JP2020082429A - Integrated compact - Google Patents

Abstract

To provide an integrated compact of a fiber reinforcement resin and a reinforcement member, which is used in an electronic device chassis or the like, has less warpage and high rigidity, and can be light-weighted and thinned.SOLUTION: An integrated compact comprising: a plate 2 that is a rectangular planar structure made of a fiber reinforcement resin; a long-sized reinforcement member 3; and a resin member 4 made of non-continuous fibers and a thermoplastic resin, in which the reinforcement member 3 is arranged in an at least a part of region of an outer periphery part of one side surface of the plate 2, the resin member 4 joins with an at least a part of region of the reinforcement member 3 and joins with at least a part of region of one side surface of the plate 2 and/or at least a part of region of a side surface 6.SELECTED DRAWING: Figure 3

Description

TECHNICAL FIELD The present invention relates to an integrated molded body which is used as a part or a housing part of, for example, a medical cassette, a personal computer, an OA equipment or a mobile phone, and which is suitable for applications requiring high strength and rigidity and thinness.

At present, as electric/electronic devices such as medical cassettes, personal computers, OA devices, AV devices, mobile phones, telephones, facsimiles, home electric appliances and toys are becoming portable, smaller size and lighter weight are required. In order to achieve this requirement, it is necessary to prevent the components that make up the equipment, especially the casing, from flexing significantly when an external load is applied, causing contact with internal components and destruction. While achieving high strength and high rigidity, thinning is required.

In addition, in order to increase the strength and rigidity of the molded body, the fiber-reinforced resin made of reinforced fiber and resin is added with another reinforcing member, etc., and integrally joined and molded to reduce the size and weight of the molded body. The reliability of the bonding strength is required.

Patent Document 1 (International Publication No. 2018/110293) describes a member (B) in an integrated molded body in which a bonding resin (C) is interposed between a plate material (A) whose one surface is a design surface and a member (B). ), the plate member (A) and the member (B) are arranged so as to be separated from each other, and at least a part of the outer peripheral edge portion of the plate member (A) is bonded to the bonding resin (C). A structure having a portion and a region where the plate material (A), the member (B), and the bonding resin (C) are exposed is described on at least a part of the surface of the integrated molded body on the design surface side. Multiple structures are joined with high joint strength, the joint boundary has good smoothness, and even if the molded body has a plate member, it is possible to reduce warpage and realize weight reduction and thinning. The effect of being able to do is disclosed.

Further, in Patent Document 2 (JP 2011-166124A), a molded product (I) made of a thermoplastic resin and a molded product (II) containing continuous reinforcing fibers and a thermosetting resin are joined together. An electric/electronic device housing, wherein the molded body (I) is a planar structure, the molded body (I) has a concave groove, and the molded body (II) extends along the groove. The molded body (II) is inserted into the cavity of the mold, and the cavity is filled with the molded body (I) by injection molding, whereby the molded body (I) and the molded body (II) are filled. ) Is integrated with an electric/electronic device housing, which allows a molded body (I) made of a thermoplastic resin suitable for forming a complicated shape and a continuous body having high rigidity and high productivity. By arranging the molded body (II) consisting of the reinforced fiber and the thermosetting resin effectively in the required part, good lightweight without compromising the characteristics such as moldability, productivity and high rigidity. There is disclosed the effect that an electric/electronic device housing that satisfies the requirements of cost efficiency, economical efficiency, and thinness, and that can be used for a required complicated shape can be obtained.

International publication 2018/110293 pamphlet JP, 2011-166124, A

However, in the configuration of Patent Document 1, a molded body in which the member (B) and the plate material (A) are integrated with the bonding resin (C) has an object to reduce the warpage and realize the reduction in weight and thickness. Since the member (B) containing the continuous fiber and the thermosetting resin is separated from the plate material (A), there is room for improvement in further increasing the rigidity of the molded body itself. ..

In addition, in the configuration of Patent Document 2, for example, strength is reduced at a portion where a weld formed by the molten thermoplastic resin of the molded body (I) colliding with each other is reduced in strength. By arranging the molded body (II) across the weld having the molded body (I), a more rigid electric/electronic device housing can be obtained. However, the molded body (I) containing a thermoplastic resin as a main component is used for the top plate portion which is the planar structure of the molded body, and the molded body (II) which is the reinforcing member is formed into the molded body (I). Although high rigidity can be obtained with the configuration in which the molded body (I) is arranged along the groove, there is a concern that the strength may become unbalanced at the boundary portion where the wall thickness of the molded body (I) is reduced. There was a difference in strength and rigidity between the portion where I) was arranged and the portion where it was not arranged, and there was room for improvement in further increasing the rigidity of the molded body itself.

Therefore, in view of the problems of the prior art, the present invention is capable of reducing the warp even if the reinforcing member is joined to a plurality of structures with high joint strength, and the molded body has a plate member component. It is an object of the present invention to provide an integrated molded body capable of increasing the rigidity of the, and making it lightweight and thin.

