阅读说明：本技术 复合材料的成形方法 (Method for forming composite material ) 是由 上原茂高 于 2017-04-10 设计创作，主要内容包括：提供一种能够获得良好的外观的复合材料的成形方法。复合材料(预浸料片(10))的成形方法是层叠预浸料片(10)并进行成形的方法,该预浸料片(10)是使树脂(基体树脂(12))浸渗于基材(碳纤维(11))而成的。在该预浸料片(10)的成形方法中,在开始与表层的第1预浸料片(10P)相邻的第2预浸料片(10Q)所含有的第2基体树脂(12Q)的硬化之前,完成第1预浸料片(10P)所含有的第1基体树脂(12P)的硬化。(Provided is a method for molding a composite material, which can obtain a good appearance. A method for molding a composite material (prepreg (10)) is a method for laminating and molding a prepreg (10), wherein the prepreg (10) is formed by impregnating a base material (carbon fibers (11)) with a resin (matrix resin (12)). In the method for forming the prepreg (10), before the curing of the 2 nd matrix resin (12Q) contained in the 2 nd prepreg (10Q) adjacent to the 1 st prepreg (10P) of the surface layer is started, the curing of the 1 st matrix resin (12P) contained in the 1 st prepreg (10P) is completed.)

1. A method for molding a composite material in which a base material is impregnated with a resin, wherein the method comprises laminating a composite material,

Curing of the 1 st resin contained in the 1 st composite is completed before curing of the 2 nd resin contained in the 2 nd composite adjacent to the 1 st composite of the skin layer is started.

2. the method of forming a composite material according to claim 1,

The resin of claim 2 has thermosetting properties.

3. The method for forming a composite material according to claim 1 or 2,

The resin according to claim 1, which has a photo-curing property,

irradiating the 1 st composite material with light to cure the 1 st resin.

4. The method of forming a composite material according to claim 3,

The resin of claim 1, which is photo-curable with respect to ultraviolet rays,

Irradiating the composite material 1 with the light containing ultraviolet rays to cure the resin 1.

5. The method for forming a composite material according to any one of claims 1 to 4,

The substrate contains a plurality of carbon fibers oriented in one direction.

6. The method for forming a composite material according to any one of claims 2 to 5,

The laminated composite material is irradiated with the light and shaped, and then is thermoformed.

7. The method for forming a composite material according to any one of claims 2 to 6,

Pressing a mold corresponding to the outer shape of the molded article against the laminated composite material to mold the composite material,

The mold transmits the light toward the laminated composite material.

Technical Field

The invention relates to a method for forming a composite material.

Background

Conventionally, the following techniques are known: for example, a composite material (prepreg) in which a base material (carbon fibers) is impregnated with a resin is laminated, and then the laminate is thermoformed to produce a molded article (see patent document 1). In the technique described in patent document 1, the surface roughness of the base material is reduced, the bundling property of the base material is improved by the sizing treatment, and the disorder of the base material is suppressed.

disclosure of Invention

Problems to be solved by the invention

In the technique described in patent document 1, it is difficult to sufficiently suppress unevenness on the surface of the laminated composite material because the resin impregnated into the base material still flows and turbulence occurs in the base material during thermoforming. That is, in the technique described in patent document 1, it is difficult to obtain a good appearance.

The invention aims to provide a method for molding a composite material capable of obtaining a good appearance.

Means for solving the problems

The method for molding a composite material of the present invention for achieving the above object is a method for laminating and molding a composite material in which a base material is impregnated with a resin. In the method for molding a composite material, before the curing of the 2 nd resin contained in the 2 nd composite material adjacent to the 1 st composite material of the surface layer is started, the curing of the 1 st resin contained in the 1 st composite material is completed.

Drawings

Fig. 1 is a flowchart showing a method of molding a composite material according to embodiment 1.

Fig. 2A is a schematic view showing a state in which a long prepreg sheet wound up is stretched and cut at constant intervals to be singulated, corresponding to a cutting step.

Fig. 2B is a schematic view showing a state where the singulated prepreg is stacked, which follows fig. 2A, and corresponds to a stacking step.

