JP2019171575A - Fiber-reinforced resin molding - Google Patents

Fiber-reinforced resin molding Download PDF

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JP2019171575A
JP2019171575A JP2018059114A JP2018059114A JP2019171575A JP 2019171575 A JP2019171575 A JP 2019171575A JP 2018059114 A JP2018059114 A JP 2018059114A JP 2018059114 A JP2018059114 A JP 2018059114A JP 2019171575 A JP2019171575 A JP 2019171575A
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resin
fiber reinforced
fiber
reinforced resin
thermoplastic resin
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JP6931850B2 (en
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英生 峯
Hideo Mine
英生 峯
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Panasonic Intellectual Property Management Co Ltd
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Abstract

To provide a fiber-reinforced resin molding, which adds an affinity to a joint between a fiber-reinforced resin layered sheet, which can be integrated with another member by injection molding, and a thermoplastic resin molding, the member to be integrated, and makes the integrated fiber-reinforced resin molding without deformations such as sink and warpage.SOLUTION: A fiber-reinforced resin molding consists of a fiber-reinforced resin layered sheet 1, a thermoplastic resin molding 2 which is made of a resin with a high affinity for the resin forming the fiber-reinforced resin layered sheet 1 or the same resin as the fiber-reinforced resin layered sheet, and a thermoplastic resin layer 3 which is made of a resin with a high affinity for the resin forming the fiber-reinforced resin layered sheet 1 or the same resin as the fiber-reinforced resin layered sheet, arranged between the fiber-reinforced resin layered sheet 1 and the thermoplastic resin molding 2 and binding the fiber-reinforced resin layered sheet 1 and the thermoplastic resin molding 2 with each other.SELECTED DRAWING: Figure 1

Description

本発明は繊維強化樹脂成形体に関し、特に、熱可塑性を有する繊維強化複合材料を用いた繊維強化樹脂成形体に関する。   The present invention relates to a fiber reinforced resin molded body, and more particularly to a fiber reinforced resin molded body using a fiber reinforced composite material having thermoplasticity.

強化繊維とマトリックス樹脂とを含む繊維強化複合材料は、比強度、比弾性率が高く、力学特性に優れ、耐候性、耐薬品性などの高機能特性を有する。このことなどから、航空機や自動車の部材、建材、スポーツ用品の部材、電子・電気機器用筐体などの用途において注目され、その需要は年々高まりつつある。   A fiber reinforced composite material including a reinforced fiber and a matrix resin has high specific strength and specific elastic modulus, excellent mechanical properties, and high functional properties such as weather resistance and chemical resistance. For this reason, it has been attracting attention in applications such as aircraft and automobile parts, building materials, sports equipment parts, and casings for electronic and electrical equipment, and the demand for these parts is increasing year by year.

繊維強化樹脂成形体の筺体への適用方法としては、筺体全体を繊維強化樹脂成形体で作製する方法や、下記特許文献１〜３に記載のように繊維強化樹脂成形体と熱可塑性樹脂とを一体化する方法などが知られている。   As a method of applying the fiber reinforced resin molded body to the housing, a method of producing the entire housing with a fiber reinforced resin molded body, or a fiber reinforced resin molded body and a thermoplastic resin as described in Patent Documents 1 to 3 below. A method of integration is known.

下記特許文献１に記載の技術は、電磁波シールド特性および薄肉・軽量化を達成するための高強度・高弾性率を有する連続繊維の炭素繊維層と、ボス、リブを含む複雑な形状を薄肉流動性の良い樹脂で形成した樹脂層とを一体化することにより、従来品より軽量で優れた性能を持つ電気・電子機器用筐体とするものである。   The technology described in the following Patent Document 1 is a thin-walled flow of a complex shape including a carbon fiber layer of continuous fibers having high strength and high elastic modulus, bosses, and ribs to achieve electromagnetic shielding characteristics and thinness and weight reduction. By integrating a resin layer formed of a resin having good properties, it is a housing for electric / electronic devices that is lighter than conventional products and has superior performance.

詳細には、特許文献１には、炭素繊維織物または一方向にシート状に並べた炭素連続繊維に樹脂を含浸した材料をプレス成形した構成のＦＲＰ（Ｆｉｂｅｒ Ｒｅｉｎｆｏｒｃｅｄ Ｐｌａｓｔｉｃｓ：繊維強化樹脂）からなる第１層と、樹脂もしくは補強用短繊維を含む樹脂により射出成形、またはトランスファ成形してなる第２層とを、接着剤もしくは接着テープにより貼合せた構造が記載されている。   Specifically, Patent Document 1 discloses a fiber reinforced resin (FRP) made of a carbon fiber fabric or a continuous carbon fiber arranged in a sheet in one direction and press-molded with a material impregnated with resin. A structure in which one layer and a second layer formed by injection molding or transfer molding with a resin or a resin containing reinforcing short fibers is bonded with an adhesive or an adhesive tape is described.