In order to solve the above problems, the present invention employs the following means. That is,
(1) From a plate material (A) that is a rectangular planar structure made of fiber-reinforced resin, a reinforcing member (B) that is a long body, and a resin member (C) that is made of discontinuous fibers and a thermoplastic resin An integrated molded body,
The reinforcing member (B) is arranged in at least a part of an outer peripheral edge portion of one surface of the plate material (A),
The resin member (C) is joined to at least a partial region of the reinforcing member (B), and at least a partial region of the outer peripheral edge portion of one side surface of the plate material (A) and/or at least a portion of a side surface thereof. An integrated molded body characterized by being bonded to the region of.
(2) The integrated molded body according to (1), wherein the cross-section of the reinforcing member (B) orthogonal to the longitudinal direction has a circular shape, an elliptical shape, or a rectangular shape.
(3) The integrated molded body according to (1) or (2), which has a curved curved shape portion in at least a part of an outer peripheral edge portion of the plate material (A).
(4) The integrated molded body according to (3), wherein the reinforcing member (B) is an elongated body having a curved surface partly corresponding to the curved shape of the curved shape portion of the plate material (A). ..
(5) The integrated molded body according to any one of (1) to (4), in which the resin member (C) is joined to the entire side surface region of the plate material (A).
(6) The shape of the resin member (C) in the region joined to at least a part of the outer peripheral edge portion of the plate material (A) is the height of the top of the reinforcing member (B) (the plate material (A The integrated molded body according to any one of (1) to (5), which has a portion formed at a height equal to or more than a distance from a joint portion between the reinforcing member (B) and the reinforcing member (B).
(7) The ratio Y/X of the projected area X (mm ² ) of the plate material (A) and the projected area Y (mm ² ) of the reinforcing member (B) is 0.01 to 0.2 (1 )-(6) integrated molding.
(8) In the cross-section portion orthogonal to the longitudinal direction of the reinforcing member (B), the cross-sectional area of the reinforcing member (B) is B2 (mm ² ) and the cross-sectional area of the resin member (C) is C2 (mm ² ). Then, the integrated molded body according to any one of (1) to (7), wherein B2/C2 is 0.01 to 0.8.
(9) The plate member (A) and the reinforcing member (B) and/or the resin member (C) are bonded to each other via a bonding layer (1) to (8). Integrated molded body.
(10) The integrated molded body according to any one of (1) to (9), wherein the reinforcing member (B) is composed of a unidirectional reinforcing fiber and a thermosetting resin.
(11) The integrated molded product according to any one of (1) to (10), in which the plate material (A) is composed of continuous fibers and a thermosetting resin.

According to the integrated molded body of the present invention, the reinforcing member is bonded to a plurality of structures with high bonding strength, and even if the molded body has a plate member constituting a planar structure, the warp can be reduced, and the molded body can be molded. The strength and rigidity of the body can be increased, and the weight and thickness can be reduced.

FIG. 3 is a plan view of an integrated molded body according to the present invention. FIG. 2 is a bottom view of the integrated molded body shown in FIG. 1. FIG. 3 is a cross-sectional view taken along the line A-A′ of FIG. 1 or 2. FIG. 3 is a sectional view taken along line B-B′ of FIG. 1 or FIG. 2. It is a perspective view of the board|plate material (A) which is a structural member of the integrated molded body which concerns on this invention. FIG. 6 is a perspective view of a reinforcing member (B) having a rectangular cross section in the constituent member of the integrated molded body according to the present invention. FIG. 2 is a cross-sectional view taken along the line A-A′ of the integrated molded body shown in FIG. 1, in which the reinforcing member (B) is arranged on the plate material (A) at different positions. FIG. 2 is a cross-sectional view taken along the line A-A′ in which the reinforcing member (B) is arranged on the plate material (A) at another position in the integrated molded body shown in FIG. 1. FIG. 3 is a perspective view of a reinforcing member (B) having a circular cross section in the constituent member of the integrated molded body according to the present invention. It is an A-A' cross section figure of the integrated molding which the reinforcing member (B) whose cross-sectional shape is circular shape integrated with the plate material (A) and the resin member (C). FIG. 6 is a perspective view of a reinforcing member (B) having an elliptical cross section. It is an A-A' cross section figure of the integrated molding which the reinforcing member (B) which made the cross-sectional shape elliptical shape integrated with the plate material (A) and the resin member (C). FIG. 4 is a plan view of an integrated molded body having a curved curved portion on at least a part of an outer peripheral edge portion of the plate material (A). FIG. 14 is a bottom view of the integrated molded body shown in FIG. 13. It is sectional drawing of the integrated molded object which has the curved curved-shape part in at least one part of the outer peripheral edge part of plate material (A). An integrated molded body in which a reinforcing member (B) having a curved curved portion at least at a part of the outer peripheral edge of the plate material (A) and having a curved surface matching the curved shape of the curved portion is joined. FIG. At least a part of the outer peripheral edge of the plate member (A) has a curved curved portion, and two or more reinforcing members (B) are arranged and integrated on the same side of the resin member (C). It is an AA' sectional view of an integrated molding. It is a partial cross-sectional enlarged view of the integrated molding which formed the resin member (C) in the height more than the height of the top of a reinforcement member (B). It is a partial cross-section enlarged view of the integrated molding of another form which formed the resin member (C) in the height more than the height of the top of a reinforcement member (B). It is a top view showing the projected area of board (A). It is a top view showing the projected area of a reinforcement member (B). An integrated structure showing a mode in which a plate material (A) and a resin member (C) are bonded together via a first bonding layer and a plate material (A) and a reinforcing member (B) are bonded via a second bonding layer. It is sectional drawing of a form. FIG. 22 is a cross-sectional view of an integrally formed body in another joining mode in which the first joining layer and the second joining layer are provided by using the reinforcing member (B) having a cross-sectional shape different from that in FIG. 21. It is the top view [1] which arrange|positioned the reinforcement member (B) in at least one part area|region of the outer peripheral part of the one side surface of the plate material (A) in the lower molding die, and C-C' sectional view [2]. It is the top view [1] which injected and injected the resin member (C) from the injection gate opening, and molded the integrated molded body, and C-C' sectional drawing "2". It is a bottom view showing the state where two opposite sides of integrated molding 1 were placed on the fixed stand of a universal testing machine. FIG. 26 is a cross-sectional view taken along the line D-D′ of FIG. 25. It is a top view which shows the state which mounted the integral molded body 1 on the fixed stand of a universal testing machine, and added the load by a load cell from the upper direction. FIG. 28 is a cross-sectional view taken along the line E-E′ of FIG. 27. FIG. 28 is a side sectional view of a region 21 of FIG. 27. It is a schematic diagram of the pultrusion molding process which is one embodiment which creates a reinforcement member (B).

Hereinafter, embodiments will be described with reference to the drawings. The present invention is not limited to the drawings and the embodiments.

