JP6118804B2 - Oil pan for transmission - Google Patents

Description

  Even when an impact is applied from the outside, the present invention comes in contact with a transmission built-in component (oil strainer, control valve, etc.) due to large deformation of the oil pan body, impairs the function, and damages to the oil pan body. The present invention relates to an oil pan for a transmission that can suppress oil leakage.

  Currently, an oil pan for transmission (hereinafter referred to as an oil pan) is mounted on the lower part of a vehicle body for the purpose of storing oil for cooling and lubrication inside the transmission. In particular, the transmissions of many FF vehicles are located beside the engine and are located in front of the axle, so the oil pan mounted at the bottom of the vehicle body easily interferes with the road surface due to unevenness of the road surface, There is a high possibility of colliding with obstacles such as curbs (Fig. 1). For this reason, oil pans are required to be largely deformed so that they do not come into contact with the parts with built-in transmission, and that the oil pan itself is broken and does not leak oil. The material used is mainly metal. Has been.

In recent years, from the viewpoint of reducing the cost of automobiles, improving fuel consumption, and reducing weight, automobile parts are also being made into resin. Since the oil pan is part of the structure, when it receives impact from the outside due to interference with the road surface or collision with obstacles, it is necessary to suppress the amount of deformation due to impact as well as shock absorption. There is. Therefore, a material that can absorb impact energy received from the outside with a small amount of deformation is required.
With respect to such required characteristics, the impact-absorbing material using a resin mainly includes a molded body of a fiber reinforced resin composition and a molded body of a non-reinforced resin composition.

  As a molded product of a fiber reinforced resin composition, for example, an exterior having a non-reinforced polyamide resin layer on both sides of a long fiber reinforced polyamide resin layer and a layer thickness ratio of the long fiber reinforced layer / non-reinforced resin layer is 1.0 or more A molded body has been proposed (see, for example, Patent Document 1). In addition, a multilayer injection-molded article having a skin layer composed of a composition comprising a polyamide and an olefin elastomer and a core layer comprising a composition comprising a polyamide and a reinforcing filler has been proposed (for example, , See Patent Document 2). However, since the molded body of the fiber reinforced resin composition absorbs the impact energy while breaking, the molded body obtained by the technology disclosed in them generates a through crack in the thickness direction when receiving the impact energy from the outside. However, since the oil easily leaks, such a molded body is not sufficient as an oil pan.

  On the other hand, as a molded body of the non-reinforced resin composition, a thermoplastic resin having a structure having ribs with a thickness of 50% or more of the planar portion and a thermoplastic resin and a resin having a reactive functional group are blended. An impact absorbing member made of a resin composition has been proposed (see, for example, Patent Document 3). However, the molded bodies obtained by the techniques disclosed therein have a problem that they are easily damaged by contact with the components with built-in transmission because the deformation becomes large and easily penetrates when subjected to impact energy from the outside. In particular, in a usage environment where the amount of deformation is limited, it is difficult to sufficiently absorb impact energy, and such a molded body is not sufficient as an oil pan.

  On the other hand, the resin oil pan is composed of a first layer portion formed of a fiber reinforced resin and a second layer portion formed of a dicyclopentadiene resin bonded to the outside of the first layer portion. A resin oil pan has been proposed (see, for example, Patent Document 4). However, since the first layer formed of fiber reinforced resin absorbs impact energy while breaking, such a resin oil pan, when subjected to impact energy from the outside, fragments due to cracks enter the transmission as contaminants, There was a possibility of adverse effects such as control valve sticks.

JP 2006-083227 A JP 2002-283522 A JP 2009-155365 A Japanese Patent Laid-Open No. 7-027016

  The present invention provides a transmission oil pan capable of suppressing oil leakage due to contact with and destruction of a transmission built-in component due to large deformation even when subjected to an impact from the outside, in view of the problems of the background art described above. Is an issue.

In order to solve the above-mentioned problems, an oil pan for transmission according to the present invention has configurations shown in the following (1) to (5).
(1) Molded body (D1) formed by molding a fiber reinforced resin composition comprising a polyamide resin, a rubbery polymer having a reactive functional group, and a fibrous inorganic filler, and a polyamide resin and a reactive functional group The molded body (D2) formed by molding a non-reinforced resin composition formed by blending a rubbery polymer having a group is placed on top of each other, and the side on which the molded body (D1) is placed has an impact force. Oil pan for transmission on the receiving side.
(2) The minimum thickness (d1) of the molded body (D1) is 1.0 to 10.0 mm, and the minimum thickness (d2) of the molded body (D2) is 0.5 to 5.0 mm. (1) Transmission oil pan.
(3) The minimum thickness (d1) of the molded body (D1) and the minimum thickness (d2) of the molded body (D2) satisfy the following formulas (I) and (II): ) Transmission oil pan.
(I) 2.3 mm ≦ (d1) + (d2) ≦ 9.0 mm
(II) 0.8 ≦ (d1) / (d2) ≦ 8.0
(4) The reactive functional group of the rubbery polymer having the reactive functional group is at least one selected from the group consisting of an epoxy group, an acid anhydride group, an amino group, a carboxyl group, a carboxyl metal salt, and an oxazoline group. The oil pan for transmission according to any one of (1) to (3) above.
(5) When the molded body (D1) and the molded body (D2) are observed with an electron microscope, the polyamide resin forms a continuous phase (A) and the rubbery polymer having a reactive functional group forms a dispersed phase (B). In addition, the dispersed phase (B) contains fine particles having a particle diameter of 1 to 100 nm made of a compound formed by the reaction of a polyamide resin and a rubbery polymer having a reactive functional group, and the dispersed phase (B) The oil pan for transmission according to any one of the above (1) to (4), having a morphology in which the area occupied by the fine particles in is 10% or more.

