheet is disclosed.

Japanese Unexamined Patent Publication No. 2013-20626

However, when the present inventor examined Patent Document 1, it was found that the fibers were bent when the continuous fiber reinforced thermoplastic resin sheet was bent. Specifically, it will be described with reference to FIG. FIG. 1 is a schematic view showing a part of a cross section showing a state in which bending processing is performed while transporting a continuous fiber reinforced thermoplastic resin sheet between a pair of roll molding dies, and FIG. 11 is a schematic view showing a part of a cross section showing a state in which a continuous fiber reinforced thermoplastic resin sheet is conveyed. One of the molds, 12 indicates the other of the pair of roll molding molds, 13 is a bent portion of the roll molding mold, 14 is a continuous fiber reinforced thermoplastic resin sheet, and 15 is the continuous fiber reinforced thermoplastic resin sheet. The continuous fibers parallel to each other are shown inside. In the form shown in FIG. 1, when the continuous fiber reinforced thermoplastic resin sheet 14 passes between the roll molding dies 11 and 12, the continuous fiber reinforced thermoplastic resin sheet 14 is formed in the bending portion 13 of the roll molding die. It is bent. However, it has been found that the continuous fiber 15 located inside the bent portion may be bent during the bending process. In FIG. 1, the continuous fiber 15 is bent in the portion surrounded by the dotted line. The deflection of such continuous fibers reduces the mechanical strength of the obtained molded product.
An object of the present invention is to solve such a problem, and when a molded product is manufactured by using a roll molding mold, a molded product in which continuous fibers in the obtained molded product do not bend is manufactured. It is an object of the present invention to provide a pair of possible roll molding dies, as well as a molding apparatus and a method for manufacturing a molded product.

As a result of the study by the present inventor based on the above problems, a mountain fold portion and a valley fold portion are provided in one bending portion, and the total bending angle of the mountain fold portion and the bending angle of the valley fold portion are determined. It was found that the above problem can be solved by adjusting so that the difference in total is approximately 0 degrees. Specifically, the above-mentioned problems were solved by the following means <1>, preferably by <2> to <12>.
<1> A pair of roll molding dies having a first heat insulating portion, a bent portion, and a second heat insulating portion adjacent to each other in the above-mentioned order in a direction perpendicular to the rotation direction of the roll. The bent portion includes a mountain fold portion and a valley fold portion, and the difference between the total fold angle of the mountain fold portion and the total fold angle of the valley fold portion is within 5 degrees. ..
<2> The pair of roll molding dies according to <1>, wherein the pair of roll molding dies are a pair of roll molding dies for roll molding a continuous fiber reinforced thermoplastic resin sheet.
<3> The pair of roll molding molds according to <2>, wherein the continuous fiber reinforced thermoplastic resin sheet has continuous fibers arranged in parallel in at least one direction.
<4> Further, a heating device is provided in a region of at least one roll molding die of the pair of roll molding dies, which is closer to the rotation axis of the roll molding die than the first heat insulating portion and the second heat insulating portion. The pair of roll molding dies according to any one of <1> to <3>.
<5> The pair of roll molding dies according to any one of <1> to <4>, wherein at least one of the ends in the direction perpendicular to the rotation direction of the rolls of the pair of roll molding dies is a heat insulating portion. ..
<6> A roll molding apparatus for a molded product, which has the pair of roll molding dies according to any one of <1> to <5>.
<7> A method for producing a molded product, which comprises transporting a sheet between the pair of roll molding dies according to any one of <1> to <5>.
<8> The sheet is a continuous fiber reinforced thermoplastic resin sheet, and the continuous fibers contained in the continuous fiber reinforced thermoplastic resin sheet are parallel at least in a direction perpendicular to the transport direction of the sheet. 7> The method for producing a molded product.
<9> The method for producing a molded product according to <8>, wherein the continuous fiber is impregnated with the thermoplastic resin contained in the continuous fiber reinforced thermoplastic resin sheet.
<10> The method for producing a molded product according to <8> or <9>, wherein the continuous fiber reinforced thermoplastic resin sheet has a thickness of 0.2 to 5.0 mm.
<11> The method for producing a molded product according to any one of <8> to <10>, wherein the thermoplastic resin contains a polyamide resin or a polypropylene resin.
<12> The thermoplastic resin contains a diamine-derived structural unit and a dicarboxylic acid-derived structural unit, and 50 mol% or more of the diamine-derived structural unit contains a polyamide resin derived from xylylenediamine. <8> to <10> The method for producing a molded product according to any one of.

According to the present invention, when a molded product is manufactured using a roll molding die, a pair of roll molding dies capable of producing a molded product in which continuous fibers in the obtained molded product do not bend, and a molding apparatus and a molded product. It has become possible to provide a manufacturing method for.

It is sectional drawing in the case of molding a continuous fiber reinforced thermoplastic resin sheet by using a known roll molding method. It is the schematic which shows an example of the molding apparatus using a pair of roll molding dies of this invention. It is sectional drawing which shows an example of a pair of roll molding dies of this invention. The enlarged view of the part A of FIG. 3 is shown. It is a partial cross-sectional schematic diagram of the bent part of the molded product manufactured by the conventional roll molding method and the roll molding method in the present invention. A schematic cross-sectional view of another example of the pair of roll molding dies of the present invention is shown. A schematic cross-sectional view of another example of the pair of roll molding dies of the present invention is shown.

