CN103561950B - 接合体 - Google Patents

接合体 Download PDF

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Publication number
CN103561950B
CN103561950B CN201280025300.4A CN201280025300A CN103561950B CN 103561950 B CN103561950 B CN 103561950B CN 201280025300 A CN201280025300 A CN 201280025300A CN 103561950 B CN103561950 B CN 103561950B
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CN
China
Prior art keywords
molded article
base plate
composite base
resin
multifilament
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CN201280025300.4A
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English (en)
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CN103561950A (zh
Inventor
加藤卓巳
齐藤清
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Teijin Ltd
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Teijin Ltd
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Publication date
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Publication of CN103561950A publication Critical patent/CN103561950A/zh
Application granted granted Critical
Publication of CN103561950B publication Critical patent/CN103561950B/zh
Expired - Fee Related legal-status Critical Current
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30221—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being point-like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/304—Joining through openings in an intermediate part of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/524—Joining profiled elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1412—Infrared [IR] radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/3408—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
    • B29C65/3416—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements comprising discontinuous fibre-reinforcements
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3484—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic
    • B29C65/3492—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic being carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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Abstract

本发明的复合成形制品是一种接合体，其具有出色的抗冲击性，并包括含有碳纤维和热塑性树脂的成形制品（B1和B2），其中所述成形制品（B1和B2）布置在含有连续纤维例如聚酯纤维和热塑性树脂的复合基板（A）的两侧上，使得所述复合基板（A）插入在所述成形制品（B1与B2）之间，并且通过所述复合基板（A）的通孔（D1）在接合部（C）处热焊接所述成形制品（B1和B2）。

Description

接合体
技术领域
本发明涉及一种接合体，其包括含有有机纤维的复合基板和含有碳纤维的两个成形制品。具体来说，本发明涉及适合应用于需要抗冲击性的车辆的接合体，在所述接合体中含有复丝的复合基板插入含有碳纤维的两个成形制品之间。
背景技术
塑料可以通过各种成型方法进行加工，并且在我们的生活中是必不可少的材料。具体来说，在塑料中，热塑性树脂柔性出色并被广泛使用。另一方面，热塑性树脂的强度或刚性在某些情况下不一定足够。例如，在需要高强度和高刚性的应用中，通过在热塑性树脂中掺入无机纤维例如玻璃纤维或碳纤维的短纤维，来增强热塑性树脂。专利文献1公开了一种由超高分子量聚乙烯树脂和甲基丙烯酸系乙烯酯树脂构成的有机纤维增强复合材料，用于提高冲击吸收能力和刚性。
专利文献2公开了一种汽车引擎盖，其包括由FRP制成的外部部分和接合到所述外部部分的后侧的内部部分。其描述了通过这样的FRP汽车引擎盖改进了与行人保护相关的表现。