Fig. 2C is a schematic view showing a state following fig. 2B, corresponding to a shaping step, in which a plurality of laminated prepregs are preformed in accordance with the outer shape of a molded article.

fig. 2D is a schematic view showing a state following fig. 2C, which corresponds to a surface layer curing step, in which light is irradiated to the surfaces of a plurality of pre-formed prepregs to cure the prepregs of the surface layer.

Fig. 2E is a schematic view showing a state where a plurality of prepregs having only the surface layer cured are thermally cured, corresponding to the thermoforming step, following the state shown in fig. 2D.

Fig. 2F is a schematic view showing a state following fig. 2E, corresponding to a mold releasing step, in which a plurality of prepregs (molded articles) after heat curing are taken out from a fixed mold and a movable mold.

fig. 3 is a schematic view showing a state in which the resin (matrix resin) of the prepreg of the surface layer among the plurality of prepregs is photo-cured, in association with the surface layer curing step shown in fig. 2D.

Fig. 4 is a graph showing a relationship between the temperature and the viscosity of the resin (matrix resin) of the prepreg, in association with the thermoforming step shown in fig. 2E.

Fig. 5 is a flowchart showing a method of molding a composite material according to embodiment 2.

Fig. 6 corresponds to the surface layer curing step and the shaping step in one embodiment 2, and is a schematic view showing a state in which a plurality of prepregs are irradiated with light having passed through a movable mold for shaping to cure the prepregs on the surface layer.

fig. 7 corresponds to the surface layer curing step and the shaping step in the second embodiment 2, and is a schematic view showing a state in which light is irradiated from the inside of the shaping moving mold to the plurality of prepregs to cure the prepregs on the surface layer.

Detailed Description

Hereinafter, embodiment 1 and embodiment 2 of the present invention will be described with reference to the attached drawings. In the drawings, the same members are denoted by the same reference numerals, and redundant description is omitted. In the drawings, the size and the ratio of each member are exaggerated for easy understanding of embodiment 1 and embodiment 2, and may be different from the actual size and ratio.

(embodiment 1)

As described in detail with reference to fig. 3, the method of molding the composite material (prepreg 10) according to embodiment 1 is a method of laminating and molding prepregs 10 in which a base material (carbon fibers 11) is impregnated with a resin (matrix resin 12). In this method for forming the prepreg 10, before the curing of the 2 nd matrix resin 12Q contained in the 2 nd prepreg 10Q adjacent to the 1 st prepreg 10P of the surface layer is started, the curing of the 1 st matrix resin 12P contained in the 1 st prepreg 10P is completed.

Here, the first prepreg 10P of the surface layer corresponds to the prepregs 10 except the prepreg 10 of the one layer (the outermost layer) on the back surface of all the prepregs 10. That is, the first prepreg 10P of the surface layer may be, for example, a layer (outermost layer) exposed to the outside only on the surface side, or may be a plurality of layers other than a layer (outermost layer) exposed to the outside on the back side, among the plurality of laminated prepregs 10.

(prepreg 10)

The prepreg 10 (composite material) is formed in a vertically long thin plate shape by impregnating a base material (carbon fibers 11) with a resin (matrix resin 12). A molded article 20 made of Carbon Fiber Reinforced Plastic (CFRP) is molded using the prepreg 10.

The substrate is not limited to the carbon fibers 11, and may be made of glass fibers, organic fibers, or the like. In the carbon fibers 11, the orientation of the fibers is made uniform by using long fibers oriented in one direction, as compared with the case of using short fibers having random orientations. That is, by using the carbon fiber 11 of the long fiber, wrinkles, twists, and irregularities due to disorder of the fiber are suppressed.

The base resin 12 is made of, for example, an epoxy resin having photo-curing property and thermosetting property, an acrylic resin having photo-curing property and thermosetting property, or a urethane resin. The matrix resin 12 may be provided with photocurability only in the 1 st prepreg 10P that is located at least on the outermost surface and is exposed to the outside among the plurality of stacked prepregs 10.

