JP2020028984A - Ud-like closed fiber-reinforced composite molded product by filament winding (fw) method and method for producing the same - Google Patents

Abstract

To provide an UD-like closed fiber-reinforced composite molded product by a filament winding (FW) method and a method for producing the same.SOLUTION: The present invention provides a closed molded product, and a method for producing the same, the closed molded product including a plurality of continuous long reinforcing fibers continuously and unidirectionally oriented in the circumferential direction in the solidified thermoplastic resin matrix; in the closed molded product, a width (b) in the P axial direction and a converted diameter (D) satisfy the relationship of b<D, when configuring as an annular molded product centered on the P axis direction; and the closed molded product including oblique continuous long reinforcing fibers for reinforcement swaying in the width (b) direction, oriented in the one-direction, traversing the continuous long reinforcing fibers over a circumferential development length (L)=3.14D.SELECTED DRAWING: Figure 7

Description

  The present invention includes a plurality of continuous long reinforcing fibers continuously and circumferentially oriented in one direction (hereinafter, also referred to as “UD-like” and “unidirectional”) in a solidified thermoplastic resin matrix. Related to closed moldings. More specifically, the present invention relates to a UD-like closed fiber-reinforced composite molded article by a filament winding (FW) method, and a method for producing the same.

  As a method of molding a resin-based composite material that is currently in practical use for the purpose of weight reduction as a metal substitute material, whether the resin used as the base matrix is a thermoplastic resin or a thermosetting resin, the volume of the reinforcing material It can be roughly categorized as to whether the content exceeds 50% and whether the reinforcement is spun continuous filaments, chopped strands or woven fabrics.

  As a reinforcing material using continuous filaments, one to several tens of rovings that have been combined are aligned, and a mandrel (mold) is mainly impregnated with a matrix that is a thermosetting resin such as epoxy or polyester. Filament winding (FW, Filament) which is a molding method of applying a tension to a predetermined thickness, winding it at a predetermined angle, heating and curing in a heating oven or the like, and removing it from the mold or integrating with a resin or metal hollow liner / inner Winding) method is known (for the outline of the FW method, see FIG. 2). In the FW method, since the volume content of the reinforcing material is high and the reinforcing fibers are substantially oriented in the circumferential direction, the strength of the reinforcing fibers is effectively used in the FRP molding method, and the pipe, It is used for manufacturing pressure vessels, fishing rods, golf club shafts, etc., but there is no example of using a thermoplastic resin by the FW method. It is known that a roving impregnated with a thermosetting resin is wound around a metal plate by a FW method at a predetermined angle, then heated and cured, and the end is cut into a flat plate. It is not used for producing a closed fiber-reinforced composite molded article using a resin.

  Injection molding using a thermoplastic resin as a matrix, and stamping sheet molding, as well as SMC molding, BMC molding, and spray molding using a thermosetting resin, include those using a chopped strand as a reinforcing material. Are known. However, those manufactured by these molding methods cannot effectively express the strength of the reinforcing fibers because the volume content of the reinforcing material is low and the chopped strands as the reinforcing fibers are randomly oriented.

  Molding obtained by press molding using, for example, a thermoplastic resin fiber or a thermoplastic resin film as a matrix resin, or hybrid (press + injection composite) molding, using a woven fabric in which continuous long reinforcing fibers are oriented in the process as a reinforcing material. The product (textile composite) has a higher volume fraction of the reinforcing fiber, tensile strength, flexural strength, flexural modulus, and maximum impact energy compared to the injection molded product obtained using short fibers of randomly oriented reinforcing fibers. Since (high-speed surface impact) is high, it is expected to be applied as a high-strength, high-rigidity reinforcing material to, for example, skeletal members, seat members, and shock absorbing members of aircraft, railway vehicles, automobiles, and the like.

Under such circumstances, Patent Literature 1 below considers the following matters.
Sheets (prepregs) impregnated with thermoplastic resin in woven fabrics such as carbon fiber and glass fiber are hard plates at room temperature, so it is difficult to laminate and mold them along a complex-shaped mold. A prepreg made of is soft and sticky, so molding is easy, but there is a problem in productivity;
If it is a mixed woven fabric made by processing thermoplastic resin into fibers and woven together with reinforcing fibers such as carbon fiber and glass fiber, it is a woven fabric, so it is rich in flexibility and can be processed into complex shapes and reinforced Since both the fiber and the resin are entangled in the state of the fiber, when the material is heated and melted to form a composite material, the mixing of the fiber and the resin becomes uniform. However, in the case of forming a mixed woven fabric, handling is difficult due to the softness of the material, and there are still difficulties in performing stable high cycle production;
On the other hand, in the field of metal forming, various high cycle forming techniques have been established over a long history, and among them, sheet metal press forming (a kind of compression forming) mainly based on drawing is the most common. This is one of the high cycle molding methods. In the field of resin-based composite materials, if a sheet (prepreg) impregnated with a thermoplastic resin in a woven fabric of carbon fiber, glass fiber, etc. can be used as the primary material, the most productive molding method, as with metal molding Therefore, a sheet obtained by impregnating a thermoplastic resin with a woven fiber having regularity and having coagulation and coagulation may be used as a material to be molded;
However, when a woven material is formed into a sheet, that is, when subjected to combination processing such as compression processing and drawing processing, deformation due to fiber elongation, fiber shape elongation, shear slip, and lattice effect occurs. , See FIGS. 1 (a)-(d));
The elongation of the fiber itself is the elongation deformation of the fiber itself due to the action of tensile force during molding. The maximum strain is about 5% or less (for example, about 5% for glass fiber and about 2% for carbon fiber). The effect of the fiber shape is small, and the elongation of the fiber shape is a deformation caused by the loosening of the warp and weft yarns during the weaving of the fiber during molding. At this time, these slacks are controlled to be as small as possible, and the influence on the overall deformation is small.In addition, the shear slip occurs at a point where sudden deformation occurs such as a corner, but the deformation due to the lattice effect Is similar to the shear strain of metal, during deformation, the fiber does not stretch but only changes the orientation direction, a relatively small force can obtain a large deformation, and in the molding of woven material, Deformation Most of the band is that it is caused by deformation due to the lattice effect;
Therefore, in order to obtain good properties without local buckling of the sheet during sheet forming, it is necessary to control so that the lattice deformation angle of the woven fabric does not exceed a certain angle during the forming, which is solved. As a technical means for doing so, in the frame part which clamps the sheet during molding, the necessary portion of the sheet is restrained by projecting fiber restraining pins so that the lattice deformation angle of the sheet does not become a certain angle or more during molding. When the molded product is taken out at the end of molding, the fiber restraining pin is automatically returned to the original position, so that the sheet is not wrinkled and the thermoplastic resin high-performance fiber reinforced composite material can be continuously molded. To provide a sheet fiber flow control method and apparatus.