专利文献3公开了一种夹层结构的复合体，其中将由连续纤维和基质树脂构成的纤维增强材料提供在芯材的两侧上。芯材在厚度方向上形成有通孔，并且纤维增强材料在通孔处通过基质树脂彼此接合。其描述了具有这样的夹层结构的复合体适合用作电气或电子装置例如便携式信息终端的外壳，因为它薄、轻并且刚性高。然而，对于是否提供车辆应用所需的抗冲击性，充满疑问。
(专利文献1)JP-A-6-126847
(专利文献2)WO 2006/025316
(专利文献3)JP-A-2009-220478
发明内容
本发明的主要目的是提供一种由有机纤维增强复合材料(OFRP)和碳纤维复合材料(CFRP)构成的新型接合体。
本发明的另一个目的是提供一种抗冲击性出色的接合体。
本发明的另一个目的是提供一种防止接合部剥离并可用作车辆构件，特别是用作汽车的结构构件的接合体。
本发明的其他目的和特点可以从下面的描述变得明显。
根据本发明，本发明的目的和优点可以通过下述接合体来实现，所述接合体包括由成形制品(B1)、复合基板(A)和成形制品(B2)依此顺序层压而构成的接合部(C)，其中所述复合基板(A)包含有机材料的复丝和热塑性树脂，并且所述成形制品(B1)和(B2)各自包含碳纤维和树脂，并且
(i)所述复合基板(A)包括所述复丝之间的空间浸渍有所述热塑性树脂的浸渍部，以及复丝内部未浸渍有所述热塑性树脂的非浸渍部，
(ii)所述复合基板(A)具有贯通部(D)，其在厚度方向上贯穿所述复合基板(A)，并且
(iii)所述成形制品(B1)和(B2)与所述复合基板(A)的贯通部(D)相接触并通过其固定。
本发明的发明人注意有机纤维增强复合材料(OFRP)作为用于提高抗冲击性的材料。例如，众所周知，通过下述步骤制造的夹层结构表现出一定程度的抗冲击性：使用有机纤维增强复合材料作为上面示例的专利文献1中的芯材；在所述芯材的顶部和底部侧面上用碳纤维复合材料(CFRP)夹心所述芯材；以及在接触表面上使用常规胶粘剂。本发明人研究了使用有机纤维增强复合材料作为车辆用结构构件的更高的抗冲击性。然后，本发明人发现，提供在芯材的两侧上的碳纤维复合材料与有机纤维增强复合材料的内部结构的接合方法是重要的，由此完成本发明。
附图说明
图1是一种接合体的实例(分解图)，在该接合体中，成形制品(B1)和成形制品(B2)布置在具有贯通部(D)的复合基板(A)的两侧上。
图2是接合部(C)的放大示意图(截面图)的实例。
图3是接合部(C)的通孔(D1)和突起(E)的部分的放大示意图(截面图)的实例。
图4是接合部(C)中成形制品(B1)和成形制品(B2)的示意图(分解图)的实例。
图5是在使用具有导能部的成形制品(B1)和成形制品(B2)来获得接合体的情形中的示意图的实例。
图6是示出其中不具有通孔的成形制品(A’)与不具有突起的成形制品(B’)彼此接合的接合体的示意图(分解图)。
图7是示出其中不具有通孔的成形制品(A’)与不具有插入部的成形制品(B’)彼此接合的接合部的示意图。
图8是接合体的实例(分解图)，在该接合体中，将成形制品(B1)和成形制品(B2)布置在具有狭缝的复合基板(A)的两侧上。
附图标记列表
A：复合基板
B1：成形制品
B2：成形制品
D：贯通部(通孔)
E：插入部(突起)
F：狭缝
X：宽度方向
Y：厚度方向，高度方向
Z：深度方向
1：冲击载荷
6：导能部
7,10：不具有通孔的复合基板(A’)
8,11：不具有插入部(突起)的成形制品(B’)
具体实施方式
下面，将描述示例性实施方式。
[复合基板(A)]
本发明中的复合基板(A)包括：多个(两个以上)包含有机材料的复丝；以及热塑性树脂。
复丝大致以多纤维束的状态存在于复合基板(A)中。复丝可以是连续纤维或短切纤维，但是具有连续长度的连续纤维是优选的。作为复丝的形式，捻合纤维线或由捻合纤维线构成的机织物或编织物是优选的。由于纤维束因捻合而紧密，因此树脂在纤维束内部中的浸渍受到抑制。捻数优选地为每1米30至700次。优选地，复丝之间的空间(有时被称为“纤维束之间的空间”)大致被热塑性树脂浸渍。此外，优选地，复丝的内部(有时也称为“纤维束的内部”)大致不被热塑性树脂浸渍。对于复丝来说，可以将不连续长度的纤维与连续纤维组合使用。
本发明中的复合基板(A)的特征在于包括其中上述复丝浸渍有热塑性树脂的浸渍部以及浸渍程度低的非浸渍部。包括复丝的复合基板(A)大致由浸渍部和非浸渍部构成。这里，在浸渍部中，纤维束之间的大多数或大致100％的空间包含热塑性树脂。在非浸渍部中，热塑性树脂不渗入纤维束的内部，并且至多不超过50％的纤维束可能包含热塑性树脂，并且优选地，大致可以没有热塑性纤维束包含热塑性树脂。
当在如上所述的复合基板(A)中存在其中纤维束内部大致未浸渍有热塑性树脂的非浸渍部时，复合基板(A)和最终获得的接合体具有出色的抗冲击性。尽管其详细原因尚不清楚，但据认为如下。复合基板(A)中热塑性树脂浸渍率低的部分(非浸渍部)不处于复丝被热塑性树脂完全束缚的状态下，而是具有一定自由度。据推测，具有这种自由度的复丝有助于抗冲击性。当热塑性树脂被用作用于提高复丝自由度的树脂时，可以调整树脂浸渍到纤维束内部的浸渍水平。当使用热固性树脂作为所述树脂时，由于热固性树脂与热塑性树脂相比具有相对低的粘度，因此难以控制浸渍率。
通过使用如上所述的纤维束之间的空间中的树脂浸渍率高并且纤维束内部的树脂浸渍率低的复合基板(A)，本发明的接合体表现出良好的物理性质。
优选地，纤维束之间的空间中的树脂浸渍率为90％以上。当纤维束之间的空间被树脂充分填充时，在纤维束之间的空间中没有空隙残留，因此复合基板(A)的强度增加。浸渍率的上限为100％。此外，纤维束之间的空间中的浸渍率不必是恒定值，并且可以具有90％至100％范围内的分布。当纤维束之间的空间未被树脂充分填充时，在纤维束之间的空间中残留有空隙，因此复合基板(A)的强度可能下降。
当考虑抗冲击性时，由于如上所述在复合基板(A)中复丝具有一定自由度，因此纤维束的内部可以有效地吸收冲击能。因此，优选地，纤维束内部中的树脂浸渍率低。优选地，纤维束内部中的树脂浸渍率为50％以下，并且更优选地，纤维束的内部大致未被树脂浸渍。也就是说，浸渍率的下限大致为0％。此外，纤维束内部中的浸渍率不必是恒定值，并且可以具有0％至50％范围内的分布。