The contents of the present invention will be described in detail below. In addition, in this specification, "~" is used in the meaning that the numerical values described before and after it are included as the lower limit value and the upper limit value.
Hereinafter, a pair of roll molding dies of the present invention, a molding apparatus, and a method for manufacturing a molded product will be described with reference to the drawings. It goes without saying that the present invention is not limited to those described in the drawings.

In the pair of roll molding dies according to the embodiment of the present invention, the first heat insulating portion, the bent portion, and the second heat insulating portion are adjacent to each other in the above-mentioned order in the direction perpendicular to the rotation direction of the roll. The bent portion includes a mountain fold portion and a valley fold portion, and the difference between the total bending angle of the mountain fold portion and the total bending angle of the valley fold portion is the difference between the pair of roll molding dies. It is characterized by being within 5 degrees.
The pair of roll forming dies in the present invention are usually used by being mounted on a forming apparatus for roll forming (roll forming apparatus). FIG. 2 shows an example of a molding apparatus incorporating the pair roll molding die of the present invention. In FIG. 2, 21 is a sheet-like material, 22 indicates one roll forming die of a pair of roll forming dies, 23 indicates the other roll forming die, and 24 indicates a forming apparatus. Further, X is the transport direction of the sheet-shaped material. On the surface of each of the roll molding dies 22 and 23 of the pair of roll molding dies, a bending portion (not shown) and a heat insulating portion (not shown) sandwiching the bent portion (not shown) depending on the desired molded product. ) Is provided. A heating device (not shown) is provided in a region closer to the rotation axis of the roll molding mold than the heat insulating portion of the roll molding mold, and the heating device heats a portion of the surface of the roll other than the heat insulating portion. , The sheet-like material is processed into a desired shape. The heating device may be separated from the pair of roll molding dies. That is, the pair of roll molding dies do not have a heating device, and the heating device may be built in a mounting portion of the roll molding dies of the molding apparatus.
Further, as the heating device, in addition to the pair of roll molding dies, a separated heating device may be used. In particular, the heating of the roll molding mold may be a method of indirectly heating from the outside of the roll molding mold. In the case of indirect heating from the outside, heat control becomes easier.
The roll molding mold of the present invention is preferably used for molding a continuous fiber reinforced thermoplastic resin sheet. Details of the sheet-shaped material will be described later.

Next, the details of the structure of the pair of roll molding dies will be described with reference to FIG. FIG. 3 is a schematic cross-sectional view of a portion of the pair of roll molding dies of FIG. 2 indicated by Y. In FIG. 3, 31 is one of the roll molding dies, 32 is the other of the roll forming dies, 33 is a sheet-like material, 34 is a heat insulating part, 35 is a bending part, and 36 is a heating device. Reference numeral 37 denotes a rotation axis of the roll molding die.

The pair of roll molding dies of the present invention have a heat insulating portion 34, a bent portion 35, and a heat insulating portion 34 adjacent to each other in the above-mentioned order in a direction perpendicular to the rotation direction of the roll. In this way, in each roll molding mold, the first heat insulating portion, the bent portion, and the second heat insulating portion are arranged side by side on the surface of the roll, and the first heat insulating portion and the bent portion are arranged side by side. And, since the second heat insulating portion faces each other, it is possible to process the bent portion of the molded product between the roll molding dies 31 and 32 so as to follow the shape of the bent portion. become.
More specifically, the bending process proceeds by transmitting the heat from the heating device 36 to the bending portion and processing along the shape of the roll forming die. The roll molding die is uniformly heated in a strip shape in a direction perpendicular to the transport direction of the sheet-shaped material by the heat from the heating device 36. However, since the heat insulating portion 34 is insulated, the heat from the heating device 36 is not conducted. With such a configuration, only the region of the sheet-like material to be bent is heated.
The heating temperature is determined according to the type of sheet-shaped material. When the sheet-like material contains a thermoplastic resin, it can be determined based on the glass transition temperature Tg of the thermoplastic resin. Specifically, Tg + 1 to Tg + 200 ° C. of the thermoplastic resin is preferable, and Tg + 10 to Tg + 150 ° C. is more preferable. When the thermoplastic resin is a crystalline resin, the melting point Tm of the thermoplastic resin can be used as a reference. Specifically, the thermoplastic resin Tm-50 to Tm + 50 ° C. is preferable, and Tm-30 to Tm + 30 ° C. is more preferable. When the sheet-shaped material contains two or more kinds of thermoplastic resins, it is preferable that the Tg or Tm of the thermoplastic resin having the highest Tg or Tm among the thermoplastic resins contained in the sheet-shaped material is in the above range. With such a range, the bending process can be appropriately advanced. In particular, by heating the crystalline resin at a temperature lower than the melting point, it is possible to improve the moldability and effectively suppress the sticking of the sheet-like material to the roll.
The glass transition temperature and melting point refer to the temperatures observed by the DSC (differential scanning calorimetry) method. The differential scanning calorimetry can be measured according to JIS K7121 and K7122. Using a differential scanning calorimeter, put the polyamide resin in the measuring pan of the differential scanning calorimeter, raise the temperature to 300 ° C at a heating rate of 10 ° C / min under a nitrogen atmosphere, and then gradually increase the temperature to 30 ° C at 10 ° C / min. The measurement is performed after cooling and pretreatment. The measurement conditions are as follows: the temperature rise rate is 10 ° C./min, the temperature is maintained at 300 ° C. for 5 minutes, and then the measurement is performed at a temperature lowering rate of -5 ° C./min to 100 ° C. ..
As the differential scanning calorimeter, "DSC-60" manufactured by Shimadzu Corporation can be used.

