JPH07314122A - Apparatus and method for continuous production of metal-based fiber-reinforced composite plate - Google Patents

Abstract

(57) [Abstract] [Purpose] To provide an apparatus and a method for continuously producing a metal-based fiber-reinforced composite plate capable of continuously producing a composite plate that can be used as a structural material or a functional material. [Structure] Three-stage mold 1 movable in the thickness direction D of the plate
The fiber feeding device 26 is provided between 1, 12, and 13 to reinforce the fiber 2
6 is continuously fed, the die 13 on the outlet side is closed and the molten metal 30 is filled in the heated die 12 by the molten metal feeding device 25, and the die 11 on the inlet side is closed to close the central portion. After the molten metal 30 is impregnated into the reinforcing fiber 29 while being pressed by the mold 12, the solidification portion is sent to the mold 13 on the outlet side for cooling and the mold 11 on the inlet side is opened. The control device 28 controls to repeat the filling of the molten metal 30 with the molten metal 30. Thereby, the metal-based fiber-reinforced composite plate can be continuously manufactured.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and method for continuously producing a metal-based fiber-reinforced composite sheet such as a fiber-reinforced aluminum sheet, which can be continuously produced without applying ultrahigh pressure.

[0002]

2. Description of the Related Art Metal matrix fiber reinforced composite materials (FRM) are
It is one of the composite materials that combines materials with different properties and adds superior characteristics and completely new functions to those of a single substance. For example, a light metal such as an aluminum alloy is used as a base and is reinforced with fibers such as carbon and ceramics. .

A high-pressure casting method (molten metal forging method) is mainly used in the method for producing the metal-based fiber-reinforced composite material.
For example, as disclosed in Japanese Examined Patent Publication (Kokoku) No. 58-57265, a preform is prepared by using reinforcing fibers, the preform is set in a mold, and then molten metal is poured into the mold to form a molten metal. A hydrostatic high pressure is applied to the preform to impregnate the molten metal into the preform, and then the pressure is maintained for a certain period of time to solidify the molten metal.

[0004]

However, in the method for producing a metal-based fiber-reinforced composite material by such a molten metal forging method, the size of the product to be produced is limited by the size of the mold, and therefore, a large size is required. Unable to manufacture plate material.

Further, the conventional method for producing a metal-based fiber-reinforced composite material by the molten metal forging method has a problem that the production efficiency is low because the batch processing is performed.

Therefore, it is desired to develop a manufacturing method and apparatus capable of continuous manufacturing, and it is considered to apply a continuous manufacturing method of fiber reinforced plastic (FRP), for example. For example, Japanese Examined Patent Publication (Kokoku) No. 5-82283 discloses a method and an apparatus for producing a fiber-reinforced synthetic resin material, in which a heating compression molding section and a compression cooling molding section are formed in one die arranged vertically. A fiber woven cloth, a resin film, and a belt conveyor are placed between the upper and lower molds.
A fiber reinforced synthetic resin molded body is continuously obtained by performing heat compression molding and compression cooling a plurality of times while sequentially feeding a molding material such as a prepreg sheet.

Even if the continuous production method of such a fiber-reinforced plastic is applied to a metal-based fiber-reinforced composite material, it is possible to produce an ultra-thin sheet having a thickness of about 0.05 to 0.3 mm. However, it is not possible to continuously manufacture thick plate materials used as structural materials or functional materials.

The present invention has been made in view of the above problems of the prior art, and is a continuous metal-based fiber-reinforced composite plate capable of continuously producing a plate material that can be used as a structural material or a functional material. A manufacturing apparatus and method are provided.

[0009]

In order to solve the problems of the above-mentioned prior art, the apparatus for continuously producing a metal-based fiber-reinforced composite plate according to the first aspect of the present invention is capable of heating and cooling in the thickness direction of the plate. At least three stages of dies capable of moving, closing and pressurizing, a fiber / metal feeder capable of continuously feeding a reinforcing fiber and a molten metal between the dies, By controlling the heating / cooling and the closing / pressurization of the mold by moving and the feeding of the reinforcing fiber / molten metal, the reinforcing fiber is fed and the heated metal is filled with molten metal It is characterized by comprising a control device which repeats cooling and solidification while pressing.