当热塑性树脂在复丝的纤维束之间的空间中和纤维束内部中的浸渍率被设定在上述范围时，形成复丝的单纤维可以具有变形或移动的自由。因此，复合基板(A)可以吸收受到的冲击，结果提供了具有出色抗冲击性的接合体。
除了如上所述的捻合纤维、机织物或编织物的构造之外，还可以通过例如选择热塑性树脂的种类，或通过在如后文中所述的用树脂浸渍纤维束之间的空间的过程中成型压力或热塑性树脂的温度，来控制树脂向纤维束内部的渗入程度。
树脂浸渍率可以通过使用例如电子显微镜或光学显微镜的显微术观察来证实。树脂浸渍率可以根据复合基板(A)的截面中空隙的面积来计算。此外，纤维束之间的空间中的树脂浸渍率可以根据能够从复合基板(A)取出的形成复丝的单纤维的数量来计算。
对于复合基板(A)中包含的含有有机材料的复丝来说，没有特别限制。然而，能够列举例如聚醚醚酮纤维、聚苯硫醚纤维、聚醚砜纤维、芳纶纤维、聚苯并噁唑纤维、聚芳基酯纤维、聚酮纤维、聚酯纤维、聚酰胺纤维、聚乙烯醇纤维和高强度聚乙烯纤维。
由于这样的复丝具有作为增强材料的作用，因此优选地使用具有不低于能够使包含在复合基板(A)中作为基质树脂的热塑性树脂成型的温度的耐热性的复丝。其中，由于物理性质例如机械性质和耐热性以及其价格平衡，所以聚酯纤维、聚酰胺纤维和聚乙烯醇纤维是优选的。特别优选的是聚酯纤维和尼龙纤维。
对于复合基板(A)中有机纤维与热塑性树脂的组成比率来说，相对于100份的复丝，热塑性树脂的体积比率优选地为20份至900份，更优选地为25份至400份。当热塑性树脂相对于100份的有机纤维的比率为20份以上时，可以显著提高复合基板(A)的机械强度。此外，当它为900份以下时，可以充分发挥有机纤维的增强效果。
在复合基板(A)中每10mm厚度的单位面积纤维重量优选地在1000g/m2至12000g/m2的范围内。更优选地为2000g/m2至10000g/m2。当单位面积纤维重量增加至1000g/m2或以上时，可以得到更高的抗冲击性。相反，当单位面积纤维重量为12000g/m2以下时，可以提高复合基板(A)的机械强度。
对于本发明的复合基板(A)中的基质树脂来说，从抗冲击性的观点来说使用热塑性树脂。其中，优选的树脂是热变形温度为80℃以上的热塑性树脂。在这里，可以使用负荷变形温度来评价热变形指数。当热变形温度为80℃以上时，复合基板(A)也可以具有高强度和高弹性。当使用热固性树脂作为基质树脂时，由于热固性树脂在固化之前具有低粘度，因此热固性树脂浸渍到纤维束的内部。另一方面，当使用热塑性树脂时，树脂不浸渍到纤维束的内部中，因此复合基板(A)的物理性质得以改进，以提高抗冲击性。
对于热塑性树脂来说，可以示例的有例如氯乙烯树脂、偏氯乙烯树脂、乙酸乙烯酯树脂、聚乙烯醇树脂、聚苯乙烯树脂、丙烯腈-苯乙烯树脂(AS树脂)、丙烯腈-丁二烯-苯乙烯树脂(ABS树脂)、丙烯酸树脂、甲基丙烯酸树脂、聚烯烃树脂(例如聚乙烯树脂和聚丙烯树脂)、聚酰胺树脂(例如聚酰胺6树脂、聚酰胺11树脂、聚酰胺12树脂、聚酰胺46树脂、聚酰胺66树脂和聚酰胺610树脂)、聚缩醛树脂、聚碳酸酯树脂、聚对苯二甲酸乙二酯树脂、聚萘二甲酸乙二酯树脂、聚对苯二甲酸丁二酯树脂、聚芳基酯树脂、聚苯醚树脂、聚苯硫醚树脂、聚砜树脂、聚醚砜树脂或聚醚醚酮树脂。这些树脂可以单独或组合使用。
其中，氯乙烯树脂、聚苯乙烯树脂、ABS树脂、聚乙烯树脂、聚丙烯树脂、聚酰胺6树脂、聚酰胺66树脂、聚缩醛树脂、聚碳酸酯树脂、聚对苯二甲酸乙二酯树脂、聚萘二甲酸乙二酯树脂、聚对苯二甲酸丁二酯树脂和聚芳基酯树脂是优选的。考虑到可成型性和制造率，聚丙烯树脂、聚对苯二甲酸乙二酯树脂、聚碳酸酯树脂、聚酰胺6树脂和聚酰胺66树脂是更加优选的。
同时，如下所述，考虑到便于焊接，复合基板(A)的热塑性树脂与形成成形制品(B1)和成形制品(B2)的树脂在热焊接中具有有利的相容性，是优选的因素。例如，可以从选自下列的至少一种中正确选择：聚酰胺，聚碳酸酯，聚甲醛，聚苯硫醚，聚苯醚，聚对苯二甲酸乙二酯，聚对苯二甲酸丁二酯，聚萘二甲酸乙二酯，聚乙烯，聚丙烯，聚苯乙烯，聚甲基丙烯酸甲酯，AS树脂和ABS树脂。
在不影响本发明的目的的情况下，除了上述复丝和热塑性树脂之外，复合基板(A)可以包括各种填充剂或添加剂，例如玻璃纤维和芳纶纤维。对于添加剂来说，可以示例的有例如阻燃剂、热稳定剂、紫外吸收剂、成核剂、增塑剂和炭黑，但不限于此。
制造复合基板(A)的方法包括：通过将热塑性树脂浸渍到纤维束之间的空间中产生复合材料；以及对获得的复合材料进行成形。对将树脂浸渍到纤维束之间的空间中的方法没有特别限制。在所使用的复丝采取机织或编织的布的形式的情形中，通过对相互堆叠而成的机织物或编织物和树脂薄膜或非机织物进行加压或减压，在热塑性树脂熔化但复丝不熔化的温度下使用压制成型机或真空成型机，获得热塑性树脂浸渍在纤维束之间的空间中的复合材料。此外，在复丝是捻合纤维线的情形中，除了压制成型或真空成型之外，复合材料也可以通过挤出成型或突出成型(protrusion molding)来获得。
对成形方法也不存在特殊限制。成形可以在将纤维束之间的空间用树脂浸渍的同时进行，或者可以在将纤维束之间的空间用树脂浸渍之后进行。当树脂浸渍和成形同时进行时，通过使用用以获得所需形状金属模具，可以容易地获得成形制品。当树脂浸渍和成形分开进行时，通过使用具有所需形状的模具形式，成形也可以相对容易地进行。以这种方式获得的成形制品可以原样用作复合基板(A)。
通过如上所述调整成形方法，可以制造小的或复杂形状的构件以及大的平坦或薄的构件。除了平坦形状之外，成形制品的形状可以是三维形状，例如波纹形状、桁架形状或蜂巢形状。
除了如上所述捻合纤维、机织物和编织物的构造或热塑性树脂种类的选择之外，还可以通过改变成型条件来正确控制树脂在纤维束之间的空间和纤维束内部中的浸渍。一般来说，当成型温度或压力提高时，树脂的熔体粘度降低，因此树脂的渗入可能增加。当树脂是结晶树脂时，温度优选地在熔点至熔点+50℃的范围内，并且当树脂是无定形树脂时，温度优选地在玻璃化转变点至熔点+50℃的范围内。压力优选地在0.01MPa至20MPa的范围内，并且时间优选地在约30秒至约1小时的范围内。
在复丝与热塑性树脂的组合中，当所使用的树脂是结晶树脂时，纤维的熔点优选地比树脂的熔点高至少10℃。此外，当所使用的树脂是无定形树脂时，纤维的熔点优选地比树脂的玻璃化转变点高至少10℃。在这种观点中，复丝是聚酯长纤维或尼龙并且热塑性树脂是聚丙烯树脂、聚对苯二甲酸乙二酯树脂、聚碳酸酯树脂、聚酰胺6树脂或聚酰胺66树脂的组合，是优选的。