In the present invention, the bent portion includes the mountain fold portion and the valley fold portion, and the difference between the total bend angle of the mountain fold portion and the total bend angle of the valley fold portion is within 5 degrees. With such a configuration, when the continuous fiber reinforced thermoplastic resin sheet is molded, the mechanical strength of the molded product can be maintained high. This point will be described with reference to FIG.
FIG. 4 is an enlarged view of the area A surrounded by the broken line in FIG. The bending portion 35 has a mountain folding portion 45 and a valley folding portion 46. In the present invention, in each of the roll molding dies of the pair of roll molding dies, the difference between the total bending angle of the mountain fold portion and the total bending angle of the valley fold portion is within 5 degrees and within 3 degrees. It is preferably present, more preferably 1 degree or less, and even more preferably 0 degree. Here, the inflection angle is an angle formed through the inflection points of the mountain fold portion and the valley fold portion. Specifically, the bending angle of the mountain fold portion means the folding angle formed by bending the mountain fold, and is α in FIG. Further, in FIG. 6 described later, the angles indicated by α1, α2, and α3 are the bending angles of the mountain folds, respectively. On the other hand, the bending angle of the valley fold portion means the folding angle formed by bending in the valley fold, and is α'in FIG. Further, in FIG. 6 described later, they are α1', α2', and α3'. Then, for each of the pair of roll forming dies, the difference between the total bending angle of the mountain fold portion and the total bending angle of the valley fold portion is set to 5 degrees or less, so that the continuous fiber reinforced heat during heat molding is achieved. The deflection of continuous fibers in the plastic resin sheet can be eliminated. That is, in FIG. 4, the bending angle α of the mountain folding portion is 90 degrees, the bending angle of the valley folding portion is 90 degrees, and the difference between these bending angles is set to be 0 degrees. With such a configuration, the deflection of the continuous fiber in the obtained molded product can be suppressed.
More specifically, it will be described with reference to FIG. That is, as shown in FIG. 5A, when the difference between the total bending angle of the mountain fold portion and the total bending angle of the valley fold portion is not 0 degrees, the continuous fiber 52 is formed in the obtained molded product 51. Among them, the continuous fibers were bent in the region inside the bent portion (53 in FIG. 5), and the continuous fibers were in a tense state outside the bent portion (54 in FIG. 5). On the other hand, in the present invention, as shown in FIG. 5 (b), the difference between the total of the folding angles α of the mountain folds and the total of the bending angles α'of the valley folds is approximately 0 degrees. By setting, in one bent portion, the bending and tension state of the continuous fiber can be offset and molded. As a result, the mechanical strength of the molded product can be improved.

Here, the bending angle can be appropriately determined in the range of more than 0 degrees and less than 180 degrees, each of which is preferably 10 to 170 degrees, more preferably 20 to 150 degrees, and 25 to 130 degrees. 30 to 120 degrees is more preferable. Since the continuous fibers are likely to bend at such a bending angle, it is appropriate to use the pair of roll molding dies of the present invention.

In addition, in FIGS. 3 to 5 above, there are two parts having a bending angle in the bending part, but it is not always necessary to have two parts. The number of bending angles is preferably 2 to 10, and more preferably 2 to 8.
FIG. 6 is another example in which the difference between the total bending angle of the mountain folding portion and the total bending angle of the valley folding portion of the bending portion located between the two heat insulating portions is approximately 0. In FIG. 6, 61 is a heat insulating portion and 62 is a bent portion. In FIG. 6, there are a bending angle of a mountain fold portion represented by α1 to α3 and a bending angle of a valley folding portion represented by α1'to α3', and the total folding angle and valley of these mountain folding portions. The difference in the total bending angles of the folded parts is approximately 0 degrees.
In the present invention, the difference between the total bending angle of the mountain fold portion of the bent portion and the total bending angle of the valley fold portion may be approximately 0 degrees, but in a complicated shape, the folding angle of the mountain fold portion It is preferable to provide a heat insulating portion at a position where the difference between the total and the total bending angle of the valley fold portion is approximately 0 degrees to shorten the width and surface length of the bent portion.
Further, the bending formed on the surface of the bent portion does not necessarily have to be linear. For example, as shown in FIG. 7, a curved curved portion may be included. In FIG. 7, 71 is a heat insulating portion and 72 is a bent portion. The bending angle in the curved curved portion is determined by the maximum or minimum point of the bent portion (for example, 73 in FIG. 7) and the apex of the bent portion adjacent to the bent portion (of the curved surface). In the case of the case, it refers to a folding angle (for example, α4'in FIG. 7) formed by connecting a maximum point or a minimum point, for example, 74 and 75 in FIG. Further, as shown in FIG. 7, when the bent portion adjacent to the heat insulating portion has a curved surface shape, the bending start point of the bent portion (for example, 75 in FIG. 7) is formed with respect to the straight line connected to the heat insulating portion. It refers to the folding angle of a straight line (for example, α4 in FIG. 7) connecting the vertices of the bending portion adjacent to the bending portion (maximum point or minimum point in the case of a curved surface, for example, 73 in FIG. 7).
Further, the bending portion shown in FIG. 7 has, in addition to the above α4 and α4', a mountain folding portion having a bending angle of α5 and a valley folding portion having a bending angle of α5'. Then, the difference between the total bending angle of the mountain fold portion (total of α4 and α5) and the total bending angle of the valley folding portion (total of α4'and α5') is approximately 0 degrees.