In the continuous method for producing a metal-based fiber-reinforced composite sheet according to the second aspect of the present invention, at the time of continuously producing the metal-based fiber-reinforced composite sheet, at least three stages that can move in the thickness direction of the sheet are used. While continuously feeding the reinforcing fiber between the molds, close the mold on the outlet side and fill the molten metal into the heated mold, then close the mold on the inlet side and use the mold in the center. After the molten metal is impregnated with the reinforcing fiber under pressure to solidify, the cooling and solidifying section is sent to the die on the outlet side for cooling and the die on the inlet side is opened and the molten metal is filled repeatedly. It is characterized by doing so.

Furthermore, the method for continuously producing a metal-based fiber-reinforced composite plate according to the third aspect of the present invention, in addition to the constitution of the second aspect,
It is characterized in that the mold is heated in the first half of the pressurization for impregnating the reinforcing fibers with the molten metal in the mold of the central part, while the mold is cooled in the latter half of the pressurization to solidify. It is what

[0012]

According to the apparatus for continuously producing a metal-based fiber-reinforced composite plate of the invention of claim 1, the fiber-feeding device inserts the reinforcing fibers between at least three stages of molds movable in the thickness direction of the plate. While continuously feeding, close the die on the outlet side and fill the molten metal in the heated die with the molten metal feeder, close the die on the inlet side and pressurize with the die in the center After the molten metal is solidified while impregnating the reinforcing fibers, the cooling and solidification part is sent to the die on the outlet side for cooling and the die on the inlet side is opened and the molten metal is repeatedly filled. It is controlled by the equipment, and it becomes possible to continuously manufacture the metal base fiber reinforced composite plate. Further, according to the method for continuously producing a metal-based fiber-reinforced composite plate according to the second aspect of the present invention, the reinforcing fiber is continuously fed between at least three stages of molds movable in the thickness direction of the plate. While closing the die on the outlet side and filling molten metal into the heated die, close the die on the inlet side and pressurize with the die in the center to solidify while impregnating the reinforcing metal with the molten metal. After that, the cooling and solidification section is sent to the die on the outlet side to be cooled, and the die on the inlet side is opened to fill the molten metal with the molten metal. Be able to manufacture.

Further, the method for continuously producing a metal-based fiber-reinforced composite plate according to the invention of claim 3 is the same as that of claim 2,
While the mold is in a heated state in the first half of the pressing in which the reinforcing metal is impregnated with the molten metal by the mold in the central portion, the mold is cooled in the latter half of the pressing to solidify the mold. In the case of impregnation in the first half of pressure, the fluidity due to heating can be utilized, and cooling in the latter half of pressurization promotes solidification to improve production efficiency.

[0014]

Embodiments of the present invention will be described in detail below with reference to the drawings. FIG. 1 is a schematic perspective view showing a partial cutaway of an embodiment of a continuous production apparatus for metal-based fiber-reinforced composite plate of the present invention.

This continuous manufacturing apparatus 10 for metal-based fiber-reinforced composite plates is a mold 11, 12, 1 which is arranged in three layers vertically.
3, the upper die 11 is composed of a pair of left and right moving dies 11a and 11b, and the middle die 1 and the lower die 1 are provided.
2 and 13 are a pair of left and right fixed molds 12a and 13a, respectively.
And the moving molds 12b and 13b.
Fluid pressure cylinders 14, 14a, 15 and 16 are connected to a, 11b, 12b and 13b, respectively, so that the left and right spaces can be narrowed to be in a closed state or a pressing force can be applied.

Such upper and lower three-stage molds 11, 12,
13 is the moving molds 11a, 11b, 12b, 13b.
The moving direction (in this embodiment, the left-right direction) of the composite plate W is the plate thickness direction D of the continuously manufactured composite plate W, and the mold 1
The widths of 1, 12 and 13 correspond to the width of the composite plate W.

The upper and lower heights of the molds 11, 12 and 13 are set in the length direction of the composite plate W, and the upper mold 11 constitutes the inlet side seal portion 17 for filling and pressurizing the molten metal. The mold 12 in the middle stage constitutes the impregnation chamber 18 and has a height corresponding to one continuous production length of the composite plate W, and the mold in the lower stage. Reference numeral 13 constitutes an outlet-side seal portion 19, which has a height required for further cooling and closing the molten metal solidified in the middle-stage mold 12 and is, for example, lower than that of the middle-stage mold 12.

