JP5828380B2 - Composite molded body and method for producing the same - Google Patents

Description

  The present invention relates to a composite molded body and a method for manufacturing the same, and more particularly to a method for manufacturing a composite molded body in which a preform is placed in a mold and insert molding, and a composite molded body manufactured by the method.

  A fiber reinforced resin obtained by melting and impregnating a reinforced fiber with a matrix resin is widely used for reinforcement of members and surface formation in various fields by utilizing its excellent mechanical properties. In order to obtain an excellent reinforcing effect, continuous fibers are often used as reinforcing fibers, and in particular, continuous reinforcing fibers are aligned in one direction in a strip shape (tape shape) and impregnated with resin. It is preferably used in the direction of a directional prepreg. For example, Patent Document 1 discloses a molding material (unidirectional prepreg) having a substantially parallelogram cross-sectional shape using a thermoplastic resin as a matrix resin.

  However, it has been difficult to form a complicated shape such as a three-dimensional shape or a structure having a rib by using such a unidirectional prepreg alone. For this reason, for example, insert-molding a plate-like fiber reinforced resin (molding in which a thermoplastic resin is injection-molded so as to cover all or part of the plate-like fiber reinforced resin is combined and integrated) is complicated. A technique for realizing a member having a shape is widely used (for example, Patent Documents 2 to 4). In this insert molding, there is a problem in that the adhesion between the fiber reinforced resin and the thermoplastic resin to be injection-molded later is not sufficient.

JP 2000-355629 A International Patent WO2004 / 60658 Pamphlet JP 2010-253801 A JP 2010-274508 A

  For example, Patent Documents 3 and 4 attempt to improve the adhesion by physical engagement. However, when the fiber reinforced resin to be inserted is, for example, a convex shape and forms a closed space with a mold as disclosed in Patent Document 3, a thermoplastic resin to be injection-molded later is a fiber reinforced resin. The problem that the objective of improving the adhesiveness, which is the original purpose, is difficult to achieve due to the fact that it does not flow well into the closed space along the form of the above. Furthermore, the grooves and spaces on the surface of the composite molded body formed without the resin flowing in are not limited to adhesion problems, and cause adverse effects in terms of environmental durability, such as moisture entering from the grooves and spaces. In addition to this, problems in the appearance of the composite molded body were also generated.

  In view of the above circumstances, the present invention provides a composite molded body and a method for producing the same, which are particularly excellent in adhesion between a fiber reinforced resin and a resin, its reliability, and its appearance.

In order to solve the above-mentioned problems, a method for producing a composite molded body according to the present invention includes pre-molding a fiber reinforced resin A whose matrix resin is made of a thermoplastic resin in a mold as a preform, A method of manufacturing a composite molded body in which a liquefied resin B is supplied around the fiber reinforced resin A and the fiber reinforced resin A is insert-molded, and the side surface of the fiber reinforced resin A that contacts the resin B in concave type least two distances between have a slanted surface inclined surface is maximized at a concave opening shape side of the extending obliquely in opposite directions from the opening of so as to form a concave, and A side surface having an undercut shape having a depth within a range of 0.1T to 0.9T with respect to the thickness T of the fiber reinforced resin A is formed on at least a part of the side surface before insert molding. Ii How the fiber-reinforced resin A prior insert molded placed in a mold on the inner surface, the fiber-reinforced resin A and supplying the resin B to be placed on at least one surface of the composite compact (First method) . In the present invention, a pre-molded fiber reinforced resin A whose matrix resin is made of a thermoplastic resin is placed in a mold as a preform, and a resin B liquefied around the fiber reinforced resin A in the mold is obtained. A method of manufacturing a composite molded body in which the fiber reinforced resin A is supplied and insert-molded, and the side surfaces of the fiber reinforced resin A that are in contact with the resin B are formed from the openings of the concave mold so as to form a concave mold. It is a side surface of a shape having two inclined surfaces extending in an inclined direction in the opposite direction, the inclined surfaces being directly connected to each other, and an inflection point is formed between the inclined surfaces, and at least a part of the side surface The side surface of the shape having an undercut shape whose depth is in the range of 0.1T to 0.9T with respect to the thickness T of the fiber reinforced resin A is formed before insert molding, and before the insert molding, Fiber reinforced resin A A method for producing a composite molded body (second method), wherein the resin B is supplied so that the fiber reinforced resin A is disposed on at least one surface of the composite molded body. ).