  According to the present invention, it is possible to provide an oil pan for transmission that can suppress oil leakage due to contact with and destruction of a transmission built-in component due to large deformation even when subjected to an impact from the outside.

It is a schematic block diagram which shows the relationship between a structure of oil pan, arrangement | positioning, and an impact direction. It is a schematic block diagram of a notch type mixing screw. It is a schematic block diagram of the oil pan used in the Example and the comparative example.

Hereinafter, the transmission oil pan of the present invention (hereinafter sometimes referred to as an oil pan) will be described in detail.
The oil pan of the present invention is formed by stacking a molded body (D1) formed by molding a fiber-reinforced resin composition and a molded body (D2) formed by molding a non-reinforced resin composition. For example, in the case of the oil pan 10 shown in FIG. 1B, a molded body (D1) formed by molding a fiber reinforced resin composition on the outer layer of a molded body (D2) 5 formed by molding a non-reinforced resin composition. 4 is arranged. The oil pan mounted on the bottom of the vehicle body is the bottom outer layer side of the oil pan when it receives an impact from the outside due to interference with the road surface due to road surface irregularities or collision with obstacles such as curbs. In addition, an impact is applied from the outer side of the side surface toward the inner layer side. The oil pan of the present invention can suppress contact with built-in components such as a control valve and an oil strainer, oil leakage, and the like even when an impact is applied from the outside.

  The fiber reinforced resin composition constituting the molded body (D1) is formed by blending a polyamide resin (A), a rubbery polymer (B) having a reactive functional group, and a fibrous inorganic filler (C). Depending on the, other components may be further blended. In the present invention, by blending the polyamide resin (A) with the fiber reinforced resin composition constituting the molded body (D1), the moldability is excellent and the heat resistance, oil resistance, and impact resistance of the oil pan are improved. Can do. In addition, by blending the rubbery polymer (B) having a reactive functional group, the impact absorption of the oil pan can be further improved, and oil leakage due to breakage can be suppressed. Moreover, by mix | blending a fibrous inorganic filler (C), the heat resistance of a oil pan, intensity | strength, and rigidity can be improved, and the contact to the components with a built-in transmission by large deformation can be suppressed.

  The non-reinforced resin composition constituting the molded body (D2) is formed by blending a polyamide resin (A) and a rubbery polymer (B) having a reactive functional group, and other components (fibers) as necessary. May be added). In the present invention, by blending the polyamide resin (A) with the fiber reinforced resin composition constituting the molded body (D2), the moldability is excellent and the heat resistance, oil resistance, and impact resistance of the oil pan are improved. Can do. In addition, by blending the rubbery polymer (B) having a reactive functional group, the impact absorption of the oil pan can be further improved, and oil leakage due to breakage can be suppressed.

  It should be noted that the polyamide resin (A) blended in the fiber reinforced resin composition, the polyamide resin (A) blended in the non-reinforced resin composition, and the rubber weight having a reactive functional group blended in the fiber reinforced resin composition. The polymer (B) and the rubbery polymer (B) having a reactive functional group blended in the non-reinforced resin composition may be the same or different.

