JP5648270B2 - Fiber-reinforced composite material molded article and its manufacturing method - Google Patents

Description

The present invention relates to a method of manufacturing a fiber-reinforced composite material molded article and its.

  BACKGROUND ART Fiber reinforced composite materials (hereinafter referred to as “FRP”) are used for aircraft, automobiles, sports, leisure, and other various industrial applications because of their light weight and high strength. In addition, FRP has a characteristic anisotropic gloss due to the orientation of the fiber bundling body constituting the FRP, and further has features such as giving a deep and heavy appearance by applying a treatment such as painting to the surface. Have.

In recent years, in addition to these features, many FRPs imparted with flame retardancy have been studied, and applications from various electrical / electronic equipment casings to aircraft interior parts, automobile interior parts, and the like are expanding. When used in these electrical / electronic equipment casings, aircraft interior parts, and automobile interior parts, a three-dimensional member obtained by joining and integrating the same type of FRP, thermoplastic resin, metal material, etc. to the FRP plate is often used. .
For example, Patent Document 1 discloses a carbon fiber composite molded article in which a thermoplastic resin is injection-molded and bonded and integrated on the surface of a flexible carbon fiber composite material plate.

Japanese Patent No. 3035409

  However, as described in Patent Document 1, when the thermoplastic resin is injection-molded into the FRP and bonded and integrated, the adhesiveness at the end face of the bonded portion between the FRP and the thermoplastic resin may be insufficient. The FRP and the thermoplastic resin sometimes peeled off.

  The present invention has been made in view of the above circumstances, and it is an object of the present invention to provide a fiber-reinforced composite material molded article having excellent adhesion and a method for producing the same, particularly at the end face of the joint portion between the fiber-reinforced composite material and the thermoplastic resin. .

The fiber-reinforced composite material molded article of the present invention is a fiber-reinforced composite material molded article obtained by injection-molding a thermoplastic resin on a surface of a sheet-like fiber-reinforced composite material in which a reinforcing resin is impregnated with a matrix resin. The fiber reinforced composite material joined to the thermoplastic resin is characterized in that an end surface is not parallel to the thickness direction of the fiber reinforced composite material.
The reinforcing fiber is preferably a carbon fiber.
Furthermore, it is preferable that the matrix resin is an epoxy resin containing phosphorus.
Moreover, it is preferable that the thermoplastic resin is an alloy resin of a polycarbonate resin and an acrylonitrile-butadiene-styrene resin.
Furthermore, it is preferable that the joining and integration be performed by an injection press.

In addition, the method for producing a fiber-reinforced composite material molded article according to the present invention is a fiber-reinforced composite in which a thermoplastic resin is injection-molded and joined and integrated on the surface of a sheet-like fiber-reinforced composite material in which a reinforcing fiber is impregnated with a matrix resin. A method for producing a material molded article, wherein after forming an end face so as not to be parallel to the thickness direction of the fiber reinforced composite material, of the joint portion of the fiber reinforced composite material with the thermoplastic resin, The thermoplastic resin is injection-molded.
Furthermore, it is preferable to injection-mold the thermoplastic resin by an injection press.

The fiber-reinforced composite material molded article of the present invention is excellent in adhesiveness particularly at the end face of the joint portion between the fiber-reinforced composite material and the thermoplastic resin.
Moreover, according to the manufacturing method of the fiber reinforced composite material molded article of the present invention, a fiber reinforced composite material molded article having excellent adhesion can be obtained particularly at the end face of the joint portion between the fiber reinforced composite material and the thermoplastic resin.