Further, in one pair of roll molding dies, there may be one bent portion located between the heat insulating portion and the heat insulating portion, or there may be two or more bent portions. In FIG. 3 described above, two bent portions 35 located between the heat insulating portion and the heat insulating portion are provided. With such a configuration, a more complicated shape can be formed.

The roll molding mold is usually composed of a material such as a metal or a resin such as Teflon (registered trademark). Further, a mold release agent, a lubricant, or the like may be applied to the surface of the roll molding mold. With such a configuration, it is possible to effectively prevent the roll molding die and the sheet-shaped material from coming into close contact with each other.

The length of the bent portion in the direction perpendicular to the rotation direction of the roll, that is, the width of the bent portion (for example, 41 in FIG. 4) is also determined by the shape of the molded product, but is 0.5 to 5 cm. The one is excellent in processing suitability.
The ratio of the length of the surface length of the bent portion (for example, the distance from 42 in FIG. 4 to 43 via two bending points) with respect to the width of the bent portion (for example, 41 in FIG. 4). (Width of bent portion / surface length of bent portion) is preferably 1: 1.5 to 1:20, more preferably 1: 2 to 1:10. Within such a range, a molded product having more excellent mechanical strength can be obtained.

The length in the direction perpendicular to the rotation direction of the roll of the heat insulating portion, that is, the width of the heat insulating portion is determined by the shape of the molded product, but the one having 1 to 20 cm is excellent in processing suitability. The surface of the heat insulating portion is usually a smooth surface having no unevenness unlike the bent portion, but may have irregularities within a range not deviating from the gist of the present invention. .. In particular, when the sheet-shaped material is preheated in the preheating zone, it may be possible to perform molding even if the heat insulating portion is provided with irregularities.

The distance between the pair of roll molding dies, that is, the distance of the portion through which the sheet-shaped material passes (for example, 44 in FIG. 4) is determined according to the thickness of the sheet-shaped material. It is preferably 0.2 to 5.0 mm, more preferably 0.5 to 2.0 mm, and even more preferably 1.0 to 2.0 mm.

In the present invention, it is also preferable that at least one of the ends in the direction perpendicular to the rotation direction of the rolls of the pair of roll molding molds is a heat insulating portion, and it is more preferable that both ends are heat insulating portions. With such a configuration, it is possible to more effectively suppress the bending of the continuous fibers at the end portion of the molded product.

Returning to FIG. 2 again, the details of the molding apparatus of the present invention will be described. In the molding apparatus of the present invention, a plurality of pair of roll molding dies (22, 23) are usually connected in series. With such a configuration, it becomes possible to mold a molded product having a complicated shape. Further, the transfer roll may be provided before, during or after the pair of roll molding dies. By providing the transport roll, the sheet-like material can be transported more smoothly. However, in the present invention, since the pair of roll molding dies have a transfer function, it is possible to configure the structure without a transfer roll.
The transport speed of the sheet-shaped material is preferably 0.1 to 100 m / min.

Further, the molding apparatus of the present invention may have a preheating zone. The preheating zone is usually preferably passed before the material is transferred to the pair of roll molds. With such a configuration, molding becomes easier when the pair of roll molding dies are conveyed. Further, by heating near the melting point by preheating or the like, the sheet-like material containing the crystalline resin can be processed at a temperature lower than the melting point and at a temperature at which crystallization does not proceed rapidly. ..
In addition, the molding apparatus of the present invention may include an impregnation step. The impregnation step is a step of impregnating continuous fibers with a thermoplastic resin. For example, a step of extruding a molten thermoplastic resin while pressurizing and impregnating it while opening a continuous fiber bundle can be mentioned. In addition, a step of extruding a molten thermoplastic resin or applying a heated thermoplastic resin film to a sheet-shaped continuous fiber and heat-pressing the fiber can be mentioned. By continuously performing the impregnation process and the bending process, heat energy can be efficiently used and cost saving can be achieved.
Furthermore, the molding apparatus of the present invention may include a supply unit for supplying a sheet-shaped material and a cooling device for cooling a molded product after heat molding. Further, when a thermoplastic resin sheet or a continuous fiber reinforced thermoplastic resin sheet is used as the sheet-shaped material, it may have a unwinding portion of the sheet-shaped material. Space saving of the molding apparatus can be achieved by winding and storing the sheet-shaped material.

Next, the sheet-shaped material will be described.
In the present invention, the material used for producing the molded product is not particularly specified as long as it is a sheet-shaped material, but it is preferably a thermoplastic resin sheet, and more preferably a continuous fiber reinforced thermoplastic resin sheet. .. The thermoplastic resin contained in the sheet-shaped material used in the present invention may be one kind or two or more kinds.

The sheet-like material used in the present invention preferably contains continuous fibers in addition to the thermoplastic resin. The continuous fibers are preferably parallel in at least one direction. In particular, it is preferable that the continuous fibers are parallel in the molding apparatus in the direction perpendicular to the transport direction of the sheet-shaped material, that is, in the width direction of the pair of roll molding dies. The term "parallel" as used herein means not only parallel in a geometrical sense but also "parallel" in the technical field of the present invention, which is generally interpreted by those skilled in the art as parallel. For example, continuous fibers in a material obtained by impregnating a thermoplastic resin while opening the fiber roving correspond to an example in which the continuous fibers are arranged in parallel. Further, in a woven fabric in which continuous fibers are used as warp and weft, the warp and weft, and further, the yarn of each axis including 30 to 60 degrees in the multi-axis woven fabric also corresponds to the example in which the continuous fibers are arranged in parallel.