  On the other hand, U.S. Pat. No. 5,049,086 discloses a load bearing element in which unidirectional (UD, Uni Direction) fibers are continuously and uniformly oriented in a unidirectional manner, for example, in an aerospace vehicle. A composite structure is disclosed in which the surface of a portion to be attached to a support is over-molded with a connecting element including discontinuous fibers that are randomly oriented in a resin matrix and that have been cut. The connection elements of such a composite material structure are unlikely to be affected by delamination due to machining and are easy to machine, unlike the load-bearing elements that are position-oriented fiber composites. It is said that a very strong connection between the two is possible. In US Pat. No. 5,077,097, the load-bearing element is made from unidirectional fibers, which can be in the form of prepreg tows or tapes, and dry UD fibers that are impregnated with resin during formation of the load-bearing element. However, the orientation of the reinforcing fibers in one direction may be determined by a UD tape (HexPly (registered trademark)) (carbon fiber / thermoplastic reinforced epoxy) which is a unidirectional prepreg tape of carbon fibers. They are merely examples. That is, Patent Document 2 uses a UD tape in which UD fibers are arranged in advance in order to orient the reinforcing fibers in one direction during press molding. However, when trying to obtain a narrow band-shaped molded product using a UD tape having a width of about several mm to 10 mm, it is not possible to cross the reinforcing fibers diagonally and to reinforce the reinforcing fibers in the width direction. There is.

Japanese Patent No. 2771692 Japanese Patent No. 6154002

  In view of the above prior art, the problem to be solved by the present invention is to provide a UD-like closed fiber-reinforced composite molded article by a filament winding (FW) method, and a method for producing the same.

  In order to solve the above-mentioned problems, the present inventors have conducted intensive studies and repeated experiments, and as a result, obtained a wrapped body of continuous long reinforcing fibers by a FW method in a molded product in which a circumferentially wrapped length is to be obtained. It has been found that a UD-like closed fiber-reinforced composite molded body reinforced in the width direction can be manufactured by preparing in advance and press-molding it to be substantially equal to the length, to complete the present invention. It has been reached.

That is, the present invention is as follows.
[1] A closed molded body containing a plurality of continuous long reinforcing fibers continuously and unidirectionally oriented in a circumferential direction in a solidified thermoplastic resin matrix, which is an annular molded body centered on a P-axis direction. At this time, the width (b) in the P-axis direction and the reduced diameter (D) satisfy the relationship of b <D, and the molded body extends over a circumferential development length (L) = 3.14D, The said closed molded object containing the continuous continuous reinforcing fiber which is inclined in the width (b) direction, and crosses the continuous continuous fiber oriented in the one direction.
[2] The closed molded article according to [1], wherein the continuous long reinforcing fiber is selected from the group consisting of glass fiber, carbon fiber, and aramid fiber.
[3] The closed molded article according to [1] or [2], wherein the thermoplastic resin is selected from the group consisting of polyamide and polypropylene.
[4] The closed molded body according to any one of [1] to [3], in a cross section orthogonal to the P axis, in a ring, polygon, cross, star, or rod shape. Closed compact.
[5] The closed molded article according to the above [4], which is a reinforcing insert for a piping system flange.
[6] The closed molded article according to the above [4], which is a structural reinforcing material for a Rono-shaped closed cross section of an automobile body.
[7] A composite structure having a composite structure of the closed molded article and the injection molded article according to any one of [1] to [4].
[8] The following steps:
Continuous reinforcement selected from the group consisting of thermoplastic resin coated yarns coated with thermoplastic resin around multifilament continuous length reinforcing fibers and mixed yarns of multifilament continuous length reinforcing fibers and multifilament yarns of the same thermoplastic resin A winding body preparing step of preparing one or more winding bodies of fibers;
The rotation axis at the center thereof, a winding member having a plurality of threading portions symmetrically arranged at an equal distance in the radial direction from the center, or a mold having a concave portion symmetric with respect to the rotation axis, The reinforcing fiber from the wound body is wound at 0 to 18 degrees with respect to the direction perpendicular to the rotation axis so that the winding length in the circumferential direction is substantially equal to the length in the molded product to be obtained. A winding / orienting step of winding in one direction by rotating the rotating shaft;
When wound around the winding member, the wound reinforcing fiber is transferred from the winding member to a press molding die, or when wound around a die having the concave portion, the die Transporting the wound reinforcing fiber together with the wound body;
The transferred wound body is press-molded at a predetermined temperature and pressure, and the thermoplastic resin is heated, melted, and cooled to be solidified, so that it is continuously oriented in one direction in the circumferential direction in the solidified thermoplastic resin matrix. Press forming step of obtaining a closed molded body containing a plurality of continuous continuous reinforcing fibers;
If necessary, the obtained molded body is further subjected to a bending process by heating and softening to form a closed molded body having a desired shape;
The method for producing a closed molded article according to any one of the above [1] to [4], comprising:
[9] The method according to [8], wherein the plurality of threading portions of the winding member are arranged in a triangular shape.
[10] The method according to [8], wherein the mold having a concave portion symmetrical with respect to the rotation axis has a triangular-octagonal concave portion in a cross section orthogonal to the rotation axis.
[11] The thermoplastic resin coating yarn in which the periphery of the multifilament continuous long reinforcing fiber is coated with a thermoplastic resin is composed of two layers, and the melting point T1 of the outer thermoplastic resin is higher than the inner heat. The method according to any one of [8] to [10], wherein press molding is performed at a temperature of at least 10 ° C. higher than the melting point T2 of the plastic resin and at most T1 + 10 ° C.
[12] The thermoplastic resin coated yarn in which the periphery of the multifilament continuous length reinforcing fiber is coated with the thermoplastic resin is composed of two layers, and the melting point T1 of the outer thermoplastic resin is higher than the inner heat. After press forming at a temperature of at least 10 ° C. higher than the melting point T2 of the thermoplastic resin and at a temperature of at least T2 + 5 ° C. and at most T1-5 ° C. to melt the thermoplastic resin inside, a temperature of at least T2 + 10 ° C. and at most T1 + 10 ° C. The method according to any one of [8] to [11], wherein the method is press-formed.
[13] The thermoplastic resin coating yarn in which the periphery of the multifilament continuous long reinforcing fiber is coated with the thermoplastic resin is composed of two layers, and the melting point T1 of the outer thermoplastic resin is higher than that of the inner heat. Press molding at a temperature of at least 10 ° C. higher than the melting point T2 of the thermoplastic resin and at a temperature of T2 + 5 ° C. or more and T1-5 ° C. or less, and after melting the inner thermoplastic resin, press molding at a temperature of T2 + 15 ° C. or more. The method according to any one of [8] to [12], further comprising the step of discharging the inner thermoplastic resin and / or the outer thermoplastic resin out of the mold to adjust Vf.
[14] The closed molded article according to the above [7], including a step of inserting the closed molded article according to any of the above [1] to [4] into an injection mold and performing injection molding. A method for producing a composite structure having a composite structure of a resin and an injection molded body.