It is sectional drawing which shows an example of the fiber reinforced composite material molded article of this invention. It is a perspective view which shows an example of the fiber reinforced composite material which comprises the fiber reinforced composite material molded article of FIG. It is a perspective view which shows the other example of a fiber reinforced composite material. It is a perspective view which shows the other example of a fiber reinforced composite material. It is a perspective view which shows the other example of a fiber reinforced composite material. It is sectional drawing which shows an example of the fiber reinforced composite material molded article using the fiber reinforced composite material shown in FIG. It is sectional drawing which shows an example of the fiber reinforced composite material molded article using the fiber reinforced composite material shown in FIG. It is sectional drawing which shows an example of the fiber reinforced composite material molded article using the fiber reinforced composite material shown in FIG. 6 is a cross-sectional view showing a fiber-reinforced composite material molded product obtained in Comparative Example 1.

Hereinafter, the present invention will be described in detail with reference to the drawings.
FIG. 1 is a cross-sectional view showing an example of a fiber-reinforced composite material molded article of the present invention. In the fiber-reinforced composite material molded article 10 of this example, an injection-molded thermoplastic resin 12 is joined and integrated on the surface of a sheet-like fiber-reinforced composite material (hereinafter referred to as “FRP”) 11.

<Fiber reinforced composite material>
As FRP11 used for this invention, what laminated | stacked multiple prepreg which impregnated the matrix resin to the reinforced fiber as needed, and shape | molded under high temperature high pressure is mentioned.
As the reinforcing fiber, various inorganic fibers or organic fibers such as carbon fiber, aramid fiber, nylon fiber, high-strength polyester fiber, glass fiber, boron fiber, alumina fiber, and silicon nitride fiber can be used. Among these, carbon fiber, aramid fiber, glass fiber, boron fiber, alumina fiber, and silicon nitride fiber are preferable from the viewpoint of flame retardancy, and carbon fiber is particularly preferable in terms of excellent specific strength and specific elasticity.
The form of the reinforcing fiber may be aligned in one direction, or may be a woven fabric or a non-crimp fabric.

Examples of the matrix resin include known thermosetting resins and thermoplastic resins.
Examples of the thermosetting resin include an epoxy resin, a phenol resin, a vinyl ester resin, a bismaleimide resin, a melamine resin, and an unsaturated polyester resin.
Examples of the thermoplastic resin include polyamide (PA) resin, acrylonitrile-butadiene-styrene (ABS) resin, acrylonitrile-ethylene-styrene (AES) resin, acrylonitrile-styrene-acrylate (ASA) resin, polyethylene terephthalate (PET) resin, Polycarbonate (PC) resin, polymethyl methacrylate (PMMA) resin, polybutylene terephthalate (PBT) resin, polyether sulfone (PES) resin, polyphenylene ether (PPE) resin, polyphenylene sulfide (PPS) resin, polyether ether ketone (PEEK) ) Resin, polyether ketone ketone (PEKK) resin, polyimide (PI) resin, polytetrafluoroethylene (PTFE) resin, polyether resin, polyolefin Resin (PO) resin, liquid crystal polymer resin, polyarylate resin, polysulfone resin, polyacrylonitrile styrene (PAS) resin, polystyrene (PS) resin, polyacrylonitrile (PAN) resin, polyvinyl chloride (PVC) resin, etc. It is done.
Among these, a thermosetting resin, particularly an epoxy resin is preferable in terms of excellent toughness and impact resistance. Furthermore, in consideration of use in electrical / electronic equipment casings, aircraft / automobile interior parts, and various industrial products, epoxy resins containing phosphorus are particularly preferable in terms of flame retardancy.

The FRP 11 is characterized in that the end surface 11 a is not parallel to the thickness T ₁ direction of the FRP 11 in the portion where the thermoplastic resin 12 is joined. Thereby, the joining area with the thermoplastic resin in the end surface 11a is expanded as compared with the fiber-reinforced composite material molded product 50 as shown in FIG. Therefore, the adhesiveness between the FRP and the thermoplastic resin is improved particularly at the end face of the joint portion between the FRP and the thermoplastic resin.
Incidentally, a fiber-reinforced composite material molded article 50 shown in FIG. 9, of the portion where the thermoplastic resin 52 is bonded to the FRP51 surface of the parallel end surfaces 51a is the thickness _{T 5} direction FRP51, thermoplastic resin 52 is injection-molded and integrated.