特開平９−４６０８２号公報JP 9-46082 A

しかしながら、特許文献１の構成では、炭素繊維織物または一方向にシート状に並べた炭素連続繊維を補強材とするＦＲＰからなる第１層と、樹脂もしくは補強用短繊維を含む樹脂からなる第２層との間で、層間剥離や、物性的な違いによる成型後の熱収縮率の差にもとづく変形を起こし易いという課題を有している。また、炭素繊維など高価な材料を使用しており、コストが高いという課題も有している。   However, in the configuration of Patent Document 1, a first layer made of FRP using a carbon fiber woven fabric or carbon continuous fibers arranged in a sheet shape in one direction as a reinforcing material, and a second layer made of resin or resin containing reinforcing short fibers. There is a problem that deformation is easily caused between layers due to delamination and a difference in heat shrinkage rate after molding due to a difference in physical properties. Moreover, since expensive materials such as carbon fiber are used, there is a problem that the cost is high.

本発明は、このような従来の課題を解決するものであり、射出成型による部材の一体化が可能な繊維強化樹脂積層シートを使用することにより、この繊維強化樹脂積層シートと一体化されるべき熱可塑性樹脂成形体との接合部で親和性があるようにするとともに、一体化により得られる繊維強化樹脂成形体において、ソリやヒケなどの変形を生じないようにすることを目的とする。   The present invention solves such a conventional problem, and should be integrated with this fiber reinforced resin laminated sheet by using a fiber reinforced resin laminated sheet capable of integrating members by injection molding. An object is to make the joint portion with the thermoplastic resin molded body have an affinity, and to prevent deformation such as warping and sinking in a fiber reinforced resin molded body obtained by integration.

本発明の繊維強化樹脂成形体は、
繊維強化樹脂積層シートと、
前記繊維強化樹脂積層シートを構成する樹脂と親和性が高い樹脂または同一の樹脂にて構成された熱可塑性樹脂成形体と、
前記繊維強化樹脂積層シートを構成する樹脂と親和性が高い樹脂または同一の樹脂にて構成されるとともに、前記繊維強化樹脂積層シートと熱可塑性樹脂成形体との間に配置されてこれら繊維強化樹脂積層シートと熱可塑性樹脂成形体とを互いに接合させている熱可塑性樹脂層と、
を有することを特徴とする。 The fiber-reinforced resin molded article of the present invention is
A fiber reinforced resin laminated sheet;
A thermoplastic resin molded body composed of a resin having a high affinity with the resin constituting the fiber-reinforced resin laminated sheet or the same resin;
The fiber reinforced resin laminate sheet is composed of a resin having a high affinity with the resin or the same resin, and is disposed between the fiber reinforced resin laminate sheet and the thermoplastic resin molded body, and these fiber reinforced resins. A thermoplastic resin layer in which the laminated sheet and the thermoplastic resin molded body are bonded to each other;
It is characterized by having.

本発明の繊維強化樹脂成形体の製造方法は、
繊維強化樹脂成形体を製造するに際し、
繊維強化樹脂シートと、前記繊維強化樹脂シートを構成する樹脂と親和性が高い樹脂または同一の樹脂にて構成された熱可塑性樹脂成形体とを成型用の型の内部に配置し、
前記成型用の型の内部における繊維強化術シートと熱可塑性樹脂成型体との間の空間に、前記繊維強化樹脂シートを構成する樹脂と親和性が高い樹脂または同一の樹脂を供給して熱可塑性樹脂層を形成することで、
この熱可塑性樹脂層によって、前記繊維強化樹脂シートと熱可塑性樹脂成形体とを互いに接合させる、
ことを特徴とする。 The method for producing a fiber-reinforced resin molded body of the present invention is as follows.
When manufacturing a fiber reinforced resin molding,
A fiber reinforced resin sheet and a thermoplastic resin molded body composed of a resin having a high affinity with the resin constituting the fiber reinforced resin sheet or the same resin are disposed inside a mold for molding,
A resin having a high affinity with the resin constituting the fiber reinforced resin sheet or the same resin is supplied to the space between the fiber reinforced sheet and the thermoplastic resin molded body in the molding die to be thermoplastic. By forming the resin layer,
By this thermoplastic resin layer, the fiber reinforced resin sheet and the thermoplastic resin molded body are bonded to each other.
It is characterized by that.

本発明によれば、繊維強化樹脂シートを射出成形で熱可塑性樹脂成形体と良好に一体化することができる。しかも、そのときに、射出成形により形成される熱可塑性樹脂層を最小限にすることができ、成形後の繊維強化樹脂成形体の収縮量を最小限にすることが出来るため、繊維強化樹脂シートと熱可塑性樹脂層と熱可塑性樹脂成形体との境界部で発生するソリ・ヒケなどの変形を防止することができる。また、繊維強化樹脂シートと熱可塑性樹脂層と熱可塑性樹脂成形体との境界部で発生するソリ・ヒケなどの変形を防止することができることから、従来方法よりも繊維強化樹脂シートと熱可塑性樹脂層との境界部の面積を広くすることが出来き、強化繊維樹脂シートと熱可塑性樹脂成形体との接合力を大きくすることが出来る。   According to the present invention, the fiber reinforced resin sheet can be satisfactorily integrated with the thermoplastic resin molded body by injection molding. In addition, at that time, the thermoplastic resin layer formed by injection molding can be minimized, and the amount of shrinkage of the fiber reinforced resin molded body after molding can be minimized. It is possible to prevent deformation such as warpage and sink marks that occur at the boundary between the thermoplastic resin layer and the thermoplastic resin molded body. In addition, since it can prevent deformation such as warpage and sink marks occurring at the boundary between the fiber reinforced resin sheet, the thermoplastic resin layer, and the thermoplastic resin molded body, the fiber reinforced resin sheet and the thermoplastic resin are more than conventional methods. The area of the boundary with the layer can be increased, and the bonding force between the reinforcing fiber resin sheet and the thermoplastic resin molded body can be increased.

