# US 11,298,896 B2 · Molding device and molded article manufacturing method

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- Number: US 11,298,896 B2
- Document ID: US11298896B2
- Status: Granted
- Kind: B2
- Application number: 16/382,598
- Filed: 2019-04-12
- Published: 2019-12-05
- Granted: 2022-04-12
- Earliest claimed: 2018-06-04
- Assignees: Toyota Jidosha Kabushiki Kaisha
- Applicants: Toyota Jidosha Kabushiki Kaisha
- Inventors: Yasuhiro Ueno; Shotaro Ishikawa; Masataka Asai
- Web page: https://patentgrep.com/patent/US11298896B2

## CPC

- B29C 45/14262: {Clamping or tensioning means for the insert}
- B29C 45/14786: {Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material}
- B29C 70/16: using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)}
- B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C 70/461: {Rigid movable compressing mould parts acting independently from opening or closing action of the main mould}
- B29C 70/48: and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum}
- B29C 70/541: {Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30)}
- B29C 70/543: {Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08)}
- B29C 70/56: Tensioning reinforcements before or during shaping
- B29D 99/001: {Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings (articles with hollow walls B29D24/00)}
- B29D 99/0014: {provided with ridges or ribs, e.g. joined ribs}
- B29C 33/14: against the mould wall
- B29C 45/14065: {Positioning or centering articles in the mould}
- B29C 45/1418: {the inserts being deformed or preformed, e.g. by the injection pressure}
- B29C 49/0031: {Making articles having hollow walls}
- B29C 2045/14163: {using springs being part of the positioning means}
- B29L 2031/3468: {Batteries, accumulators or fuel cells (battery cases B29L2031/7146)}
- Y02E 60/10: Energy storage using batteries
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A pressing member is configured to press a portion-to-be-pressed of a continuous-fiber sheet against a recessed surface of a first mold in a state where the continuous-fiber sheet is placed between the first mold and a second mold. A pulling member is configured to bring the continuous-fiber sheet into close contact with the main surface and the recessed surface by pulling a portion of the continuous-fiber sheet located on an outer peripheral side of the portion-to-be-pressed after the pressing member presses the portion-to-be-pressed against the recessed surface.

## Claims

### Claim 1

A molding device comprising:
a first mold; and
a second mold, wherein:
the molding device is configured to shape a continuous-fiber sheet configured to be placed between the first mold and the second mold;
the first mold and the second mold face each other;
at least one of the first mold and the second mold is configured to be movable in a separating direction, in which the first mold and the second mold are separated relatively farther away from each other, and in an approaching direction, in which the first mold and the second mold are brought relatively closer to each other;
the first mold includes a placing surface on which the continuous-fiber sheet is configured to be placed between the first mold and the second mold;
the placing surface includes a main surface and at least one recessed surface that is connected to the main surface and that is located farther away from the second mold than the main surface;
the second mold includes at least one pressing member configured to press the continuous-fiber sheet which is configured to be placed on the placing surface against the recessed surface, and a pulling member configured to pull the continuous-fiber sheet;
the pressing member is configured to press a portion-to-be-pressed of the continuous-fiber sheet against the recessed surface in a state where the continuous-fiber sheet is placed between the first mold and the second mold; and
the pulling member includes a contact member having a base and a protrusion extending vertically downward from the base, and is configured to bring the continuous-fiber sheet into close contact with the main surface by pulling a portion of the continuous-fiber sheet located on an outer peripheral side of the portion-to-be-pressed after the pressing member presses the portion-to-be-pressed against the recessed surface,
wherein the continuous-fiber sheet which is configured to be placed on the placing surface includes an outer peripheral portion that projects outward from an outer peripheral edge portion of the placing surface, and the pulling member is configured to bring the continuous-fiber sheet into close contact with the main surface by pulling the outer peripheral portion.

### Claim 2 (depends on 1)

The molding device according to claim 1, further comprising a third mold, wherein:
the first mold includes a peripheral surface that is connected to the outer peripheral edge portion of the placing surface and extends in a direction away from the second mold;
the pulling member is configured to bring the continuous-fiber sheet into close contact with the main surface by moving the outer peripheral portion in the approaching direction and shaping the outer peripheral portion so as to fit the peripheral surface; and
the third mold is configured to press against the peripheral surface, an outer edge of the outer peripheral portion, that has been shaped by the pulling member, so as to fit the peripheral surface.