Shape of the end face 11a of the FRP11 may if not parallel to the thickness _{T 1} direction is not particularly limited. For example, as shown in FIGS. 1 and 2, a shape in which R processing is performed on both sides of the ridge angle of the end surface 11 a of the FRP 11, and a shape in which R processing is performed only on the upper side of the ridge angle of the end surface 21 a of the FRP 21 as illustrated in FIG. 3. consists in one plane 31a of the upper dihedral angle of the end face 31a of the FRP31 is chamfered 'as shown in FIG. 4, the shape of different orientations of the flat surface to the thickness T ₃ direction, the thickness of FRP41 as shown in FIG. 5 For example, the shape changes gradually.
As shown in FIG. 5, when the end face 41a of the FRP41 has two or more planes 41a ', if the orientation of at least one plane different from the thickness _{T 4} direction FRP41, orientation of the remaining plane thickness may be the same as the T ₄ direction, it may be different.

<Thermoplastic resin>
As the thermoplastic resin to be injection-molded on the surface of the FRP, for example, the thermoplastic resin exemplified above in the description of the matrix resin, polyvinyl formal (PVF), or an alloy resin formed by combining these resins can be injection-molded. Any resin can be used, and it can be appropriately selected and used in consideration of adhesiveness with FRP. Among these, ABS resin, AES resin, ASA resin, polyamide resin, alloy resin of PC resin and ABS resin, alloy resin of PC resin and AES resin, PC resin and ASA resin are excellent in toughness and versatility. And an alloy resin of an ABS resin, a PC resin and an ABS resin are particularly suitable.
In addition, additives such as reinforcing fibers, reinforcing fillers, flame retardants, colorants, stabilizers and the like may be appropriately blended in the thermoplastic resin that is injection-molded on the surface of the FRP.

<Production method of fiber-reinforced composite material molded product>
The fiber-reinforced composite material molded article of the present invention can be produced as follows.
First, the end face is formed so that the end face is not parallel to the thickness direction of the FRP in the joining portion of the FRP with the thermoplastic resin. As a method for forming the end face, for example, a method of scraping the end of the FRP so that the end face is not parallel to the thickness direction of the ERP can be mentioned.
The way of cutting the end of the FRP is not particularly limited. For example, as shown in FIGS. 1 and 2, a method of chamfering all of the end 11b of the FRP 10 (that is, a method of performing R processing on both the top and bottom of the ridge angle), FIG. As shown in FIG. 4, a method of chamfering a part of the end portion 21b of the FRP 20 (that is, a method of performing R processing only on the upper side of the ridge angle), and as shown in FIG. 4, the end portion 31b of the FRP ₃₀ is different from the thickness T3 direction. A method of cutting in the direction, a method of cutting the end portion 41b of the FRP 40 so that two or more planes 41a ′ are formed on the end surface 41a as shown in FIG. 5 and the directions of the adjacent planes 41a ′ are different from each other. Etc.

Next, the FRP with the end cut off is put into a mold and a thermoplastic resin is injection-molded to obtain a fiber-reinforced composite material molded product in which the FRP and the thermoplastic resin are joined and integrated.
The injection conditions are not particularly limited, and may be set as appropriate according to the type of FRP and thermoplastic resin used and the shape of the mold.

  For example, when the FRP 11 shown in FIG. 2 is used, a fiber reinforced composite material molded article 10 in which the FRP 11 and the thermoplastic resin 12 are joined and integrated as shown in FIG. 1 is obtained. When the FRP 21 shown in FIG. 3 is used, a fiber reinforced composite material molded product 20 in which the FRP 21 and the thermoplastic resin 22 are joined and integrated as shown in FIG. 6 is obtained. When the FRP 31 shown in FIG. 4 is used, a fiber-reinforced composite material molded product 30 in which the FRP 31 and the thermoplastic resin 32 are joined and integrated as shown in FIG. 7 is obtained. When the FRP 41 shown in FIG. 5 is used, a fiber reinforced composite material molded product 40 in which the FRP 41 and the thermoplastic resin 42 are joined and integrated as shown in FIG. 8 is obtained.