  In the present invention, the polyamide resin (A) used for the molded body (D1) and the molded body (D2) is a resin composed of a polymer having an amide bond. The polyamide resin (A) is mainly composed of amino acid, lactam or diamine and dicarboxylic acid. Examples of amino acids include 6-aminocaproic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid, paraaminomethylbenzoic acid, and the like. Examples of the lactam include ε-caprolactam and ω-laurolactam. Examples of the diamine include tetramethylene diamine, pentamethylene diamine, hexamethylene diamine, 2-methylpentamethylene diamine, nonamethylene diamine, decamethylene diamine, undecamethylene diamine, dodecamethylene diamine, 2,2,4- / 2. , 4,4-trimethylhexamethylenediamine, aliphatic diamines such as 5-methylnonamethylenediamine, aromatic diamines such as metaxylylenediamine and paraxylylenediamine, 1,3-bis (aminomethyl) cyclohexane, 1, 4-bis (aminomethyl) cyclohexane, 1-amino-3-aminomethyl-3,5,5-trimethylcyclohexane, bis (4-aminocyclohexyl) methane, bis (3-methyl-4-aminocyclohexyl) methane, 2 , 2-bis 4-aminocyclohexyl) propane, bis (aminopropyl) piperazine, an alicyclic diamines such as aminoethyl piperazine. Examples of the dicarboxylic acid include aliphatic dicarboxylic acids such as adipic acid, suberic acid, azelaic acid, sebacic acid, and dodecanedioic acid, terephthalic acid, isophthalic acid, 2-chloroterephthalic acid, 2-methylterephthalic acid, and 5-methyl. Aromatic dicarboxylic acids such as isophthalic acid, 5-sodium sulfoisophthalic acid, 2,6-naphthalenedicarboxylic acid, hexahydroterephthalic acid, hexahydroisophthalic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, And alicyclic dicarboxylic acids such as 1,3-cyclopentanedicarboxylic acid. Two or more of these raw materials may be used, and the polyamide resin (A) may be a homopolymer or a copolymer.

In the present invention, a polyamide resin having a crystal melting temperature of 150 ° C. or higher is preferable, and the heat resistance and strength of the oil pan can be further improved.
Specific examples of polyamide resins having a crystal melting temperature of 150 ° C. or higher include polycaproamide (polyamide 6), polyhexamethylene adipamide (polyamide 66), polypentamethylene adipamide (polyamide 56), poly Tetramethylene adipamide (polyamide 46), polyhexamethylene sebacamide (polyamide 610), polypentamethylene sebacamide (polyamide 510), polytetramethylene sebacamide (polyamide 410), polyhexamethylene dodecamide (polyamide) 612), polyundecanamide (polyamide 11), polydodecanamide (polyamide 12), polycaproamide / polyhexamethylene adipamide copolymer (polyamide 6/66), polycaproamide / polyhexamethylene terephthalamide copolymer (Polyamide 6 / 6T), polyhexamethylene adipamide / polyhexamethylene terephthalamide copolymer (polyamide 66 / 6T), polyhexamethylene adipamide / polyhexamethylene isophthalamide copolymer (polyamide 66 / 6I), polyhexamethylene Adipamide / polyhexamethylene isophthalamide / polycaproamide copolymer (polyamide 66 / 6I / 6), polyhexamethylene terephthalamide / polyhexamethylene isophthalamide copolymer (polyamide 6T / 6I), polyhexamethylene terephthalamide / polydecane Amide copolymer (polyamide 6T / 12), polyhexamethylene adipamide / polyhexamethylene terephthalamide / polyhexamethylene isophthalamide copolymer (polyamide 6 / 6T / 6I), polyxylylene adipamide (polyamide XD6), polyhexamethylene terephthalamide / poly-2-methylpentamethylene terephthalamide copolymer (polyamide 6T / M5T), polyhexamethylene terephthalamide / polypentamethylene terephthalate Amide copolymer (polyamide 6T / 5T), polypentamethylene terephthalamide / polypentamethylene adipamide copolymer (5T / 56), polynonamethylene terephthalamide (polyamide 9T), polydecamethylene terephthalamide (polyamide 10T) and these A copolymer etc. are mentioned. Two or more of these may be used depending on the required properties such as moldability of the fiber reinforced resin composition and non-reinforced resin composition, heat resistance, oil resistance, and impact resistance of the oil pan.
Among these, polyamide 6, polyamide 66, polyamide 56, polyamide 610, polyamide 510, polyamide 410, polyamide 612, polyamide 11, polyamide 12, polyamide 6/66, polyamide 66 / 6T, polyamide 6T / 6I, polyamide 66 / 6I / 6, polyamide 6T / 5T and the like are more preferable. Polyamide 6, polyamide 66, and polyamide 610 are more preferable, and the moldability of the fiber reinforced resin composition and the non-reinforced resin composition, the shock absorption and rigidity of the oil pan can be made compatible at a higher level.

The end group amount of the polyamide resin (A) is not particularly limited, but the amino end group amount is preferably 3 × 10 ⁻⁵ mol / g or more, and the rubbery polymer (B) having a reactive functional group. And the oil pan's shock absorption and rigidity can be balanced at a higher level. The amount of amino end group here can be determined by dissolving a polyamide resin in an 85 wt% phenol-ethanol solution and titrating with an aqueous hydrochloric acid solution using thymol blue as an indicator.

  The degree of polymerization of the polyamide resin (A) is not particularly limited, but the viscosity number VN is preferably 70 to 200 ml / g. By setting VN to 70 ml / g or more, the shock absorption and rigidity of the oil pan can be made compatible at a higher level. VN is more preferably 85 ml / g or more, and even more preferably 100 ml / g or more. On the other hand, the moldability of a fiber reinforced resin composition and a non-reinforced resin composition can be improved by setting VN to 200 ml / g or less. VN is more preferably 180 ml / g or less, and further preferably 150 ml / g or less. The viscosity number VN here refers to a value measured according to ISO 307 using 96% sulfuric acid as a solvent.