### Claim 3 (depends on 2)

The molding device according to claim 2, further comprising a supply device, wherein:
the molding device is configured such that a cavity to house the continuous-fiber sheet is formed, as the first mold, the second mold, and the third mold are moved closer to one another; and
the supply device is configured to supply resin into the cavity.

### Claim 4 (depends on 1)

The molding device according to claim 1, wherein:
the placing surface includes a first recessed surface and a second recessed surface that is located closer to an outer peripheral edge portion of the placing surface than the first recessed surface;
the second mold includes a first pressing member and a second pressing member;
the portion-to-be-pressed of the continuous-fiber sheet includes a first portion-to-be-pressed and a second portion-to-be-pressed;
the first pressing member is configured to press the first portion-to-be-pressed of the continuous-fiber sheet against the first recessed surface;
the second pressing member is configured to press the second portion-to-be-pressed of the continuous-fiber sheet against the second recessed surface;
the second pressing member is configured to press the second portion-to-be-pressed against the second recessed surface after the first pressing member presses the first portion-to-be-pressed against the first recessed surface; and
the pulling member is configured to pull a portion of the continuous-fiber sheet located on an outer peripheral side of the second portion-to-be-pressed after the second pressing member presses the second portion-to-be-pressed against the second recessed surface.

### Claim 5

A molded article manufacturing method comprising:
preparing a first mold and a second mold placed so as to face each other;
placing a continuous-fiber sheet between the first mold and the second mold; and
processing the continuous-fiber sheet by the first mold and the second mold, wherein:
at least one of the first mold and the second mold is configured to be movable in a separating direction, in which the first mold and the second mold are separated relatively farther away from each other, and in an approaching direction, in which the first mold and the second mold are brought relatively closer to each other;
the first mold includes a placing surface on which the continuous-fiber sheet is configured to be placed between the first mold and the second mold;
the placing surface includes a main surface and at least one recessed surface that is connected to the main surface and is located farther away from the second mold than the main surface; and
processing the continuous-fiber sheet includes pressing a portion-to-be-pressed of the continuous-fiber sheet against the recessed surface, and after pressing the portion-to-be-pressed against the recessed surface, bringing the continuous-fiber sheet into close contact with the main surface by pulling a portion of the continuous-fiber sheet located on an outer peripheral side of the portion-to-be-pressed,
wherein the continuous-fiber sheet which is configured to be placed on the placing surface includes an outer peripheral portion that projects outward from an outer peripheral edge portion of the placing surface, and the bringing of the continuous-fiber sheet into close contact with the main surface included in the processing includes bringing the continuous-fiber sheet into close contact with the main surface by pulling the outer peripheral portion with a pulling member including a contact member having a base and a protrusion extending vertically downward from the base.

### Claim 6 (depends on 5)

The molded article manufacturing method according to claim 5, further comprising pressing an outer edge of the outer peripheral portion that has been shaped so as to fit a peripheral surface of the first mold, against the peripheral surface by a third mold, wherein:
the peripheral surface of the first mold is connected to the outer peripheral edge portion of the placing surface and extends in a direction away from the second mold; and
the bringing of the continuous-fiber sheet into close contact with the main surface included in the processing includes bringing the continuous-fiber sheet into close contact with the main surface by moving the outer peripheral portion in the approaching direction and shaping the outer peripheral portion so as to fit the peripheral surface.

### Claim 7 (depends on 6)

The molded article manufacturing method according to claim 6, further comprising forming a cavity to house the continuous-fiber sheet by moving the first mold, the second mold, and the third mold closer to one another, and then supplying resin into the cavity.

### Claim 8 (depends on 5)

The molded article manufacturing method according to claim 5, wherein:
the portion-to-be-pressed of the continuous-fiber sheet includes a first portion-to-be-pressed and a second portion-to-be-pressed;
the placing surface includes a first recessed surface and a second recessed surface that is located closer to an outer peripheral edge portion of the placing surface than the first recessed surface;
the pressing of the portion-to-be-pressed against the recessed surface included in the processing includes pressing a first portion-to-be-pressed of the continuous-fiber sheet against the first recessed surface, and pressing a second portion-to-be-pressed of the continuous-fiber sheet located on an outer peripheral side of the first portion-to-be-pressed against the second recessed surface; and
bringing the continuous-fiber sheet into close contact with the main surface includes pulling the second portion-to-be-pressed after pressing the first portion-to-be-pressed against the first recessed surface.