  The fiber-reinforced composite material molded product of the present invention can be manufactured using an existing injection molding machine, but can be molded into a large molded product, and the adhesiveness between the FRP and the thermoplastic resin becomes stronger. It is preferable to use an injection press.

  In the present invention, an FRP is prepared by laminating a plurality of prepregs having different sizes so that the end of the FRP has a shape as shown in FIGS. 2 to 5, for example, and thermoplasticity is produced using the FRP. A resin reinforced composite material molded product may be manufactured by injection molding.

As described above, according to the present invention, the FRP having an end surface that is not parallel to the thickness direction of the FRP is used for injection molding of the thermoplastic resin on the surface of the FRP. Therefore, the bonding area with the thermoplastic resin at the end of the FRP is expanded. Therefore, a fiber-reinforced composite material molded article having excellent adhesion at the end face of the joint portion between the FRP and the thermoplastic resin and being difficult to peel off the FRP and the thermoplastic resin can be obtained.
In addition, the fiber-reinforced composite material molded product obtained by the present invention has the characteristics inherent to FRP, that is, light weight, excellent strength, rigidity, dimensional stability, durability, shock absorption, and a depth unique to FRP. Has a heavy appearance.

  Hereinafter, the present invention will be specifically described with reference to examples. However, the present invention is not limited to these.

[Example 1]
<FRP production>
A prepreg (Pyrofil prepreg manufactured by Mitsubishi Rayon Co., Ltd., “product number: TR380G200S”, fiber basis weight 200 g / m ² , resin content 33 mass%) is cut into 300 mm × 300 mm, and the carbon fiber is 0 ° / 90 ° / 90. 4 sheets were stacked so that the orientation was at 0 ° / 0 °, and cured in an autoclave under conditions of 130 ° C. × 90 minutes, heating rate 2 ° C./minute, pressure 0.6 MPa, and 0.8 mm thick FRP was obtained. .
Next, after cutting the obtained FRP into 280 mm × 220 mm, the end of the FRP was shaved so that the thickness of the FRP was changed stepwise as shown in FIG.

<Manufacture of fiber reinforced composite material molded products>
FRP with the end cut off is set on the bottom of the mold, and a thermoplastic resin (flammable polycarbonate resin and ABS resin alloy made by UMGABS Co., Ltd., “Product No .: CX55A”) is set at a cylinder temperature of 230 ° C. Under the condition of a temperature of 60 ° C., injection molding is performed so that the height of the thermoplastic resin becomes 5 mm, and FRP 41 (thickness T ₄ : 0.8 mm) and the thermoplastic resin 42 (height as shown in FIG. 8). H: 5 mm) was joined and integrated to obtain a fiber reinforced composite material molded product 40.

The obtained fiber reinforced composite material molded article has good adhesion between the FRP and the thermoplastic resin, particularly at the end face of the joint portion between the FRP and the thermoplastic resin, and even when dropped from a height of 1 m. FRP and the thermoplastic resin were not peeled off.
In addition, the appearance has a high-class profound feeling peculiar to FRP, and can be effectively used for various industrial products such as electrical and electronic equipment casings, aircraft and automobile interior parts.