In the manufacturing method (first method) of the composite molded body according to the present invention as described above, in the fiber reinforced resin A to be insert-molded, a concave shape is formed at different angles as side surfaces in contact with the resin B, in particular. side shape distance between have at least two inclined surfaces extending obliquely in opposite directions from the opening of the concave type inclined surface is maximized at a recessed opening such that is formed before the insert molding Has been. At the time of insert molding, the resin B also flows into the side surface portion of the fiber reinforced resin A having the inclined surface. If a closed space in which the resin B does not easily flow into the side surface portion is formed, As described above, it is difficult to achieve the purpose of improving the adhesion between the fiber reinforced resin A and the resin B, and undesirable grooves and spaces are formed in the portion, causing environmental durability problems due to intrusion of moisture, etc. There is a possibility of causing a problem of deteriorating the appearance quality of the molded body. In the present invention, however, the side surface of the fiber reinforced resin A is formed on the side surface of the shape having at least two inclined surfaces, the two inclined surfaces in the opposite directions from the opening of the concave type so as to form a concave since the distance between the extending inclined surface inclined to become from the side of the shape becomes maximum in recessed openings, the angle between the two inclined surfaces, for example, a side surface (e.g., one of the inclined surface made of one surface side ) And the inner surface of the mold on which the fiber reinforced resin A is disposed (for example, the inner surface of the mold on which one of the upper and lower surfaces of the fiber reinforced resin A is in contact) is easily a much larger angle. It is said. Moreover, since the distance between the inclined surfaces is a side surface having a maximum shape at the concave opening, it is difficult to form a closed space in which the resin B hardly flows between the inclined surfaces, and the resin B is a fiber-reinforced resin A. It becomes possible to flow in until it makes good contact over the entire side surface. As a result, the adhesion between the fiber reinforced resin A and the resin B and the reliability thereof are ensured, and the deterioration of the appearance of the resulting composite molded article is also prevented. The side surface of the fiber reinforced resin A has at least two inclined surfaces inclined in a concave shape in opposite directions, and the resin B is good without forming an undesired closed space between the inclined surfaces as described above. As a composite molded body, a form in which the fiber reinforced resin A portion hardly falls off from the resin B is achieved (that is, the side surface of the fiber reinforced resin A has a concave shape that has entered the fiber reinforced resin A main body side. Shape, in particular, a form in which an undercut shape is formed is achieved in the present invention), and a composite molded body having extremely high bonding strength between the fiber reinforced resin A and the resin B is realized. Also in the method for producing a composite molded body according to the present invention as the second method, the side surfaces of the fiber reinforced resin A that are in contact with the resin B are inclined in opposite directions from the opening of the concave mold so as to form a concave mold. The side surfaces of the shape in which the inclined surfaces are directly connected to each other and the inflection points are formed between the inclined surfaces (that is, the shapes as shown in FIGS. 1 and 2 described later). Therefore, the distance between the two inclined surfaces is inevitably a side surface having a maximum shape at the concave opening, and a closed space in which the resin B does not easily flow is formed between the two inclined surfaces. It becomes difficult, and the resin B can flow in until it contacts well over the entire side surface of the fiber reinforced resin A. As a result, as described above, the adhesion between the fiber reinforced resin A and the resin B and the reliability thereof are ensured, and the deterioration of the appearance of the resulting composite molded article is also prevented. Moreover, the composite molded body in which the bonding strength between the fiber reinforced resin A and the resin B is extremely high is realized by forming the undercut shape.