The structure of the integrated molded body 1 according to the present invention includes a plate material (A) 2 which is a rectangular planar structure made of a fiber reinforced resin, a reinforcing member (B) 3 which is an elongated body, a discontinuous fiber and a thermoplastic material. An integrated molded body 1 composed of a resin member (C) 4 made of a resin, wherein a reinforcing member (B) 3 is arranged in at least a part of an outer peripheral edge portion of one surface of a plate material (A) 2. The resin member (C) 4 is joined to at least a partial region of the reinforcing member (B) 3, and at least one region and/or side face of at least a part of the outer peripheral edge of the one side surface of the plate material (A) 2. It is the structure which joins with the area|region of a part.

A plate material (A) 2 which is a planar structure shown in FIG. 5 and a reinforcing member (B) 3 which is a long body shown in FIG. 6 are separately prepared in advance, and as shown in FIGS. The reinforcing member (B) 3 is arranged along a pair of opposing long sides of the outer peripheral edge portion of one surface of the plate material (A) 2, and along a pair of opposing short sides, and further, a resin. The plate member (A) 2 and the reinforcing member (B) are joined and integrated by the member (C) 4.

By disposing the reinforcing member (B) 3 in at least a part of the outer peripheral edge portion of the plate material (A) 2, it is possible to suppress warpage of the molded body 1 and to increase the strength and rigidity of the integrated molded body 1. it can. Further, the resin member (C) 4 is joined to at least a part of the area of the reinforcing member (B) 3, and at least a part of the outer peripheral edge part of one surface of the plate material (A) 2 and at least the side surface part 6. Joining of the resin member (C) 4 and the plate material (A) 2 by adopting a form of joining to a part of the region or at least a part of the outer peripheral edge part and at least a part of the side face part 6 The strength can be increased.

Here, the outer peripheral edge portion of the plate material (A) 2 is a flat portion region near the outer peripheral portion of the plate material (A) 2 of the planar structure, and with respect to the length of one side of the plate material (A) 2. It is preferable that the length is within a range of 0 to 15% from the outer peripheral end. It is preferable to arrange the reinforcing member (B) 3 so that a part of the reinforcing member (B) 3 is located at the outer peripheral edge of the plate member (A) 2. In FIG. 3, a part of the reinforcing member (B) 3 is in contact with the outer peripheral end portion of the plate material (A) 2, and one surface thereof is arranged flush with the side surface portion 6 of the plate material (A) 2 in the same plane. 1 illustrates an embodiment. Further, if the reinforcing effect of the reinforcing member (B) 3 can be exhibited, as shown in FIG. 7, the reinforcing member (B) 3 is displaced inward from the outer peripheral end portion of the plate material (A) 2 and the outer peripheral edge portion thereof. 8 may be arranged. Alternatively, as shown in FIG. 8, a part of the reinforcing member (B) 3 is arranged so as to be offset so as to protrude outside the outer peripheral end of the plate material (A) 2. But it doesn't matter. The outer peripheral end portion refers to the outermost peripheral edge portion of the plate material (A) 2 and is a portion in contact with the side surface portion 6.

FIG. 3 or FIG. 4 is a cross-sectional view taken along the line AA′ or BB′ of FIG. 1 or FIG. 2, respectively, but in order to clarify the arrangement configuration of the same members, a pattern similar to that of FIG. Shows. The same applies hereinafter.

Further, the plate material (A) 2 which is a planar structure has a surface shape in which the side surface area is smaller than the projected area of a plane, and the projected area of the side surface portion 6 is 10,000 to 250,000 mm ² . The plate thickness of the plate material (A) 2 having a height is preferably in the range of 0.2 to 5 mm. More preferably in the range of the projected area of 40,000~240,000mm ^2, ranges plate thickness of 0.5 to 3 mm, more preferably in the range of 90,000~220,000mm ^2, plate thickness 1~2mm The range is. For example, in the case of a thin-walled rectangular parallelepiped shape whose side surface area is smaller than the projected area such as the case of a cassette or a personal computer, it is necessary to secure its strength and rigidity and to have a strong strength against bending and impact. Even in such a form, strong strength and high rigidity can be maintained by adopting the configuration of the present invention.

The resin member (C) 4 is preferably made of injection-moldable thermoplastic resin. By injection molding the resin member (C) 4, it is possible to join and integrate the plate member (A) 2 and the reinforcing member (B) 3.

There is no particular limitation on the kind of the thermoplastic resin forming the resin member (C) 4, and any of the thermoplastic resins exemplified below can be used. For example, polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, polyethylene naphthalate (PEN resin), polyester resin such as liquid crystal polyester resin, polyethylene (PE resin), polypropylene ( PP resin), polybutylene resin or other polyolefin resin, polyoxymethylene (POM) resin, polyamide (PA) resin, polyphenylene sulfide (PPS) resin or other polyarylene sulfide resin, polyketone (PK) resin, polyether ketone (PEK) ) Resin, polyetheretherketone (PEEK) resin, polyetherketoneketone (PEKK) resin, polyethernitrile (PEN) resin, fluorine resin such as polytetrafluoroethylene resin, crystalline resin such as liquid crystal polymer (LCP) , Styrene resin, polycarbonate (PC) resin, polymethylmethacrylate (PMMA) resin, polyvinyl chloride (PVC) resin, polyphenylene ether (PPE) resin, polyimide (PI) resin, polyamideimide (PAI) resin, poly Amorphous resins such as ether imide (PEI) resin, polysulfone (PSU) resin, polyether sulfone resin, polyarylate (PAR) resin, and other phenolic resins, phenoxy resins, polystyrene resins, polyolefin resins, Thermoplastic elastomer such as polyurethane resin, polyester resin, polyamide resin, polybutadiene resin, polyisoprene resin, fluororesin, and acrylonitrile resin, and heat selected from copolymers and modified products of these. A plastic resin may be used. Among them, polyolefin resin is preferable from the viewpoint of lightness of the obtained molded product, polyamide resin is preferable from the viewpoint of strength, and polycarbonate resin or styrene resin from the viewpoint of surface appearance, amorphous such as modified polyphenylene ether resin. Resin is preferred, polyarylene sulfide resin is preferred from the viewpoint of heat resistance, and polyether ether ketone resin is preferably used from the viewpoint of continuous use temperature.