In the solidified thermoplastic resin matrix according to the present invention, a closed molded body including a plurality of continuous length reinforcing fibers continuously and circumferentially oriented in one direction is a plurality of continuous length reinforcing fibers literally continuous in the circumferential direction. Since it is oriented in a UD-like manner, it is reinforced in the radial direction and in the circumferential direction. Further, even when the molded body according to the present invention is an annular molded body having a narrow width as shown in FIG. 5, the molded body is swung in the width direction over the developed length in the circumferential direction and is oriented in the one direction. Since it includes diagonally continuous continuous reinforcing fibers obliquely crossing the continuous reinforcing fibers, the reinforcing fibers are also reinforced in the width direction.
Further, in the method for producing a molded article according to the present invention, by adopting the FW method, not a woven fabric, but a length substantially equal to the length in the molded article to be obtained, and uniformly oriented in one direction. Since a wound body of the reinforcing fiber is prepared in advance and used as a reinforcing material, equipment costs relating to weaving are not required. For example, a coating yarn manufacturing apparatus, a FW apparatus, a thermoforming press apparatus, and heating and softening as necessary. A series of manufacturing processes up to the final product can be completed with only bending equipment and trimming equipment, etc., so it is easy to respond to high-mix low-volume production. And relatively inexpensive untwisted roving yarn can be used as the reinforcing fiber, and the thickness of the closed fiber-reinforced composite molded article to be obtained can be increased. In order, or increase the number of turns of FW, or can use multiple sets of winding member by FW method. In addition, when a predetermined shape is to be formed, it is necessary to cut the material into a predetermined shape in the case of a woven material, and the yield is poor due to the generation of scraps, but the use of the FW method improves the yield. In general, when a UD tape is used, since the UD tape is thin, it takes a long time for a laminating step to form a predetermined thickness, and it is difficult to form a closed shape as in the FW method. Further, the closed molded body according to the present invention can have various forms such as a ring, a polygon, a cross, a star, and a rod in a cross section orthogonal to the P axis (see FIGS. 11, 13, and 14). In addition, since a structure (see FIG. 15) in which the respective P-axes are joined to each other so as not to overlap with each other and a composite structure having a composite structure with an injection molded body (see FIG. 12) can be provided, piping System flange reinforcing inserts, Rono-shaped closed cross-section structural reinforcing material for automobile bodies, such as hood, front pillar, roof, door, rear hatch door, trunk, floor, battery case, center, rear reinforcement as shown in FIG. And a reinforcing member such as a tire wheel and a suspension arm (not shown).

It is explanatory drawing of the elongation of the fiber itself (a), the elongation of the fiber shape (b), the shear sliding (c), and the deformation (d) due to the lattice effect when the woven material is formed into a sheet. It is explanatory drawing of the shaping | molding by the conventional FW method. Mixed yarn (a) of multifilament continuous long reinforcing fiber and multifilament yarn of the same thermoplastic resin, thermoplastic resin coated yarn (b) coated with thermoplastic resin around multifilament continuous long reinforcing fiber, and multifilament It is sectional drawing of the thermoplastic resin coating yarn (c) which coat | covered the circumference | surroundings of filament continuous-length reinforcing fiber with the thermoplastic resin of two layers from which a melting point differs. It is the side view and front view of an example of the winding member (4) used for the winding and orientation process of the manufacturing method of the closed molded object of this embodiment. In the case of four threading portions (1a to 1d). When the closed molded body of the present embodiment is an annular molded body centered on the P-axis direction, the width (b) in the P-axis direction and the reduced diameter (D) satisfy the relationship of b <D, and The formed body is a continuous length reinforcement for oblique reinforcement crossing the continuous length reinforcing fiber oriented in one direction by swinging in the width (b) direction over a development length (L) of 3.14D in the circumferential direction. It is a figure for explaining the feature containing a fiber. It is a drawing for explaining a press molding process of a manufacturing method of a closed molded object of this embodiment. When compressing and heating in the width and radial directions. It is a perspective view of an example of a metal mold which has a concave part symmetrical to a rotation axis used for a winding and orientation process of a manufacturing method of a closed molded object of this embodiment, and the concave part. In addition, the dimensions of the concave portion winding portion are examples. It is an example of a winding method in the case where a reinforcing fiber is wound around a concave portion of a mold having a concave portion symmetrical with respect to a rotation axis. (A) First layer of parallel winding, (b) First layer of helical winding, (c) Second layer of parallel winding, (d) Second layer of helical winding. In the method for producing a closed molded body of the present embodiment, when wound around a mold having a concave portion, the wound body transferring step of transporting the wound reinforcing fibers together with the mold; and a subsequent press. It is a perspective view (a) explaining a moving direction of a metallic mold in a molding process, and is a sectional view of (b). In the method for producing a closed molded body of the present embodiment, a cross-shaped molding die is disposed at the center of a rectangular reinforcing fiber wound body or a partially molded body to form a hollow cross-shaped molded body. It is sectional drawing for demonstrating the press molding process at the time of shaping | molding. (A) Before press molding, (b) After press molding. It is sectional drawing of an example of the closed UD molded object obtained by the press molding shown in FIG. FIG. 12 is a cross-sectional view of an example of a composite structure having a composite structure in which a reinforced short fiber injection molded body is disposed inside (hollow portion) of the closed UD molded body shown in FIG. 11. It is a perspective view and a sectional view when the closed molded object (7) of this embodiment is annular. In the case where the closed molded body of the present embodiment is square in a cross section orthogonal to the P axis, a shaping step of further performing a bending process by heating and softening to obtain a cross-shaped closed molded body is performed. It is a drawing for explanation. It is a perspective view for explaining the structure where two closed molded objects (7, rectangular cross section) of the present embodiment are joined to each other with their P axes orthogonal to each other. Rono-shaped closed cross-section structural reinforcing material of the automobile body, for example, a hood, a front pillar, a roof, a door, a rear hatch door, a trunk, a floor, a battery case, a center, a closed member of the present embodiment as a reinforcing member for rear reinforcing. It is a drawing for explaining application of a compact.