Note that at least two inclined surfaces formed on the side surfaces of the fiber reinforced resin A and inclined in a concave shape at different angles are directly connected to each other at the ends of both inclined surfaces as in the second method. It can be configured to have an inflection point of an angle between the inclined surfaces, or can be configured to have a side surface portion having an intermediate angle between the inclined surfaces, or a cross section between the inclined surfaces. It can also be set as the form which the shape connected in the side part of circular arc shape. In addition, the at least two inclined surfaces inclined concavely at different angles do not necessarily have to be inclined at the same angle in the opposite direction, but may be inclined in the opposite direction at different angles.

In the method for producing a composite molded article according to the present invention, as the side surface of the fiber-reinforced resin A, have at least two inclined surfaces inclined in opposite directions to each other, more or less fiber reinforced any part of the side surface An undercut shape that enters the resin A main body side is formed, but the depth is within a range of 0.1 T to 0.9 T with respect to the thickness T of the fiber reinforced resin A at least part of the side surface. All clauses to form a certain undercut shape before insert molding. If the depth of the undercut shape is less than 0.1T, not only the possibility of forming the above-mentioned closed space remains, but also the holding strength of the fiber reinforced resin A of the resin B due to the undercut shape becomes low, and after molding There is a possibility that the bonding strength between the fiber reinforced resin A and the resin B at the time may decrease. If the depth of the undercut shape exceeds 0.9T, not only the retention strength of the fiber reinforced resin A of the resin B due to the undercut shape is lowered, but also the undercut shape with respect to the thickness T of the fiber reinforced resin A Since the depth of the resin is too deep and the inclination angle of the inclined surface may be too large, the resin B may not easily flow into the side surface portion of the fiber reinforced resin A.

And in which position in the composite molded body in which the fiber reinforced resin A is to be molded , in the present invention, the fiber reinforced resin A is disposed on the inner surface of the mold before insert molding, and the fiber The resin B is supplied so that the reinforced resin A is disposed on at least one surface of the composite molded body. That is, when the fiber reinforced resin A is disposed on at least one surface of the composite molded body, the fiber reinforced resin A may be disposed on the inner surface of the mold before insert molding. The arrangement of the fiber reinforced resin A, and hence the insert molding by supplying the resin B is facilitated.

  The configuration of the fiber reinforced resin A itself is not particularly limited. For example, the configuration may be a single fiber reinforced resin, which is obtained by laminating and integrating a plurality of fiber reinforced resins. There may be. In particular, in the latter form, the degree of freedom of the shape of the fiber reinforced resin A can be expanded, and the formation of the desired side surface shape can be facilitated.

  Moreover, it does not specifically limit about the form of the reinforced fiber of the said fiber reinforced resin A, It is possible to employ | adopt from the discontinuous fiber to the continuous fiber, and also the form of a textile fabric. However, in the production of the composite molded body of the present invention in which the fiber reinforced resin A is insert-molded, the fiber reinforced resin A is required to have a function of a reinforcing material. From this aspect, it is preferable that the fiber reinforced resin A is made of a fiber reinforced resin containing reinforced fibers having a number average fiber length of 2 mm or more.

  In particular, when the reinforcing fiber of the fiber reinforced resin A is a continuous fiber and is oriented in one direction, it is possible to efficiently enhance the mechanical characteristics in that specific one direction. Therefore, such a form is particularly effective when improvement of mechanical properties in a specific direction of the composite molded body is required.

  Further, the method for supplying the liquefied resin B into the mold is not particularly limited, but in order to achieve good moldability and productivity, the molten resin B is injected into the mold by injection molding or injection compression molding. The method of supplying to is preferable.