The discontinuous fibers constituting the resin member (C) 4 include polyacrylonitrile (PAN)-based, rayon-based, lignin-based, pitch-based carbon fibers, graphite fibers, and insulating fibers such as glass, Examples thereof include organic fibers such as aramid resin, polyphenylene sulfide resin, polyester resin, acrylic resin, nylon resin and polyethylene resin, and inorganic fibers such as silicon carbide and silicon nitride. These reinforcing fibers may be used alone or in combination of two or more. Among them, PAN-based, pitch-based, rayon-based carbon fibers which are excellent in specific strength and specific rigidity are preferably used from the viewpoint of the effect of weight reduction. Further, from the viewpoint of increasing the economical efficiency of the obtained molded product, glass fiber is preferably used, and it is particularly preferable to use carbon fiber and glass fiber in combination from the viewpoint of the balance between mechanical properties and economic efficiency. Further, aramid fibers are preferably used from the viewpoint of enhancing the impact absorbency and shapeability of the obtained molded product, and it is particularly preferred to use carbon fiber and aramid fiber in combination from the viewpoint of balance between mechanical properties and impact absorbability. Among these, PAN-based carbon fibers which are excellent in mechanical properties such as strength and elastic modulus can be more preferably used.

The weight average fiber length of the discontinuous fibers forming the resin member (C) 4 is preferably 0.3 to 5 mm.

Here, continuous fibers and discontinuous fibers will be defined. The continuous fiber is a state in which the reinforcing fibers contained in the integrated molded body 1 are arranged substantially continuously over the entire length or the entire width of the integrated molded body 1, and the discontinuous fibers are intermittently separated from the reinforcing fibers. It is the one that is arranged and arranged. Generally, unidirectional fiber reinforced resin obtained by impregnating unidirectionally aligned reinforcing fibers with resin corresponds to continuous fiber, SMC base material used for press molding, pellet material containing reinforcing fiber used for injection molding, etc. Corresponds to discontinuous fiber.

Among the discontinuous fibers, as a pellet material used for injection molding, the weight-average fiber length remaining in the member composed of the discontinuous fibers has a constant fiber length, so that the fiber-reinforced resin can be molded at the time of injection molding. It is possible to uniformly fill up to the corners of the molding die. When the weight average fiber length is less than 0.3 mm, sufficient strength and rigidity may not be obtained, or the warp of the integrated molded body 1 may not be sufficiently reduced. When the weight average fiber length exceeds 5 mm, the fluidity of the resin deteriorates, and it may be difficult to uniformly fill the resin member (C) 4 to the corners of the molding die during injection molding. The weight average fiber length of the discontinuous carbon fibers is preferably 0.4 to 3 mm, more preferably 1 to 2.5 mm, further preferably 1.4 to 1.9 mm.

In addition, the fiber weight content of the resin member (C) 4 is preferably 10 to 30% by weight. As a result, it is possible to suppress the shrinkage of the resin member (C) 4 and reduce the warp of the integrated molded body 1. When it is less than 10% by weight, it may be difficult to secure the strength of the integrated molded body 1, and when it exceeds 30% by weight, the resin member (C) 4 may be partially insufficiently filled in the injection molding. There is. The fiber weight content is more preferably 15 to 30% by weight, further preferably 20 to 30% by weight.

Further, in the present invention, it is preferable that the cross section of the reinforcing member (B) 3 that is orthogonal to the longitudinal direction has a circular shape, an elliptical shape, or a rectangular shape.

When the reinforcing member (B) 3 has a rectangular sectional shape such as a rectangle shown in FIG. 6 or a square shown in the sectional view of FIG. 3, positioning with the plate material (A) 2 is facilitated and the plate material (A) is ) 2, and the bonding strength can be improved.

Further, by making the cross-sectional shape of the reinforcing member (B) 3 circular as shown in FIGS. 9 and 10, the strength of the reinforcing member (B) 3 itself is improved, and the strength of the integrated molded body 1 is increased. You can do things. The same effect can be obtained by making the cross-sectional shape of the reinforcing member (B) 3 oval as shown in FIGS. 11 and 12.

Also. In the present invention, it is preferable that at least a part of the outer peripheral edge portion of the plate material (A) 2 has a curved curved shape portion 5.

As shown in FIG. 15, the bending strength and rigidity of the plate material (A) 2 can be improved by providing the curved curved shape portion 5 on the outer peripheral edge of the plate material (A) 2. In the integrally molded body 1 having the cross-sectional shape shown in FIG. 15, the reinforcing member (B) 3 having an elliptical cross-sectional shape is arranged near the curved shape portion 5 at the outer peripheral edge portion, and the resin member (C) 4 is reinforced. The surface of the member (B) 3 is covered, and the member (B) 3 is joined to the region of the curved shape portion 5 of the plate (A) 2.

The radius of curvature of the curved shape of the curved shape portion 5 is preferably 0.5 to 10 mm. If the radius of curvature is less than 0.5 mm, the carbon fiber will meander at the bent portion, and the strength and rigidity of the bent portion will decrease. If the radius of curvature exceeds 10 mm, the bending rigidity and strength of the side wall portion may not be sufficiently exhibited. The radius of curvature is preferably 0.8 to 8 mm, more preferably 1 to 7 mm, and further preferably 2 to 6 mm.

Also. In the present invention, the reinforcing member (B) 3 is preferably an elongated body having a curved surface partly matching the curved shape of the curved shape portion 7 of the plate material (A) 2.

As shown in FIG. 16, one surface 8 of the cross-sectional shape of the reinforcing member (B) 3 has a curved shape, and the surface has a shape along the curved shape of the curved shape portion 5 of the plate material (A) 2. Are joined together. With such a joining mode, the joining strength between the plate material (A) 2 and the reinforcing member (B) 3 can be improved, and the bending strength of the integrated molded body 1 can be improved. Further, in the joining form shown in FIG. 16, the resin member (C) 4 is joined to the surface of the reinforcing member (B) 3 and the side surface portion 6 of the plate material (A) 2. By joining the two surfaces in this manner, the joining strength between the plate material (A) 2 and the reinforcing member (B) 3 can be improved, and the bending strength and rigidity of the integrated molded body 1 can be further enhanced. it can. Further, as shown in FIG. 17, two or more resin members (C) may be arranged as the reinforcing member (B).