(method of Forming prepreg 10)

The method of forming the prepreg 10 is embodied by the following steps. That is, the method of forming the prepreg 10 is embodied by the cutting step S11 of cutting and singulating the lengthwise prepreg 10, the laminating step S12 of laminating the singulated prepregs 10, and the shaping step S13 of preforming a plurality of laminated prepregs 10. The method of molding the prepreg 10 is embodied by the surface layer curing step S14 of curing the 1 st prepreg 10P of the surface layers of the plurality of pre-formed prepregs 10, the thermoforming step S15 of thermally curing the entire plurality of prepregs 10 with only the surface layers cured, and the mold releasing step S16 of taking out the plurality of thermally cured prepregs 10 (molded articles 20) from the mold.

A method of molding the prepreg 10 (embodied by the cutting step S11 to the releasing step S16) will be described with reference to fig. 1 and fig. 2A to 2F. Fig. 1 is a flowchart illustrating a method of forming a prepreg 10. Fig. 2A to 2F are schematic views showing a method of forming the prepreg 10.

(cutting step S11)

As shown in fig. 2A, the cutting step S11 is a step of cutting the lengthwise prepreg 10 into individual pieces.

Fig. 2A corresponds to the cutting step S11, and is a schematic view showing a state in which the long prepreg sheet 10 that has been wound up is cut at a constant interval while being stretched and singulated.

as shown in fig. 2A, the wound longitudinal prepreg 10 is cut at a constant interval by a cutter 101 while being stretched to be singulated. The singulated prepreg 10 is conveyed to the laminating step S12.

(laminating step S12)

As shown in fig. 2B, the laminating step S12 is a step of laminating the singulated prepregs 10.

Fig. 2B is a schematic view showing a state where the singulated prepreg 10 is stacked, which follows the state shown in fig. 2A, and corresponds to the stacking step S12.

As shown in fig. 2B, a plurality of singulated prepregs 10 are stacked. The prepreg 10 is stacked several to several tens of sheets depending on the thickness of the molded article 20 in a state of being elongated so as not to generate wrinkles.

(shaping step S13)

As shown in fig. 2C, the shaping step S13 is a step of preforming a plurality of stacked prepregs 10.

Fig. 2C is a schematic view, corresponding to the shaping step S13, of a state following fig. 2B, showing a state in which a plurality of laminated prepregs 10 are preformed in accordance with the outer shape of the molded article 20.

As shown in fig. 2C, the plurality of stacked prepregs 10 are preformed by a preliminary metal mold (a shaping fixed mold 102 and a shaping moving mold 103). The shape-forming fixed mold 102 and the shape-forming movable mold 103 correspond to the main shape of the molded product 20. After the shaping movable mold 103 is raised and the plurality of prepregs 10 are placed on the shaping stationary mold 102, the shaping movable mold 103 is lowered. The plurality of prepregs 10 are clamped by the shaping stationary mold 102 and the shaping moving mold 103 and clamped.

(surface hardening step S14)

As shown in fig. 2D and 3, the surface layer hardening step S14 is a step of hardening the 1 st prepreg 10P of the surface layers of the plurality of pre-formed prepregs 10.

Fig. 2D is a schematic view showing a state following fig. 2C, corresponding to the surface layer curing step S14, in which light L is irradiated to the surfaces of the plurality of pre-formed prepregs 10 to cure the first prepreg 10P of the surface layer. Fig. 3 is a schematic view associated with the surface layer curing step S14 shown in fig. 2D, showing a state in which the resin (matrix resin 12) of the 1 st prepreg 10P of the surface layers of the plurality of prepregs 10 is photo-cured.

As shown in fig. 2D and 3, the shaping movable mold 103 is separated from the shaping fixed mold 102, and the light source 104 is opposed to the plurality of prepregs 10 held by the shaping fixed mold 102. The light source 104 is constituted by a lamp, a light emitting diode, or a laser diode that emits light L including ultraviolet rays. The light source 104 is mounted on a linear motion stage (not shown) so as to approach and separate from the preliminary metal mold (the fixed shaping mold 102 and the movable shaping mold 103). Light L is irradiated from the light source 104 to the surfaces of the plurality of prepregs 10. As shown in fig. 3, the 1 st matrix resin 12P contained in at least the 1 st prepreg 10P, which is located on the outermost surface and exposed to the outside, of the plurality of stacked prepregs 10 is hardened by the light L.