  Moreover, although the kind of matrix resin of the said fiber reinforced resin A is a thermoplastic resin, as a kind of the said resin B, both a thermoplastic resin and a thermosetting resin are possible. In particular, when the resin B is made of a thermoplastic resin, it is more preferable because good moldability and productivity can be obtained. In particular, when it is made of the same kind of thermoplastic resin as the matrix resin of the fiber reinforced resin A, it can be said that it is the most preferable embodiment in the present invention because excellent adhesiveness is easily obtained. In the present invention, the type of the thermoplastic resin used for the fiber reinforced resin A and / or the resin B is not particularly limited. For example, polyamide (nylon 6, nylon 66, aromatic polyamide, etc.), polyolefin (polyethylene, polypropylene, etc.) , Polyester (polyethylene terephthalate, polybutylene terephthalate, etc.), polycarbonate, polyphenylene sulfide, polyphenylene oxide, polysulfone, polyethersulfone, polyetheretherketone, polyetherketoneketone, polyketone, polyimide, polyetherimide, polystyrene, ABS, liquid crystal polyester Alternatively, a copolymer of acrylonitrile and styrene can be used. A mixture of these may also be used. Moreover, what was copolymerized like the copolymer nylon of nylon 6 and nylon 66 may be used. In particular, polyphenylene sulfide, polyetheretherketone, polyetherketoneketone, polyetherimide, and aromatic polyamide increase the necessity of using continuous reinforcing fibers having an excellent reinforcing effect. I can say that. Furthermore, depending on the required properties of the molded product to be obtained, flame retardants, weather resistance improvers, other antioxidants, heat stabilizers, UV absorbers, plasticizers, lubricants, colorants, compatibilizers, conductive fillers, etc. It can be added. The kind of thermosetting resin used for the resin B in the present invention is not particularly limited. For example, epoxy, phenol, polybenzimidazole, benzoxazine, cyanate ester, unsaturated polyester, vinyl ester, urea, melamine, bismaleimide, polyimide Polyamideimide and the like, copolymers thereof, modified products and resins blended in two or more types, and resins added with elastomers, rubber components, curing agents, curing accelerators, catalysts, and the like can be used.

  In addition, the resin B may be formed of a resin alone, or may be formed of a resin containing reinforcing fibers. In the latter case, in order to ensure good moldability and ensure good fluidity of the resin B, it is preferable that the resin B is made of a resin containing reinforcing fibers having a number average fiber length of less than 2 mm.

  Furthermore, as the reinforcing fiber of the fiber reinforced resin A and / or the reinforcing fiber of the resin B, any reinforcing fiber such as carbon fiber, glass fiber, and aramid fiber can be used, but it is preferable to include carbon fiber. . However, other reinforcing fibers such as glass fibers and aramid fibers, and further mixed forms and mixed forms of these other reinforcing fibers and carbon fibers are also possible. Among these, when it is desired to improve mechanical properties such as strength of the final molded product, it is preferable to use carbon fibers. Among carbon fibers, it is more preferable to use a high-strength one that hardly generates fuzz in the fiber bundle thickness reduction step or the resin impregnation step. Specifically, it refers to those having a tensile strength of 4,500 MPa or more, and further 5,000 MPa or more. Moreover, as a sizing agent provided to the reinforcing fiber, it is preferable to use a sizing agent having a heat loss at 300 ° C. of 5% or less. More preferably, the heat loss at 350 ° C. is 15% or less. Use of a sizing agent that is difficult to thermally decompose makes it difficult to generate fluff in the fiber bundle thickness reduction process and the resin impregnation process, and can minimize the generation of gas in the die, thereby maximizing the effects of the present invention. can do. This effect is particularly remarkable in heat-resistant thermoplastic resins whose processing temperature exceeds about 300 ° C. (for example, polyphenylene sulfide, polyether ether ketone, polyether ketone ketone, polyether imide, aromatic polyamide, etc.). Play. When carbon fiber that does not have a sizing agent is used, there is an advantage that almost no gas is generated. However, fluffing is remarkable and not only a high-quality sheet-like prepreg cannot be obtained, but also high productivity is realized. May be difficult. The above heat loss is a TG (thermogravimetric analysis) method that is heated from 25 ° C. to 400 ° C. at a rate of temperature increase of 10 ° C./min in the air atmosphere, and the sizing agent is reduced at 300 ° C. and 350 ° C. Refers to the ratio.