复合基板(A)具有在厚度方向上贯穿复合基板(A)的贯通部(D)。如下所述，为了连接成形制品(B1)和(B2)而需要贯通部(D)。成形制品通过贯通部(D)而互相固定。
贯通部(D)的重要之处在于复合基板(A)的两个表面彼此相通。贯通部(D)通常采取通孔(D1)的形式。孔的形状可以是例如截面为圆形或椭圆形的柱体形状、锥体形状、棱柱形状、截短的棱锥形状或其组合。当截面是圆形形状时，底面或截面的直径在0.01mm至20mm，优选地在1mm至20mm的范围内。当截面是四边形时，四边形优选地为边长在0.01mm至20mm，优选地在1mm至10mm的范围内的正方形或矩形。在贯通部中，在复合基板(A)的一个表面中孔的形状或尺寸可以与另一个表面中孔的形状或尺寸相同或不同。
在本发明中，对复合基板(A)的厚度没有特别限制，但是可以在约0.5mm至约10mm的范围内。复合基板(A)在接合部(C)处的厚度优选地在0.5mm至10mm的范围内。更优选地，它在1mm至5mm的范围内。
此外，在本发明中，复合基板(A)具有包括贯通部(D)的接合部(C)。在这里，贯通部相对于在后文中描述的夹在成形制品(B-1)与成形制品(B-2)之间的部分的面积，优选地在0.01％至10％(面积占有率)的范围内。当占有率被设定为0.01％以上时，可以容易地维持复合基板(A)、成形制品(B1)和成形制品(B2)的良好的接合性质，并且当它被设定为10％以下时，可以容易地满足所要求的接合体本身的强度或耐久性特性。
例如，如图8中所示，除了贯通部(D)之外，复合基板(A)可以具有从复合基板(A)的末端向内延伸的狭缝。狭缝具有与贯通部(D)相同的功能。
在本发明中，贯通部(D)被设置在接合部(C)处。接合部(C)通过将设置在复合基板(A)的一个侧面上的成形制品(B1)与设置在复合基板(A)的另一个侧面上的成形制品(B2)层压来形成。
[成形制品(B1)和(B2)]
成形制品(B1)和(B2)包含碳纤维和树脂。
碳纤维的典型实例包括PAN系碳纤维和沥青系碳纤维。可以根据用途来选择任何PAN系碳纤维和沥青系碳纤维。然而，当需要较高强度时，可以使用PAN系碳纤维。
对碳纤维的类型没有特别限制，可以是连续纤维或不连续纤维。连续纤维可以是例如其中增强纤维在一个轴向方向上排列的单向基材或非机织物，但是不限于此。就纤维长度而言，对不连续纤维也没有特别限制。“不连续”碳纤维是指平均纤维长度在0.1mm至300mm范围内的碳纤维。“不连续纤维”之外的纤维被称为“连续纤维”。对于碳纤维来说，从可成型性和通过金属模具的成形性质的观点来看，不连续纤维是优选的。平均纤维长度优选地在5mm至100mm，更优选地8mm至50mm，进一步优选地10mm至80mm，特别优选地10mm至30mm的范围内。
在这里，平均纤维长度如下获得。使用卡尺和小型放大镜将100根随机抽取的碳纤维的长度测量并记录至1mm单位，并且根据碳纤维的所有实测长度(Li，其中i是1至100的整数)，通过下式获得平均纤维长度(La)。
La＝ΣLi/100
包含在成形制品(B1)和成形制品(B2)中的碳纤维的平均纤维长度可以彼此相等或不同。
以下，将详细描述使用具有如上所述平均纤维长度的不连续纤维作为碳纤维的情形。
在成形制品(B1)和(B2)的每一个中，相对于成形制品的总体积，成形制品中碳纤维的含量以体积比(Vf)计优选地为10％至90％。当Vf为10％以上时，可以获得具有高强度的材料。此外，当Vf为90％以下时，能够稳定地制造可成型性出色的成形制品。更优选地，Vf为20％至55％，并且进一步优选地，Vf为20％至50％。
在成形制品(B1)和(B2)中，优选地，碳纤维以随机状态交叠而没有特别取向，也就是说，碳纤维是无序且随机放置的。当碳纤维随机放置时，可以获得平均而言在平面内方向上各向同性且强度出色的成形制品。此外，就物理性质例如例如弹性和导电性来说，成形制品大致不是各向异性的并且在平面内方向上是各向同性的。
优选地，上述不连续碳纤维以相对于碳纤维的总体积为20％以上并低于99％的体积比包含碳纤维束，每个碳纤维束都包括不少于由下式(1)所定义的临界单纤维数的单纤维。
临界单纤维数＝600/D(1)
(这里，D是碳纤维的平均纤维直径(μm))
对于平均纤维直径来说，使用显微镜将纤维的截面放大1000倍以上的倍数并照相，随机选择50根纤维的截面，并记录截面的外接圆的直径作为纤维直径。然后，根据所有测量到的纤维直径(Di，其中i是1至50的整数)，通过下式获得平均纤维直径(Da)。
Da＝ΣDa/50
在上述范围之外的范围内，由于成形制品(B1)和(B2)的可成型性良好，因此优选地存在处于单纤维状态或包括少于临界单纤维数的单纤维的其他打开的纤维束。在这里，当碳纤维束与碳纤维的总体积的体积比变为小于20％时，可能存在着可以获得具有出色表面质量的接合体的优点。然而，由于均匀加热成形制品(B1)和(B2)变得困难，因此可能无法获得具有出色机械性质的成形制品(B1)和(B2)。当碳纤维束的体积比变为99％以上并因此局部增加碳纤维相交部分的厚度时，可能难以获得薄的成形制品。此外，成形制品(B1)和(B2)的随机性质倾向于容易降低。碳纤维束的体积比的优选范围为不低于30Vol.％并低于90Vol.％。
优选地，包括临界单纤维数以上的单纤维的碳纤维束中的纤维平均数量(N)满足下式(2)。
0.7×104/D2<N<1×105/D2(2)
(这里，D是碳纤维的平均纤维直径(μm))
对于纤维平均数量来说，用镊子从尺寸约为100mm×100mm的成形制品样品取出所有纤维束，并测量和记录碳纤维束(A)的束数量(I)以及碳纤维束的长度(Li)和重量(Wi)。对于太小而不能用镊子取出的纤维束来说，在结束时一起测量纤维束的总重量(Wk)。在重量的测量中，使用能够测量到1/100mg(0.01mg)的一副天平。根据碳纤维的纤维直径(D)，计算临界单纤维数并将碳纤维束分类成具有临界单纤维数以上的单纤维的碳纤维束(A)和其他纤维束。当使用两种以上碳纤维时，将碳纤维束按种类分类并测量和评价每一种类。获得碳纤维束(A)中纤维的平均数量(N)的方法如下。根据所使用的碳纤维的tex(F)，通过下式获得每个碳纤维束中纤维的数量(Ni)。
Ni＝Wi/(Li×F)