本発明の実施の形態１における繊維強化樹脂成形体の一構成例の主要部を示す側断面図Side sectional view which shows the principal part of the example of 1 structure of the fiber reinforced resin molding in Embodiment 1 of this invention 本発明の実施の形態１における繊維強化樹脂成形体の成形装置の一構成例の主要部を示す側断面図Side sectional view which shows the principal part of one structural example of the shaping | molding apparatus of the fiber reinforced resin molded object in Embodiment 1 of this invention 本発明の実施の形態１における繊維強化樹脂成形体を構成する繊維強化樹脂積層シートと熱可塑性樹脂成形体との断面図Sectional drawing of the fiber reinforced resin laminated sheet which comprises the fiber reinforced resin molded object in Embodiment 1 of this invention, and a thermoplastic resin molded object 本発明の実施の形態１における繊維強化樹脂成形体の成形装置の一構成例に繊維強化樹脂積層シートと熱可塑性樹脂成形体とを配置した時の主要部側断面図Main part side sectional drawing when the fiber reinforced resin lamination sheet and the thermoplastic resin molding are arrange | positioned to one structural example of the shaping | molding apparatus of the fiber reinforced resin molding in Embodiment 1 of this invention. 本発明の実施の形態１における繊維強化樹脂成形体の成形装置の一構成例について型締めをした時の主要部の側断面図Side sectional view of the main part when the mold is clamped for one configuration example of the molding apparatus for the fiber-reinforced resin molded body according to Embodiment 1 of the present invention. 本発明の実施の形態１における繊維強化樹脂成形体の一構成例の部分拡大断面図The partial expanded sectional view of the example of 1 composition of the fiber reinforced resin fabrication object in Embodiment 1 of the present invention. 本発明の実施の形態２における繊維強化樹脂成形体の一構成例の主要部を示す側断面図Side sectional view which shows the principal part of the example of 1 structure of the fiber reinforced resin molding in Embodiment 2 of this invention 本発明の実施の形態３における繊維強化樹脂成形体の一構成例の主要部を示す側断面図Side sectional view which shows the principal part of the example of 1 structure of the fiber reinforced resin molding in Embodiment 3 of this invention

以下、本発明の実施の形態について、図面を参照しながら説明する。但し、同じ構成要素には同じ符号を付して、重複する説明を省略する場合もある。また、図面は、理解し易くするために、それぞれの構成要素を主体に模式的に示す。また、図示された各構成要素の厚み、長さ等は図面作成の都合上から、実際とは異なる。なお、以下の実施の形態で示す各構成要素の形状や寸法等は一例であって特に限定されるものではなく、本発明の効果から実質的に逸脱しない範囲で種々の変更が可能である。   Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the same components may be denoted by the same reference numerals, and redundant description may be omitted. Further, the drawings schematically show the respective constituent elements mainly for easy understanding. In addition, the thickness, length, and the like of each illustrated component are different from the actual one for the convenience of drawing. In addition, the shape, dimension, etc. of each component shown by the following embodiment are examples, and are not specifically limited, A various change is possible in the range which does not deviate substantially from the effect of this invention.

（実施の形態１）
図１は本発明の実施の形態１の繊維強化樹脂成形体の一構成例の主要部を示す側断面図である。図１に示される繊維強化樹脂成形体の主要部は、繊維強化樹脂シートとしての繊維強化樹脂積層シート１と、熱可塑性樹脂成形体２とを、熱可塑性樹脂層３にて接合した構成である。繊維強化樹脂積層シート１は、ポリプロピレンを主成分とする樹脂シート１ａと、芯鞘複合繊維を含む糸で構成されている織物層１ｂとを含む。織物層１ｂを構成する芯鞘複合繊維は、芯成分がポリプロピレンにて構成され、マトリックス樹脂である鞘成分が前記芯成分より低融点のポリオレフィン成分にて構成されている。樹脂シート１ａと織物層１ｂとは、それぞれ適当数を積層することができる。図示の例では、樹脂シート１ａと織物層１ｂとが交互に２層ずつ積層されている。 (Embodiment 1)
FIG. 1 is a side sectional view showing a main part of one structural example of the fiber-reinforced resin molded body according to Embodiment 1 of the present invention. The main part of the fiber reinforced resin molded body shown in FIG. 1 has a configuration in which a fiber reinforced resin laminated sheet 1 as a fiber reinforced resin sheet and a thermoplastic resin molded body 2 are joined by a thermoplastic resin layer 3. . The fiber reinforced resin laminated sheet 1 includes a resin sheet 1a mainly composed of polypropylene and a woven fabric layer 1b composed of yarns including core / sheath composite fibers. In the core-sheath composite fiber constituting the woven fabric layer 1b, the core component is composed of polypropylene, and the sheath component, which is a matrix resin, is composed of a polyolefin component having a melting point lower than that of the core component. An appropriate number of resin sheets 1a and fabric layers 1b can be laminated. In the illustrated example, the resin sheets 1a and the fabric layers 1b are alternately laminated in two layers.