Composite compact according to the present invention, the maximum distance between have at least two inclined surfaces extending obliquely in opposite directions from the opening of the concave type so as to form a concave inclined surface is in concave openings in the composed shape aspect, and at least a portion of its side surface, the depth to the thickness T has a side surface shape having an undercut shape in the range of 0.9T from 0.1 T, the matrix resin The fiber reinforced resin A made of a thermoplastic resin is insert-molded so as to be disposed on at least one surface of the composite molded body by supplying the liquefied resin B. In addition, the present invention has two inclined surfaces extending in an opposite direction from the concave opening so as to form a concave shape, and the inclined surfaces are directly connected to each other so that an inflection point is formed between the inclined surfaces. And at least a part of the side surface has a side surface having an undercut shape having a depth in the range of 0.1 T to 0.9 T with respect to the thickness T. A composite molded body characterized in that the fiber reinforced resin A whose matrix resin is a thermoplastic resin is insert-molded so as to be disposed on at least one surface of the composite molded body by supplying the liquefied resin B. provide. These composite molded bodies according to the present invention can be produced by the method as described above.

Moreover, in the composite molded body which concerns on this invention, it is also a preferable form that the said fiber reinforced resin A is what laminated | stacked and integrated the fiber reinforced resin.

  Moreover, it is also a preferable form that the said fiber reinforced resin A consists of fiber reinforced resin containing the reinforced fiber whose number average fiber length is 2 mm or more.

  Moreover, it is also a preferable form that the reinforcing fiber of the fiber reinforced resin A is a continuous fiber and is oriented in one direction.

  It is also a preferred form that the liquefied resin B is supplied into the mold by injection molding or injection compression molding.

  It is also a preferred form that the resin B is made of a thermoplastic resin.

  It is also a preferred embodiment that the resin B is made of a resin containing reinforcing fibers having a number average fiber length of less than 2 mm.

  Furthermore, it is also a preferable form that the reinforcing fiber of the fiber reinforced resin A and / or the reinforcing fiber of the resin B contains carbon fiber.

  As described above, according to the composite molded body and the manufacturing method thereof according to the present invention, the adhesiveness between the fiber reinforced resin A and the resin B in the insert molding can be improved, and the reliability of the bonding can be improved. It is possible to perform insert molding with excellent moldability, and it is possible to easily obtain a composite molded body excellent in appearance.

It is a schematic sectional drawing which shows the composite molded object which concerns on one embodiment of this invention, and its manufacturing method. It is a schematic sectional drawing which shows the composite molded object which concerns on another embodiment of this invention, and its manufacturing method. It is a schematic sectional drawing which shows the composite molded object which concerns on another embodiment of this invention, and its manufacturing method. It is a schematic sectional drawing which shows the composite molded object which concerns on another embodiment of this invention, and its manufacturing method. It is a schematic block diagram which shows an example in the case of insert-molding the composite molded object which concerns on this invention by injection molding. It is a schematic sectional drawing which shows the comparative example of this invention. It is a schematic sectional drawing which shows another comparative example of this invention.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 shows a composite molded body and a method for producing the same according to one embodiment of the present invention. In FIG. 1, reference numeral 1 denotes a composite molded body that is insert-molded in a mold 4 including a lower mold 2 and an upper mold 3. In the insert molding of the composite molded body 1, a preformed fiber reinforced resin A (5) made of a thermoplastic resin is disposed in the mold 4 as a preform (in this embodiment, the fiber reinforced resin A). (5) One surface is disposed on one inner surface of the mold 4), and the resin B (6) liquefied (melted in this embodiment) around the fiber reinforced resin A (5) in the mold 4 Is supplied and fiber reinforced resin A (5) is insert-molded. The side surfaces of the fiber reinforced resin A (5) that are in contact with the resin B (6) are inclined concavely at different angles (in this embodiment, with respect to the virtual surface 8 that is perpendicular to the inner surface of the mold 4). Side surfaces 7 having a shape having at least two inclined surfaces 7a and 7b (inclined in opposite directions and having an undercut depth of 0.6T) are formed before insert molding. In other words, as shown in FIG. 1, it has at least two inclined surfaces 7a and 7b extending in the opposite directions from the opening of the concave shape so as to form a concave shape, and the distance between the inclined surfaces is a concave shape. The side surface 7 having the maximum shape at the opening is formed before insert molding. Moreover, in this embodiment, since the edge parts of inclined surface 7a, 7b are directly connected, the inflection point 9 is formed between inclined surface 7a, 7b. The resin B (6) melted around the fiber reinforced resin A (5) including the side surface 7 having the inclined surfaces 7a and 7b formed as described above flows, the resin B (6) is solidified, and the fiber reinforced resin A The composite molded body 1 in which (5) and the resin B (6) are bonded and integrated is molded.