Further, in the present invention, it is preferable that the resin member (C) 4 is bonded to the entire area of the side surface portion 6 of the plate material (A) 2.

As shown in the cross-sectional view of FIG. 3 or FIG. 4, by bonding with the resin member (C) over the entire circumference of the side surface portion 6 of the plate material (A) 2, high bonding strength and thinning of the entire integrated molded body 1 are realized. be able to.

Further, in the present invention, the shape of the resin member (C) 4 in the region joined to at least a part of the outer peripheral edge portion of the plate material (A) 2 has a height of 11 or more at the top of the reinforcing member (B) 3. It is preferable to have the portion 12 formed at the height of.

As shown in FIG. 18 in which a part of FIG. 3 is enlarged and in FIG. 19 in which a part of FIG. 15 is enlarged, the resin member (C) 4 has a height of 11 or more at the top of the reinforcing member (B) 3. It is preferable that the portion 12 formed in the height is provided on at least a part of the outer peripheral edge portion of the plate material (A) 2. The height of the top of the reinforcing member (B) 3 refers to the distance from the joint between the plate member (A) 2 and the reinforcing member (B) 3 to the most distant position. In the case of being reinforced by a plurality of reinforcing members (B) as shown in FIG. 17, the distance is from the plate material (A) to the position separated from the reinforcing member (B) arranged most distant.

By forming the resin member (C) 4 so that the height 12 at the top of the resin member (C) 4 is larger than the height 11 at the top of the reinforcing member (B) 3, the resin member ( The joint strength between the C) 4 and the reinforcing member (B) 3 can be improved, and the bending strength and rigidity of the integrated molded body 1 can be further increased. 18 or 19, since the reinforcing member (B) 3 and the resin member (C) 4 are formed on the lower side when viewed from the plate material (A), the uppermost portion is formed on the lower side. is there.

In the present invention, the ratio Y/X of the projected area X (mm ² ) of the plate material (A) 2 and the projected area Y (mm ² ) of the reinforcing member (B) 3 is 0.01 to 0.2. Preferably. When there are a plurality of reinforcing members (B), the sum of the projected areas of the respective reinforcing members is the projected area Y (mm ² ), and when there is a portion where the projected areas overlap, the projected areas of the overlapping portions are the same.

When the Y/X ratio is in the range of 0.01 to 0.2, it is possible to satisfy the high rigidity of the integrated molded body 1 and the reduction in thickness and weight. The projected area is the area of the shadow formed when the member is illuminated with light, and the area of the shadow formed when illuminated with the light perpendicular to the plane of the plate material (A) 2 shown in FIG. In the bottom view in which the reinforcing member (B) 3 is arranged on the plate member (A) 2 shown in FIG. 21, the projected area Y of the reinforcing member (B) 3 is the projected area on the plane parallel to the plane of the plate member (A). Stipulate. The same applies to FIG. 10, FIG. 12, FIG. 15, FIG. 16, or FIG. 17, and the projected area on a plane parallel to the plane of the plate material (A) is defined as the projected area Y.

If Y/X is less than 0.01, the function as a reinforcing material may be reduced, and the rigidity of the integrated molded body 1 may be reduced. If Y/X exceeds 0.2, the amount of the reinforcing member (B) 4 used increases, and it may be difficult to satisfy the requirements for thinness and light weight. Y/X is preferably 0.02 to 0.18, more preferably Y/X is 0.02 to 0.15, and still more preferably Y/X is 0.025 to 0.10.

Further, in the present invention, in the cross-section portion orthogonal to the longitudinal direction of the reinforcing member (B) 3, the cross-sectional area of the reinforcing member (B) 3 is B2 (mm ² ) and the cross-sectional area of the resin member (C) 4 is C2 ( mm ² ), B2/C2 is preferably 0.01 to 0.8. When there are a plurality of reinforcing members (B), the sectional area B2 (mm ² ) is the sum of the sectional areas of the reinforcing members (B).

By increasing the cross-sectional area of the resin member (C) 4 by a certain amount with respect to the cross-sectional area of the reinforcing member (B) 3, the joint strength between the plate material (A) 2 and the reinforcing member (B) 3 can be improved. In addition, the bending strength and rigidity of the integrated molded body 1 can be further increased.

When B2/C2 is less than 0.01, the proportion of the reinforcing member (B) 3 present becomes small, and it becomes difficult to improve the bending strength and rigidity of the integrated molded body 1. When B2/C2 exceeds 0.8, the existence ratio of the resin member (C) 4 becomes small, and the bonding strength between the plate material (A) 2 and the resin member (C) 4 may not be sufficiently obtained. B2/C2 is preferably 0.05 to 0.5, more preferably B2/C2 is 0.1 to 0.4, and further preferably 0.15 to 0.35.

To express high rigidity and thin and lightweight integrally formed article 1, the preferred cross-sectional area B2 of the reinforcing member (B) 3 is 1 to 100 mm ^2, more preferably 4～50Mm ^2, more preferably 9 ˜30 mm ² . When the cross-sectional area B2 exceeds 100 mm ² , the thickness and/or width of the reinforcing member (B) 3 increases, the amount of the reinforcing member (B) 3 used increases, and it becomes difficult to satisfy the requirement for lightweight. There is. When the cross-sectional area B2 is less than 1 mm ² , it may be difficult to exert the function as the reinforcing member, and it may be difficult to obtain the reinforcing member (B) 3.

Further, it is preferable that the reinforcing member (B) 3 has an elongated shape and that the cross-sectional shape at any position in the longitudinal direction thereof is substantially the same. Substantially the same is defined as the difference in the projected area of the observation cross section being ±10% or less in the observation cross section cut out in the longitudinal direction. Even when there are a plurality of reinforcing members (B), it is preferable that each reinforcing member has substantially the same cross-sectional shape at any position in the longitudinal direction. Further, in order to realize high rigidity, thinness and lightness of the integrated molded body 1, the ratio B2/B3 of the maximum length B3 of the reinforcing member (B) 3 to the cross-sectional area B2 is 0.002 to 0. It is preferable to have a shape of 0.2.