根据碳纤维束(A)的束数量(I)，通过下式获得碳纤维束(A)中纤维的平均数量(N)。
N＝ΣNi/I
利用碳纤维的密度(ρ)，通过下式获得碳纤维束(A)与纤维总体积的比率(VR)。
VR＝Σ(Wi/ρ)×100/((Wk+ΣWi)/ρ)
具体来说，当碳纤维的平均纤维直径为5μm至7μm时，临界单纤维数变成86至120。当碳纤维的平均纤维直径为5μm时，纤维束中纤维的平均数量在280至4000，优选地600至2500的范围内。当碳纤维的平均纤维直径为7μm时，纤维束中纤维的平均数量在142至2040，优选地300至1600的范围内。
当碳纤维束中纤维的平均数量(N)为0.7×104/D2以下时，可能难以获得高纤维体积含量(Vf)。此外，当碳纤维束中纤维的平均数量(N)为1×105/D2以上时，可能局部形成厚的部分，这易于引起空隙的存在。如果为了获得1mm以下的薄成形制品(B1)和(B2)而仅仅使用分开的纤维，成形制品中的纤维密度的不均匀性可能变大，因此可能无法获得良好的物理性质。此外，当所有纤维被打开时，可以获得更薄的成形制品，但是纤维的交叉可能增加，因此可能无法获得高纤维体积含量。当含有不少于由上述式(1)所定义的临界单纤维数的单纤维的碳纤维束和处于单纤维状态或包括低于临界单纤维数的单纤维的碳纤维两者都存在时，可以获得可能变薄并具有高物理性质表征率(physical property development)的成形制品(B1)和(B2)。
在本发明中，优选地，在碳纤维随机放置的成形制品(B1)和(B2)中，碳纤维包括平均纤维长度为5mm至100mm的不连续碳纤维，并且碳纤维以25g/m2至3000g/m2的单位面积纤维重量在平面内方向上大致二维地随机取向。
同时，在本发明中，通过在最终获得的接合体的平面内的任意方向以及与所述任意方向正交的方向上各自进行拉伸试验来测量拉伸模量，并且在模量值之间，通过用较大值除以较小值来计算比率Eδ。当Eδ值不超过2时，认为是各向同性的，而当Eδ不超过1.3时，认为各向同性更好。
包含在成形制品(B1)和(B2)中的树脂可以是热固性树脂或热塑性树脂。然而，从制造率的观点来看，热塑性树脂更适合于使用。
对这样的热塑性树脂没有特别限制，并且可以从选自下列的至少一种中适当地选择：例如聚酰胺，聚碳酸酯，聚甲醛，聚苯硫醚，聚苯醚，聚对苯二甲酸乙二酯，聚对苯二甲酸丁二酯，聚萘二甲酸乙二酯，聚乙烯，聚丙烯，聚苯乙烯，聚甲基丙烯酸甲酯，AS树脂和ABS树脂。成形制品(B1)和(B2)可以由相同树脂或不同树脂制成。然而，从热焊接的观点来看，优选地选择相同的树脂作为成形制品(B1)和成形制品(B2)的树脂。从焊接的观点来看，更优选地，所有复合基板(A)、成形制品(B1)和成形制品(B2)的热塑性树脂是相同的。当所有树脂相同时，复合基板(A)与成形制品(B1)以及复合基板(A)与成形制品(B2)可以容易地彼此热焊接。此外，在接受冲击时，可以充分地防止接合部(C)的剥离，并且可以进一步提高抗冲击性。此外，即使树脂不相同，例如优选地可以示例的是ABS树脂与聚碳酸酯，以及ABS树脂与丙烯酸树脂的组合，但组合不限于此。
在不影响本发明的目的情况下，除了碳纤维之外，成形制品(B1)和成形制品(B2)可以含有各种填充剂或各种添加剂，例如玻璃纤维和芳纶纤维。对于添加剂来说，可以示例的有例如阻燃剂、热稳定剂、紫外吸收剂、成核剂、增塑剂和炭黑，但不限于此。
成形制品(B1)和(B2)中的接合部(C)中所包含的不连续碳纤维的重量比，优选地为每100重量份的热塑性树脂10至1000重量份。不连续碳纤维的重量比更优选地为每100重量份的热塑性树脂10至300重量份，进一步优选地为10至150重量份。然而，接合部(C)之外的任何复合材料中包含的碳纤维的重量比不限于此。
每个成形制品(B1)和(B2)都可以具有所需形状。例如，可以示例的有平板状、波纹板状和盒状。然而，为了形成复合基板(A)夹在成形制品(B1)与(B2)之间并且成形制品(B1)与(B2)彼此固定的结构，需要具有接合部(C)。通常，接合部(C)优选地具有平坦形状，因此优选地，例如至少成形制品(B1)和(B2)的构成接合部(C)的部分是平坦的。
成形制品(B1)和(B2)可以具有相同形状或不同形状。例如，当成形制品(B2)以截面如图1中所示的帽子形状形成时，复合基板(A)与成形制品(B2)之间的空间变成冲击吸收空间，这是优选的。
对制造成形制品(B1)和(B2)的方法没有特别限制。例如，当使用不连续纤维作为碳纤维时，通过用树脂包覆碳纤维然后切断碳纤维来形成颗粒(长纤维颗粒)，也就是说，通过以具有调整过的粘度的融化树脂来浸渍碳纤维，随后切断碳纤维来获得颗粒，并且可以使用注塑机使获得的颗粒成形。此外，作为另一种方法，通过将碳纤维与片、薄膜、颗粒或粉末形式的热塑性树脂重叠，并对它们进行加热和压制，来制造含有碳纤维的片状复合材料。随后，例如，可以使用例如金属模具将这样的复合材料的单层或多个堆叠层压制成形为所需形状。
如上所述，优选地，上述不连续碳纤维被随机放置。在这里，对随机放置不连续碳纤维的方法没有特别限制。为了防止不连续纤维在平面内以特定方向放置，例如，可以将不连续碳纤维机械或人工地无方向性喷洒，并且例如如果需要，送入空气。
成形制品(B1)和(B2)通过复合基板(A)的贯通部(D)来固定。在本发明中，贯通部(D)形成在接合部(C)处。在接合部(C)中，形成复合基板(A)作芯材被夹在成形制品(B1)和(B2)之间的结构。
优选地，成形制品(B1)和(B2)形成有突起(E)，该突起(E)能够插入到夹层结构中的贯通部(D)中。突起(E)可以形成在任一成形制品(B1)和(B2)上，但是也可以形成在每个成形制品(B1)和(B2)上。
突起(E)的形状可以与贯通部(D)的形状相同或不同。例如，可以适当地选择圆柱形、锥形或棱柱形。突起(E)在平面方向上的尺寸(长度)只需要不超过贯通部(D)的尺寸即可。此外，突起(E)在垂直于平面方向的方向上的长度(高度)只需不超过贯通部(D)的长度(深度)即可。然而，突起的高度可以不小于复合基板(A)在厚度方向上的长度，优选地不超过突起的截面积的平方根的1.35倍。不超过突起的截面积的平方根的1.35倍的突起高度是优选的，因为当通过焊接固定时，突起(E)是稳定的而不会掉落。