  In the molding of the composite molded body 1, at least two inclined surfaces 7 a and 7 b inclined concavely at different angles are inserted as side surfaces 7 that contact the resin B (6) of the fiber reinforced resin A (5). Although formed before molding, the angle (opening angle) between the inclined surfaces 7a and 7b inclined in opposite directions can be easily formed larger than the angle α as shown in FIG. When B (6) flows into the side surface, the resin B (6) is satisfactorily in contact with the entire surfaces of the inclined surfaces 7a and 7b without forming a closed space filled with gas or air. Flows in. That is, in the comparative example shown in FIG. 6, the side surface 102 of the fiber reinforced resin A (101) disposed in the mold 4 is formed as one inclined surface. The angle α formed between the two sides must be a small angle, and when the resin B (6) flows into the side surface portion, gas and air are enclosed so that the resin B (6) does not flow easily. In addition, there is a high possibility that the unfilled portion 103 is formed. However, in the above-described embodiment of the present invention, the angle between the two inclined surfaces 7a and 7b inclined in opposite directions is surely formed larger than the angle α in the comparative example, so that it is not filled with gas or air. Generation of a portion is prevented, and good adhesion between the fiber reinforced resin A (5) and the resin B (6) over the entire surface is achieved. Moreover, as a result of achieving good adhesion over the entire surface, reliability of adhesion is also ensured. Furthermore, when it arrange | positions on the inner surface of the lower mold | type 2 as shown in FIG.1 and FIG.6, the boundary part of the fiber reinforced resin A and resin B will appear on the outer surface of the composite molded object shape | molded. Therefore, when the unfilled portion 103 as described above is formed at the boundary portion, it appears as a groove-like defect portion on the outer surface of the molded composite molded body, and the quality of the molded body is impaired. However, in the present invention, the occurrence of such an unfilled portion 103 can be prevented, so that an excellent appearance can be obtained and the quality of the molded body can be improved.

  In the embodiment of the present invention described above, the inclined surfaces 7a and 7b are inclined surfaces that are inclined in opposite directions, so that the portion between the inclined surfaces 7a and 7b is necessarily in relation to the resin B (6). Thus, an undercut shape is formed. That is, the undercut shape which entered the fiber reinforced resin A (5) main body side is formed in the side surface 7 portion of the fiber reinforced resin A (5). Such an undercut shape constitutes a structure in which the fiber reinforced resin A (5) portion is not easily dropped from the resin B (6) portion after molding, and therefore the fiber reinforced resin A (5) and the resin B ( The joint strength with 6) is further increased. However, if only the function of the undercut shape is seen, the same function can be obtained in the form shown in the comparative example of FIG. 6, but the side surface 102 formed by only one inclined surface shown in FIG. As a result, there is a high possibility that problems such as insufficient adhesion and poor appearance due to the unfilled portion 103 will occur, so that both the prevention of dropout due to the undercut shape and the improvement of adhesion and appearance quality due to the prevention of unfilled portion occurrence are achieved. It is not possible.

  In addition, as shown in FIG. 7, the fiber reinforced resin A (111) has a rectangular cross-sectional shape, and the angle β formed between the side surface 112 and the inner surface of the lower mold 2 is Although an angle with an angle of 90 degrees or the vicinity thereof is also conceivable, the angle is smaller than the angle between the two inclined surfaces 7a and 7b inclined in opposite directions shown in FIG. The possibility of is not removed. Moreover, in such a form, since the improvement effect of the drop-off prevention function by the undercut shape as described above cannot be expected, this aspect is inferior to both forms shown in FIGS. 1 and 6.