上記から明らかなように、また図示されているように、熱可塑性樹脂層３は、繊維強化樹脂積層シート１と熱可塑性樹脂成形体２との間に挟まれた形で設けられている。繊維強化樹脂積層シート１において、熱可塑性樹脂層３に接する面は、織物層１ｂによって構成されている。   As apparent from the above and as shown in the figure, the thermoplastic resin layer 3 is provided between the fiber reinforced resin laminated sheet 1 and the thermoplastic resin molded body 2. In the fiber reinforced resin laminated sheet 1, the surface in contact with the thermoplastic resin layer 3 is constituted by the fabric layer 1b.

熱可塑性樹脂成形体２および熱可塑性樹脂層３は、いずれも、繊維強化樹脂積層シート１を構成するポリプロピレンおよび、または低融点のポリオレフィン成分と親和性が高い樹脂または同一の樹脂にて構成されている。また、熱可塑性樹脂層３と繊維強化樹脂積層シート１との境界部４は、熱可塑性樹脂層３と熱可塑性樹脂成形体２との境界部５よりも大きな面積で形成されている。   Each of the thermoplastic resin molded body 2 and the thermoplastic resin layer 3 is made of a resin having a high affinity with the polypropylene constituting the fiber-reinforced resin laminated sheet 1 and / or a polyolefin component having a low melting point, or the same resin. Yes. Further, the boundary portion 4 between the thermoplastic resin layer 3 and the fiber reinforced resin laminated sheet 1 is formed with a larger area than the boundary portion 5 between the thermoplastic resin layer 3 and the thermoplastic resin molded body 2.

ここで、「親和性が高い樹脂」とは、互いにつながりやすい樹脂すなわち互いに密着しやすい樹脂であると定義される。詳細には、ポリオレフィン系樹脂、ポリエステル系樹脂、スチレン系樹脂などが、「親和性が高い樹脂」に該当する。より詳細には、上述のように繊維強化樹脂積層シート１の樹脂シート１ａがポリプロピレンを主成分とする場合には、ポリプロピレン、低密度ポリエチレン、ポリエステルなどの樹脂が「親和性が高い樹脂」に該当する。   Here, the “resin having high affinity” is defined as a resin that is easily connected to each other, that is, a resin that is easily adhered to each other. Specifically, polyolefin resins, polyester resins, styrene resins, and the like correspond to “high affinity resins”. More specifically, when the resin sheet 1a of the fiber reinforced resin laminated sheet 1 is mainly composed of polypropylene as described above, resins such as polypropylene, low density polyethylene, and polyester correspond to “resins with high affinity”. To do.

図２は、本発明の実施の形態１の繊維強化樹脂成形体のための成形装置の一構成例の主要部を示す側断面図である。図２において、固定側金型１０は凹状のキャビティ形成面１０ａを有し、可動側金型１１は凹状のキャビティ形成面１１ａおよび１１ｂを有する。可動側金型１１の凹状のキャビティ形成面１１ａおよび１１ｂは、固定側金型１０の凹状のキャビティ形成面１０ａと共に、成形品を成形するための成形空間を形成する。可動側金型１１は、キャビティ形成面１１ｂにて構成される成形空間に連通するゲート１１ｃを備える。   FIG. 2 is a side sectional view showing a main part of one configuration example of the molding apparatus for the fiber-reinforced resin molded body according to Embodiment 1 of the present invention. In FIG. 2, the fixed mold 10 has a concave cavity forming surface 10a, and the movable mold 11 has concave cavity forming surfaces 11a and 11b. The concave cavity forming surfaces 11a and 11b of the movable mold 11 and the concave cavity forming surface 10a of the fixed mold 10 form a molding space for molding a molded product. The movable mold 11 includes a gate 11c that communicates with a molding space formed by the cavity forming surface 11b.

図３は、本発明の実施の形態１における繊維強化樹脂成形体を構成するための繊維強化樹脂積層シート１と熱可塑性樹脂成形体２の断面図を示す。繊維強化樹脂積層シート１はシートそのままの平面状態のものであるか、またはシートに予め予備成形を行って所望の形状に変形させたものである。熱可塑性樹脂成形体２は、予め別途成形された、リブ・ボス等の形状を有する成形体である。   FIG. 3 shows a cross-sectional view of the fiber reinforced resin laminate sheet 1 and the thermoplastic resin molded body 2 for constituting the fiber reinforced resin molded body in Embodiment 1 of the present invention. The fiber reinforced resin laminated sheet 1 is a flat sheet as it is, or is preliminarily formed on a sheet and deformed into a desired shape. The thermoplastic resin molded body 2 is a molded body having a shape such as a rib and a boss that is separately molded in advance.

