# US 2019/0168425 A1 · Molding method and molding system for resin molded member

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- Number: US 2019/0168425 A1
- Document ID: US20190168425A1
- Status: Published application
- Kind: A1
- Application number: 16/310,008
- Filed: 2017-05-11
- Published: 2019-06-06
- Earliest claimed: 2016-06-17
- Assignees: Honda Motor Co., Ltd.; Subaru Corporation; Suzuki Motor Corporation; Toyota Jidosha Kabushiki Kaisha; Toray Industries, Inc.; Kyowa Industrial Co., Ltd.; National University Corporation Nagoya University; Aisin Seiki Kabushiki Kaisha; Mitsubishi Jidosha Kogyo Kabushiki Kaisha; Toho Tenax Co., Ltd.
- Applicants: Honda Motor Co., Ltd.; Subaru Corporation; Suzuki Motor Corporation; Toyota Jidosha Kabushiki Kaisha; Toray Industries, Inc.; Kyowa Industrial Co., Ltd.; National University Corporation Nagoya University; Aisin Seiki Kabushiki Kaisha; Mitsubishi Jidosha Kogyo Kabushiki Kaisha; Toho Tenax Co., Ltd.
- Inventors: Satoshi Hirawaki; Masashi Horikawa; Shusuke Sanai; Kanji Takaoka; Kazuaki Amaoka; Munehito Kawakami; Kazuki Baba
- Web page: https://patentgrep.com/patent/US20190168425A1

## CPC

- B29C 43/58: Measuring, controlling or regulating {(for bank adjustment in calendering B29C43/245)}
- B29C 33/005: {characterised by the location of the parting line of the mould parts}
- B29C 33/10: with incorporated venting means
- B29C 43/003: {characterised by the choice of material}
- B29C 43/02: of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)}
- B29C 43/04: using movable moulds
- B29C 43/3642: {Bags, bleeder sheets or cauls for isostatic pressing}
- B29C 43/56: Compression moulding under special conditions, e.g. vacuum
- B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C 33/0038: {with sealing means or the like (seals on envelopes used in tyre retreading B29D30/542; for injection moulding footwear B29D35/0045)}
- B29C 2043/3644: {Vacuum bags; Details thereof, e.g. fixing or clamping}
- B29C 2043/563: {combined with mechanical pressure, i.e. mould plates, rams, stampers}
- B29C 2043/5808: {pressure or compressing force}
- B29C 2043/5833: {movement of moulds or mould parts, e.g. opening or closing, actuating}
- B29K 2101/12: Thermoplastic materials
- B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K 2307/04: Carbon
- B29L 2031/30: Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)}
- B29L 2031/3005: {Body finishings}
- B29L 2031/3055: {Cars}
- 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)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A molding method and a molding system for improving a molding speed of a resin molded member. In the method, firstly a thermoplastic resin composite material is filled in a metal mold (i.e., at time T0), and subsequently a mold-clamping process gets started. As the mold-clamping process progresses, a first decompression circuit starts to decompress an inside of a cavity when the cavity is closed by a sealing member provided on the metal mold. Then, as the mold-clamping process further progresses, the thermoplastic resin composite material thus filled in the metal mold contacts an upper mold of the metal mold (i.e., at time T2). After that, a second decompression circuit starts to decompress the inside of the cavity, thereby to complete the mold-clamping process (i.e., at time T3).

## Claims

### Claim 1

A method for molding a resin molded member by press-molding a thermoplastic resin composite material, prepared by dispersing reinforced fibers in a thermoplastic resin composition, in a metal mold having an upper mold and a lower mold while decompressing an inside of the metal mold,
the method comprising the steps of:
starting a mold-clamping process at a timing after the thermoplastic resin composite material is filled on the lower mold of the metal mold;
starting to decompress an inside of a cavity by a first decompression circuit at a timing when the cavity is closed by a sealing member arranged on an engagement surface of the upper mold and/or the lower mold of the metal mold as the mold-clamping process progresses and before the thermoplastic resin composite material thus filled on the lower mold of the metal mold contacts the upper mold of the metal mold; and
completing the mold-clamping process via starting to decompress the inside of the cavity by a second decompression circuit at a timing after the thermoplastic resin composite material thus filled on the lower mold contacts the upper mold of the metal mold as the mold-clamping process further progresses.

### Claim 2 (depends on 1)

The method for molding a resin molded member described in claim 1, wherein the reinforced fibers are randomly oriented.

### Claim 3 (depends on 1)

The method for molding a resin molded member described in claim 1, wherein the reinforced fibers comprise carbon fibers each of which has a fiber length of 5 mm or more and 50 mm or less.

### Claim 4

A system for molding a resin molded member, the system comprising:
a metal mold including an upper mold and a lower mold both of which are arranged in a mutually and relatively approachable and separable manner and configured of at least a vertical parting line structure;
a decompression circuit including at least two or more lines of passages connected to a cavity of the metal mold;
a switching valve switching the passages of the decompression circuit; and
a sealing member keeping airtightness inside the cavity of the metal mold, wherein
a mold-clamping process operated by speed control is carried out and subsequently a mold-clamping process operated by pressure control is carried out respectively, after the sealing member is engaged between the upper mold and the lower mold, and
a mold-clamping speed operated by the speed control is higher than a mold-clamping speed operated by the pressure control.