As described above, the sheet-like material used in the present invention is preferably partially or wholly impregnated with the thermoplastic resin in the continuous fibers. With such a configuration, it is possible to make it difficult for the continuous fibers in the sheet to move.

In the present invention, regarding the impregnated state, the sheet-shaped material used in the present invention is embedded with epoxy resin, the cross section perpendicular to the longitudinal direction of the continuous fibers of the embedded material is polished, and the cross section is colored in ultra-depth. This can be confirmed by taking a picture using a 3D shape measuring microscope VK-9500 (controller unit) / VK-9510 (measurement unit) (manufactured by KEYENCE).
Further, when determining the impregnation rate, the region where the polyamide resin is melted and impregnated is selected from the photograph of the cross section of the obtained material using the image analysis software ImageJ, and the area is measured and calculated. it can.
The impregnation rate can be shown as = (region in which the polyamide resin is impregnated in the continuous fiber in the photographed cross section) / (photographed cross-sectional area) × 100 (unit%).
In the present invention, the impregnation rate is preferably 70% or more, more preferably 80% or more, and further preferably 90% or more.

Preferred embodiments of the sheet-shaped material used in the present invention exemplify the following.
(1) A material in which continuous fibers are arranged in parallel in one direction and impregnated with a thermoplastic resin (2) A material in which a woven fabric in which continuous fibers are used as warp and weft is impregnated with a thermoplastic resin (3) With continuous fibers Woven fabric with one of the continuous thermoplastic resin fibers as the warp and the other as the weft (4) Woven fabric containing continuous fibers and mixed fiber containing continuous thermoplastic resin fibers for both the warp and weft (5) Continuous fiber and continuous heat Woven fabric using mixed fiber containing plastic resin fiber for one of warp and weft, and continuous fiber and / or continuous thermoplastic resin fiber for the other (6) In the above (3) to (5), the thermoplastic resin Materials in which continuous fibers are impregnated with fibers Here, woven fabrics include plain weaves, twill weaves, woven fabrics such as Saiko weaves and fish weaves that interlace warp threads and weft threads, and woven fabrics that do not interlace warp threads and weft threads and are fixed by stitching. Includes non-crimp fabrics.

The thickness of the sheet-shaped material is appropriately determined depending on the shape of the molded product and the like, but is preferably 0.2 to 5.0 mm, and more preferably 0.5 to 2.0 mm.
The width of the sheet-like material used in the present invention is preferably 5 to 100 cm, more preferably 10 to 50 cm.
The length of the sheet-shaped material used in the present invention is preferably 0.1 m to 10 m, more preferably 0.2 to 5 m.

Next, a thermoplastic resin that can be used as a sheet-shaped material will be described.
Examples of the thermoplastic resin that can be used for the sheet-like material include polyolefin resins such as polyethylene and polypropylene, polyamide resins, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polycarbonate resins, polyoxymethylene resins, polyether ketones, and poly. Examples thereof include ether sulfone and thermoplastic polyetherimide, and a polyamide resin and a polypropylene resin are preferable, and a polyamide resin is more preferable.

Examples of the polyamide resin used in the present invention include polyamide 4, polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 66, polyamide 610, polyamide 612, polyhexamethylene terephthalamide (polyamide 6T), and polyhexamethylene isophthalamide. (Polyamide 6I), Polyamide 66 / 6T, Polyamide ylene adipamide, Polyamide lylen sebacamide, Polyamide lidedecamide, Polyamide 9T, Polyamide 9I / 9T, Polyamide 6I / 6T, Polyamide 1,3-bis Polyamide (1,3-BAC6) composed of aminomethyl) cyclohexane and adipic acid, polyamide 1,3-BAC6I, polyamide 1,3-bis (aminomethyl) cyclohexane and polyamide composed of sebacic acid (polyamide 1, 3-BAC10), Polyamide 1,3-BAC10I, Polyamide 1,4-BAC6, Polyamide 1,4-BAC6I, Polyamide 1,4-BAC10, Polyamide xylylene 6I, Polyamide xylylene 10I, including one or more of these polyamides. Examples thereof include a copolymer and a mixture of these polyamides.

Among the above-mentioned polyamide resins, from the viewpoint of moldability and heat resistance, a diamine-derived structural unit and a dicarboxylic acid-derived structural unit are included, and 50 mol% or more of the diamine-derived structural unit is derived from xylylenediamine. It is preferably a polyamide resin (hereinafter, may be referred to as "XD-based polyamide").
When the polyamide resin is a mixture, the ratio of the XD-based polyamide in the polyamide resin is preferably 50% by mass or more, and more preferably 80% by mass or more.

The XD-based polyamide preferably contains 70 mol% or more, more preferably 80 mol% or more, still more preferably 90 mol% or more, and particularly preferably 95 mol% or more of the diamine-derived constituent unit as metaxylylene diamine and / or para. The constituent units derived from xylylene diamine and derived from dicarboxylic acid are preferably 50 mol% or more, more preferably 70 mol% or more, still more preferably 80 mol% or more, still more preferably 90 mol%, still more preferably 95 mol. % Or more are derived from α, ω-linear aliphatic dicarboxylic acid having 4 to 20 carbon atoms.