図４は、図２に示される成形装置に繊維強化樹脂積層シート１と熱可塑性樹脂成形体２とを配置したときの様子を示す。詳細には、固定側金型１０のキャビティ形成面１０ａにて形成される成形空間には繊維強化樹脂積層シート１を配置し、可動側金型１１のキャビティ形成面１１ａにて形成される成形空間には熱可塑性樹脂成形体２を配置する。   FIG. 4 shows a state where the fiber reinforced resin laminated sheet 1 and the thermoplastic resin molded body 2 are arranged in the molding apparatus shown in FIG. Specifically, the fiber reinforced resin laminated sheet 1 is disposed in the molding space formed by the cavity forming surface 10 a of the fixed mold 10, and the molding space formed by the cavity forming surface 11 a of the movable mold 11. The thermoplastic resin molded body 2 is disposed in the case.

図５は、図４の状態から次に成形装置の型締めを行ったときの様子を示す。このとき、可動側金型１１のキャビティ形成面１１ｂにて形成される成形空間が、密閉された空間として存在する。すなわち、この成形空間は、固定側金型１０に配置された繊維強化樹脂積層シート１と、可動側金型１１に配置された熱可塑性樹脂成形体２と、キャビティ形成面１１ｂとによって形成された空間である。   FIG. 5 shows a state when the mold is clamped next from the state of FIG. At this time, the molding space formed by the cavity forming surface 11b of the movable mold 11 exists as a sealed space. That is, this molding space was formed by the fiber reinforced resin laminated sheet 1 arranged in the fixed mold 10, the thermoplastic resin molded article 2 arranged in the movable mold 11, and the cavity forming surface 11 b. It is space.

そして、この成形空間へ、繊維強化樹脂積層シート１のポリプロピレンまたは低融点のポリオレフィン成分と親和性が高い樹脂または同一の樹脂をゲート１１ｃから射出成形することにより、図１に示される熱可塑性樹脂層３を形成する。熱可塑性樹脂層３が形成される際に、図１に示される熱可塑性樹脂層３と繊維強化樹脂積層シート１との境界部４では、熱可塑性樹脂層３を構成する樹脂が、繊維強化樹脂積層シート１のポリプロピレンおよび、または低融点のポリオレフィン成分と親和性の高い樹脂または同一の樹脂であるため、相互の樹脂が溶融して、熱可塑性樹脂層３の樹脂が、繊維強化樹脂積層シート１においてこの熱可塑性樹脂層３に接している織物層１ｂの中に入り込んだ状態で、境界部４を形成する。   And the thermoplastic resin layer shown in FIG. 1 is injection-molded from the gate 11c into the molding space by resin or the same resin having high affinity with the polypropylene or low melting point polyolefin component of the fiber reinforced resin laminated sheet 1 3 is formed. When the thermoplastic resin layer 3 is formed, at the boundary part 4 between the thermoplastic resin layer 3 and the fiber reinforced resin laminated sheet 1 shown in FIG. 1, the resin constituting the thermoplastic resin layer 3 is a fiber reinforced resin. Since the resin of the laminated sheet 1 is a resin having a high affinity with the polypropylene component and / or the low melting point polyolefin component or the same resin, the mutual resin is melted and the resin of the thermoplastic resin layer 3 becomes the fiber reinforced resin laminated sheet 1. The boundary portion 4 is formed in a state of entering the fabric layer 1b in contact with the thermoplastic resin layer 3 in FIG.

図６は、熱可塑性樹脂層３によって繊維強化樹脂積層シート１と熱可塑性樹脂成形体２とが一体化された状態を示す。繊維強化樹脂積層シート１の織物層１ｂは芯鞘複合繊維を含む糸６で構成されているが、芯鞘複合繊維における芯成分よりも低融点の鞘成分が熱処理を受けて溶融固化することで、マトリックス樹脂７が形成されている。図示のように、熱可塑性樹脂層３と繊維強化樹脂積層シート１との境界部４では、熱可塑性樹脂層３を構成する樹脂の一部が繊維強化樹脂積層シート１の織物層１ｂの中に入り込んでいる。これによって、境界部４は凸凹形状になっている。   FIG. 6 shows a state in which the fiber reinforced resin laminated sheet 1 and the thermoplastic resin molded body 2 are integrated by the thermoplastic resin layer 3. The woven fabric layer 1b of the fiber reinforced resin laminated sheet 1 is composed of the yarn 6 including the core-sheath composite fiber, but the sheath component having a melting point lower than that of the core component in the core-sheath composite fiber is subjected to heat treatment to be melted and solidified. A matrix resin 7 is formed. As shown in the drawing, at the boundary portion 4 between the thermoplastic resin layer 3 and the fiber reinforced resin laminated sheet 1, a part of the resin constituting the thermoplastic resin layer 3 is in the fabric layer 1 b of the fiber reinforced resin laminated sheet 1. It has entered. Thereby, the boundary part 4 is uneven.