Such upper and lower three-stage molds 11, 12,
13 is mounted on a frame 20, fixed dies 12a and 13a in the middle and lower stages are attached via fixed blocks, and moving dies 11a, 11b, 12b, and 13b are fluid pressure cylinders 14, 14a, 15, and 16, respectively. It is attached to the frame 20 via.

A funnel-shaped pool 21 of molten metal is formed in the upper part of the frame 20 so as to open between the pair of molds 11, and an opening 22 for drawing out the composite plate W is formed in the lower part. Are formed to open between the pair of molds 13.

Side frames 23 are attached to both side faces of the frame 20 so as to close the side faces of the three-stage molds 11, 12, 13 and the side faces such as the molten metal pool 21 and the opening 22.

Further, each of the molds 11, 12 and 13 is provided with a heating / cooling zone 24, and the upper mold 11 is heated to prevent the temperature of the molten metal from lowering and the middle mold to be heated. In the mold 12, heating and cooling are switched to promote impregnation and solidification, and in the lower mold 13, switching between heating and cooling is performed at the upper part to prevent temperature decrease of the molten metal and solidification, and at the lower part to cool. Done to promote coagulation. Heating / cooling zone 24
For example, a heat exchanger to which a heat medium is supplied, an electric heater, or the like is installed for heating, and cooling is performed by a heat exchanger in which cooling water or the like is circulated.

A heating / cooling zone 24 is also provided around the molten metal pool 21 of the frame 20 to heat it.
It is designed to prevent the temperature of the molten metal from decreasing.

Further, a molten metal feeding device 25 for feeding the molten metal to the molten metal reservoir 21 is provided above the frame 20, and reinforcing fibers are passed through the molten metal reservoir 21 between the molds 11, 12, and 13. A reinforcing fiber feeding device 26 is provided for feeding to.

Below the frame 20, the composite material W is
A pull-out roll 27 for pulling out is provided.

The fluid pressure cylinders 14, 14a, 15, 16 for moving the molds 11, 12, 13 and the heating / cooling temperature of the heating / cooling zone 24, the molten metal feeding device 2
5, a controller 28 is provided to control the reinforcing fiber feeder 26 and the draw roll 27.

In the continuous manufacturing apparatus 10 for such metal-based fiber-reinforced composite plate, it is used for continuously manufacturing a composite plate reinforced with carbon or ceramic fibers based on a light metal such as an aluminum alloy. Moreover, as a metal,
Non-ferrous metals such as copper, zinc and tin are used. As the reinforcing fibers, carbon fibers, alumina fibers and the like woven into a cloth or mat are used.

Further, in order to prevent the molten metal from coming into contact with air, the upper side of the three-stage molds 11 to 13 of the continuous metal-fiber-reinforced composite plate manufacturing apparatus 10 is covered with a vacuum container, and the molten metal is kept in a vacuum state. It is desirable to be able to supply, impregnate, and coagulate the reinforcing fibers.

Next, together with the operation of the apparatus 10 for continuously producing a metal-based fiber-reinforced composite sheet thus constructed, an embodiment of the method for continuously producing a metal-based fiber-reinforced composite sheet according to the present invention is shown in FIG. It will be described with reference to the drawing.

First, the upper, middle and lower molds 11, 12, 13 are opened by the fluid pressure cylinders 14, 14a, 15, 16 and the reinforcing fibers 29 are fed out by the reinforcing fiber feeding device 26 to collect the molten metal. It is in a state of being fed to the pull-out roll 27 from 21 through the dies 11, 12, and 13.

Thereafter, as shown in FIG. 2 (a), the lower die 13 constituting the outlet side seal portion 19 is closed by a fluid pressure cylinder 16 and the molten metal leaks even if a pressure of about 30 atm is applied. Put in a sealed state that does not eject.

Then, with the upper and middle molds 11 and 12 in an open state, the molten metal feeding device 25 to the frame 2
The molten metal pool 21 of 0 is filled with a molten metal 30 such as an aluminum alloy. In addition, when filling the molten metal 30,
The lower part of the lower mold 13 of the cooling zone 24 is in a cooling state, but all other parts are in a heating state, and the inlet side seal part 17
The heating temperature of the upper mold 11 and the surrounding heating temperature of the molten metal pool 21 are made to be higher than the melting temperature of the aluminum alloy, and the middle mold 12 forming the impregnation chamber 18 is made of aluminum alloy. The heating temperature is lower than the solidification temperature of.