Further, in the present invention, it is preferable that the plate material (A) 2 and the reinforcing member (B) 3 and/or the resin member (C) 4 are bonded via the bonding layer 13.

In particular, it is preferable to provide a bonding layer between the plate material (A) 2 and the resin member (C) 4. At this time, when the reinforcing member (B) 3 is arranged, if it is not possible to sufficiently bond it with one bonding layer, as shown in FIG. 22 and FIG. The layer 14 can be provided and then bonded to the first bonding layer 13. By providing such a joining layer, the joining force between the members can be strengthened.

When a nonwoven fabric of a thermoplastic resin is used as the first bonding layer 13, the plate material (A) 2 and the resin member (C) 4 can be bonded by being melted by the heat at the time of injection molding of the resin member (C) 4. Can be In this case, it is preferable to use the same kind of thermoplastic resin for the first bonding layer 13 and the resin member (C) 4. Even if they are not of the same type, they are not particularly limited as long as they have good compatibility, and the most suitable one can be selected depending on the type of resin constituting the resin member (C) 4. The first bonding layer 13 is not limited to a non-woven fabric, and its form is not particularly limited as long as it is a sheet shape such as a film.

If an adhesive is used as the second bonding layer 14, the reinforcing member (B) 3 can be positioned and fixed with high accuracy. As the adhesive, an acrylic-based, epoxy-based, styrene-based, nylon-based, or ester-based adhesive can be used.

Also. In the present invention, the reinforcing member (B) 3 is preferably composed of unidirectional reinforcing fibers and a thermosetting resin.

The reinforcing fibers contained in the reinforcing member (B) 3 are arranged in one continuous direction, and the thermosetting resin is used as the matrix resin, so that the reinforcing member effectively acts as a reinforcing member to increase the strength and rigidity of the integrated molded body 1. To do.

The reinforcing member (B) 3 is an elongated body having a constant length as shown in FIG. 6, FIG. 9 or FIG. 11, and is substantially the same as the outer periphery of the plate material (A) 2 whose longitudinal direction is a planar structure. It is preferable to arrange them in parallel, and it is preferable that the longitudinal direction of the reinforcing member (B) 3 and the fiber arrangement direction of the unidirectional fibers are substantially parallel to each other. The term “substantially parallel” means not only the case where the angles are perfectly parallel and the deviation angle is 0°, but also the range in which the deviation of ±10° from the parallel angle is allowable.
Further, as the material of the unidirectional reinforcing fibers forming the reinforcing member (B) 3, the reinforcing fibers described above for the resin member (C) 4 can be preferably used.

Examples of the thermosetting resin that constitutes the reinforcing member (B) 3 include unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol (resole type) resin, urea/melamine resin, polyimide resin, and maleimide resin. Thermosetting resins such as benzoxazine resins can be preferably used. You may apply the resin etc. which blended 2 or more types to these. Among these, the epoxy resin is particularly preferable from the viewpoint of mechanical properties of the molded body and heat resistance. The epoxy resin is preferably contained as the main component of the resin used in order to exhibit its excellent mechanical properties, and specifically, it is preferably contained in an amount of 60% by weight or more based on the resin composition.

Moreover, it is also preferable to use a thermoplastic resin as the resin forming the reinforcing member (B) 4. The thermoplastic resin of the reinforcing member (B) 4 is fused and fixed to the resin member (C) 3 to form a joint structure. As a result, higher joint strength can be realized as the integrated molded body 1. The melted and fixed joint structure refers to a joint structure in which mutual members are melted by heat, cooled, and fixed. As the kind of the thermoplastic resin, the thermoplastic resins exemplified for the resin member (C) 4 described above can be preferably used.

Further, in the present invention, the fiber weight content of the reinforcing member (B) 3 is preferably 65 to 82% by weight.

As a result, the bending strength and rigidity of the side wall portion of the integrated molded body 1 can be enhanced, and the warp of the integrated molded body 1 can be reduced. If it is less than 65% by weight, it may be difficult to secure the strength and rigidity of the integrated molded body 1, while if it exceeds 82% by weight, the resin impregnation into the carbon fiber is deteriorated, and the bending strength and rigidity of the side wall portion are increased. May be insufficient. The fiber weight content is preferably 68 to 80% by weight, more preferably 70 to 78% by weight, and further preferably 72 to 76% by weight.

Further, in the present invention, the plate material (A) 2 is preferably composed of continuous fibers and a thermosetting resin.

By using carbon fiber as the reinforcing fiber of the fiber-reinforced resin and continuous carbon fiber resin using thermosetting resin as the matrix resin, high rigidity, light weight and thinning can be realized. As the plate material (A) 2, from the viewpoint of enhancing the strength and rigidity of the integrated molded body 1, it is preferable to use a member having high strength and high rigidity and further excellent in lightness. As the reinforcing fiber and the thermosetting resin, the reinforcing fiber and the thermosetting resin described above can be used.

Next, a method for producing the integrated molded body according to the present invention will be described with reference to the drawings.

A plate material (A) 2 that is a rectangular planar structure made of fiber reinforced resin and a reinforcing member (B) 3 that is a long body are prepared in advance. Next, as shown in FIG. 24 [1] or [2], the plate material (A) 2 is placed in the lower molding die 15, and at least a part of the outer peripheral edge portion of the one side surface of the plate material (A) 2 is placed. The reinforcing member (B) 3 is arranged in the area. After that, as shown in FIG. 25[1], the upper molding die 16 is lowered to a position in contact with the plate material (A) 2 and discontinuous in the space formed by the lower molding die 15 and the molding die 16. A resin member (C) 4 made of fibers and a thermoplastic resin is injection molded from an injection gate 17. Thereby, the resin member (C) 4 can be joined so as to cover the reinforcing member (B) 3 and can be joined and integrated with the outer peripheral edge portion and the side surface region of the one side surface of the plate material (A) 2. FIG. 25 [2] shows the integrated molded body 1 molded in the lower molding die 15 after the upper molding die 16 is raised. According to such a manufacturing method, the plate material (A) 2, the reinforcing member (B) 3, and the resin member (C) 4 are bonded to each other, and the bonding strength between the reinforcing member (B) 3 and the plate material (A) 2 is increased. In addition, the strength and rigidity of the integrated molded body 1 can be increased.