The 1 st matrix resin 12P in the surface layer curing step S14 is cured not only in a state in which the curing is completed but also in a state in which the curing is not completed and the curing is advanced to a hardness that maintains a certain shape-fixing property.

(thermoforming step S15)

As shown in fig. 2E and 4, the thermoforming step S15 is a step of thermally curing the entire plurality of prepregs 10 in a state in which only the surface layers are cured.

Fig. 2E is a schematic view showing a state in which a plurality of prepregs 10 having only their surface layers cured are thermally cured, corresponding to the thermoforming step S15, following the state shown in fig. 2D. Fig. 4 is a graph showing a relationship between the temperature and the viscosity of the resin (matrix resin 12) of the prepreg 10, in association with the thermoforming step S15 shown in fig. 2E.

As shown in fig. 2E, the plurality of prepregs 10 whose preforming has been completed are subjected to main molding by a mold (a fixed mold 105 for thermoforming and a movable mold 106 for thermoforming). At least one of the fixed mold 105 for thermoforming and the movable mold 106 for thermoforming contains a heater for heating. The fixed mold 105 for thermoforming and the movable mold 106 for thermoforming correspond to the shape of the molded article 20. After raising the movable thermoforming mold 106 and placing the plurality of prepregs 10 whose preforming has been completed on the fixed thermoforming mold 105, the movable thermoforming mold 106 is lowered. The plurality of pre-formed prepregs 10 are clamped and clamped by a fixed thermoforming mold 105 and a movable thermoforming mold 106.

As shown in fig. 4, when heat is input to the plurality of laminated prepregs 10 and the temperature of the matrix resin 12 rises, the viscosity of the matrix resin 12 temporarily decreases before the matrix resin is cured, and the matrix resin starts to flow. Here, the 1 st prepreg 10P of the surface layer in the plurality of laminated prepregs 10 has been accelerated to be hardened in the surface layer hardening process S14. Therefore, even when heat is applied to the surfaces of the plurality of laminated prepregs 10, the viscosity of the matrix resin 12 does not extremely decrease, and the flow of the matrix resin 12 can be suppressed. That is, the orientation of the carbon fibers 11 is not disturbed even when heat is input to the surfaces of the plurality of laminated prepregs 10, and wrinkles, twists, irregularities, and local contraction due to disturbance of the fibers can be suppressed. Therefore, the surfaces of the plurality of laminated prepregs 10 can maintain good appearance.

The prepregs 10 other than the 1 st prepreg 10P of the surface layer among the plurality of laminated prepregs 10 are not irradiated with the light L in the surface layer hardening step S14. That is, the prepreg 10 other than the 1 st prepreg 10P of the surface layer starts the flow of the impregnated matrix resin 12 in accordance with the input of heat in the thermoforming step S15. Therefore, in the prepregs 10 other than the first prepreg 10P of the surface layer, the matrix resin 12 flows into the fine gaps of the adjacent prepregs 10 in a state of low viscosity, and the impregnation property can be improved. Therefore, the plurality of laminated prepregs 10 can prevent a decrease in peel strength and a decrease in durability due to voids and the like while maintaining good appearance.

(mold-releasing step S16)

As shown in fig. 2F, the releasing step S16 is a step of taking out the plurality of thermally cured prepregs 10 (molded articles 20) from the mold.

Fig. 2F is a schematic view showing a state in which the plurality of prepregs 10 (molded articles 20) after thermal curing are taken out from the fixed thermoforming mold 105 and the movable thermoforming mold 106, corresponding to the mold-releasing step S16, following the state of fig. 2E.

As shown in fig. 2F, after the plurality of prepregs 10 (molded articles 20) after the thermosetting are cooled to room temperature, the movable mold for thermoforming 106 is separated from the fixed mold for thermoforming 105, and the molded articles 20 are taken out to the outside. Thereafter, the outer edge of the molded article 20 is cut by a cutting blade and trimmed as necessary (trimming step). Further, the molded article 20 is coated (coating step).

the operational effects of embodiment 1 described above will be described.

