JP2001293746A - Resin molded article - Google Patents
Resin molded articleInfo
- Publication number
- JP2001293746A JP2001293746A JP2000118546A JP2000118546A JP2001293746A JP 2001293746 A JP2001293746 A JP 2001293746A JP 2000118546 A JP2000118546 A JP 2000118546A JP 2000118546 A JP2000118546 A JP 2000118546A JP 2001293746 A JP2001293746 A JP 2001293746A
- Authority
- JP
- Japan
- Prior art keywords
- mat
- resin molded
- molded product
- reinforcing material
- resin
- 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.)
- Pending
Links
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、強度を必要とする
部位にマット状の補強材をインサート成形した樹脂成形
品に係り、特に、例えば、自動車のフロントエンドキャ
リア及びインスツルメントパネルなどの高強度かつ軽量
な樹脂成形品に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded product in which a mat-like reinforcing material is insert-molded at a site where strength is required, and particularly to a resin molded product such as a front end carrier of an automobile and an instrument panel. The present invention relates to a strong and lightweight resin molded product.
【０００２】[0002]
【従来の技術】従来より、高強度な樹脂成形品を得る方
法としては、鉄板をインサート成形する方法があった。
しかしこの方法では、インサート品が鉄板のため重量が
非常に重くなってしまうという欠点があった。また、イ
ンサート品が鉄板であるため、インサート部や形状等に
制約があり、実用的でなかった。軽量化のために、軽量
金属材を使用しようとしても、非常に高価なものとなる
ため、経済性の面から採用できないという問題があっ
た。2. Description of the Related Art Conventionally, as a method of obtaining a high-strength resin molded product, there has been a method of insert-molding an iron plate.
However, this method has a drawback that the weight of the insert is extremely heavy because the insert is an iron plate. Further, since the insert product is an iron plate, there are restrictions on the insert portion, shape, and the like, which is not practical. Even if an attempt is made to use a lightweight metal material to reduce the weight, it becomes very expensive, and there has been a problem that it cannot be adopted from the viewpoint of economy.
【０００３】更に、従来においては、自動車の樹脂製フ
ロントエンドキャリアは、ＧＭＴ（Glass Mat Thermopl
astic ）と呼ばれる成形方法で製作されている。これ
は、ガラスの長繊維を熱可塑性樹脂で含浸したマット状
の材料を所定の大きさに切り、熱を加えて溶融状態と
し、成形金型内にセットし、プレスをする圧縮成形によ
って製品とするものである。この場合、ガラスを大量に
入れることで製品の強度を上げることができるが、材料
費が高くなり、また工程も複雑でコストが高くなる。更
にプレスでの成形になるため、成形可能な形状に制約が
あり複雑な成形品は作れないという問題点があった。[0003] Further, conventionally, a resin front end carrier of an automobile is made of GMT (Glass Mat Thermopl).
astic). This involves cutting a mat-shaped material, in which long fibers of glass are impregnated with a thermoplastic resin, into a predetermined size, applying heat to make it into a molten state, setting it in a molding die, and pressing it to produce a product by compression molding. Is what you do. In this case, the strength of the product can be increased by adding a large amount of glass, but the material cost is increased, and the process is complicated and the cost is increased. Furthermore, since it is formed by pressing, there is a problem that a shape that can be formed is limited and a complicated molded product cannot be produced.
【０００４】このフロントエンドキャリアに新たな機能
を持たせるためには、複雑な形状を成形する必要があ
り、この圧縮成形で生産することは難しい。そこで、高
強度、軽量化及び低コスト化を目的として長繊維ガラス
含有樹脂材での射出成形が注目されてきている。しかし
ながら、この射出成形においても、長い繊維を樹脂に含
有させて送り込んでも、その途中のスクリューシリンダ
等において繊維が折損又は切断されてしまい、結局は長
い繊維を樹脂中に含有させた成形品を得ることができ
ず、そのため衝撃強度の高い成形品を得ることができな
い。このように長繊維ガラス含有樹脂材の射出成形のみ
では、強度的に限界があった。In order to impart a new function to the front end carrier, it is necessary to form a complicated shape, and it is difficult to produce the front end carrier by compression molding. Therefore, injection molding with a long fiber glass-containing resin material has been receiving attention for the purpose of high strength, light weight, and low cost. However, even in this injection molding, even if a long fiber is contained in the resin and fed, the fiber is broken or cut in a screw cylinder or the like in the middle thereof, and eventually, a molded article containing the long fiber in the resin is obtained. Therefore, a molded article having high impact strength cannot be obtained. Thus, there is a limit in strength only by injection molding of a long fiber glass-containing resin material.