As a method for setting the VN of the polyamide resin (A) in the above range, for example, a method of selecting and using a polyamide resin having a desired degree of polymerization, or a combination of two or more types of polyamide resins (A) having different degrees of polymerization. And a method of adjusting VN within the above range.
In the present invention, the rubbery polymer (B) having a reactive functional group used for the molded body (D1) and the molded body (D2) is a polymer having a glass transition temperature lower than room temperature, This refers to polymers that are partially constrained by covalent bonds, ionic bonds, van der Waals forces, entanglements, and the like. For example, polybutadiene, polyisoprene, styrene / butadiene random copolymers and block copolymers, hydrogenated block copolymers, acrylonitrile / butadiene copolymers, diene rubbers such as butadiene / isoprene copolymers, Random copolymer and block copolymer of ethylene / propylene, random copolymer and block copolymer of ethylene / butene, copolymer of ethylene / α-olefin, ethylene / acrylic acid ester, ethylene / methacrylic acid ester, etc. Ethylene / unsaturated carboxylic acid ester copolymer, acrylic acid ester / butadiene copolymer such as butyl acrylate / butadiene copolymer, ethylene / vinyl acetate copolymer such as ethylene / vinyl acetate copolymer, Ethylene / propylene / ethylene Thermoplastic elastomers such as dennorbornene copolymers, ethylene / propylene non-conjugated diene terpolymers such as ethylene / propylene / hexadiene copolymers, butylene / isoprene copolymers, chlorinated polyethylene, polyamide elastomers, polyester elastomers, etc. Is a preferred example.

  Among these, from the viewpoint of compatibility with the polyamide resin (A), an ethylene / unsaturated carboxylic acid ester copolymer is preferably used. As unsaturated carboxylic acid ester, (meth) acrylic acid ester is mentioned, Preferably it is ester of (meth) acrylic acid and alcohol. Specific examples of (meth) acrylic acid esters include methyl (meth) acrylate, ethyl (meth) acrylate, (meth) acrylic acid-2-ethylhexyl, stearyl (meth) acrylate, and the like. The weight ratio of the ethylene component to the unsaturated carboxylic acid ester component (ethylene component / unsaturated carboxylic acid ester component) in the copolymer is not particularly limited, but is preferably 90/10 or less, more preferably 85/15 or less. On the other hand, it is preferably 10/90 or more, more preferably 15/85 or more. The number average molecular weight of the ethylene / unsaturated carboxylic acid ester copolymer is not particularly limited, but by setting the number average molecular weight in the range of 1000 to 70000, the moldability of the fiber reinforced resin composition and the non-reinforced resin composition, the impact absorption of the oil pan Property and rigidity can be further improved.

  The reactive functional group present in the rubbery polymer (B) having a reactive functional group in the present invention is not particularly limited as long as it reacts with the functional group of the polyamide resin (A). Groups, acid anhydride groups, amino groups, carboxyl groups, carboxyl metal salts, oxazoline groups, hydroxyl groups, isocyanate groups, mercapto groups, sulfonic acid groups and the like. You may have 2 or more types of these. Among these, an epoxy group, an acid anhydride group, an amino group, a carboxyl group, a carboxyl metal salt, and an oxazoline group are preferably used because of high reactivity and few side reactions such as decomposition and crosslinking. In particular, the rubbery polymer (B) preferably has an epoxy group, an acid anhydride group, a carboxyl group, or a carboxyl metal salt that has high reactivity with the terminal amino group of the polyamide resin.

  Examples of the acid anhydride in the acid anhydride group include maleic anhydride, itaconic anhydride, endic acid anhydride, citraconic acid anhydride, 1-butene-3,4-dicarboxylic acid anhydride, and the like. Two or more of these may be used in combination. Of these, maleic anhydride and itaconic anhydride are preferably used.

  As a method for introducing an acid anhydride group into a rubbery polymer, there are usually known techniques, and there is no particular limitation. For example, an acid anhydride and a monomer that is a raw material of a rubbery polymer are used together. A polymerization method, a method of grafting an acid anhydride onto a rubber polymer, and the like can be used.

  Moreover, as a method for introducing an epoxy group into a rubbery polymer, there are usually known techniques, and there is no particular limitation. For example, α such as glycidyl acrylate, glycidyl methacrylate, glycidyl ethacrylate, glycidyl itaconate, etc. , Β-unsaturated acid glycidyl ester compound and the like, a method of copolymerizing a vinyl monomer having an epoxy group with a monomer which is a raw material of a rubbery polymer, an epoxy group-containing polymerization initiator or chain transfer agent A method of polymerizing a rubbery polymer using the above, a method of grafting an epoxy compound onto a rubbery polymer, and the like can be used.