Hereinafter, embodiments of the present invention will be described in detail.
The first embodiment is a closed molded body including a plurality of continuous long reinforcing fibers continuously and circumferentially oriented in one direction in a solidified thermoplastic resin matrix, and has an annular shape centered on a P-axis direction. When a molded body is formed, the width (b) in the P-axis direction and the reduced diameter (D) satisfy the relationship of b <D, and the molded body has a developed length (L) in the circumferential direction = 3. The closed molded body comprising continuous continuous reinforcing fibers which are inclined in the width (b) direction and cross the continuous continuous fibers oriented in one direction over 14D.
A second embodiment comprises the following steps:
Continuous reinforcement selected from the group consisting of thermoplastic resin coated yarns coated with thermoplastic resin around multifilament continuous length reinforcing fibers and mixed yarns of multifilament continuous length reinforcing fibers and multifilament yarns of the same thermoplastic resin A winding body preparing step of preparing one or more winding bodies of fibers;
The rotation axis at the center thereof, a winding member having a plurality of threading portions symmetrically arranged at an equal distance in the radial direction from the center, or a mold having a concave portion symmetric with respect to the rotation axis, The reinforcing fiber from the wound body is wound at 0 to 18 degrees with respect to the direction perpendicular to the rotation axis so that the winding length in the circumferential direction is substantially equal to the length in the molded product to be obtained. A winding / orienting step of winding in one direction by rotating the rotating shaft;
When wound around the winding member, the wound reinforcing fiber is transferred from the winding member to a press molding die, or when wound around a die having the concave portion, the die Transporting the wound reinforcing fiber together with the wound body;
The transferred wound body is press-molded at a predetermined temperature and pressure, and the thermoplastic resin is heated, melted, and cooled to be solidified, so that it is continuously oriented in one direction in the circumferential direction in the solidified thermoplastic resin matrix. Press forming step of obtaining a closed molded body containing a plurality of continuous continuous reinforcing fibers;
If necessary, the obtained molded body is further subjected to a bending process by heating and softening to form a closed molded body having a desired shape;
The method for producing a closed molded article according to any one of the above [1] to [4], comprising:

FIG. 13 is a perspective view and a cross-sectional view when the closed molded body of the present embodiment is annular.
As described above, when trying to obtain a narrow band-shaped molded body using a UD tape having a width of several mm to about 10 mm according to the related art, the reinforcing fibers are traversed diagonally, and the reinforcing fibers extend in the width direction. Although there is a problem that it cannot be reinforced, in the closed molded body of the present embodiment, as shown in FIG. 5, the width (b) in the P-axis direction and the reduced diameter (D) have a relationship of b <D. In the case where the width of the annular molded body satisfying the formula (1) is narrow, it includes an oblique continuous continuous reinforcing fiber which is swayed in the width direction and traverses the continuous continuous reinforcing fiber oriented in the one direction over the extended length in the circumferential direction. Therefore, it is reinforced in the width direction.
In the present specification, the term "annular molded body" means a molded body having a closed form, and such a form is not limited to a circle and an ellipse, and may be any polygon including a quadrangle. Is included.
Further, the term "converted diameter" is a diameter when such a polygon is transformed (converted) into a circle, and the "development length in the circumferential direction" is a perimeter when converted into a circle. .

  In the present specification, "continuously oriented in one direction in the circumferential direction" means that the continuous length reinforcing fibers are continuous beyond the development length in the circumferential direction, in other words, the continuous length reinforcing fibers are It means that it has been wound by one or more turns. For example, in press molding, when a wound body having 100 windings is used as a reinforcing material, a winding body having 2 windings and a winding body having 98 windings may be used separately. Because, in the molded body after the thermoplastic resin has been solidified, as long as the continuous reinforcing fibers continue beyond the circumferential development length, they may be continuous at all lengths or not. This is because there is no substantial difference between the strengths.

  In general, high strength and elastic modulus cannot be expected for woven fabrics and chopped long fiber-based thermosetting and thermoplastic resin composite materials because the strength and elastic modulus of the process are averaged (isotropic). On the other hand, a UD-like thermosetting, thermoplastic resin composite material in which reinforced long fibers are oriented in one direction has high anisotropy, and high elastic modulus and high strength can be expected. However, in order to produce a UD-like thermoplastic resin composite in which reinforced long fibers are oriented in one direction in order to expect a high modulus of elasticity and high strength, it is difficult to use a thermoplastic resin during press molding or hybrid (press + injection composite) molding. Fiber orientation disorder is caused by the flow of the resin. In order to avoid fiber orientation disturbances during press molding and hybrid (press + injection composite) molding, the inventors of the present application have proposed a method of obtaining a winding length in the circumferential direction in a molded product to be obtained. Reinforcing fibers wound in one direction are prepared in advance by rotating the rotation axis at 0 to 18 degrees with respect to a direction orthogonal to the rotation axis so as to be substantially equal to each other, and this is transferred to a mold. Or, in a mold having a concave portion symmetrical with respect to the rotation axis, the reinforcing fibers from the wound body are wound so that the winding length in the circumferential direction is substantially equal to the length in the molded product to be obtained. Then, by rotating the rotating shaft at 0 to 18 degrees with respect to a direction orthogonal to the rotating shaft, the wound mold itself wound in one direction is transferred, and the transferred winding body is heated to a predetermined temperature.・ Press molding under pressure to heat, melt and cool the thermoplastic resin By, in which it was possible to obtain a closed molded body continuously in a thermoplastic resin matrix which has solidified in the circumferential direction comprises a plurality of continuous long reinforcing fibers oriented in one direction. In the closed molded body of the present embodiment, the plurality of continuous long reinforcing fibers are literally continuously oriented in the UD-like direction in the circumferential direction, and thus are reinforced in the radially expanding direction and the circumferential direction. The step of winding in one direction by rotating the rotation axis at 0 to 18 degrees with respect to the direction perpendicular to the rotation axis is performed by using the winding member (4) shown in FIG. It can be carried out by the FW method using a mold (13) having a concave portion (14) symmetrical with respect to the rotation axis shown.