Next, as shown in FIG. 2B, the upper die 11 which constitutes the inlet side seal portion 17 is attached to the fluid pressure cylinder 1.
It is closed by 4, 14a so that the molten metal does not leak even when a pressure of about 30 atm is applied, and the impregnation chamber 1
A state in which the middle-stage die 12 constituting 8 is extruded by the fluid pressure cylinder 15 to an interval corresponding to the thickness of the composite plate W, and the molten metal 30 filled in the impregnation chamber 18 is pressurized to about 30 atm. (Corresponding to the molten metal forging process at 30 atm).

Then, the molten metal 30 kept at a temperature higher than the melting temperature of the aluminum alloy is impregnated into the reinforcing fibers 29 by the pressing force.

Thus, the molten metal 30 is added to the reinforcing fiber 29.
After the impregnation of the molten metal 3 is performed, the heating / cooling zone 24 of the mold 12 in the middle stage constituting the impregnation chamber 18 is switched to cooling.
0 is solidified under a pressure of 30 atm.

That is, the molten metal 30 is reinforced with the reinforcing fiber 29.
In the case of impregnation, the temperature of the molten metal 30 is maintained at the melting temperature or higher to increase its fluidity to promote impregnation, and after impregnation, cooling is performed to accelerate solidification.

In this way, the composite plate W
After the mold is made, as shown in FIG.
2 and the lower die 13 are slightly retracted by the fluid pressure cylinders 15 and 16 to form a small gap with the solidified composite plate W portion, and the solidified portion of the composite plate W is drawn by the pull-out roll 27 to the lower die 13 portion. Located in.

When the drawer roll 27 is used for drawing, the upper mold 11 forming the inlet seal portion 17 may be loosened as necessary so that the molten metal 30 does not leak out.

Thereafter, the solidified portion of the drawn composite plate W is sandwiched by the lower mold 13 constituting the exit side seal portion 19 to be in a sealed state, and the heating / cooling zone 24 of the lower mold 13 is set. Allow to cool and solidify. In this way, a part of the composite plate W is completed.

Therefore, after this, the above-mentioned FIG.
By repeating steps (c) to (c), the composite plate W is continuously manufactured by continuously impregnating and solidifying the portion on which the molten metal 30 has been impregnated and solidified.

According to the continuous manufacturing apparatus 10 for a metal-based fiber-reinforced composite plate and the continuous manufacturing method for a metal-based fiber-reinforced composite plate as described above, the die 12 in the middle stage forming the impregnation chamber 18 is kept at a high temperature. Since the molten metal 30 is filled, the fluidity is good, and the composite plate W can be continuously manufactured while the reinforcing fibers 29 are uniformly impregnated.

Further, the composite plate W can be continuously manufactured, and the productivity is remarkably improved as compared with the conventional manufacturing method in which a super-high pressure of 500 to 1000 atm is applied by molten metal forging.

Compared with the conventional batch type manufacturing method, it is not necessary to handle the manufactured composite plates one by one, and the handling becomes extremely easy. Depending on the thickness of the composite plate W, a winding facility may be provided on the delivery side. The installation can be further facilitated in handling.

Further, when the molten metal pool 21 and the impregnation chamber 18 are covered with a vacuum vessel to be in a vacuum state, defects due to the gas contained in the molten metal 30 can be prevented and a higher quality composite plate W can be manufactured. You can

Further, since the applied pressure for impregnating the reinforcing metal 29 with the molten metal 30 is about 30 atm, the structure can be simplified and the manufacturing is easy as compared with the conventional manufacturing apparatus using the molten metal forging method. At the same time, less energy is required for manufacturing.

In the above embodiment, the case where three stages of dies are arranged one above the other and the dies are sandwiched in the horizontal direction and the composite plate is vertically sent out for continuous production is explained.
It is also possible to arrange the dies in at least three stages in the horizontal direction, and send the composite plate in the horizontal direction so as to be sandwiched in the vertical direction for continuous production.