  As a method for introducing a carboxyl group into a rubbery polymer, there are usually known techniques, and there is no particular limitation. For example, an unsaturated carboxylic acid monomer having a carboxyl group is used as a raw material for a rubbery polymer. A method of copolymerizing with a certain monomer can be used. Specific examples of the unsaturated carboxylic acid include (meth) acrylic acid.

  A carboxyl metal salt in which at least a part of the carboxyl group is a metal salt is also effective as a reactive functional group, and examples thereof include (meth) acrylic acid metal salts. Although the metal of a metal salt is not specifically limited, Preferably, alkali metals, such as sodium, alkaline-earth metals, such as magnesium, zinc etc. are mentioned. Examples of the rubbery polymer (B) having a carboxyl metal salt as a reactive functional group include ethylene / unsaturated carboxylic acid / ethylene / acrylic acid / acrylic acid metal salt, ethylene / methacrylic acid / methacrylic acid metal salt, and the like. Examples thereof include unsaturated carboxylic acid metal salt copolymers. The weight ratio of the unsaturated carboxylic acid component to the unsaturated carboxylic acid metal salt component in the copolymer (unsaturated carboxylic acid component / unsaturated carboxylic acid metal salt component) is not particularly limited, but is preferably 95/5 or less, more Preferably it is 90/10 or less, on the other hand, preferably 5/95 or more, more preferably 10/90 or more.

  In the rubbery polymer (B) having a reactive functional group, the number of functional groups per molecular chain is not particularly limited, but usually 1 to 10 is preferable to reduce side reactions such as crosslinking. 1 to 5 is preferable. Moreover, although the molecular chain which does not have a functional group at all may be contained, it is so preferable that the ratio is small.

  In this invention, the compounding quantity of the rubber-like polymer (B) which has the reactive functional group in the fiber reinforced resin composition which comprises a molded object (D1), and the non-reinforced resin composition which comprises a molded object (D2) is , 50 to 99 parts by weight of the polyamide resin (A) and the rubbery polymer having a reactive functional group with respect to a total of 100 parts by weight of the polyamide resin (A) and the rubbery polymer (B) having a reactive functional group (B) It is preferable that it is 1-50 weight part. By making the blending amount of the polyamide resin (A) 99 parts by weight or less and the blending amount of the rubbery polymer (B) having a reactive functional group 1 part by weight or more, the impact absorption of the oil pan is further improved. be able to. The amount of the rubbery polymer (B) having a reactive functional group is more preferably 10 parts by weight or more, and further preferably 20 parts by weight or more. On the other hand, the blending amount of the polyamide resin (A) is 50 parts by weight or more, and the blending amount of the rubbery polymer (B) having a reactive functional group is 50 parts by weight or less, so that the fiber-reinforced resin composition and the non-reinforced The moldability of the resin composition, the strength and rigidity of the oil pan can be further improved. The amount of the rubbery polymer (B) having a reactive functional group is more preferably 45 parts by weight or less, and still more preferably 40 parts by weight or less.

In the present invention, examples of the fibrous inorganic filler (C) used in the fiber reinforced resin composition constituting the molded body (D1) include glass fibers, carbon fibers, wollastonite fibers, metal fibers, and the like. It may be hollow. Two or more of these may be used in combination. These fibrous inorganic fillers may be pretreated with a coupling agent such as an isocyanate compound, an organic silane compound, an organic titanate compound, an organic borane compound, an epoxy compound, The rigidity can be further improved.
Among the fibrous inorganic fillers shown above, glass fibers and carbon fibers are more preferably used.

  There is no restriction | limiting in particular in the glass fiber used for this invention, A well-known thing can be used. Usually, glass fibers have shapes such as chopped strands, roving strands, and milled fibers cut to a predetermined length, and those having an average fiber diameter of 5 to 15 μm are preferably used.

  In this invention, the compounding quantity of the fibrous inorganic filler (C) in the fiber reinforced resin composition which comprises a molded object (D1) is the rubber-like polymer (B) which has a polyamide resin (A) and a reactive functional group. 1 to 150 parts by weight is preferable with respect to 100 parts by weight in total. By setting the blending amount of the fibrous inorganic filler (C) to 1 part by weight or more, the heat resistance, strength, and rigidity of the oil pan can be further improved. The blending amount of the fibrous inorganic filler (C) is more preferably 10 parts by weight or more, and further preferably 15 parts by weight or more. On the other hand, when the blending amount of the fibrous inorganic filler (C) is 150 parts by weight or less, the moldability of the fiber reinforced resin composition and the impact absorption of the oil pan can be further improved. The blending amount of the fibrous inorganic filler (C) is more preferably 120 parts by weight or less, and further preferably 100 parts by weight or less.