As shown in FIGS. 4 and 8, in the winding and orientation step (FW) of the method for producing a closed fiber-reinforced composite molded article of the present embodiment, it is not necessary to prepare a reinforcing fiber fabric in advance, and Thermoplastic resin coated yarn (FIGS. 3 (a) and 3 (c)) in which the periphery of the filament continuous reinforcing fiber (10) is coated with a thermoplastic resin (11, 12). ) And a multifilament yarn (FIG. 3B) of a multifilament continuous-length reinforcing fiber (10) and a multifilament yarn (11) of the same thermoplastic resin. Since it is sufficient to prepare one or more wound fiber bodies of the reinforcing fibers selected from the group, in weaving, unwinding, warping, gluing, warping, hanging, pipe winding, weaving, and trimming of greige etc. Complex Degree is lightly capital investment to become unnecessary, also, correspondence is likely to be to the high-mix low-volume production.
When a woven fabric of reinforcing fibers is used, for example, from a wound body of glass fiber and a wound body of thermoplastic long fiber, a mixed fiber of glass fiber and thermoplastic long fiber is produced, and this is warped and / or The woven fabric must be woven and finished using the weft and the resulting greige trimmed.
Of course, if the FW method is adopted, preparation of a coating yarn or a mixed fiber yarn is necessary, but at least in terms of weaving, finishing, and trimming, the capital investment is much lower than in the case of using a woven fabric. Become.

FIGS. 3A, 3B, and 3C show cross sections of the mixed fiber, the coating yarn, and the two-layer coating yarn, respectively.
FIG. 3A shows a mixed fiber in which a single fiber (10) of a glass fiber and a single fiber (11) of a thermoplastic long fiber are mixed, but a bundle of a multifilament glass fiber and a multifilament thermoplastic fiber are shown. It may be a simple bundle of resin long fibers.
The coating yarn shown in FIG. 3B is obtained by coating a thermoplastic fiber (11) that has been heated and melted around a bundle of multifilament glass fibers (10) with a constant thickness. The coating yarn is reinforced by, for example, using a die having an inlet side hole A and an outlet side hole B larger than the hole A, supplying a molten resin to the hole B while passing a bundle of reinforcing fibers through the hole A. After coating the fiber bundle, the resin can be cooled and solidified to produce the resin. The coating yarn is preferable to the mixed fiber or the impregnated yarn in that the glass fiber inside is protected by the resin coating and the glass fiber can be prevented from being damaged in the subsequent steps.
The two-layer coating yarn shown in FIG. 3C is obtained by coating thermoplastic resin having different melting points on the inner (11) and outer (12) layers. Coating of thermoplastic resin coated yarn in which the periphery of the multifilament continuous long reinforcing fiber is coated with a thermoplastic resin When the thermoplastic resin is composed of two layers, the melting point T1 of the outer thermoplastic resin is the melting point of the inner thermoplastic resin. It is preferable to press-mold at a temperature higher than T2 by 10 ° C. or more and T1 + 10 ° C. or less. By doing so, at the time of press molding, while suppressing the fluidity of the outer resin, the inner resin is highly fluidized, and the resin impregnation into the bundle of multifilament continuous length reinforcing fibers can be promoted. it can. Further, when the thermoplastic resin coating yarn in which the periphery of the multifilament continuous long reinforcing fiber is coated with the thermoplastic resin is composed of two layers, the melting point T1 of the outer thermoplastic resin is changed to the inner thermoplastic resin. Press molding at a temperature of 10 ° C. or higher and T2 + 5 ° C. or higher and T1-5 ° C. or lower, and melting the inner thermoplastic resin, followed by press molding at a temperature of T2 + 15 ° C. or higher. The inside thermoplastic resin and / or the outside thermoplastic resin can be discharged out of the mold to adjust Vf. When the fiber is not a continuous long reinforcing fiber, for example, when a short fiber is used, the resin inside flows out from the cut end face of the short fiber, and therefore, such a promoting effect cannot be expected. For example, when the inner layer (inside) resin melting point is 210 ° C. and the outer layer (outer) resin melting point is 260 ° C., if the press molding is performed at a mold temperature of 260 ° C., the outer layer resin undergoes softening deformation but does not flow. . On the other hand, the inner layer resin sufficiently melts and fluidizes and impregnates the inside of the bundle of continuous reinforcing fibers. Further, by heating the resin to 280 ° C. to fluidize the outer layer resin, forming a thin rib from the annular member and discharging the molten resin out of the product, the Vf volume content of the annular member can be increased, and the strength and rigidity can be improved. . For example, when the coating yarn Vf is 40%, the Vf of the molded body annular portion can be set to 50%. In this case, the Vf improvement of the molded body annular portion does not depend on the two-layer structure of the coating yarn.

The reinforced continuous long fibers contained in the coating yarn and the mixed yarn are not limited to glass fibers, but widely include organic-oriented reinforcing fibers such as carbon fibers, alumina fibers, aramid fibers, and basalt fibers. These reinforced continuous filaments may be used alone or as a mixture of two or more.
In addition, in view of the volume ratio of the reinforcing fibers in the fiber-reinforced composite sheet of the present embodiment, the amount of the thermoplastic resin (fiber) or the thermosetting resin to the reinforcing fibers in the coating yarn, the mixed yarn, and the impregnated yarn is used. It is necessary to adjust.
The thermoplastic resin (fiber) or the thermosetting resin to be used is not particularly limited. For example, as the thermoplastic resin, polyamide (PA) 66, PA6, polypropylene (PP), polyphenylene sulfide (PPS), polyether ether ketone (PEEK).
Various additives such as dyes and pigments and release agents may be appropriately added to these resins according to the required characteristics of the product.