例如，在只有成形制品(B1)上的突起(E)被插入到贯通部(D)中的情况下，假设贯通部(D)的深度为100，优选地，突起(E)的高度不小于90并小于100。此外，在成形制品(B1)和(B2)两者上的突起(E)都被插入到贯通部(D)中时，优选地，两个成形制品的突起的高度之和在不小于90至小于100的范围内。在如后文中所述使用超声波焊接来焊接成形制品(B1)和(B2)的情形中，所述范围优选地不小于90并小于100。
此外，优选地，突起(E)的总体积大于在复合基板(A)中形成的贯通部(D)的体积的1％并小于100％。当总体积大于1％时，突起(E)与贯通部(D)之间的间隙被热塑性树脂填充。因此，可以在接合部(C)处获得高强度。相反，当总体积优选地小于100％时，树脂不会变得过量，使得在接合部(C)处可以不形成不需要的毛刺并且可以不产生扭曲。所述范围优选地大于50％并小于100％。
突起(E)的数量可以为1个或2个以上，并且它可以不超过贯通部(D)的数量。在设置2个以上突起的情形中，对相邻突起之间的间隔没有特别限制，但是优选地在15mm至150mm的范围内。所述间隔可以彼此不相等。
当压制形成如上所述含有碳纤维的板状复合材料时，可以使用所需金属模具将突起(E)形成在成形制品(B1)和/或成形制品(B2)的表面上。以这种方式形成的突起(E)与成形制品(B1)和/或成形制品(B2)具有相同组成(材料)，并且强度出色。此外，突起(E)可以分开制造并使用胶粘剂粘结于成形制品(B1)和/或成形制品(B2)的表面。
[接合部(C)]
在本发明中，接合部(C)是大致平坦的，并将成形制品(B1)、复合基板(A)和成形制品(B2)依此顺序层压。然后，在接合部(C)中，至少成形制品(B1)和(B2)通过贯通部(D)固定，由此形成本发明的抗冲击性和强度出色的接合体。
如图2和3中所示例的，复合基板(A)被形成有在厚度方向上贯穿的贯通部(D)。成形制品(B1)和成形制品(B2)中的至少一个形成有突起(E)。成形制品(B1)和成形制品(B2)通过插入到贯通部(D)中的突起(E)彼此接触并彼此固定。在成形制品(B1)和成形制品(B2)二者都设置有突起的情形中，当突起的尖端在贯通部(D)中彼此接合时，完成固定。在成形制品(B1)和(B2)中的一个设置有突起的情形中，当突起的尖端与未设置有突起的另一个成形制品的表面相接触时，完成固定。
在本发明中，如图2和3中所示，为了通过提高接合部(C)的强度来提高抗冲击性，成形制品(B1)或成形制品(B2)的一个末端可以具有L-形状(图2中的F)，以覆盖复合基板(A)的末端。在这样的情形中，成形制品(B2)的L-型尖端可以与另一侧的成形制品(B1)接触并例如通过热焊接或胶粘剂与其接合。
[接合顺序]
将参考图2至5以下列顺序描述制造本发明的接合体的优选方法。然而，本发明不限于此。
1.在复合基板(A)中形成贯通部(D)，以及
2.通过将突起(E)插入到贯通部(D)中来固定成形制品(B-1)和成形制品(B-2)。
1.贯通部(D)的形成
首先，加工在厚度方向上贯穿复合基板(A)的贯通部(D)(图4的D)。优选地，熔化切割热塑性树脂和复丝同时进行钻孔加工。这里，“熔化切割”是在通过加热熔化热塑性树脂和复丝的同时切割热塑性树脂和复丝。其他方法，例如利用钻孔机的机械钻孔加工可以被例举为钻孔加工。在熔化切割的情况下，加工期间毛刺的产生不会成为问题。另外，由于熔化切割不会在孔周围引起当向复丝施加不必要的张力时可能造成的物理性质下降，因此它是优选的。此外，通过超声波进行熔化切割是特别优选的，因为它在焊接复合基板(A)、成形制品(B1)和成形制品(B2)时也可以使用。
2.通过将突起(E)插入到贯通部(D)中来固定成形制品(B1)和成形制品(B2)
如图4中所示，成形制品(B1)和成形制品(B2)被设置在复合基板(A)的两侧，以制造如图2和3所示的接合部。突起(E)可以形成在成形制品(B1)和成形制品(B2)中的至少一个上。然而，从定位的观点来看，优选地在成形制品(B1)和成形制品(B2)的每一个上都形成突起(E)。
将突起(E)插入到待固定的贯通部(D)中。固定方法可以是利用含有热塑性树脂或热固性树脂的胶粘剂或利用热焊接的接合方法。在本发明中，通过热焊接固定是优选的，因为它方便并且强度出色。热焊接方法可以是例如热板焊接、通过红外射线加热焊接、通过电磁感应加热焊接、振动焊接、超声焊接、电阻焊接或激光焊接，但不限于此。在本发明中，从加工过程的效率来看超声焊接是特别优选的，因为它也可以用于复合基板(A)的钻孔加工。
在使用超声焊接的情形中，用于有效焊接目的，可以在成形制品(B1)和(B2)的存在突起的每个表面上形成被称为导能部的突出物(图5中的6)。导能部被构造成集中地接收振动，以容易地熔化包含树脂的成形制品并均匀地焊接成形制品。优选地，在成形制品(B1)和成形制品(B2)的接合面(图5中的4和5)上形成导能部。对于复合基板(A)与成形制品(B1)的接合面(图5中的2)和复合基板(A)与成形制品(B2)的接合面(图5中的3)来说，优选地也在(B1)和(B2)侧处设置导能部。对导能部的形状没有限制。然而，例如，任何导能部可以具有如图5中所示的三角棱锥形状，以便使导能部的顶端与接合相对侧产生接触(图5中的6)。
在使用超声焊接的情形中，优选地超声波焊机的超声振动部与接合面彼此接近。这是由于随着树脂层厚度的减小，超声振动的衰减降低，因此焊接效率提高。因此，尽管对超声振动侧的成形制品(B1)或成形制品(B2)的板厚度没有限制，但板厚度优选地不超过10mm，更优选地不超过5mm。相反，从提高接合体的抗冲击性的观点来看，不低于0.5mm的板厚度是优选的。
此外，取决于实施情况，复合基板(A)和成形制品(B2)可以通过在其间使用胶粘剂接合。此外，可以利用树脂将突起与复合基板(A)接合。
[接合体]
由于本发明的接合体在接合部(C)处具有夹层结构，因此它在强度和抗冲击性方面出色。此外，接合体在其表面上具有本身在抗冲击性方面出色的复合基板(A)。特别是，在复合基板(A)中，复丝、严格来说在纤维束内部的纤维，具有变形或移动的自由度。利用这种构造，在复合基板(A)处直接施加于接合体的冲击可以被涉及破坏的自由度吸收。因此，本发明的接合体在抗冲击性方面出色。
总体来说，在接受冲击的成形体的抗冲击性弱的情形中，直接接受冲击的成形制品在接合体的接合部剥离之前被破坏。然而，在本发明的带有具有特定结构的接合部的接合体中，剥离接合部所需的力量增加，因此接合部难以剥离。结果，接合体的抗冲击性得到总体改进。