【０００５】[0005]
【発明が解決しようとする課題】本発明は、上記問題に
鑑みてなされたもので、その目的は、強度の必要とする
部分を部分的に補強することで、高強度、軽量でかつ低
コストであると共に、形状の自由度を兼ね備えたインサ
ートによる樹脂成形品を提供することである。SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to provide a high-strength, light-weight and low-cost device by partially reinforcing a portion requiring strength. Another object of the present invention is to provide a resin molded product using an insert having a degree of freedom in shape.
【０００６】[0006]
【課題を解決するための手段】本発明は、前記課題を解
決するための手段として、特許請求の範囲の各請求項に
記載された樹脂成形品を提供する。請求項１に記載の樹
脂成形品においては、母材より強度が高い線状素材を使
用したマット状の補強材をインサート成形することで、
強度が優れたかつ軽量な成形品を低コストで得られるも
のである。According to the present invention, there is provided, as a means for solving the above-mentioned problems, a resin molded product described in each of the claims. In the resin molded product according to claim 1, a mat-like reinforcing material using a linear material having higher strength than the base material is insert-molded,
It is possible to obtain a lightweight molded article having excellent strength at low cost.
【０００７】請求項２に記載の樹脂成形品では、多数の
線状素材が引っ張り方向と同方向を向くようにすること
で、更に一層の強度をもたせるようにしたものである。
請求項３に記載の樹脂成形品では、多数の線状素材を引
っ張り方向と同方向及び更に直交方向にも配置すること
で、引っ張り方向のみならず直交する方向での強度をも
改善したものである。[0007] In the resin molded product according to the second aspect, a large number of linear materials are oriented in the same direction as the pulling direction so as to have further strength.
In the resin molded product according to claim 3, by arranging a large number of linear materials in the same direction as the tensile direction and further in the orthogonal direction, the strength in the orthogonal direction as well as the tensile direction is improved. is there.
【０００８】請求項４に記載の樹脂成形品では、母材の
表面に補強材を設けたもので、金型内に容易に補強材を
セットでき、インサート成形が簡単に行える。当然高強
度の成形品が得られる。請求項５に記載の樹脂成形品で
は、母材の両面に補強材を設けることで一層の強度化を
計っている。In the resin molded product according to the fourth aspect, the reinforcing material is provided on the surface of the base material, so that the reinforcing material can be easily set in the mold and the insert molding can be easily performed. Naturally, a high-strength molded product can be obtained. In the resin molded product according to the fifth aspect, the reinforcing material is provided on both surfaces of the base material to further increase the strength.
【０００９】請求項６に記載の樹脂成形品は、線状素材
としてガラス繊維又はカーボン繊維を採用したもので、
これにより樹脂成形品の軽量化が計れ、高強度と相俟っ
て優れた樹脂成形品が得られる。請求項７に記載の樹脂
成形品は、マット状の補強材としてガラス繊維又はカー
ボン繊維を使用した不織布を用いたものであり、軽量で
高強度の樹脂成形品が得られる。請求項８に記載の樹脂
成形品は、マット状の補強材としてステンレス製の網状
マットを用いたものであり、この網状マットにおいて
も、十分に軽量かつ高強度の樹脂成形品が得られる。The resin molded product according to claim 6 employs glass fiber or carbon fiber as the linear material.
As a result, the weight of the resin molded product can be reduced, and an excellent resin molded product can be obtained in combination with high strength. The resin molded product according to claim 7 uses a nonwoven fabric using glass fiber or carbon fiber as a mat-like reinforcing material, and a lightweight and high-strength resin molded product can be obtained. The resin molded product according to the eighth aspect uses a stainless steel net mat as a mat-like reinforcing material. Even with this net mat, a sufficiently lightweight and high-strength resin molded product can be obtained.
【００１０】[0010]
【発明の実施の形態】以下、本発明の実施の形態の樹脂
成形品について、図面に基づいて説明する。図１は、本
発明の実施の形態の樹脂成形品を示しており、１はマッ
ト状補強材、２は母材である成形樹脂であり、マット状
補強材１をインサート成形して樹脂成形品としたもので
ある。この場合成形用金型内にマット状補強材１をイン
サートしておき、この金型内に樹脂を射出注入するが、
この成形過程において、マット状補強材１が成形樹脂２
に接着して一体化される。なお、図１では、成形樹脂２
の表面と裏面の両面にマット状補強材１を設けた樹脂成
形品が示されているが、片面のみにマット状補強材１を
設けたものでも十分に強度化が計れるものである。な
お、成形樹脂２として長繊維ガラス含有材料を使用すれ
ば、一層強度の増加を計れる。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a resin molded product according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a resin molded product according to an embodiment of the present invention, in which 1 is a mat-like reinforcing material, 2 is a molding resin as a base material, and a mat-like reinforcing material 1 is insert-molded into a resin molded product. It is what it was. In this case, the mat-like reinforcing material 1 is inserted into a molding die, and a resin is injected and injected into the die.