FIG. 4 shows a side view and a front view of an example of the winding member (4) used in the winding / orienting step of the method for manufacturing a closed molded body according to the present embodiment. In the winding / orienting step of the method for manufacturing a closed molded body of the present embodiment, the rotation axis (3) is provided at the center thereof at a plurality of threaded portions (1a) symmetrically arranged at an equal distance in the radial direction from the center. , 1b...), The reinforcing fiber from the wound body (0) becomes substantially equal to the length in the molded product to be wound in the circumferential direction. As described above, this is a step of winding in one direction by rotating the rotation axis at 0 to 18 degrees with respect to a direction orthogonal to the rotation axis. FIG. 4 illustrates a case where the number of the threaded portions (1a to 1d) is four. The threaded portion has a length corresponding to the circumferential length of the reinforcing fibers in the molded article to be obtained. In order to prepare a wound body, there are a plurality of symmetrically disposed radially equidistant from the center of rotation on the rotary base (2), and a radial direction is provided so that the winding length can be changed. It may have a mechanism for adjusting the distance. From the viewpoints of productivity, suppression of vibration caused by the increase in winding speed, and suppression of change in peripheral speed, winding forms may be substantially circular or polygonal, for example, triangular, quadrangular, hexagonal, or octagonal. preferable.
Further, by shaking the heald (15) in the width direction and arranging the continuous continuous reinforcing fibers diagonally across the continuous long reinforcing fibers oriented in one direction, the molded product finally reinforced also in the width direction. Can be obtained.
The layer structure of the parallel winding (0 degrees) and the helical winding (maximum 18 degrees) can be appropriately designed depending on the strength required for the closed fiber-reinforced composite molded body. For example, the UD strength is further increased. If desired, the ratio of the parallel winding may be increased. In the step of winding in one direction by rotating a direction orthogonal to the rotation axis, the angle is preferably 0 to 18 degrees, and more preferably 0 to 10 degrees.
The tension at the time of winding the reinforcing fiber may be appropriately adjusted, but if the tension at the time of winding is too high, the reinforcing fiber may be broken.

  FIG. 6 is a drawing for explaining the press forming step of the method for manufacturing a closed molded body according to the present embodiment, and illustrates a case where compression and heating are performed in the width direction and the radial direction. First, the wound body (6) prepared as described above is transferred from the winding member (4) to the press molding die (5a). Such transfer can be achieved by loosening the tension of the reinforcing fibers of the wound body using a mechanism for adjusting the radial distance so that the winding length of the threading portion can be changed. Next, the thermoplastic resin is heated by performing press molding in which the distance between the mold (5a) and the mold (5b) facing the mold (5b) and the radial molds (5c, 5d) is reduced, and compression and heating are performed. By melting and cooling and solidifying, it is possible to obtain a closed molded body containing a plurality of continuous long reinforcing fibers continuously and unidirectionally oriented in the circumferential direction in the solidified thermoplastic resin matrix. When the closed molded body is annular, a product as shown in FIG. 13 is obtained.

  If it is attempted to make a molded body of a complicated shape from the wound body (6) at a stretch, it may be impossible to achieve a structure due to the mold. If necessary, the obtained molded body may be bent by heating and softening. Is performed to obtain a closed molded body having a desired shape, whereby a molded body having a desired complicated shape can be manufactured. For example, as shown in FIG. 14, first, after preparing a closed rectangular shaped body, and performing bending in the direction shown by the arrow, a closed shaped body in a cross shape can be manufactured. Such bending by heating and softening becomes possible by using a thermoplastic resin coated yarn. The desired complex shape is not particularly limited, but may be, for example, a ring, a polygon, a cross, a star, or a bar in a cross section orthogonal to the P axis.

Instead of the winding member (4) used in the winding / orienting step of the manufacturing method of the closed molded body of the present embodiment, a mold (13) having a concave portion symmetrical with respect to the rotation axis as shown in FIG. ) Can be used. In addition, the mold (13) shown in FIG. 7 releases the winding body or the partially molded body wound around the concave portion by releasing the fitting of the block sandwiching the concave portion (14) up and down, and further removing this. It can be subjected to a forming step and a bending step.
In the concave portion (14) of the mold, for example, as shown in FIG. 8, helical windings (FIGS. 8B and 8D) are provided between layers of parallel windings (see FIGS. 8A and 8C). See)) One (one time) can be inserted.
The cross-sectional shape of the concave portion (14) can be substantially circular or polygonal, for example, triangular, quadrangular, hexagonal, octagonal, or the like, similarly to the above-described winding member (4).

  When the continuous reinforcing fiber is wound around a mold (13) having a concave portion symmetrical with respect to the rotation axis, as shown in FIG. 9, the molds (15a to 15d) are fixed with respect to the concave portion (14). After being moved with a gap, press-molding is performed by heating and compression to produce a closed UD molded body.

  Further, as shown in FIG. 10, the winding member (4) used in the winding / orienting step of the manufacturing method of the closed molded body according to the present embodiment has a concave portion which is symmetric with respect to the rotation axis. Using a mold (13), a wound body (6) of a substantially quadrangular coating yarn (6) or a partially formed body thereof is prepared in advance, and a substantially cross-shaped shaping mold is provided at the center thereof. The mold (metal) (16) is arranged (see FIG. 10 (a)), and the slide cores (17a to 17d) are moved from the four corners toward the center, and are heated and compressed (see FIG. 10 (b)). 11), a hollow substantially cruciform closed UD molded body as shown in FIG. 11 can be manufactured.

  After press molding, it is preferable to trim the peripheral edge of the molded product according to the desired product shape. As the trimming device, for example, a laser, a water jet (a polishing agent and a laser) may be used.

  As illustrated in FIG. 15, it is possible to manufacture a structure by preparing two closed molded bodies produced as described above and joining them together so that their P-axes do not overlap. it can. In principle, it is also possible to manufacture a double-ringed structure in which the P-axis is coincident. The joining method at this time is not particularly limited, and may be, for example, thermocompression bonding, bolt / nut, fitting, or the like. The structural body illustrated in FIG. 15 is, for example, a Rono-shaped closed-section structural reinforcing material of the automobile body illustrated in FIG. 16, for example, a hood, a front pillar, a roof, a door, a rear hatch door, a trunk, a floor, a battery case, a center, It can be used as a reinforcing member such as a rear reinforcing member and a reinforcing member such as a tire wheel and a suspension arm (not shown).