熱可塑性樹脂層３と熱可塑性樹脂成形体２とは、上述のように、いずれも、繊維強化樹脂積層シート１を構成するポリプロピレンおよび、または低融点のポリオレフィン成分と親和性が高い樹脂または同一の樹脂にて構成されている。すなわち互いに接合性の良好な樹脂にて構成されている。このため、熱可塑性樹脂成形体２と射出成形された熱可塑性樹脂層３との境界部５は、良好な接着状態が達成されている。   As described above, the thermoplastic resin layer 3 and the thermoplastic resin molded body 2 are both resins having the same affinity as the polypropylene constituting the fiber-reinforced resin laminated sheet 1 and / or the low melting point polyolefin component or the same resin. It is made of resin. That is, they are composed of resins having good bonding properties. For this reason, a favorable adhesion state is achieved at the boundary portion 5 between the thermoplastic resin molded body 2 and the injection-molded thermoplastic resin layer 3.

以上によれば、繊維強化樹脂積層シート１を射出成形で熱可塑性樹脂成形体２と一体化する方法において、射出成形により注入する熱可塑性樹脂層３の樹脂量を従来よりも少なく、最小限にすることができ、したがって成形後の繊維強化樹脂成形体の収縮量を最小限にすることができる。このため、繊維強化樹脂積層シート１と熱可塑性樹脂層３と熱可塑性樹脂成形体２との境界部４、５で発生するソリ・ヒケなどの変形を防止することができる。また、繊維強化樹脂積層シート１と熱可塑性樹脂層３と熱可塑性樹脂成形体２との境界部４、５で発生するソリ・ヒケなどの変形を防止することができることから、従来方法よりも強化繊維樹脂シート１と熱可塑性樹脂層３との境界部４の面積を広くすることができ、このため繊維強化樹脂積層シート１と熱可塑性樹脂成形体２との接合力を大きくすることができる。   According to the above, in the method of integrating the fiber reinforced resin laminated sheet 1 with the thermoplastic resin molded body 2 by injection molding, the amount of the thermoplastic resin layer 3 to be injected by injection molding is smaller than before and minimized. Therefore, the shrinkage amount of the fiber-reinforced resin molded body after molding can be minimized. For this reason, it is possible to prevent deformation such as warpage and sink marks generated at the boundary portions 4 and 5 of the fiber reinforced resin laminated sheet 1, the thermoplastic resin layer 3, and the thermoplastic resin molded body 2. In addition, since deformation such as warpage and sink marks occurring at the boundary portions 4 and 5 of the fiber reinforced resin laminated sheet 1, the thermoplastic resin layer 3, and the thermoplastic resin molded body 2 can be prevented, it is stronger than the conventional method. The area of the boundary portion 4 between the fiber resin sheet 1 and the thermoplastic resin layer 3 can be increased, and therefore, the bonding force between the fiber reinforced resin laminated sheet 1 and the thermoplastic resin molded body 2 can be increased.

また、熱可塑性樹脂層３と熱可塑性樹脂成形体２との境界部５の面積よりも熱可塑性樹脂層３と繊維強化樹脂積層シート１の境界部４の面積を大きくすることで、接合強度が大きくなる。   Further, by increasing the area of the boundary portion 4 between the thermoplastic resin layer 3 and the fiber reinforced resin laminated sheet 1 to be larger than the area of the boundary portion 5 between the thermoplastic resin layer 3 and the thermoplastic resin molded body 2, the bonding strength is increased. growing.

また、熱可塑性樹脂層３と繊維強化樹脂積層シート１との境界部４が図６に示すように凸凹形状になることで、境界部４の接合強度が大きくなる。   Moreover, when the boundary part 4 between the thermoplastic resin layer 3 and the fiber reinforced resin laminated sheet 1 has an uneven shape as shown in FIG. 6, the bonding strength of the boundary part 4 is increased.

念のために接明すると、境界部５の面積とは、熱可塑性樹脂層３と熱可塑性樹脂成形体２との接触部の面積のことであり、境界部４の面積とは、熱可塑性樹脂層３と繊維強化樹脂積層シート１との接触部の面積のことである。   As a reminder, the area of the boundary portion 5 is the area of the contact portion between the thermoplastic resin layer 3 and the thermoplastic resin molded body 2, and the area of the boundary portion 4 is the thermoplastic resin. It is the area of the contact portion between the layer 3 and the fiber-reinforced resin laminated sheet 1.