[车辆部件]
本发明的接合体在抗冲击性和刚性方面出色，因此它可以优选地用于车辆部件，例如汽车的结构部件、外部部件或内部部件。特别是，由于出色的抗冲击性，它适用于吸收冲击的构件，例如座椅、底板底盘、发动机罩或车门。
综上所述，显然，本发明包括如下具体特点。
接合体包括由成形制品(B1)、复合基板(A)和成形制品(B2)依此顺序层压而构成的接合部，其中复合基板(A)含有多个聚酯复丝和热塑性树脂，成形制品(B1)和(B2)含有碳纤维和热塑性树脂，并且所述碳纤维被随机放置在成形制品(B1)和(B2)中，并且此外
(i)复合基板(A)包括其中所述复丝之间的空间浸渍有所述热塑性树脂的浸渍部，以及复丝内部未浸渍有所述热塑性树脂的非浸渍部，
(ii)复合基板(A)具有通孔(D1)，其在厚度方向上贯穿复合基板(A)，并且
(iii)利用复合基板(A)的通孔(D1)，通过热焊接固定成形制品(B1)和(B2)，并且
(iv)成形制品(B1)和(B2)中的至少一个在其表面上具有突起(E)，并且突起(E)被布置在通孔(D1)内。
实施例
下面将基于实施方式对本发明进行详细描述，但本发明不限于此。
[评价方法]
(落锤试验)
通过将复合基板(A)侧面朝上放置，并将重量已知的铁球从复合基板上方落下，使得铁球落于复合基板(A)的中心，来评价抗冲击性。在测试中，使用8Kg铁球，并且逐渐增加下落高度，以便评价复合基板(A)、成形制品(B1)和成形制品(B2)在接合部(C)处的剥离。测量结果示出在表1中。
(复丝之间的空间中的树脂浸渍率)
使用显微切片机切开复合基板(A)并使用显微镜观察截面。尽管未示出，但在截面中观察到的多个圆形形状是复丝中单纤维的截面轮廓线，并且观察到的处于密集状态下的每个圆圈都是复丝(纤维束)。在每个圆圈外部周围观察到的白色是热塑性树脂。观察到的黑色是孔部分(空隙)。通过对截面(100μm×100μm)中复丝之间的空间进行二值化处理来计算空隙率，并计算从100％中减去空隙率后剩下的值，作为复丝之间的空间中的树脂浸渍率。
(复丝内部中的树脂浸渍率)
对于可以取出的形成复丝的单纤维的数量进行测量，所述复丝从复合基板(A)取出。假设复丝的单纤维数量为X，被取出的单纤维数量为Y，则复丝内部的树脂浸渍率等于1-Y/X(％)。
制造例1：由聚对苯二甲酸乙二酯制成的捻合纤维线的制备
使用由Teijin Fiber Co.,Ltd.制造的聚对苯二甲酸乙二酯纤维(P900M 1100T250细丝)作为原始纤维和由Kaji Tech Co.,Ltd.制造的圆环纤维捻合机，在Z-方向上进行275次/m的初始捻合(捻合系数为3.0)。接下来，将两条初级捻合纤维合股，并在S-方向上进行200次/m的最终捻合(捻合系数为3.0)，由此获得捻合纤维线。一根捻合纤维线的直径为0.5mm。
制造例2：复合基板(A)的制造
将在制造例1中获得的捻合纤维线在大致一个方向上缠绕在平坦铝板上，以获得均匀厚度和200g/m2的单位面积纤维重量，所述铝板具有粘附于平坦铝板的一侧的聚酰胺6薄膜(由Unitika Ltd.制造的Emblem ON薄膜，标准等级，厚度为25μm)。随后，使用设置有加热装置的手动压机，在270℃下对缠绕有捻合纤维线的铝板进行60秒的热压。最后，将铝板的未粘附有聚酰胺6薄膜的一侧上的捻合纤维线切除，从而获得部分浸渍有树脂的捻合纤维线的单向材料。
制备3片这样的单向材料片。
通过将3片单向材料片相对于单层材料的纤维方向分别以0度方向、90度方向和0度方向顺序堆叠，获得层状体。将层状体切割成适合尺寸，并再次在270℃下加热并压制，以获得宽度150mm×深度300mm×厚度3.0mm的成形制品(宽度：图1中的X轴方向，深度：图1中的Z轴方向，厚度：图1中的Y轴方向)。
最后，使用超声处理机(超声波频率：20kHz，加压力：500N，角型件直径：Φ3.5)在成形制品中形成通孔，以获得总树脂含量为30％的复合基板(A)。该复合基板的复丝空间中的树脂浸渍率为95％，复丝内部的树脂浸渍率为30％，并且纤维的体积分数为40％(参见表1)。成形制品(A’)是指未形成有通孔的成形制品。
制造例3：成形制品(B1)和成形制品(B2)的制造
将其中碳纤维(由Toho Tenax Co.,Ltd.制造，STS40，平均纤维直径：7μm)被切断成平均20mm的成形制品用作成形制品(B1)和成形制品(B2)。作为基质树脂，使用聚酰胺6(由Unitika Ltd.制造的Unitika Nylon 6)。在聚酰胺6薄膜上，将上述切断的碳纤维以平面内方向随机放置，使得平均单位面积纤维重量变为540g/m2，并且碳纤维的重量比率变为52％(Vf 40％)(参见表1)。
将以这种方式获得的成形制品(B1)和(B2)的前体材料，在250℃的材料预热温度、100℃的模具温度和10MPa压力下，使用形成突起的给定金属模具压力成型60秒。由此制造如图1中所示的厚度为的1.5mm的平坦成形制品(B1)和厚度为的1.5mm的草帽形成形制品(B2)。在这里，碳纤维的临界单纤维数为86，包括临界单纤维数以上单纤维的碳纤维束中的纤维平均数量(N)为142至2040。在这里，接合部(C)的宽度被设定为20mm，成形制品(B1)和(B2)两者在接合部(C)处的厚度被设定为1.5mm(宽度：图1中的X-轴方向，深度：图1中的Z-轴方向，厚度：Y-轴方向)。如图2和3中所示，突起(E)被形成为截短的圆锥形状，其中底部直径为3mm，相对于与底面垂直的方向的倾斜度为5°，并且高度为1.6mm。突起在制造成形制品时(与模制同时)形成在每个成形制品(B1)和成形制品(B2)的一个侧表面上，使得一个成形制品上的突起一一对应于另一个成形制品上的突起。
作为成形制品(B1)，制备了两种成形制品(B11)和(B12)。成形制品(B11)不具有覆盖复合基板(A)的末端(图2中的F)的部分，成形制品(B12)具有覆盖复合基板(A)的所述末端(图2中的F)的部分。
成形制品(B11)被设定为宽度300mm×长度22mm×厚度1.5mm。成形制品(B12)被设定为宽度300mm×长度22mm×厚度1.5mm，并且成形制品(B12)的末端部分在厚度方向上延伸3mm，以具有4.5mm的高度(高度：图1中在成形制品的整个长度上的Y-方向)，以便覆盖复合基板(A)的末端。