  In the present invention, the fiber reinforced resin composition that constitutes the molded body (D1) and / or the non-reinforced resin composition that constitutes the molded body (D2) may be variously selected as necessary, as long as the characteristics are not impaired. You may mix | blend an additive. Additives include, for example, crystal nucleating agents, anti-coloring agents, hindered phenols, hindered amines, hydroquinone series, phosphite series and substituted products thereof, copper halides, iodide compounds and other antioxidants and heat stabilizers, Weathering agent such as resorcinol, salicylate, benzotriazole, benzophenone, hindered amine, release agent such as aliphatic alcohol, aliphatic amide, aliphatic bisamide, ethylene bisstearylamide, higher fatty acid ester, p-oxybenzoic acid Plasticizers such as octyl acid and N-butylbenzenesulfonamide, lubricants, dye-based colorants such as nigrosine and aniline black, pigment-based colorants such as cadmium sulfide, phthalocyanine, and carbon black, alkyl sulfate type anionic antistatic agents, Quaternary ammonium Type cationic antistatic agent, nonionic antistatic agent such as polyoxyethylene sorbitan monostearate, betaine amphoteric antistatic agent, melamine cyanurate, ammonium polyphosphate, brominated polystyrene, brominated polyphenylene oxide, brominated polycarbonate Flame retardants such as brominated epoxy resins or combinations of these brominated flame retardants and antimony trioxide, and foaming agents. Two or more of these may be used.

  Among these, hindered phenol compounds and phosphorus compounds are preferably used as antioxidants and heat stabilizers. As the hindered phenol compound, an ester type polymer hindered phenol type is preferable, and specifically, tetrakis [methylene-3- (3 ′, 5′-di-t-butyl-4′-hydroxyphenyl) propionate. ] Methane, pentaerythrityltetrakis [3- (3 ', 5'-di-t-butyl-4'-hydroxyphenyl) propionate], 3,9-bis [2- (3- (3-t-butyl- 4-hydroxy-5-methylphenyl) propionyloxy) -1,1-dimethylethyl] -2,4,8,10-tetraoxaspiro [5,5] undecane. Specific examples of phosphorus compounds include bis (2,6-di-t-butyl-4-methylphenyl) pentaerythritol-di-phosphite, bis (2,4-di-t-butylphenyl) pentaerythritol- Di-phosphite, bis (2,4-di-cumylphenyl) pentaerythritol-di-phosphite, tris (2,4-di-t-butylphenyl) phosphite, tetrakis (2,4-di-t-butyl) Phenyl) -4,4'-bisphenylene phosphite, di-stearyl pentaerythritol di-phosphite, triphenyl phosphite, 3,5-di-butyl-4-hydroxybenzyl phosphonate diethyl ester, etc. .

  In the present invention, the compounding amount of the additive in the fiber reinforced resin composition constituting the molded body (D1) is not particularly limited, but the polyamide resin (A), a rubbery polymer having a reactive functional group (B ) And the fibrous inorganic filler (C) are preferably 0.01 to 20 parts by weight with respect to 100 parts by weight in total.

  In the present invention, the compounding amount of the additive in the non-reinforced resin composition constituting the molded body (D2) is not particularly limited, but the polyamide resin (A) and the rubbery polymer having reactive functional groups (B ) Is preferably 0.01 to 20 parts by weight per 100 parts by weight in total.

  In the present invention, the molding method of the molded body (D1) and the molded body (D2) is not particularly limited, and is injection molding, injection compression molding, hollow molding, extrusion molding, sheet molding, compression molding, vacuum molding, foaming. Examples include molding. Among these, injection molding is preferable.

  The oil pan of the present invention comprises a molded body (D1) formed by molding a fiber reinforced resin composition and a molded body (D2) formed by molding a non-reinforced resin composition, and the molding is performed as described above. The side on which the body (D1) is arranged is a side that receives impact force. Here, “arranged in an overlapping manner” may be either a simple superposition of individually formed compacts or a joint of individual compacts. In addition, from the viewpoint of heat dissipation of the oil pan, it is preferable to join individual molded bodies.

  In the present invention, as a method of joining individual molded bodies, for example, a method of mechanically joining individual molded bodies with bolts, a method of chemically bonding with an adhesive, etc., a part of the individual molded bodies After melting, the method of joining by hot plate welding, ultrasonic welding, vibration welding, laser welding, etc., individual moldings simultaneously or one by one, lamination molding, two-color molding, double molding, rotational molding And a method of molding by a method such as stampable molding.

  In FIG. 1, the schematic block diagram which shows the relationship between the structure of the oil pan of this invention, arrangement | positioning, and the direction of an impact force is shown. FIG. 1A shows an automobile 100 as an example of an automobile provided with an oil pan 10 for protecting the transmission 101 from a curb 110 or the like, and FIG. An enlarged longitudinal sectional view is shown.