The method of molding the prepreg 10 is a method of laminating and molding the prepreg 10 in which the base material (carbon fibers 11) is impregnated with the resin (matrix resin 12). In this method for forming the prepreg 10, before the curing of the 2 nd matrix resin 12Q contained in the 2 nd prepreg 10Q adjacent to the 1 st prepreg 10P of the surface layer is started, the curing of the 1 st matrix resin 12P contained in the 1 st prepreg 10P is completed.

According to this method for forming the prepreg 10, after the 1 st matrix resin 12P of the 1 st prepreg 10P of the surface layer of the stacked prepregs 10 is cured, the 2 nd matrix resin 12Q of the 2 nd prepreg 10Q inside is cured. That is, when the stacked prepregs 10 are cured, even if the viscosity of the matrix resin 12 impregnated with the carbon fibers 11 is lowered and flows in the stacked prepregs 10, the influence on the surface of the stacked prepregs 10 can be sufficiently suppressed. Therefore, according to the method for forming the prepreg 10, a good appearance can be obtained.

In the method of molding the prepreg 10, the 2 nd matrix resin 12Q is preferably a resin having thermosetting properties.

According to the method for molding the prepreg 10, the 2 nd matrix resin 12Q having high versatility and thermosetting property with which curing control is easy can be used for molding.

In the method of molding the prepreg 10, it is preferable that the 1 st matrix resin 12P has photo-curing properties, and the 1 st matrix resin 12P is cured by irradiating the 1 st prepreg 10P with the light L.

According to this method for molding the prepreg 10, when the 1 st matrix resin 12P of the 1 st prepreg 10P is partially cured, the 1 st matrix resin 12P of a desired portion (region) can be selectively cured by irradiating the desired portion (region) with the light L. In addition, when the 1 st base resin 12P is partially cured, the 1 st base resin 12P in the necessary portion (region) can be selectively cured by irradiating the entire 1 st prepreg 10P with the light L after covering the portion other than the necessary portion (region) with a reflective sheet or the like. Therefore, according to the method of forming the prepreg 10, a desired portion (region) can be selected to obtain a good appearance.

Further, according to the method of forming the prepreg 10, the light L is incident on the 1 st prepreg 10P while being absorbed by the 1 st prepreg 10P. That is, it is possible to suppress the light L from reaching (entering) the 2 nd prepreg 10Q located directly below the 1 st prepreg 10P and hardening the 2 nd matrix resin 12Q of the 2 nd prepreg 10Q. Further, an interface is generated between the 1 st prepreg 10P and the 2 nd prepreg 10Q, and therefore, even if light L exits from the 1 st prepreg 10P, it can be difficult to enter the 2 nd prepreg 10Q. Thus, the 1 st matrix resin 12P of the 1 st prepreg 10P located at the outermost layer among the plurality of laminated prepregs 10 can be selectively cured. Therefore, according to the method of forming the prepreg 10, a desired portion (region) can be selected to obtain a good appearance.

In the method of molding the prepreg 10, it is preferable that the 1 st matrix resin 12P has photocurability with respect to ultraviolet rays, and the 1 st matrix resin 12P is cured by irradiating the 1 st prepreg 10P with light L including ultraviolet rays.

According to the method of forming the prepreg 10, the 1 st prepreg 10P can be efficiently cured by using the light L of the ultraviolet ray having a relatively short wavelength and a large energy. Therefore, according to the method for forming the prepreg 10, a good appearance can be obtained.

In addition, according to the method of forming the prepreg 10, by using the light L of the ultraviolet ray having a relatively short wavelength and a large energy, the light L can be sufficiently attenuated in the first prepreg 10P. That is, it is possible to suppress the light L from reaching (entering) the 2 nd prepreg 10Q located directly below the 1 st prepreg 10P and hardening the 2 nd matrix resin 12Q of the 2 nd prepreg 10Q. Thus, the 1 st matrix resin 12P of the 1 st prepreg 10P located at the outermost layer among the plurality of laminated prepregs 10 can be selectively cured. Therefore, according to the method for forming the prepreg 10, a good appearance can be obtained.