[Example 2]
Except for using a carbon fiber cloth prepreg (manufactured by Mitsubishi Rayon Co., Ltd., “Part No .: TR3110 380GMP”, fiber basis weight 200 g / m ² , resin content 40% by mass) as the prepreg for FRP, the same as in Example 1. As shown in FIG. 2, the end portion of the FRP was cut so that the end surface of the FRP was rounded by R processing on both the upper and lower sides of the ridge angle. Next, in the same manner as in Example 1, a fiber-reinforced composite material molded article in which the FRP and the thermoplastic resin were joined and integrated was obtained.
The obtained fiber-reinforced composite material molded article had good adhesion between the FRP and the thermoplastic resin, in particular, the adhesion at the end face of the joined portion of the FRP and the thermoplastic resin, as in Example 1. Even when dropped from the height, the FRP and the thermoplastic resin did not peel off.
In addition, the appearance has a high-class profound feeling peculiar to FRP, and can be effectively used for various industrial products such as electrical and electronic equipment casings, aircraft and automobile interior parts.

[Example 3]
As a prepreg for FRP, carbon fiber (Mitsubishi Rayon Co., Ltd., “Product No .: TR50S15L”) aligned in one direction is impregnated with an epoxy resin containing phosphorus (fiber basis weight 225 g / m ² , resin content 30 (Mass%) Except for using 4 sheets, FRP was produced in the same manner as in Example 1, and the end face of the FRP was chamfered at the upper ridge angle and the cross-section was trapezoidal as shown in FIG. Sharpened the edge. Next, in the same manner as in Example 1, a fiber-reinforced composite material molded article in which the FRP and the thermoplastic resin were joined and integrated was obtained.
The obtained fiber-reinforced composite material molded article had good adhesion between the FRP and the thermoplastic resin, in particular, the adhesion at the end face of the joined portion of the FRP and the thermoplastic resin, as in Example 1. Even when dropped from the height, the FRP and the thermoplastic resin did not peel off.
In addition, the appearance has a high-class profound feeling peculiar to FRP, and can be effectively used for various industrial products such as electrical and electronic equipment casings, aircraft and automobile interior parts.

[Comparative Example 1]
A thermoplastic resin was injection molded on the surface of the FRP under the same conditions as in Example 1 except that the end of the FRP was not cut, and the FRP 51 and the thermoplastic resin 52 were joined and integrated as shown in FIG. A fiber-reinforced composite material molded product 50 was obtained.
The obtained fiber reinforced composite material molded article had good adhesion between FRP and thermoplastic resin at first glance, but when dropped from a height of 1 m, FRP and thermoplastic resin were peeled off.

10, 20, 30, 40, 50: Fiber-reinforced composite material molded article,
11, 21, 31, 41, 51: fiber reinforced composite material,
11a, 21a, 31a, 41a, 51a: end face,
11b, 21b, 31b, 41b: end,
12, 22, 32, 42, 52: thermoplastic resin,
T ₁ , T ₃ , T ₄ , T ₅ : thickness.

Claims (4)

A fiber-reinforced composite material molded product obtained by injection-molding a thermoplastic resin on a surface of a sheet-like fiber-reinforced composite material impregnated with a matrix resin in a reinforced fiber,
The fiber-reinforced composite material to be bonded to the thermoplastic resin has two or more planes adjacent to the end surface, rather parallel orientation of at least one plane with respect to the thickness direction of the fiber-reinforced composite material In addition, a fiber-reinforced composite material molded article in which the thickness at the end face changes stepwise . The fiber-reinforced composite material molded article according to claim 1, wherein the joint integration is performed by an injection press. On the surface of the fiber-reinforced composite material of the sheet which the matrix resin is impregnated into reinforcing fibers, a method for producing a fiber-reinforced composite material molded article integrally bonding a thermoplastic resin injection molding to,
Two or more planes adjacent to the end face are formed in the joint portion of the fiber reinforced composite material with the thermoplastic resin, and the direction of at least one plane is parallel to the thickness direction of the fiber reinforced composite material. A method for producing a fiber-reinforced composite material molded article, in which the thermoplastic resin is injection-molded after forming the end face so that the thickness at the end face changes stepwise . The method for producing a fiber-reinforced composite material molded article according to claim 3 , wherein the thermoplastic resin is injection-molded by an injection press.

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