  The embodiment of the present invention can take various forms other than that shown in FIG. For example, as shown in FIG. 2, a fiber reinforced resin A (22) composed of a laminated structure of a reinforced fiber resin 22a and a reinforced fiber resin 22b, and an inclined surface 23a inclined in opposite directions to the reinforced fiber resins 22a and 22b. , 23b and the fiber-reinforced resin A (22) having an inflection point 24 between the two inclined surfaces 23a, 23b can be used as a preform, and the composite molded body 21 can be insert-molded.

  Further, for example, as shown in FIG. 3, as the fiber reinforced resin A (32), inclined surfaces 32 a and 32 b that are inclined in opposite directions are formed on the side surfaces of the fiber reinforced resin A (32). It is also possible to insert-mold the composite molded body 31 using the fiber reinforced resin A (32) as a preformed body formed by connecting the surfaces 32c at an intermediate angle between the inclined surfaces 32a and 32b.

  Further, for example, as shown in FIG. 4, yet another embodiment of the fiber reinforced resin A (42) is formed with inclined surfaces 42a, 42b inclined in opposite directions on the side surface and between the inclined surfaces 42a, 42b. It is also possible to insert-mold the composite molded body 41 using the fiber reinforced resin A (42) as a preformed body formed in a side shape connected by the arc-shaped surface 42c.

  The insert molding of the composite molded body according to the present invention is particularly preferably applied by injection molding or injection compression molding. For example, as shown in FIG. 5, an injection molding machine 51 provided with a mold 53 at the tip of an extruder 52 is used, and a fiber reinforced resin A (54) formed in advance as described above is used as a preform. Placed in the mold 53 (FIG. 5 (A)), the mold 53 is closed, molten resin B (55) supplied from the extruder 52 is injected into the mold 53, and fiber reinforced by the resin B (55) Resin A (54) is insert-molded (FIG. 5B). After cooling, the mold 53 is opened and the composite molded body 56 that has been insert-molded is taken out (FIG. 5C). By such injection molding, a desired molded product can be easily manufactured in a form that can be mass-produced while achieving the above-described advantages due to the side shape of the fiber reinforced resin A (54) in the present invention.

  The method for producing a composite molded body according to the present invention can be applied to the production of any composite molded body using continuous reinforcing fibers and a thermoplastic resin. The composite molded body obtained from such a production method can be suitably used for transportation equipment such as automobiles, airplanes, ships, etc., leisure / sports members, pressure vessels, oil field excavations, civil engineering structural / quasi-structural members. .

1, 21, 31, 41, 56 Composite molded body 2 Lower mold 3 Upper mold 4, 53 Molds 5, 22, 32, 42, 54 Fiber reinforced resin A
6, 55 Resin B
7 Sides 7a, 7b, 23a, 23b, 32a, 32b, 42a, 42b Inclined surface 8 Virtual surfaces 9, 24 perpendicular to one inner surface of the mold Inflection points 22a, 22b Fiber reinforced resin 32c In the middle of both inclined surfaces Angle surface 42c Arc-shaped surface 51 Injection molding machine 52 Extruder

Claims (17)