In the method of forming the prepreg 10, the substrate preferably contains a plurality of carbon fibers 11 oriented in one direction.

According to the method for forming the prepreg 10, unevenness on the surface of the prepreg 10 can be suppressed as compared with the case of using a substrate configured as a woven fabric and containing carbon fibers oriented orthogonally to each other. Therefore, according to the method for forming the prepreg 10, a good appearance can be obtained. In addition, in general, when a plurality of carbon fibers 11 oriented in one direction are used, there is a fear that the binding force in the fiber orthogonal direction is weak and the orientation is easily disturbed even if the resin flows slightly, but as in embodiment 1, the 1 st matrix resin 12P of the 1 st prepreg 10P of the surface layer is cured, and then the 2 nd matrix resin 12Q of the 2 nd prepreg 10Q inside is cured, thereby eliminating the above-mentioned fear.

(embodiment 2)

As shown in fig. 5, the method for molding the prepreg 10 according to embodiment 2 is different from the method for molding the prepreg 10 according to embodiment 1 described above in that the surface layer curing step (the surface layer curing step and the shaping step S23) is performed together with the shaping step. In embodiment 1 described above, the surface layer hardening step S14 is performed after the shaping step S13 and before the thermoforming step S15.

A method of forming the prepreg 10 according to embodiment 2 will be described with reference to fig. 5 (a flowchart of embodiment 2), fig. 6 (one embodiment of embodiment 2), and fig. 7 (the second embodiment of embodiment 2).

in embodiment 2, when performing the plurality of stacked prepregs 10 by the preliminary metal mold (the shaping fixed mold 102 and the shaping moving mold 203 or 303), the light L is irradiated from the light source 104 to the plurality of stacked prepregs 10. That is, the surface layer hardening step and the shaping step are performed simultaneously.

(one of embodiment 2)

Fig. 5 is a flowchart showing a method of forming the prepreg 10 according to embodiment 2. Fig. 6 corresponds to the surface layer curing step and the shaping step S23 in one embodiment of embodiment 2, and is a schematic view showing a state in which the 1 st prepreg 10P of the surface layer is cured by irradiating the plurality of prepregs 10 with the light L having passed through the shaping moving mold 203.

As shown in fig. 6, the outer shape of the shaping moving mold 203 is the same as that of the shaping moving mold 103 according to embodiment 1, but the material is made of glass such as synthetic quartz having heat resistance and transmitting ultraviolet rays. The shaping moving mold 203 is not limited to synthetic quartz as long as it has heat resistance and transmits ultraviolet rays. The light source 104 is disposed behind the shaping moving mold 203. Light L derived from a light source 104 is transmitted through the shaping moving mold 103 and irradiated to the plurality of laminated prepregs 10.

(second embodiment)

Fig. 7 corresponds to the surface layer curing step and the shaping step S23 in the second embodiment 2, and is a schematic view showing a state in which light L is irradiated from the inside of the shaping moving mold 303 to the plurality of prepregs 10 to cure the 1 st prepreg 10P of the surface layer.

As shown in fig. 7, the outer shape of the shaping movable mold 303 is the same as that of the shaping movable mold 103 according to embodiment 1, and a light source 304 is provided at a portion facing the shaping fixed mold 102. The shaping moving mold 303 is made of glass such as synthetic quartz, and a portion thereof which transmits the light L emitted from the light source 304 to the outside is formed of synthetic quartz. The light source 304 is constituted by, for example, a light emitting diode or a laser diode. The light L led out from the light source 304 is irradiated to the plurality of stacked prepregs 10.

The operational effects of embodiment 2 described above will be described.

In the method of molding the prepreg 10, it is preferable that the laminated prepreg 10 is shaped by irradiating light L thereto, and then is thermoformed.