The molded body prepared as described above is inserted into an injection molding die, and overmolded by injection molding using a thermoplastic resin containing chopped strands of reinforcing fibers as a matrix resin, thereby forming the closed molded body. A composite structure having a composite structure with an injection molded body can be manufactured. As such a composite structure, a reinforcing insert for a piping system flange can be mentioned. Further, for example, if a composite structure in which a short fiber reinforced fiber injection molded body is arranged inside (hollow portion) of a hollow substantially cruciform closed UD molded body as shown in FIG. 11 is formed, as shown in FIG. It is possible to manufacture a complex molded article. By adopting a composite structure with an injection molded body, a flat shape or rib reinforcement shape is added to the closed molded body, insert reinforcement is applied to a box-shaped plunge, etc., warpage is reduced by improving rigidity, The wear property can be improved, and the sealing property of oil or the like can be improved.
The resin to be overmolded is preferably a resin whose main component is the same as that of the matrix resin of the closed fiber-reinforced composite molded article. For example, PA66-based PA66-based and PP-based PP-based PP-based resins are preferred. It may be a resin having a polymerization composition.

Hereinafter, examples of the present invention will be specifically described.
[Example 1]
[Winding process]
A coating yarn having an outer diameter of about 0.5 mm and Vf = 46%, in which glass reinforced fiber was covered with PA612 on a core material, and PA66 was further coated on the periphery thereof, was prepared.
The glass reinforcing fiber used was a glass fiber manufactured by NEC Corporation, a fineness of 685 dtex, and the number of single yarns was 400.
As a FW device, "1000P" manufactured by Asahi Kasei Engineering Corporation was used. Note that “1000” means for 1000 mm, and “P” means 5-axis control. The maximum diameter φ was 400 mm.
One of the coating yarns was attached to a creel (tension control feeding device) and wound around a winding jig (a mold (13) having a concave portion (14) symmetrical with respect to the rotation axis) shown in FIG.
The winding conditions were as follows: the tension was 50 g / one coating yarn, the number of rotations was 20 rpm, and as shown in FIG. A thread hooking die (13) in which the helical winding is performed once, then the parallel winding is wound in one layer at a pitch of 0.5 mm and the width is 30 mm, and then the helical winding is repeated once, and the coating yarn is wound in the parallel winding four layers and the helical winding four times ) Was prepared. In addition, the thickness of these thread layers was 2.5 mm, and the perimeter was 400 mm.

[Inner layer impregnation process]
Next, as shown in FIG. 9, a mold (13) in which the coating yarn is wound around the concave portion (14) is coated on the coating yarn by pressing and heating the slide core (dies 15a to 15d) 4 surfaces. Resin was melted and impregnated.
First, the temperature of the slide core is raised to 260 ° C. (not less than the melting point of PA612 and not more than the melting point of PA66), a pressure of 1 MPa is applied, the recess (14) is pressed, and the outer layer of the PA66 is held for 5 minutes. The inner layer of the coating yarn was impregnated with PA12 while preventing the inner layer of PA12 from flowing out.
Next, while maintaining the pressure of 1 MPa, the temperature of the slide core (the molds 15a to 15d) was increased to 270 ° C., and held for 3 minutes to melt the outer layer of the coating yarn.
Next, while maintaining the pressure of 1 MPa, the temperature of the slide core (the molds 15a to 15d) is increased to 280 ° C., and the resin is intentionally discharged out of the mold by fluidizing the outer layer of the coating yarn. As a result, Vf was improved.
Thereafter, the slide cores (dies 15a to 15d) were cooled to 150 ° C., and the pressure was removed, thereby producing a closed partial molded body in which the glass fiber was impregnated with the resin.
As shown in FIG. 9, the clearance between the slide cores (dies 15a to 15d) at the end of pressurization was 0.5 mm, and the clearance between the slide cores after heating was 0.1 mm. By sandwiching a thin metal plate between the mold clearances, it is possible to control the outflow condition of the resin, and by controlling the outflow condition of the resin, it is possible to control the resin volume ratio and the thickness.

[UD molding process]
The obtained partially formed body is removed from the concave portion (14) of the mold (13) having the concave portion (14) symmetrical with respect to the rotation axis, heated by an IR heater, and immediately after heating until the surface layer reaches 300 ° C. As shown in FIG. 10, the slide cores (17a to 17d) are set in a mold having a substantially cross-shaped shaping mold (metal) (16) and pressed and deformed on four surfaces of the slide cores (17a to 17d). Then, a substantially cruciform hollow closed UD molded body as shown in FIG. 11 was manufactured.
The pressure at this time was 1 MPa, and the temperature of the slide cores (17a to 17d) was 200 ° C.

[Insert injection process]
A resin composition of polyamide 66 resin [trade name: Leona (registered trademark) 14G50] containing 50% by weight of short fiber GF was injection-molded inside the obtained closed UD molded body, and the periphery thereof was, as shown in FIG. A composite structure having a unidirectional continuous fiber reinforced resin and the inside formed of an injection thermoplastic resin was manufactured.

In the solidified thermoplastic resin matrix according to the present invention, a closed molded body including a plurality of continuous length reinforcing fibers continuously and circumferentially oriented in one direction is a plurality of continuous length reinforcing fibers literally continuous in the circumferential direction. Since it is oriented in a UD-like manner, it is reinforced in the radial direction and in the circumferential direction. Further, even when the molded body according to the present invention is an annular molded body having a narrow width as shown in FIG. 5, the molded body is swung in the width direction over the developed length in the circumferential direction and is oriented in the one direction. Since it includes diagonally continuous continuous reinforcing fibers obliquely crossing the continuous reinforcing fibers, the reinforcing fibers are also reinforced in the width direction.
Further, in the method for producing a molded article according to the present invention, by adopting the FW method, not a woven fabric, but a length substantially equal to the length in the molded article to be obtained, and uniformly oriented in one direction. Since a wound body of reinforcing fibers is prepared in advance and used as a reinforcing material, equipment costs relating to weaving are not required. For example, a coating yarn manufacturing apparatus, a FW apparatus, a thermoforming press apparatus, and bending by heating and softening as necessary. A series of manufacturing processes up to the final product can be completed with only processing equipment and trimming equipment, so it is easy to respond to high-mix, low-volume production. It is possible to use a relatively inexpensive untwisted roving-type yarn as the reinforcing fiber, and to increase the wall thickness of the closed fiber-reinforced composite molded product to be obtained. In order, or they increase the number of turns of FW, or can use multiple sets of winding member by FW method. In addition, when a predetermined shape is to be formed, it is necessary to cut the material into a predetermined shape in the case of a woven material, and the yield is poor due to the generation of scraps, but the use of the FW method improves the yield. In general, when a UD tape is used, since the UD tape is thin, it takes a long time for a laminating step to form a predetermined thickness, and it is difficult to form a closed shape as in the FW method. Further, the closed molded body according to the present invention can have various forms such as a ring, a polygon, a cross, a star, and a rod in a cross section orthogonal to the P axis (see FIGS. 11, 13, and 14). In addition, since a structure (see FIG. 15) in which the respective P-axes are joined to each other so as not to overlap with each other and a composite structure having a composite structure with an injection molded body (see FIG. 12) can be provided, piping System flange reinforcing inserts, Rono-shaped closed cross-section structural reinforcing material for automobile bodies, such as hood, front pillar, roof, door, rear hatch door, trunk, floor, battery case, center, rear reinforcement as shown in FIG. And a reinforcing member such as a tire wheel and a suspension arm (not shown).