Hereinafter, the integrated molded body 1 of the present invention and the method for producing the same will be specifically described by way of examples, but the following examples do not limit the present invention.

The measuring methods used in the examples are described below.

(1) Measurement of weight average fiber length The weight average fiber length Lw of the reinforcing fibers contained in the resin member (C) 4 was measured as follows. First, a part of the resin member (C) 4 to be measured was cut out from the integrated molded body 1 and heated in an electric furnace at 500° C. for 60 minutes to sufficiently incinerate and remove the resin to separate only the reinforcing fibers. Next, 400 or more were randomly extracted from the separated reinforcing fibers. The fiber lengths of these extracted reinforcing fibers were measured using an optical microscope, the lengths of 400 fibers were measured to the unit of 1 μm, and the weight average fiber length Lw was calculated using the following formula.
Weight average fiber length Lw=Σ(Mi ² ×Ni)/Σ(Mi×Ni)
Mi: Fiber length (mm)
Ni: Number of reinforcing fibers having a fiber length Mi

(2) Measurement of fiber weight content rate The fiber weight content rate of the plate material (A) 2, the reinforcing member (B) 3 or the resin member (C) 4 was measured by the following method. The plate material (A) 2, the reinforcing member (B) 3 or the resin member (C) 4 to be measured was cut out from the integrated molded body 1, and the weight w0 (g) thereof was measured. Next, the cut-out sample was heated in air at 500° C. for 1 hour to sufficiently incinerate and remove the resin component, and the weight w1 (g) of the remaining reinforcing fiber was measured. The fiber weight content (% by weight) was calculated using the following formula. The measurement was performed at n=3, and the average value was used.
Fiber weight content (% by weight)=(weight of reinforcing fiber w1/weight of cut sample w0)×100

(3) Evaluation of integrated molded body The integrated molded body 1 was placed in a universal testing machine, a load was applied to the outer peripheral edge portion by a load cell, and its deflection was evaluated.

First, a plate member (A) 2 having a square shape of 450×450 mm and a plate thickness of 1.2 mm, a reinforcing member (B) 3 and a resin member (C) that are long members having the same length as one side of the plate member (A) 2. As shown in FIGS. 1 to 4, an integrated molded body 1 was prepared in which 4 were arranged on the four sides of the plate material (A) 2. The preparation method was as in Example 1 described later.

Next, as shown in FIGS. 26 and 27, the two opposite sides of the integrated molded body 1 were placed on a horizontal fixed base 18. The fixing base is a square whose one side of the cross section has the same length as the lower one side of the resin member (C) 4 and has the same length as one side of the plate material (A) 2. did.

Next, as shown in FIG. 28 and FIG. 29, a load was applied by using the load cell 20 to one of the sides of the integrally molded body 1 which was not fixed to the fixed base. The load cell 20 was lowered in a direction perpendicular to the central portion of one side of the integrated molded body 1. The load was 500N. In addition, the support base 19 was arranged at a position separated by ±30 mm in the left-right direction in the longitudinal direction of the side from the point of applying a load by the load cell 20. The distance between the support stands 19 was 60 mm. The support 19 has a triangular prism shape, and is placed horizontally and supported by the top side. The length in contact with the integrated molded body 1 was the same as one side below the resin member (C) 4.

As shown in FIG. 30, the load cell 20 is pressed from above the position where the reinforcing member (B) 3 is located, and the diameter of the cross section perpendicular to the load direction where the load cell 20 contacts the integrally molded body 1 is the reinforcing member. (B) The width was set to be substantially the same as the horizontal width in the cross section perpendicular to the longitudinal direction of (3).

(Material composition example 1) Adjustment of bidirectional cloth prepreg Epoxy resin film (base resin: dicyandiamide/dichlorophenylmethylurea curing epoxy) on a sheet-shaped bidirectional cloth using a PAN-based carbon fiber bundle (Toray, product number: T300) Resin) and two epoxy resin films are stacked from both sides of the carbon fiber bundle, and the resin is impregnated by heating and pressing to produce a bidirectional cross prepreg having a carbon fiber weight content of 56% and a thickness of 0.24 mm. ..

(Material Composition Example 2) Adjustment of Reinforcement Member (B) 3 Reinforcement member (B) 3 was produced by the pultrusion process shown in FIG. First, the reinforcing fiber bundle 30 (manufactured by Toray, product number: T700) is pulled out from the creel 31, the reinforcing fiber bundle 30 is introduced into the resin bath 32 through the guide roll, and the thermosetting resin composition is attached thereto. The squeeze 33 was rubbed to impregnate the reinforcing fiber bundle 30 with the thermosetting resin composition and the excess thermosetting resin composition was partially removed. Further, the positions of the reinforcing fibers were determined one by one by the guide, so that the reinforcing fibers were made to enter into the pultrusion molding die 34 having a desired cross-sectional shape with good balance. The resin that cannot pass through the die together with the reinforcing fibers and eventually becomes the excess resin was backflowed from the mold and drooped from the die entrance to be removed. The resin-impregnated fiber base material 35 impregnated with the thermosetting resin composition is heated while passing through the pultrusion molding die 34 to cure the thermosetting resin composition, and is discharged from the outlet of the pultrusion molding die. A long-sized reinforcing member (B) 3 was produced.

(Material composition example 3) Adjustment of resin member (C) 4 Carbon fiber pellets (manufactured by Toray Industries, Inc., product number: TLP1040, long fiber carbon fiber reinforced 6 nylon, fiber weight content is shown in Table 1).