成形制品(B2)和不具有通孔的成形制品(B’)各自在截面中具有草帽形状，如图1中的(B2)和图6中的8所示，并且各自具有宽度300mm×长度150mm×厚度1.5mm，并且其高度为30mm。
实施例1
如图1至3中所示，使用在制造例3中获得的成形制品(B11)和成形制品(B2)，并将在制造例2中获得的复合基板(A)的两个末端部分插入到成形制品之间。随后，将被插入层压的成形制品中的这些部分(接合部(C))通过超声焊接进行焊接，以获得接合体。(B11)和(B2)的Eδ为1.0。此时，超声波频率为20kHz，加压力为1500N。随后，在获得的接合体上进行落锤试验。铁球下落高度从0.2m起以0.25m增加。结果，在高度为1.95m处，接合部(C)剥离。结果示出在表1中。
实施例2
除了将在制造例3中获得的成形制品(B12)作为成形制品(B1)外，在与实施例1中相同的条件下制造接合体。(B1)和(B12)的Eδ为1.0。在获得的接合体上进行重量试验。铁球下落高度从0.2m起以0.25m增加。结果，在高度为2.45m处，接合部(C)被剥离。结果示出在表1中。
比较例1
除了使用未形成通孔的成形制品(A’)和不具有突起的成形制品(B’)外，通过以与实施例1中相同的方式将被插入层压的成形制品的部分通过超声焊接接合，制造了具有如图7中示出的形状的接合体。(B11)和(B2)的Eδ为1.0。
在接合体上进行落锤试验。当铁球下落高度为1.7m时，接合部被剥离。结果示出在表1中。
实施例3
在与实施例2中相同的条件下制造接合体，区别在于通过减少加压时间，使纤维束内部的树脂浸渍率为60％。(B1)和(B12)的Eδ为1.0。在获得的接合体上进行落锤试验。铁球下落高度从0.2m起以0.25m增加。结果，在高度为1.95m处，接合部(C)被剥离。结果示出在表1中。
表1
参比例
通过使用由TPIC Co.,Ltd.制造的TP15型单螺杆挤出机，将切断长度为1mm的聚对苯二甲酸乙二酯纤维和作为基质树脂的聚酰胺6树脂(由Unitika Ltd.制造的Unitika Nylon 6)在210℃下捏合1分钟，获得聚对苯二甲酸乙二酯短纤维混合在聚酰胺6树脂中的链形复合材料。随后，对复合材料进行造粒，并使用由Nissei Plastic Industrial Co.,Ltd.制造的EP5型紧凑式注射模制机，在210℃的注射温度下制造用于落锤试验的模制片(试验样本)。使用激光显微镜观察试验样本的截面。将短纤维分离至单纤维水平，并均匀分散在树脂中(不存在非浸渍部，并且纤维束之间的空间中的树脂浸渍率为100％)。同时，树脂含量为80％。
在其中聚对苯二甲酸乙二酯纤维被基质树脂完全浸渍的成形制品(A”)上进行落锤试验。在铁球下落高度为0.7m时，成形制品(A”)被破坏。结果示出在表1中。
实施例4
以与实施例2中相同的方式制造接合体，区别在于用于复合基板(A)的热塑性树脂是聚丙烯，并且模制期间的温度为180℃。在获得的接合体上进行落锤试验。铁球下落高度从0.2m起以0.25m增加。结果，在达到2.45m的高度之前，接合部(C)剥离。
工业实用性
本发明的接合体在抗冲击性和刚性方面出色。因此，它可用于车辆目的，例如作为汽车的结构部件、外部部件或内部部件。

Claims (11)

1.一种接合体，该接合体包括：由成形制品B1、复合基板A和成形制品B2依此顺序层压而构成的接合部C，
其中，所述复合基板A包含多个有机材料的复丝和热塑性树脂，并且所述成形制品B1和B2各自包含碳纤维和树脂，
其中，
(i)所述复合基板A包括所述复丝之间的空间浸渍有所述热塑性树脂的浸渍部，以及复丝内部未浸渍有所述热塑性树脂的非浸渍部，
(ii)所述复合基板A具有贯通部D，该贯通部D在厚度方向上贯穿所述复合基板A，并且
(iii)所述成形制品B1和B2与所述复合基板A的所述贯通部D相接触并通过所述复合基板A的所述贯通部D被固定，并且
其中，所述热塑性树脂在所述复丝之间的所述空间中的浸渍比率在90％至100％的范围内，并且
所述复丝的所述内部中的浸渍率在0％至50％的范围内。
2.根据权利要求1所述的接合体，其中，所述复丝含有连续纤维。
3.根据权利要求1所述的接合体，其中，以体积比率计，所述复合基板A以相对于100份所述复丝在20份至900份范围内包含所述热塑性树脂。
4.根据权利要求1所述的接合体，其中，所述碳纤维具有0.1mm至300mm范围内的平均纤维长度。
5.根据权利要求4所述的接合体，其中，所述碳纤维被随机放置在所述成形制品B1和B2中。
6.根据权利要求1所述的接合体，其中，所述成形制品B1和B2的所述树脂是热塑性树脂，并且以重量比率计，所述热塑性树脂以相对于100份碳纤维在10份至300份的范围内被包含。
7.根据权利要求1所述的接合体，其中，所述成形制品B1和B2中的至少一个在其表面上具有突起E。
8.根据权利要求7所述的接合体，其中，所述突起E布置在所述贯通部D中。
9.根据权利要求7所述的接合体，其中，所述突起E包括与所述成形制品B1或B2相同的材料。
10.根据权利要求1所述的接合体，其中，所述成形制品B1与B2通过热焊接彼此接触并固定。
11.一种接合体，该接合体包括：由成形制品B1、复合基板A和成形制品B2依此顺序层压而构成的接合部C，
其中，所述复合基板A包含多个聚酯复丝和热塑性树脂，所述成形制品B1和B2各自包含碳纤维和热塑性树脂，并且碳纤维随机放置在所述成形制品B1和B2中，
其中，
(i)所述复合基板A包括所述复丝之间的空间浸渍有所述热塑性树脂的浸渍部，以及复丝内部未浸渍有所述热塑性树脂的非浸渍部，
(ii)所述复合基板A具有通孔D1，该通孔D1在厚度方向上贯穿所述复合基板A，
(iii)所述成形制品B1和B2通过所述复合基板A的通孔D1，利用热焊接而固定，并且
(iv)所述成形制品B1和B2中的至少一个在其表面上具有突起E，并且所述突起E布置在所述通孔D1中，并且
其中，所述热塑性树脂在所述复丝之间的所述空间中的浸渍比率在90％至100％的范围内，并且
所述复丝的所述内部中的浸渍率在0％至50％的范围内。
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WO2012161348A1 (ja) 2012-11-29
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