（実施の形態２）
以下、本発明の実施の形態２について、図７を参照して、前述した実施の形態１と異なる点を主に説明する。図７は、本発明の実施の形態２における繊維強化樹脂成形体の一構成例の主要部を示す側断面図である。ここでは、繊維強化樹脂積層シート１と熱可塑性樹脂成形体２とを接合する役割を果たす熱可塑性樹脂層３が、繊維強化樹脂積層シート１の端部１ｅを覆うように一体化した構成となっている。 (Embodiment 2)
In the following, the second embodiment of the present invention will be described mainly with respect to the differences from the first embodiment described above with reference to FIG. FIG. 7 is a side sectional view showing a main part of one configuration example of the fiber-reinforced resin molded body in Embodiment 2 of the present invention. Here, the thermoplastic resin layer 3 that plays the role of joining the fiber reinforced resin laminate sheet 1 and the thermoplastic resin molded body 2 is integrated so as to cover the end 1e of the fiber reinforced resin laminate sheet 1. ing.

かかる構成によれば、熱可塑性樹脂層３が、繊維強化樹脂積層シート１の端部１ｅを覆う部分においては、繊維強化樹脂積層シート１と熱可塑性樹脂層３との境界の隙間を完全になくすことができ、美観性を向上できるとともに、異物混入等の隙間があることによる不具合を解消できる。さらに、繊維強化樹脂積層シート１の端部１ｅの積層密着力を向上することができる。   According to such a configuration, in the portion where the thermoplastic resin layer 3 covers the end 1e of the fiber reinforced resin laminated sheet 1, the gap at the boundary between the fiber reinforced resin laminated sheet 1 and the thermoplastic resin layer 3 is completely eliminated. It is possible to improve the aesthetics, and to solve problems caused by the presence of a gap such as contamination of foreign matter. Furthermore, the lamination | stacking adhesive force of the edge part 1e of the fiber reinforced resin lamination sheet 1 can be improved.

（実施の形態３）
以下、本発明の実施の形態３について、図８を参照して、前述した実施の形態１と異なる点について主に説明する。図８は本発明の実施の形態３における繊維強化樹脂成形体の一構成例の主要部を示す側断面図である。ここでは、繊維強化樹脂積層シート１と熱可塑性樹脂成形体２とを接合する役割を果たす熱可塑性樹脂層３が、繊維強化樹脂積層シート１の端部１ｅを覆うとともに、この端部１ｅに連なるところの、繊維強化樹脂積層シート１における熱可塑性樹脂成形体２が配置している面とは反対側の面の少なくとも一部を覆った状態で、一体化した構成されている。 (Embodiment 3)
Hereinafter, the third embodiment of the present invention will be described mainly with respect to differences from the first embodiment described above with reference to FIG. FIG. 8 is a side sectional view showing a main part of one configuration example of the fiber-reinforced resin molded body according to Embodiment 3 of the present invention. Here, the thermoplastic resin layer 3 that plays a role of joining the fiber reinforced resin laminate sheet 1 and the thermoplastic resin molded body 2 covers the end portion 1e of the fiber reinforced resin laminate sheet 1 and continues to the end portion 1e. However, the fiber-reinforced resin laminate sheet 1 is integrated with at least a part of the surface opposite to the surface on which the thermoplastic resin molded body 2 is disposed.

かかる構成によれば、繊維強化樹脂積層シート１と熱可塑性樹脂成形体２とを接着剤等で一体化する方法では構成することができない、繊維強化樹脂積層シート１に対するアンダーカット形状も形成することができる。   According to such a configuration, an undercut shape for the fiber reinforced resin laminated sheet 1 that cannot be formed by a method of integrating the fiber reinforced resin laminated sheet 1 and the thermoplastic resin molded body 2 with an adhesive or the like is also formed. Can do.

なお、以上説明した実施の形態１から３は、適宜組み合わせることが可能である。   The first to third embodiments described above can be combined as appropriate.

本発明にかかる熱可塑性樹脂成形体は、細かく複雑な形状を有していたり、高い剛性を有していたりするボス・リブ形状を一体で形成することができる。このため、軽量・薄型・高剛性が必要とされる様々な成形品に有用である。   The thermoplastic resin molded body according to the present invention can integrally form a boss / rib shape having a fine and complicated shape or a high rigidity. For this reason, it is useful for various molded products that require light weight, thinness, and high rigidity.

１ 繊維強化樹脂積層シート（繊維強化樹脂シート）
１ａ ポリプロピレンを主成分とする樹脂シート
１ｂ 織物層
１ｅ 端部
２ 熱可塑性樹脂成形体
３ 熱可塑性樹脂層
４ 境界部
５ 境界部
６ 芯鞘複合繊維
７ マトリックス樹脂
１０ 可動側金型
１０ａ キャビティ形成面
１１ 固定側金型
１１ａ キャビティ形成面
１１ｂ キャビティ形成面 1 Fiber reinforced resin laminate sheet (fiber reinforced resin sheet)
DESCRIPTION OF SYMBOLS 1a Resin sheet | seat which has a polypropylene as a main component 1b Textile layer 1e End part 2 Thermoplastic resin molding 3 Thermoplastic resin layer 4 Boundary part 5 Boundary part 6 Core-sheath composite fiber 7 Matrix resin 10 Movable side mold 10a Cavity formation surface 11 Fixed side mold 11a Cavity forming surface 11b Cavity forming surface

Claims (7)