In this molding process, the mat-like reinforcing material 1 is
To be integrated. In FIG. 1, the molding resin 2
Although the resin molded product in which the mat-like reinforcing material 1 is provided on both the front surface and the back surface is shown, a material in which the mat-like reinforcing material 1 is provided only on one surface can sufficiently achieve the strength. If a material containing long fiber glass is used as the molding resin 2, the strength can be further increased.
【００１１】図２は、樹脂成形品の真ん中、即ち成形樹
脂２でサンドイッチされる形でマット状補強材１を設け
た本発明の変形例を示している。この場合においては、
インサート成形中にマット状補強材１を成形用金型のキ
ャビティ内の中間部に配置する必要があるため、マット
状補強材１を位置決めして保持するための位置決め具の
穴３が樹脂成形品に残される。FIG. 2 shows a modification of the present invention in which a mat-like reinforcing material 1 is provided in the middle of a resin molded product, that is, sandwiched by a molding resin 2. In this case,
Since it is necessary to arrange the mat-like reinforcing member 1 in the middle part of the cavity of the molding die during the insert molding, the hole 3 of the positioning tool for positioning and holding the mat-like reinforcing member 1 is made of a resin molded product. Will be left.
【００１２】図３〜５は、本発明の樹脂成形品に用いら
れるマット状補強材１の実施例を示しており、図３は直
列マット１ａの例であり、図４は直交マット１ｂの例で
あり、図５は不織布１ｃの例である。図３の直列マット
１ａは、ガラス繊維、カーボン繊維等の線状素材４が多
数、一方向に均一に配列され、ポリプロピレン等のバイ
ンダー５でマット状に固めたものである。この方向は引
っ張り方向とほぼ同方向を向いているものであり、引っ
張り方向とは製品としての使用時に、荷重が加わった際
の引張応力の発生する方向である。このバインダー５
は、母材となる成形樹脂２よりも融点が低く、インサー
ト成形時にバインダー５が成形樹脂の熱により溶融し成
形樹脂に接着して、マット状補強材１と成形樹脂２とが
一体化した樹脂成形品が得られる。図４の直交マット１
ｂは、上記と同様な線状素材４を多数、直交状に均一に
配列し、同様にバインダー５でマット状に固めたもので
ある。図５の不織布１ｃは、ガラス繊維、カーボン繊維
等の長い繊維（線状素材）４を織らずにからませるよう
にして配置し、バインダー５でマット状に固めたもので
ある。なお、図示していないが、ステンレス製の金網を
バインダーでマット状とした網状マットをマット状補強
材１として使用してもよい。3 to 5 show an embodiment of a mat-like reinforcing material 1 used for a resin molded product of the present invention. FIG. 3 shows an example of an in-line mat 1a, and FIG. 4 shows an example of an orthogonal mat 1b. FIG. 5 shows an example of the nonwoven fabric 1c. The series mat 1a in FIG. 3 is formed by arranging a large number of linear materials 4 such as glass fibers and carbon fibers uniformly in one direction, and solidifying them in a mat shape with a binder 5 such as polypropylene. This direction is substantially the same as the pulling direction, and the pulling direction is a direction in which a tensile stress is generated when a load is applied during use as a product. This binder 5
The resin has a lower melting point than the molding resin 2 serving as a base material, and the binder 5 is melted by the heat of the molding resin at the time of insert molding and adheres to the molding resin. A molded article is obtained. Orthogonal mat 1 of FIG.
b is obtained by arranging a large number of linear raw materials 4 similar to the above in an orthogonal manner and similarly hardening them in a mat shape with a binder 5. The nonwoven fabric 1c shown in FIG. 5 is arranged such that long fibers (linear materials) 4 such as glass fibers and carbon fibers are entangled without weaving, and solidified in a mat shape with a binder 5. Although not shown, a net-like mat in which a stainless steel wire net is matted with a binder may be used as the mat-like reinforcing member 1.