According to the method for molding the prepreg 10, the laminated prepreg 10 can be shaped and the skin layer can be cured to improve the rigidity, and then the thermal molding can be performed. That is, when the laminated prepreg 10 is moved from the shaping step to the hot forming step, the shape thereof can be maintained and the positioning accuracy can be ensured. Therefore, according to the method for molding the prepreg 10, it is possible to obtain a good appearance without being influenced by the movement from the shaping step to the thermoforming step or the positioning accuracy in the thermoforming step.

Further, according to the method of molding the prepreg 10, only the 1 st matrix resin 12P can be efficiently cured by irradiating the 1 st prepreg 10P with the light L in a state where the influence of heat is eliminated in the step of forming without heating. Therefore, according to the method for forming the prepreg 10, the influence of heat can be eliminated and a good appearance can be obtained.

In the method of forming the prepreg 10, it is preferable that the shaping traveling mold 203 or the shaping traveling mold 303 corresponding to the outer shape of the molded article 20 is pressed against the stacked prepregs 10 to perform molding, and the shaping traveling mold 203 or the shaping traveling mold 303 transmits the light L toward the stacked prepregs 10.

According to the method for molding the prepreg 10, the surface layer prepreg 10 can be cured while the stacked prepregs 10 are pressed (restrained) by the shaping traveling mold 203 or the shaping traveling mold 303. That is, the shape of the shaping movable mold 203 or the shaping movable mold 303 is transferred well to the laminated prepreg 10. Therefore, according to the method for molding the prepreg 10, a good appearance can be obtained in which the shape of the shaping movable mold 203 or the shaping movable mold 303 is transferred.

The present invention can be variously modified based on the structures described in the claims, and these are also the scope of the present invention.

In embodiment 1 and embodiment 2, the surface layer curing step is performed by irradiating the 1 st prepreg 10P of the surface layer with ultraviolet light, but the 1 st prepreg 10P of the surface layer may be cured by irradiating the surface layer with visible light or infrared light having a wavelength longer than that of ultraviolet light.

In embodiment 1 and embodiment 2, the carbon fibers 11 of the prepreg 10 are oriented in one direction, and carbon fibers woven in a different manner may be used. In this case, carbon fibers 11 woven into the prepregs 10 other than the first prepreg 10P of the surface layer may be used.

In embodiment 1, the surface layer curing step S14 is performed in the molds (the shaping fixed mold 102 and the shaping movable mold 103) of the shaping step S13 after the shaping step S13 is completed. However, the surface hardening step S14 may be performed in the molds (the fixed mold 105 for thermoforming and the movable mold 106 for thermoforming) of the thermoforming step S15 before the thermoforming step S15 is started.

In embodiment 2, the surface layer curing step and the shaping step S23 may be configured as follows: for example, the fixed shaping mold 102 is formed of synthetic quartz instead of the movable shaping mold 103, and the light L transmitted through the fixed shaping mold 102 is irradiated to the surface of the laminated prepreg 10.

The surface layer hardening step of embodiment 2 may be configured as follows: the movable mold 106 for thermoforming or the fixed mold 105 for thermoforming is made of, for example, synthetic quartz, and the light L transmitted through the movable mold 106 for thermoforming or the fixed mold 105 for thermoforming is irradiated to the surface of the laminated prepreg sheets 10. That is, the surface layer hardening step of embodiment 2 may be performed simultaneously with the thermoforming step S15 of embodiment 1.

In embodiment 1 and embodiment 2, the matrix resin 12 (resin) is a resin having thermosetting properties, but a resin having thermoplastic properties may be used.

Description of the reference numerals

10. Prepreg (composite material); 10P, 1 st prepreg (1 st composite); 10Q, No. 2 prepreg (No. 2 composite); 11. carbon fibers (substrate); 12. a matrix resin (resin); 12P, 1 st matrix resin (1 st resin); 12Q, 2 nd matrix resin (2 nd resin); 20. a molded article; 101. a cutting knife; 102. a fixed mold for shaping; 103. 203, 303, a shaping moving die; 104. 304, a light source; 105. a fixed die for thermoforming; 106. a movable mold for thermoforming; l, light; s11, cutting; s12, a laminating procedure; s13, a shaping procedure; s14, hardening the surface layer; s15, thermoforming; s16, demolding; s23, a surface layer hardening step and a shaping step.