  The oil pan of the present invention is characterized in that at least one surface of a molded body (D1) formed by molding a fiber-reinforced resin composition is on the side receiving impact force. For example, in FIG. 1B, since the shape of the oil pan 10 and the shape of the obstacle such as the curb 110 cannot be specified, the input direction of the impact force 1 cannot be limited, but in any case, the fiber reinforced resin composition The side on which the molded body (D1) 4 formed is disposed is the side 11 that receives the impact force 1, and the side on which the molded body (D2) 5 formed by molding the non-reinforced resin composition is disposed is the opposite side 12. In addition, the molded body (D1) 4 and the molded body (D2) 5 are arranged so as to overlap each other. By disposing the molded body (D1) 4 and the molded body (D2) in this way, the oil pan 10 is moved into the built-in component 102 (for example, the control valve 103, the oil strainer 104, etc.) of the transmission 101 due to the large deformation of the oil pan 10 main body. ), The function of the transmission 101 is impaired, and oil leakage due to damage to the main body of the oil pan 10 can be more effectively suppressed.

  In the oil pan of the present invention, a molded body (D1) formed by molding a fiber reinforced resin composition disposed on the side receiving impact force is responsible for impact absorption and deformation suppression. Moreover, the molded object (D2) formed by shape | molding the non-reinforced resin composition arrange | positioned on the opposite side bears a residual impact absorption, penetration failure suppression, and the entrance prevention of a foreign material. Therefore, the molded body (D1) can absorb the impact energy received from the outside with a small amount of deformation, and the oil pan comes into contact with the transmission built-in component due to the large deformation of the oil pan body, and the function of the transmission is impaired. In addition, oil leakage due to damage to the oil pan body can be more effectively suppressed. In addition, since the molded body (D2) absorbs the remaining impact energy, broken pieces due to cracks in the molded body (D1) enter the transmission as foreign matters, adversely affect the control valve stick, etc. Oil leakage due to damage is more effectively prevented.

  On the other hand, in the case of the molded body (D1) alone, when impact energy is received from the outside, a through-crack is generated in the thickness direction, and the oil is likely to leak. In the case of the molded body (D2) alone, when impact energy is received from the outside, the impacted material penetrates the molded body (D2), and oil easily leaks, or the deformation amount of the molded body (D2) is likely to increase. Easy to contact with built-in parts. Further, when the molded body (D2) is disposed on the side that receives the impact force and the molded body (D1) is disposed on the opposite side, the impact body penetrates the molded body (D2) and receives the impact energy from the outside. The broken piece (D1) is broken into the transmission as a foreign substance and may adversely affect the control valve stick or the like, and the oil pan body is easily damaged and oil is liable to leak.

  In the oil pan of the present invention, the minimum thickness (d1) of the molded body (D1) formed by molding the fiber reinforced resin composition is preferably 1.0 to 10.0 mm. By setting the minimum thickness (d1) of the molded body (D1) to 1.0 mm or more, the moldability of the fiber reinforced resin composition and the non-reinforced resin composition, contact with the parts with built-in transmission due to large deformation of the oil pan, and destruction Oil leakage due to can be more effectively suppressed. As a minimum of minimum thickness (d1), 1.5 mm or more is more preferred, and 2.0 mm or more is still more preferred. On the other hand, an oil pan can be reduced in weight by making the minimum thickness (d1) of a molded object (D1) into 10.0 mm or less. The upper limit of the minimum thickness (d1) is more preferably 8.0 mm or less, and even more preferably 6.0 mm or less. If it exceeds 10.0 mm, vacuum voids and sink marks are generated, which is not preferable.

  In the oil pan of the present invention, the minimum thickness (d2) of the molded body (D2) formed by molding the non-reinforced resin composition is preferably 0.5 to 5.0 mm. By setting the minimum thickness (d2) of the molded body (D2) to 0.5 mm or more, the moldability of the fiber reinforced resin composition and the non-reinforced resin composition, contact with the parts with built-in transmission due to large deformation of the oil pan, and destruction Oil leakage due to can be more effectively suppressed. As a minimum of minimum thickness (d2), 0.8 mm or more is more preferred, and 1.0 mm or more is still more preferred. On the other hand, an oil pan can be reduced in weight by making the minimum thickness (d2) of a molded object (D2) into 5.0 mm or less. The upper limit of the minimum thickness (d2) is more preferably 4.0 mm or less, and even more preferably 3.0 mm or less. If it exceeds 5.0 mm, vacuum voids and sink marks are generated, which is not preferable.

  In the present invention, regarding the measuring method of the minimum thickness (d1) of the molded body (D1) and the minimum thickness (d2) of the molded body (D2), the cutting cross section of the molded body and / or the molded body is measured with a micrometer, a caliper, The thickness can be obtained by magnifying and observing the dimensions with a microscope. However, when a drained screw hole or the like is provided in the molded body, such a portion is excluded.