Further, the mold may be provided with at least a mold forming an inlet side and an outlet side seal part and a mold forming an impregnation chamber, and further, the seal part and the impregnation chamber are provided in a plurality of molds. It is also possible to increase the number of molds such as by configuring.

[0047]

As described above in detail with reference to the embodiment, according to the apparatus for continuously producing a metal-based fiber-reinforced composite plate of the invention of claim 1, there are at least three stages movable in the thickness direction of the plate. While continuously feeding the reinforcing fibers between the molds with the fiber feeder, close the mold on the outlet side and fill the heated metal mold with the molten metal feeder to fill the molten metal on the inlet side. After the mold is closed and molten metal is impregnated into the reinforcing fiber while being pressed by the mold in the center to solidify, the cooling and solidifying part is sent to the mold on the outlet side for cooling and the mold on the inlet side is also cooled. Since it is controlled by the control device so as to repeatedly open and fill the molten metal, it is possible to continuously manufacture the metal-based fiber-reinforced composite plate.

According to the method for continuously producing a metal-based fiber-reinforced composite plate according to the second aspect of the present invention, the reinforcing fiber is continuously provided between at least three stages of molds movable in the thickness direction of the plate. While feeding, the mold on the outlet side is closed and molten metal is filled in the heated mold, and the mold on the inlet side is closed and the molten metal is impregnated into the reinforcing fiber while pressurizing with the mold in the center. While solidifying while solidifying, the cooling and solidifying part is sent to the die on the outlet side for cooling, and the die on the inlet side is opened to fill the molten metal repeatedly. A composite board can be manufactured.

Further, according to the method for continuously producing a metal-based fiber-reinforced composite plate of the invention described in claim 3, in addition to the structure of claim 2, molten metal is impregnated into the reinforcing fiber with the mold of the central portion. While the mold was heated in the first half of pressurization, the mold was cooled in the latter half of pressurization so that it solidifies. It is possible to improve the production efficiency by promoting solidification by cooling in the latter half of pressurization.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing a partially cutaway view of an embodiment of an apparatus for continuously producing a metal-based fiber-reinforced composite plate of the present invention.

FIG. 2 is a process drawing according to an example of a continuous method for producing a metal-based fiber-reinforced composite plate of the present invention.

[Explanation of symbols]

 10 Continuous production apparatus for metal-based fiber-reinforced composite plate 11 Upper mold 12 Middle mold 13 Lower mold 14, 15, 16 Fluid pressure cylinder 17 Inlet side seal part 18 Impregnation chamber 19 Outlet side seal part 20 Frame 21 Molten Metal Pool 22 Opening 23 Side Frame 24 Heating / Cooling Zone 25 Molten Metal Feeding Device 26 Reinforcing Fiber Feeding Device 27 Drawing Roller 28 Control Device 29 Reinforcing Fiber 30 Molten Metal W Composite Plate D Thickness Direction

Claims (3)

[Claims] 1. A mold having at least three stages that can be heated and cooled and can be closed and pressed by moving in the thickness direction of a plate, and a reinforcing fiber and a molten metal are continuously provided between these molds. And a fiber / metal feeding device capable of feeding, and closing / pressurizing by heating / cooling and moving of the at least three stages of the die and fiber for strengthening / feeding of molten metal to control the fiber for strengthening. A continuous manufacturing apparatus for a metal-based fiber-reinforced composite plate, comprising: a molten metal filled into a fed and heated mold, and a control device that repeatedly cools and solidifies while pressurizing. 2. When continuously producing a metal-based fiber-reinforced composite plate, the reinforcing fiber is continuously fed between at least three stages of molds movable in the thickness direction of the plate, while the reinforcing fiber is continuously fed. After closing the mold and filling the molten metal into the heated mold, closing the mold on the inlet side and pressing the central mold to impregnate the reinforcing metal with the molten metal and solidify, A method for continuously producing a metal-based fiber-reinforced composite plate, characterized in that the cooling and solidifying section is sent to a die on the outlet side for cooling and the die on the inlet side is opened to fill molten metal repeatedly. 3. The mold is placed in a heated state in the first half of pressurization in which the reinforcing metal is impregnated with the mold in the central portion, while the mold is heated.
The method for continuously producing a metal-based fiber-reinforced composite plate according to claim 2, wherein the mold is cooled to solidify in the latter half of the pressurization.