Examples of diamines other than m-xylylenediamine and paraxylylenediamine that can be used as the raw material diamine component of XD-based polyamide include tetramethylenediamine, pentamethylenediamine, 2-methylpentanediamine, hexamethylenediamine, heptamethylenediamine, and octa. An aliphatic diamine such as methylenediamine, nonamethylenediamine, decamethylenediamine, dodecamethylenediamine, 2,2,4-trimethyl-hexamethylenediamine, 2,4,4-trimethylhexamethylenediamine, 1,3-bis (amino) Methyl) cyclohexane, 1,4-bis (aminomethyl) cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane, bis (4-aminocyclohexyl) methane, 2,2-bis (4-aminocyclohexyl) propane , Bis (aminomethyl) decarin, bis (aminomethyl) tricyclodecane and other alicyclic diamines, bis (4-aminophenyl) ether, paraphenylenediamine, bis (aminomethyl) naphthalene and other diamines having an aromatic ring, etc. Can be exemplified, and one kind or a mixture of two or more kinds can be used.
When a diamine other than xylylenediamine is used as the diamine component, it is less than 50 mol% of the constituent unit derived from diamine, preferably 30 mol% or less, more preferably 1 to 25 mol%, still more preferably. It is used at a ratio of 5 to 20 mol%.

Examples of α, ω-linear aliphatic dicarboxylic acids having 4 to 20 carbon atoms that are preferable to be used as a raw material dicarboxylic acid component of a polyamide resin include succinic acid, glutaric acid, pimeric acid, suberic acid, azelaic acid, and adipic acid. , Sebacic acid, undecanedioic acid, dodecanedioic acid and other aliphatic dicarboxylic acids can be exemplified, and one kind or a mixture of two or more kinds can be used. Among these, the melting point of the polyamide resin is suitable for molding. Adipic acid or sebacic acid is preferable because it is in the range.

Examples of the dicarboxylic acid component other than the α, ω-linear aliphatic dicarboxylic acid having 4 to 20 carbon atoms include phthalic acid compounds such as isophthalic acid, terephthalic acid, and orthophthalic acid, 1,2-naphthalenedicarboxylic acid, 1, 3-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 1,7-naphthalenedicarboxylic acid, 1,8-naphthalenedicarboxylic acid, 2,3- Examples thereof include naphthalenedicarboxylic acids such as isomers such as naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, and 2,7-naphthalenedicarboxylic acid, and one kind or a mixture of two or more kinds can be used.

When a dicarboxylic acid other than α, ω-linear aliphatic dicarboxylic acid having 4 to 20 carbon atoms is used as the dicarboxylic acid component, terephthalic acid or isophthalic acid may be used from the viewpoint of molding processability and barrier property. preferable. The ratio of terephthalic acid and isophthalic acid is preferably 30 mol% or less of the dicarboxylic acid constituent unit, more preferably 1 to 30 mol%, and further preferably 5 to 20 mol%.

Further, in addition to the diamine component and the dicarboxylic acid component, as components constituting the polyamide resin, lactams such as ε-caprolactam and laurolactam, and aliphatic compounds such as aminocaproic acid and aminoundecanoic acid, as long as the effects of the present invention are not impaired Aminocarboxylic acids can also be used as copolymerization components.

The polyamide resin used in the present invention preferably has a number average molecular weight (Mn) of 6,000 to 30,000, more preferably 8,000 to 28,000, and even more preferably 9,000 to 26, It is 000, more preferably 10,000 to 24,000, and even more preferably 11,000 to 22,000. Within such a range, heat resistance, elastic modulus, dimensional stability, and molding processability become better.

The number average molecular weight (Mn) referred to here is expressed by the following formula from the terminal amino group concentration [NH ₂ ] (μ equivalent / g) and the terminal carboxyl group concentration [COOH] (μ equivalent / g) of the polyamide resin. It is calculated.
Number average molecular weight (Mn) = 2,000,000 / ([COOH] + [NH ₂ ])

Examples of the polypropylene resin include isotactic polypropylene, syndiotactic polystyrene, atactic polypropylene, polypropylene-based polymer alloy and the like.

Among the above polypropylene resins, isotactic polypropylene is preferably used from the viewpoint of crystallinity, thermophysical properties, processability, and mechanical properties. Isotactic polypropylene is roughly classified into homopolymers, block copolymers, and random copolymers. Among them, homopolymers and block copolymers grafted with a functional group such as maleic anhydride are particularly preferably used.

The thermoplastic resin used in the present invention may contain other components as long as the gist of the present invention is not deviated. Other ingredients include mold release agents, light stabilizers, heat stabilizers, elastomers, pigments, alkalis, UV absorbers, optical brighteners, anti-dripping agents, antistatic agents, anti-fog agents, lubricants, anti-blocking agents. , Fluidity improver, plasticizer, dispersant, antibacterial agent and the like. These may be used in combination of two or more.
These descriptions are described in paragraphs 0027, 0028, 0038 to 0054 of the International Publication WO2012 / 128219 Pamphlet, JP-A-2007-314766, JP-A-2008-127485, JP-A-2009-51989, JP-A-2012. -72338 Publications and the like can be taken into consideration, and these contents are incorporated in the present specification.
The sheet-like material used in the present invention preferably contains 15 to 70% by mass of a thermoplastic resin. The lower limit of the content of the thermoplastic resin is preferably 20% by mass or more, more preferably 24% by mass or more. The upper limit of the content of the thermoplastic resin is preferably 60% by mass or less, more preferably less than 50% by mass, further preferably 45% by mass or less, still more preferably 42% by mass or less.