繊維強化樹脂成形体であって、
繊維強化樹脂シートと、
前記繊維強化樹脂シートを構成する樹脂と親和性が高い樹脂または同一の樹脂にて構成された熱可塑性樹脂成形体と、
前記繊維強化樹脂シートを構成する樹脂と親和性が高い樹脂または同一の樹脂にて構成されるとともに、前記繊維強化樹脂シートと熱可塑性樹脂成形体との間に配置されてこれら繊維強化樹脂シートと熱可塑性樹脂成形体とを互いに接合させている熱可塑性樹脂層と、
を有することを特徴とする繊維強化樹脂成形体。 A fiber reinforced resin molded article,
A fiber reinforced resin sheet;
A thermoplastic resin molded body composed of a resin having a high affinity with the resin constituting the fiber-reinforced resin sheet or the same resin;
The fiber reinforced resin sheet is composed of a resin having high affinity with the resin constituting the fiber reinforced resin sheet or the same resin, and is disposed between the fiber reinforced resin sheet and the thermoplastic resin molded body. A thermoplastic resin layer that joins the thermoplastic resin molded body to each other;
A fiber-reinforced resin molded article characterized by comprising: 繊維強化樹脂シートと熱可塑性樹脂層との間の第１の境界部と、熱可塑性樹脂層と熱可塑性樹脂成形体との間の第２の境界部とは、いずれも、境界部を構成する相互の樹脂どうしが溶融一体化していることを特徴とする請求項１記載の繊維強化樹脂成形体。   The first boundary portion between the fiber reinforced resin sheet and the thermoplastic resin layer and the second boundary portion between the thermoplastic resin layer and the thermoplastic resin molded body each constitute a boundary portion. 2. The fiber-reinforced resin molded article according to claim 1, wherein the mutual resins are fused and integrated. 繊維強化樹脂シートと熱可塑性樹脂層との間の第１の境界部の面積が、熱可塑性樹脂層と熱可塑性樹脂成形体との間の第２の境界部の面積より大きいことを特徴とする請求項１または２記載の繊維強化樹脂成形体。   The area of the first boundary part between the fiber reinforced resin sheet and the thermoplastic resin layer is larger than the area of the second boundary part between the thermoplastic resin layer and the thermoplastic resin molded body. The fiber-reinforced resin molded product according to claim 1 or 2. 繊維強化樹脂シートの端面が熱可塑性樹脂層にて覆われていることを特徴とする請求項１から３までのいずれか１項記載の繊維強化樹脂成形体。   The fiber reinforced resin molded article according to any one of claims 1 to 3, wherein an end face of the fiber reinforced resin sheet is covered with a thermoplastic resin layer. 繊維強化樹脂シートの端面と、繊維強化樹脂シートにおける熱可塑性樹脂層が接合されている面とは反対側の面の少なくとも一部とが、熱可塑性樹脂層にて覆われていることを特徴とする請求項１から４までのいずれか１項記載の繊維強化樹脂成形体。   The end surface of the fiber reinforced resin sheet and at least a part of the surface of the fiber reinforced resin sheet opposite to the surface to which the thermoplastic resin layer is bonded are covered with the thermoplastic resin layer. The fiber-reinforced resin molded article according to any one of claims 1 to 4. 繊維強化樹脂シートはマトリックス樹脂と強化繊維とを含み、前記マトリックス樹脂は強化繊維よりも融点が低いことを特徴とする請求項１から５までのいずれか１項記載の繊維強化樹脂成形体。   The fiber reinforced resin sheet according to any one of claims 1 to 5, wherein the fiber reinforced resin sheet includes a matrix resin and a reinforced fiber, and the matrix resin has a melting point lower than that of the reinforced fiber. 繊維強化樹脂成形体を製造するに際し、
繊維強化樹脂シートと、前記繊維強化樹脂シートを構成する樹脂と親和性が高い樹脂または同一の樹脂にて構成された熱可塑性樹脂成形体とを成型用の型の内部に配置し、
前記成型用の型の内部における繊維強化術シートと熱可塑性樹脂成型体との間の空間に、前記繊維強化樹脂シートを構成する樹脂と親和性が高い樹脂または同一の樹脂を供給して熱可塑性樹脂層を形成することで、
この熱可塑性樹脂層によって、前記繊維強化樹脂シートと熱可塑性樹脂成形体とを互いに接合させる、
ことを特徴とする繊維強化樹脂成形体の製造方法。 When manufacturing a fiber reinforced resin molding,
A fiber reinforced resin sheet and a thermoplastic resin molded body composed of a resin having a high affinity with the resin constituting the fiber reinforced resin sheet or the same resin are disposed inside a mold for molding,
A resin having a high affinity with the resin constituting the fiber reinforced resin sheet or the same resin is supplied to the space between the fiber reinforced sheet and the thermoplastic resin molded body in the molding die to be thermoplastic. By forming the resin layer,
By this thermoplastic resin layer, the fiber reinforced resin sheet and the thermoplastic resin molded body are bonded to each other.
The manufacturing method of the fiber reinforced resin molding characterized by the above-mentioned.
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