  Pre-molded fiber reinforced resin A whose matrix resin is a thermoplastic resin is placed in a mold as a preform, and liquefied resin B is supplied around the fiber reinforced resin A in the mold to supply the fiber reinforced resin. A method of manufacturing a composite molded body in which resin A is insert-molded, wherein the side surfaces of the fiber reinforced resin A in contact with the resin B are inclined in opposite directions from the opening of the concave mold so as to form a concave mold. A side surface of the shape having at least two inclined surfaces extending so that the distance between the inclined surfaces is maximized at the concave opening, and at least part of the side surface has a depth T of the thickness T of the fiber reinforced resin A. On the other hand, a side surface having an undercut shape in a range of 0.1T to 0.9T is formed before insert molding, and the fiber reinforced resin A is disposed on the inner surface of the mold before insert molding. The fiber Reinforced resin A and supplying the resin B to be placed on at least one surface of the composite molded body, method for manufacturing a composite molding.   Pre-molded fiber reinforced resin A whose matrix resin is a thermoplastic resin is placed in a mold as a preform, and liquefied resin B is supplied around the fiber reinforced resin A in the mold to supply the fiber reinforced resin. A method of manufacturing a composite molded body in which resin A is insert-molded, wherein the side surfaces of the fiber reinforced resin A in contact with the resin B are inclined in opposite directions from the opening of the concave mold so as to form a concave mold. The side surface of the shape which has two inclined surfaces which extend, the inclined surfaces are directly connected, and an inflection point is formed between the inclined surfaces, and the depth is at least a part of the side surface. A side surface having an undercut shape in the range of 0.1T to 0.9T with respect to the thickness T of the reinforced resin A is formed before insert molding, and the fiber reinforced resin A is molded before insert molding. Placed on the inner surface of , Characterized in that said supplying the resin B as the fiber-reinforced resin A is disposed on at least one surface of the composite molded body, method for manufacturing a composite molding.   The method for producing a composite molded body according to claim 1 or 2, wherein the fiber reinforced resin A is obtained by laminating and integrating fiber reinforced resins.   The manufacturing method of the composite molded object in any one of Claims 1-3 in which the said fiber reinforced resin A consists of fiber reinforced resin containing the reinforced fiber whose number average fiber length is 2 mm or more.   The manufacturing method of the composite molded object in any one of Claims 1-4 with which the reinforced fiber of the said fiber reinforced resin A is a continuous fiber, and is orientated to one direction.   The manufacturing method of the composite molded object in any one of Claims 1-5 with which the said liquefied resin B is supplied in a type | mold by injection molding or injection compression molding.   The method for producing a composite molded body according to claim 1, wherein the resin B is made of a thermoplastic resin.   The method for producing a composite molded body according to any one of claims 1 to 7, wherein the resin B is made of a resin containing reinforcing fibers having a number average fiber length of less than 2 mm.   The manufacturing method of the composite molded object in any one of Claims 1-8 in which the reinforced fiber of the said fiber reinforced resin A and / or the reinforced fiber of the said resin B contain carbon fiber.   A side surface having at least two inclined surfaces extending obliquely in opposite directions from the concave opening so as to form a concave shape, and having a distance between the inclined surfaces that is maximum in the concave opening; and A fiber reinforced resin A in which the matrix resin is a thermoplastic resin having a side surface having an undercut shape with a depth in the range of 0.1T to 0.9T with respect to the thickness T on at least a part of the side surface. Is formed by insert molding so as to be disposed on at least one surface of the composite molded body by supplying the liquefied resin B.   A shape having two inclined surfaces extending in the opposite directions from the concave opening so as to form a concave shape, wherein the inclined surfaces are directly connected to each other, and an inflection point is formed between the inclined surfaces. And a matrix resin having a side surface having an undercut shape with a depth within a range of 0.1T to 0.9T with respect to the thickness T on at least a part of the side surface A composite molded body, wherein the fiber reinforced resin A is made of insert molding so as to be arranged on at least one surface of the composite molded body by supplying the liquefied resin B.   The composite molded body according to claim 10 or 11, wherein the fiber reinforced resin A is obtained by laminating and integrating a fiber reinforced resin.   The composite molded body according to any one of claims 10 to 12, wherein the fiber reinforced resin A is made of a fiber reinforced resin containing reinforcing fibers having a number average fiber length of 2 mm or more.   The composite molded body according to any one of claims 10 to 13, wherein the reinforcing fibers of the fiber reinforced resin A are continuous fibers and are oriented in one direction. The resin B is formed of a thermoplastic resin, composite molded article according to any one of claims 10 to 14. The composite molded body according to any one of claims 10 to 15 , wherein the resin B is made of a resin containing reinforcing fibers having a number average fiber length of less than 2 mm. The composite molded body according to any one of claims 10 to 16 , wherein the reinforcing fiber of the fiber-reinforced resin A and / or the reinforcing fiber of the resin B includes carbon fiber.

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