0 Winding body 15 Heald 1a-1d Threading part (4 pieces)
2 Rotating pedestal 3 Rotating shaft 4 Winding member 5a to 5d Press molding die (in the case of width direction and radial direction)
Reference Signs List 6 Winding body (annular bundle of coating yarn or mixed fiber) or partial molded body 7 Closed molded body 10 Reinforced continuous long fiber 11 Thermoplastic or continuous long fiber 12 (outer) thermoplastic resin 13 With respect to rotation axis Mold with concave and symmetric concave part 14 concave part (winding part)
15a to 15d Mold (slide core) used with mold 13
16 Die for cruciform shaping (metal)
17a to 17d Slide core 18 Cross-shaped closed UD molded body 19 Reinforced short fiber injection molded body 100 Creel 101 Resin tank 102 Mandrel

Claims (14)

  A closed molded body containing a plurality of continuous long reinforcing fibers continuously and circumferentially oriented in one direction in a solidified thermoplastic resin matrix, and when an annular molded body centered on the P-axis direction, The width (b) in the axial direction and the reduced diameter (D) satisfy the relationship of b <D, and the formed body has a width (b) extending over a circumferential development length (L) = 3.14D. )) The closed molded body comprising a continuous continuous reinforcing fiber obliquely swaying in a direction and crossing the continuous continuous fiber oriented in the one direction.   The closed molded article according to claim 1, wherein the continuous long reinforcing fiber is selected from the group consisting of glass fiber, carbon fiber, and aramid fiber.   The closed molded article according to claim 1, wherein the thermoplastic resin is selected from the group consisting of polyamide and polypropylene.   The closed molded body according to any one of claims 1 to 3, wherein the closed molded body has a ring, polygon, cross, star, or rod shape in a cross section orthogonal to the P axis. .   The closed molded body according to claim 4, which is a reinforcing insert for a piping system flange.   The closed molded body according to claim 4, which is a structural reinforcing material for a vehicle body having a Lono-shaped closed cross section.   A composite structure having a composite structure of the closed molded article according to claim 1 and an injection molded article. The following steps:
Continuous reinforcement selected from the group consisting of thermoplastic resin coated yarns coated with thermoplastic resin around multifilament continuous length reinforcing fibers and mixed yarns of multifilament continuous length reinforcing fibers and multifilament yarns of the same thermoplastic resin A winding body preparing step of preparing one or more winding bodies of fibers;
The rotation axis at the center thereof, a winding member having a plurality of threading portions symmetrically arranged at an equal distance in the radial direction from the center, or a mold having a concave portion symmetric with respect to the rotation axis, The reinforcing fiber from the wound body is wound at 0 to 18 degrees with respect to the direction perpendicular to the rotation axis so that the winding length in the circumferential direction is substantially equal to the length in the molded product to be obtained. A winding / orienting step of winding in one direction by rotating the rotating shaft;
When wound around the winding member, the wound reinforcing fiber is transferred from the winding member to a press molding die, or when wound around a die having the concave portion, the die Transporting the wound reinforcing fiber together with the wound body;
The transferred wound body is press-molded at a predetermined temperature and pressure, and the thermoplastic resin is heated, melted, and cooled to be solidified, so that it is continuously oriented in one direction in the circumferential direction in the solidified thermoplastic resin matrix. Press forming step of obtaining a closed molded body containing a plurality of continuous continuous reinforcing fibers;
If necessary, the obtained molded body is further subjected to a bending process by heating and softening to form a closed molded body having a desired shape;
The method for producing a closed molded article according to any one of claims 1 to 4, comprising:   9. The method according to claim 8, wherein the plurality of threading portions of the winding member are arranged in a triangular shape.   The method according to claim 8, wherein the mold having the concave portion symmetrical with respect to the rotation axis has a triangular-octagonal concave portion in a cross section orthogonal to the rotation axis.   The thermoplastic resin coated yarn of the thermoplastic resin coating yarn in which the periphery of the multifilament continuous long reinforcing fiber is coated with the thermoplastic resin is composed of two layers, and the melting point T1 of the outer thermoplastic resin is higher than that of the inner thermoplastic resin. The method according to any one of claims 8 to 10, wherein press molding is performed at a temperature higher than the melting point T2 by 10C or more and T1 + 10C or lower.   The thermoplastic resin coated yarn of the thermoplastic resin coating yarn in which the periphery of the multifilament continuous long reinforcing fiber is coated with the thermoplastic resin is composed of two layers, and the melting point T1 of the outer thermoplastic resin is higher than that of the inner thermoplastic resin. Press molding at a temperature of at least 10 ° C higher than the melting point T2 and at a temperature of T2 + 5 ° C or more and T1-5 ° C or less, and after melting the inner thermoplastic resin, press molding at a temperature of T2 + 10 ° C or more and T1 + 10 ° C or less. The method according to any one of claims 8 to 11, wherein   The thermoplastic resin coated yarn of the thermoplastic resin coating yarn in which the periphery of the multifilament continuous long reinforcing fiber is coated with the thermoplastic resin is composed of two layers, and the melting point T1 of the outer thermoplastic resin is higher than that of the inner thermoplastic resin. Press molding at a temperature of 10 ° C. or more higher than the melting point T2 and at a temperature of T2 + 5 ° C. or more and T1-5 ° C. or less, and after melting the thermoplastic resin inside, press molding at a temperature of T2 + 15 ° C. or more. The method according to any one of claims 8 to 12, comprising discharging the inner thermoplastic resin and / or the outer thermoplastic resin out of the mold and adjusting Vf.   The closed molded article and the injection molded article according to claim 7, comprising a step of inserting the closed molded article according to any one of claims 1 to 4 into an injection mold and performing injection molding. A method for producing a composite structure having a composite structure.

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