【００１３】図６（ａ）は、マット状補強材１を使用し
ない場合と、上記した各種のマット状補強材１を使用し
た場合の樹脂成形品の曲げ弾性率を比較したグラフであ
り、図６（ｂ）は、その曲げ強度を比較したグラフであ
る。テストピースの形状は、２１０mm×２０mm×３mmで
あり、テストピースの表裏に各種マット状補強材をイン
サート成形し作製した。成形材料はポリプロピレン樹脂
である。この補強材による効果の比較は、８０℃の温度
下で実施されたものである。これらのグラフから、ガラ
ス繊維を用いた直列マット１ａ（直列ＧＦマット）を使
用した場合には、補強材１を使用しないものに比べて、
曲げ強度及び曲げ弾性率ともに１．８倍程強度を上げる
ことがわかる。またガラス繊維を用いた不織布１ｃ（不
織布ＧＦマット）を使用したものでは、同様に曲げ強度
及び曲げ弾性率ともに１．１倍程強度を上げることがわ
かる。更に、ステンレス製の金網を用いた網状マット
（金網）では、曲げ強度で１．３倍程、曲げ弾性率で
１．６倍程強度を上げることがわかる。このように、マ
ット状補強材１をインサート成形した樹脂成形品におい
ては、その強度が著しく改善される。そのうえ鉄のよう
な重い素材を使用しないので軽量化できるものである。FIG. 6 (a) is a graph comparing the flexural modulus of the resin molded product when the mat-like reinforcing material 1 is not used and when the above-mentioned various mat-like reinforcing materials 1 are used. FIG. 6B is a graph comparing the bending strengths. The shape of the test piece was 210 mm × 20 mm × 3 mm, and various mat-like reinforcing materials were insert-molded on the front and back of the test piece. The molding material is a polypropylene resin. The comparison of the effect of the reinforcing material was performed at a temperature of 80 ° C. From these graphs, when the in-line mat 1a (in-line GF mat) using glass fiber is used, compared to the case where the reinforcing material 1 is not used,
It can be seen that both the bending strength and the flexural modulus are increased by about 1.8 times. Also, in the case of using the nonwoven fabric 1c (nonwoven fabric GF mat) using glass fiber, it can be seen that the bending strength and the flexural modulus are increased by about 1.1 times in the same manner. Further, it can be seen that the reticulated mat (wire mesh) using the stainless steel wire mesh increases the bending strength by about 1.3 times and the bending elastic modulus by about 1.6 times. As described above, the strength of the resin molded product obtained by insert-molding the mat-like reinforcing material 1 is remarkably improved. In addition, since a heavy material such as iron is not used, the weight can be reduced.
【００１４】図７は、自動車のフロントエンドの樹脂キ
ャリアにマット状補強材１を使用したものであり、強度
を補強する部分にマット状補強材１をインサート成形し
たもので、この部分を斜線で示している。なお、本発明
の樹脂成形品は、この自動車のフロントエンドキャリア
に限らず、インスツルメントパネルやコックピットなど
の大物の樹脂成形品に適用できる外、床材、タイル材、
パネル材等の建材用、及び排水用埋設管継手等の土木
用、ビーム管、レガースなど各種の樹脂成形品に適用で
きるものである。FIG. 7 shows a case in which a mat-like reinforcing material 1 is used as a resin carrier for a front end of an automobile. The mat-like reinforcing material 1 is insert-molded in a portion for reinforcing strength. Is shown. In addition, the resin molded product of the present invention is not limited to the front end carrier of this automobile, and can be applied to large resin molded products such as instrument panels and cockpits, floor materials, tile materials,
It can be applied to various resin molded products such as building materials such as panel materials, civil engineering such as buried pipe fittings for drainage, beam pipes, and leggers.
【図１】マット状補強材を両面に設けた場合の本発明の
実施の形態の樹脂成形品を示す概略図である。FIG. 1 is a schematic view showing a resin molded product according to an embodiment of the present invention when a mat-like reinforcing material is provided on both surfaces.
【図２】マット状補強材を母材の中央に設けた場合の本
発明の別の実施の形態の樹脂成形品を示す概略図であ
る。FIG. 2 is a schematic view showing a resin molded product according to another embodiment of the present invention when a mat-like reinforcing material is provided at the center of a base material.
【図３】マット状補強材の実施例である直列マットを説
明する図である。FIG. 3 is a diagram illustrating a series mat as an example of a mat-like reinforcing material.
【図４】マット状補強材の別の実施例である直交マット
を説明する図である。FIG. 4 is a view for explaining an orthogonal mat which is another embodiment of the mat-like reinforcing member.