Next, the details of the continuous fiber used in the present invention will be described.
The continuous fiber in the present invention has a length of 10 cm or more, preferably a length of 50 cm or more, and more preferably 1 m or more. The upper limit is not particularly specified, but from the viewpoint of ease of winding around the core material, it is preferably 10,000 m or less, and more preferably 1000 m or less. Examples of continuous fibers used in the present invention are roving fibers.
The continuous fiber material used in the present invention includes glass fiber, carbon fiber, plant fiber (including Kenaf, bamboo fiber, etc.), alumina fiber, boron fiber, ceramic fiber, metal fiber (steel fiber, etc.), and aramid. Examples thereof include fibers, polyoxymethylene fibers, polyparaphenylene benzobisoxazole fibers, ultrahigh molecular weight polyethylene fibers, and basalt fibers. Among them, it is preferable to select from carbon fiber and glass fiber, and glass fiber is more preferable.
As the continuous fiber, those surface-treated with a surface treatment agent or a sizing agent may be used.

The amount of continuous fibers in the sheet-shaped material used in the present invention is preferably 30 to 85% by mass of the material. The lower limit of the content of the continuous fiber is preferably 40% by mass or more, more preferably more than 50% by mass, further preferably 55% by mass or more, still more preferably 58% by mass or more. The upper limit of the content of the continuous fiber is preferably 80% by mass or less, more preferably 76% by mass or less.
Further, in the sheet-like material used in the present invention, 90% by mass or more of its constituent components are made of a thermoplastic resin (preferably at least one kind of polyamide resin and polypropylene resin, and more preferably at least one kind of polyamide resin). It is preferably composed of continuous fibers.

Examples of the molded product obtained by the method for producing a molded product of the present invention include parts such as automobiles, ships, aircraft, electrical products, buildings, furniture, and office equipment.

After manufacturing the molded product by the method for producing a molded product of the present invention, injection molding may be further performed on the molded product. Specifically, by injection molding, the molded product obtained by the production method of the present invention can be reinforced or additional parts can be added. In particular, injection molding can be performed continuously with the method for producing a molded product of the present invention. With such a configuration, various functions can be efficiently added to the molded product, and the cost can be reduced.

In addition, in the present invention, JP-A-7-323397, JP-A-2007-268799, JP-A-2009-249877, JP-A-11-19998, JP-A-11-9998 The description of Gazette 2013-6389 can be taken into consideration and these contents are incorporated in the present specification.

Hereinafter, the present invention will be described in more detail with reference to examples. The materials, amounts used, ratios, treatment contents, treatment procedures, etc. shown in the following examples can be appropriately changed as long as they do not deviate from the gist of the present invention. Therefore, the scope of the present invention is not limited to the specific examples shown below.

<Polyamide resin>
MPXD10 was used as the polyamide resin.
Synthesis of MPXD10 8950 g (44.25 mol) of sebacic acid, which has been precisely weighed, in a reaction vessel having an internal volume of 50 L equipped with a stirrer, a condenser, a cooler, a thermometer, a dropping device and a nitrogen introduction tube, and a strand die. 12.54 g (0.074 mol) of calcium phosphate and 6.45 g (0.079 mol) of sodium acetate were weighed and charged. After sufficiently replacing the inside of the reaction vessel with nitrogen, the pressure was increased to 0.4 MPa with nitrogen, the temperature was raised from 20 ° C. to 190 ° C. with stirring, and sebacic acid was uniformly melted in 55 minutes. Then, a mixed diamine of 4172 g (30.63 mol) of metaxylylenediamine and 1788 g (13.13 mol) of paraxylylenediamine was added dropwise under stirring. During this period, the temperature inside the reaction vessel was continuously increased to 293 ° C. In the dropping step, the pressure was controlled to 0.42 MPa, and the generated water was removed from the system through a condenser and a cooler. The temperature of the demultiplexer was controlled in the range of 145 to 147 ° C. After completion of the dropping of the mixed diamine, the polycondensation reaction was continued for 20 minutes at a pressure of 0.42 MPa in the reaction vessel. During this period, the temperature inside the reaction vessel was raised to 296 ° C. Then, the pressure inside the reaction vessel was reduced from 0.42 MPa to 0.12 MPa in 30 minutes. During this period, the internal temperature was raised to 298 ° C. Then, the pressure was reduced at a rate of 0.002 MPa / min, and the pressure was reduced to 0.08 MPa in 20 minutes to adjust the amount of components having a molecular weight of 1,000 or less. The temperature inside the reaction vessel at the completion of depressurization was 301 ° C. After that, the inside of the system is pressurized with nitrogen, the polymer is taken out from the strand die in a strand shape at a reaction vessel temperature of 301 ° C. and a resin temperature of 301 ° C., cooled with cooling water of 20 ° C., and pelletized to about 13 kg. Polyamide resin (hereinafter, sometimes referred to as "MPXD10") was obtained. The obtained MPXD10 had a melting point of 213 ° C., a crystallization temperature at lower temperature of 162 ° C., and a number average molecular weight of 16300.

<Continuous fiber>
A glass fiber woven fabric, manufactured by Nitto Boseki, KS1210 1080S-935N, a basis weight of 90 g / m ² , and a thickness of 0.08 mm per sheet were used.