(Material composition example 4) Adjustment of bonding layer (thermoplastic adhesive film) Pellets of polyamide resin (CM8000 manufactured by Toray Industries, Inc., quaternary copolyamide 6/66/610/12, melting point 130°C) are press-molded. Then, a thermoplastic adhesive film having a thickness of 0.05 mm was obtained. This was used as the bonding layer 13.

(Example 1)
The bidirectional cross prepreg obtained in Material Composition Example 1 was adjusted to a size of 450 mm square, 5 ply was laminated, and the bonding layer 1 ply obtained in Material constitution 4 was laminated thereon. The laminate was placed on a press die having a board surface temperature of 150° C., the board surface was closed, and hot pressing was performed at 3 MPa. After a lapse of 10 minutes from the pressurization, the board surface was opened to obtain a flat plate-shaped thermosetting carbon fiber reinforced resin board having a board thickness of 1.2 mm. This was designated as plate material (A)2.

Next, as shown in FIG. 22, on the rectangular reinforcing member (B) 3 shown in FIG. 6 obtained in Material Composition Example 2, as shown in FIG. 22, an epoxy resin adhesive (manufactured by Henkel Japan KK, The product number: E-120HP) was applied and then applied on the outer peripheral edge of the plate material (A) 2. Thereafter, as shown in FIG. 24, the plate material (A) 2 to which the reinforcing member (B) 3 was attached was placed on the lower molding die 15.

Next, as shown in FIG. 25, the upper molding die 16 is lowered to a position in contact with the plate material (A) 2, the upper molding die 16 is set, and after clamping the mold, the lower molding die 15 is formed. A resin member (C) 4 composed of the discontinuous carbon fiber obtained in Material Composition Example 3 and a thermoplastic resin is injection-molded from an injection gate port 17 into a space formed by the molding die 16 and the molding die 16, as shown in FIG. -The integrated molded body 1 illustrated in FIG. 4 was manufactured. The material composition, physical properties, etc. of the integrated molded body 1 are summarized in (Table 1). After Example 2, the material composition shown in (Table 1) was used.

The plate material (A) 2 was square in Examples 1 to 6, and in Example 7 four sides of the outer peripheral edge were bent so that the radius of curvature was 4 mm to form the curved shape section 5.

In Examples 1 to 7 in which the reinforcing member was arranged, the evaluation value of strain was 1.4 or less, and the integrated molded body 1 having high rigidity with a level of no problem in practical use was obtained. In Comparative Example 1 in which no reinforcing member was provided, the deflection evaluation value was high, which was a problematic level in practical use.

INDUSTRIAL APPLICABILITY The integrated molded body of the present invention can be effectively used for automobile interiors and exteriors, electric/electronic device casings, bicycles, sports material structural materials, aircraft interior materials, transportation boxes, and the like.

1 Integrated molded body 2 Plate material (A)
3 Reinforcement member (B)
4 Resin member (C)
5 curved shape part 6 side surface part 7 of the plate material (A) 7 one surface part under the resin member (C) 8 one surface part 9 of the cross-sectional shape of the reinforcing member (B) 9 another surface part 11 of the reinforcing member (B) 11 reinforcing member (B) Height of top part 12 12 Height of top part of resin member (C) 13 First bonding layer 14 provided on at least a part between the reinforcing member (B) and the resin member (C) Reinforcement Second bonding layer 15 provided on at least a part between the member (B) and the plate material (A) Lower molding die 16 Upper molding die 17 Injection gate port 18 Fixed base 19 Support base 20 Load cell 21 Expanded area 30 Reinforcing fiber bundle 31 Creel 32 Resin bath 33 Squeeze 34 Pultrusion mold

Claims (11)

A plate member (A) that is a rectangular planar structure made of fiber reinforced resin, a reinforcing member (B) that is a long body, and a resin member (C) that is made of discontinuous fibers and a thermoplastic resin. It is an integrated molded body,
The reinforcing member (B) is arranged in at least a part of an outer peripheral edge portion of one surface of the plate material (A),
The resin member (C) is joined to at least a partial region of the reinforcing member (B), and at least a partial region of the outer peripheral edge portion of one side surface of the plate material (A) and/or at least a portion of a side surface thereof. An integrated molded body characterized by being bonded to the region of. The integrated molded body according to claim 1, wherein the shape of the cross section of the reinforcing member (B) orthogonal to the longitudinal direction is any one of a circular shape, an elliptical shape, and a rectangular shape. The integrated molded body according to claim 1, wherein at least a part of an outer peripheral edge portion of the plate material (A) has a curved curved shape portion. The integrated molded body according to claim 3, wherein the cross-sectional shape of the reinforcing member (B) is an elongated body that partially has a curved surface that matches the curved shape of the curved shape portion of the plate material (A). The integrated molded body according to any one of claims 1 to 4, wherein the resin member (C) is joined to the entire area of the side surface of the plate material (A). The shape of the resin member (C) in the region joined to at least a part of the outer peripheral portion of the plate member (A) is the height of the top of the reinforcing member (B) (the plate member (A) and the plate member (A)). The integrated molded body according to any one of claims 1 to 5, which has a portion formed at a height equal to or more than a distance from a joint portion with the reinforcing member (B) to a position farthest from the joint portion. The ratio Y/X of the projected area X (mm ² ) of the plate material (A) and the projected area Y (mm ² ) of the reinforcing member (B) is 0.01 to 0.2. The integrated molded body according to any one of 1. When the cross-sectional area of the reinforcing member (B) is B2 (mm ² ) and the cross-sectional area of the resin member (C) is C2 (mm ² ) in the cross-sectional portion orthogonal to the longitudinal direction of the reinforcing member (B), B2/C2 is 0.01-0.8, The integrated molding in any one of Claims 1-7. The integrated molded body according to any one of claims 1 to 8, wherein the plate material (A) and the reinforcing member (B) and/or the resin member (C) are bonded via a bonding layer. The integrated molded body according to any one of claims 1 to 9, wherein the reinforcing member (B) is composed of a unidirectional reinforcing fiber and a thermosetting resin. The integrated molded body according to any one of claims 1 to 10, wherein the plate material (A) is composed of continuous fibers and a thermosetting resin.