【図５】マット状補強材のさらに別の実施例である不織
布を説明する図である。FIG. 5 is a diagram illustrating a nonwoven fabric which is still another example of the mat-like reinforcing material.
【図６】マット状補強材を使用しない場合と、本発明の
実施の形態であるマット状補強材を使用した場合の樹脂
成形品の強度を比較したグラフであり、（ａ）は曲げ弾
性率の、（ｂ）は曲げ強度の比較グラフである。FIG. 6 is a graph comparing the strength of a resin molded product when no mat-like reinforcing material is used and when a mat-like reinforcing material according to an embodiment of the present invention is used. (B) is a comparison graph of bending strength.
【図７】自動車のフロントエンドの樹脂キャリアに、本
発明を適用した事例の斜視図である。FIG. 7 is a perspective view of a case where the present invention is applied to a resin carrier at a front end of an automobile.
１…マット状補強材 ２…成形樹脂 ３…マット位置決め具の穴 ４…線状素材 ５…バインダー DESCRIPTION OF SYMBOLS 1 ... Mat-shaped reinforcement material 2 ... Molding resin 3 ... Hole of mat positioning tool 4 ... Linear material 5 ... Binder
フロントページの続き (72)発明者 茅野 久 愛知県刈谷市昭和町１丁目１番地 株式会 社デンソー内 (72)発明者 志水 正 愛知県刈谷市一ツ木町茶煎坊下１番地 シ ミズ工業株式会社内 (72)発明者 神谷 智治 愛知県刈谷市一ツ木町茶煎坊下１番地 シ ミズ工業株式会社内 Ｆターム(参考） 3D003 AA01 AA04 CA02 3D044 BA01 BA03 BB01 BC04 4F206 AA11 AD03 AD16 AD35 AH17 JA07 JB12 JB20 JF05 Continuing on the front page (72) Inventor Hisashi Chino 1-1-1, Showa-cho, Kariya-shi, Aichi Prefecture Inside DENSO Corporation (72) Inventor Tadashi Shimizu 1-chome, Sentsu-cho, Hittsugi-cho, Kariya-shi, Aichi Prefecture Shimizu Corporation (72) Inventor Tomoya Kamiya 1-chome, Senzokucho, Kariya-shi, Aichi Prefecture Shimizu Industry Co., Ltd.F-term (reference)
Claims (8)
り形成したマット状の補強材をインサート成形すること
を特徴とする樹脂成形品。1. A resin molded product characterized by insert-molding a mat-like reinforcing material formed of a large number of linear materials having strength higher than that of a base material.
多数の線状素材が向いていることを特徴とする請求項１
に記載の樹脂成形品。2. The method according to claim 1, wherein the plurality of linear materials are oriented substantially in the same direction as the pulling direction.
The resin molded product according to the above.
に多数の線状素材を更に含んでいることを特徴とする請
求項２に記載の樹脂成形品。3. The resin molded article according to claim 2, further comprising a plurality of linear materials in a direction substantially perpendicular to the pulling direction.
ていることを特徴とする請求項１に記載の樹脂成形品。4. The resin molded product according to claim 1, wherein the reinforcing material is provided on a surface of the base material.
設けられていることを特徴とする請求項１に記載の樹脂
成形品。5. The resin molded product according to claim 1, wherein the reinforcing material is provided on a front surface and a back surface of the base material.
繊維であることを特徴とする請求項１〜５のいずれか一
項に記載の樹脂成形品。6. The resin molded product according to claim 1, wherein the linear material is glass fiber or carbon fiber.
繊維であり、前記マット状の補強材が不織布であること
を特徴とする請求項１，４又は５に記載の樹脂成形品。7. The resin molded article according to claim 1, wherein the linear material is glass fiber or carbon fiber, and the mat-like reinforcing material is a non-woven fabric.
マット状補強材が網状マットであることを特徴とする請
求項１又は３〜５のいずれか一項に記載の樹脂成形品。8. The resin molded product according to claim 1, wherein the linear material is stainless steel, and the mat-like reinforcing material is a net-like mat.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000118546A JP2001293746A (en) | 2000-04-14 | 2000-04-14 | Resin molded article |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000118546A JP2001293746A (en) | 2000-04-14 | 2000-04-14 | Resin molded article |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2001293746A true JP2001293746A (en) | 2001-10-23 |
Family
ID=18629660
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2000118546A Pending JP2001293746A (en) | 2000-04-14 | 2000-04-14 | Resin molded article |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2001293746A (en) |
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