Example 1
<Manufacturing of polyamide resin film>
Using the above-mentioned polyamide resin MPXD10, films were produced by the following methods, respectively.
Polyamide resin dried by a vacuum dryer is melt-extruded by a single-screw extruder having a screw with a diameter of 30 mm, extruded through a T-die with a width of 500 mm, and a pair of stainless steel with uneven texture on the surface. The roll was pressed at a roll temperature of 70 ° C. and a roll pressure of 0.4 MPa to form a film having grain on the film surface.
The average thickness of the obtained polyamide resin film was 50 μm.

<Making sheet-shaped material>
The above-mentioned polyamide resin film and the above-mentioned glass fiber woven fabric were alternately laminated and put into a steel belt of a double belt press machine manufactured by HELD at a transport speed of 1.0 minute / m at 300 ° C. and 4 MPa. The glass fiber woven fabric was impregnated with a polyamide resin film by continuous heat pressing with pressure for 2 minutes, and cooled at 140 ° C. for 1 minute while being continuously pressurized to 4 MPa to obtain a fiber reinforced thermoplastic resin sheet. The ratio of the glass fiber in the obtained sheet-like material was 61% by mass, and the thickness of the sheet was 1.5 mm.

<Roll forming molding>
After preheating the sheet-shaped material obtained above until the sheet surface temperature reaches 220 ° C., one mountain fold (bending angle of 90 degrees) is formed between the heat insulating part and the heat insulating part, and The valley fold portion (bending angle 90 degrees) was conveyed between one pair of roll molding dies, molded by a heating device so that the roll surface temperature became 200 ° C., and then cooled at room temperature. When the obtained molded product was confirmed, it was confirmed that the continuous fibers did not bend in the bent portion of the molded product, and the deflection of each bent portion was offset.

Example 2
A sheet-like material was preheated from LANXESS TepexR dynalite 104 (the main component of the resin component is polypropylene resin, the proportion of glass fiber is 71% by mass, and the sheet thickness is 1.0 mm) until the sheet surface temperature reaches 165 ° C. Later, between the heat insulating part and the pair of roll molding dies having one mountain fold part (bending angle 90 degrees) and one valley fold part (bending angle 90 degrees). It was conveyed, molded by a heating device so that the roll surface temperature became 145 ° C., and then cooled at room temperature. When the obtained molded product was confirmed, it was confirmed that the continuous fibers did not bend in the bent portion of the molded product, and the deflection of each bent portion was offset.

Comparative Example 1
After preheating the sheet-shaped material obtained in Example 1 until the sheet surface temperature reaches 220 ° C., one mountain fold portion (bending angle 90 degrees) is possessed between the heat insulating portion and the heat insulating portion. It was conveyed between a pair of roll molding dies having a bent portion, molded by a heating device so that the roll surface temperature became 200 ° C., and then cooled at room temperature. When the obtained molded product was confirmed, it was confirmed that the continuous fibers were bent at the bent portion of the molded product.

11/12/22/23/31/32 Roll forming mold 13 Folding part 14 Continuous fiber reinforced thermoplastic resin sheet 15.52 Continuous fiber 21.33 Sheet-like material 24 Molding device 36 Heating device 37 Roll rotating shaft 34 ・ 61 ・ 71 Insulation part 35 ・ 62 ・ 72 Bending part 45 Mountain fold part 46 Valley fold part 51 Molded product

Claims (11)

A pair of roll molding dies having a first heat insulating portion, a bent portion, and a second heat insulating portion adjacent to each other in this order in a direction perpendicular to the rotation direction of the roll, wherein the bent portion is formed. The processed portion includes a mountain fold portion and a valley fold portion, and a continuous fiber reinforced thermoplastic resin sheet in which the difference between the total fold angle of the mountain fold portion and the total fold angle of the valley fold portion is within 5 degrees. A pair of roll molding dies, which is a pair of roll molding dies for roll molding. The pair of roll molding molds according to claim 1 , wherein the continuous fiber reinforced thermoplastic resin sheet has continuous fibers arranged in parallel in at least one direction. Further, claim 1. A heating device is provided in a region of at least one roll molding die of the pair of roll molding dies, which is closer to the rotation axis of the roll molding die than the first heat insulating portion and the second heat insulating portion. or a pair of roll forming die according to 2. The pair of roll molding dies according to any one of claims 1 to 3 , wherein at least one of the ends in the direction perpendicular to the rotation direction of the rolls of the pair of roll molding dies is a heat insulating portion. A roll molding apparatus for a molded product, which has the pair of roll molding molds according to any one of claims 1 to 4 . A method for producing a molded product, which comprises transporting a continuous fiber reinforced thermoplastic resin sheet between the pair of roll molding dies according to any one of claims 1 to 3 . The sheet is continuous fiber contained in the continuous fiber-reinforced thermoplastic resin sheet, at least, are in parallel in a direction perpendicular to the conveying direction of the sheet, a manufacturing method of a molded article according to claim 6. The method for producing a molded product according to claim 6 or 7 , wherein the continuous fiber is impregnated with the thermoplastic resin contained in the continuous fiber reinforced thermoplastic resin sheet. The method for producing a molded product according to any one of claims 6 to 8, wherein the continuous fiber reinforced thermoplastic resin sheet has a thickness of 0.2 to 5.0 mm. The method for producing a molded product according to any one of claims 6 to 9 , wherein the thermoplastic resin contains a polyamide resin or a polypropylene resin. Any of claims 6 to 10, wherein the thermoplastic resin contains a diamine-derived structural unit and a dicarboxylic acid-derived structural unit, and 50 mol% or more of the diamine-derived structural unit contains a polyamide resin derived from xylylenediamine. The method for producing a molded product according to item 1.

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