In the oil pan of the present invention, the minimum thickness (d1) of the molded body (D1) formed by molding the fiber-reinforced resin composition and the minimum thickness (d2) of the molded body (D2) formed of the non-reinforced resin composition. Preferably satisfies the following (I) and (II).
(I) 2.3 mm ≦ (d1) + (d2) ≦ 9.0 mm
(II) 0.8 ≦ (d1) / (d2) ≦ 8.0
By setting (d1) + (d2) to 2.3 mm or more, moldability of the fiber reinforced resin composition and the non-reinforced resin composition, oil leakage due to contact with and destruction of transmission built-in parts due to large deformation of the oil pan It can suppress more effectively. (D1) + (d2) is more preferably 3.0 mm or more. On the other hand, an oil pan can be reduced in weight by setting (d1) + (d2) to 9.0 mm or less. (D1) + (d2) is more preferably 7.0 mm or less.

  Further, the ratio (d1) of the minimum thickness (d1) of the molded body (D1) mainly responsible for shock absorption and deformation suppression and the minimum thickness (d2) of the molded body (D2) mainly responsible for residual impact absorption and penetration fracture suppression ( By setting (d1) / (d2)) to 0.8 or more, the deformation amount of the oil pan when receiving impact energy from the outside can be further suppressed. (D1) / (d2) is more preferably 1.0 or more. On the other hand, by setting (d1) / (d2) to 8.0 or less, penetration failure of the oil pan can be suppressed. (D1) / (d2) is more preferably 6.0 or less.

  In the present invention, the fiber reinforced resin composition constituting the molded body (D1) and / or the non-reinforced resin composition producing method constituting the molded body (D2) may be manufactured in a molten state or in a solution state. However, from the viewpoint of improving the reactivity, production in a molten state can be preferably used. For production in a molten state, melt kneading with an extruder, melt kneading with a kneader, or the like can be used. From the viewpoint of productivity, melt kneading with an extruder that can be continuously produced can be preferably used. For melt kneading by an extruder, one or more extruders such as a single-screw extruder, a twin-screw extruder, a multi-screw extruder having three or more axes, and a twin-screw single-screw compound extruder can be used. From the viewpoint of improving productivity and productivity, a multi-screw extruder such as a twin-screw extruder or a four-screw extruder can be preferably used, and a method by melt kneading using a twin-screw extruder is most preferred.

  As a manufacturing method of the fiber reinforced resin composition which comprises a molded object (D1), a polyamide resin (A), the rubbery polymer (B) which has a reactive functional group, a fibrous inorganic filler (C), and as needed Various additives can be added and melt-kneaded at any stage. For example, a polyamide resin (A), a rubbery polymer (B) having a reactive functional group, a fibrous inorganic filler (C) and, if necessary, various additives are melt kneaded, a polyamide resin (A ), While adding a rubbery polymer (B) having a reactive functional group and, if necessary, various additives and melting and kneading, the fibrous inorganic filler (C) is added and melted by a method such as side feed. Method of kneading, preliminarily adding polyamide resin (A), rubbery polymer (B) having a reactive functional group and various additives as necessary, and melt-kneading, then adding fibrous inorganic filler (C) And melt kneading.

  Among these, the polyamide resin (A), the rubbery polymer (B) having a reactive functional group and, if necessary, various additives are added to the polyamide resin-rubbery polymer composite composition (A -B), a method of melt-kneading by adding a fibrous inorganic filler (C) by a method such as side feed, a polyamide resin (A), a rubbery polymer having a reactive functional group (B) in advance Further, if necessary, various additives are added and melt-kneaded to produce a polyamide resin-rubber polymer composite composition (AB), and then the fibrous inorganic filler (C) is added and melt-kneaded. The method is preferred.

As a method for producing the non-reinforced resin composition constituting the molded body (D2), the polyamide resin (A), the rubbery polymer (B) having a reactive functional group, and various additives as required may be used at any stage. And can be melt kneaded. For example, a polyamide resin (A), a rubbery polymer (B) having a reactive functional group and a method of melt kneading by adding various additives as necessary, a polyamide resin (A) and a rubber having a reactive functional group A method of melt-kneading a polymer (B) while melt-kneading it and adding various additives as required by a method such as side feed, a rubber polymer having a polyamide resin (A) and a reactive functional group in advance Examples thereof include a method in which various additives are added if necessary after melt kneading (B) and melt kneading.
Among these, a polyamide resin (A), a rubbery polymer (B) having a reactive functional group, and various additives as necessary are melt-kneaded and polyamide resin-rubbery polymer composite composition (A -B) is preferred.

In the present invention, the polyamide resin-rubber polymer composite composition (AB), which is an intermediate raw material of the fiber reinforced resin composition constituting the molded body (D1), and the non-reinforced resin constituting the molded body (D2) The polyamide resin-rubber polymer composite composition (AB), which is a composition, can be produced by a known method, for example, the methods shown in the following (1) to (4). it can.
(1) The method described in Japanese Patent Application Laid-Open No. 2008-156604, that is, a thermoplastic resin (A) and a resin (B) having a reactive functional group, the ratio L / D of the screw length L to the screw diameter D is Put into a twin screw extruder with multiple full flight zones and kneading zones at 50 or more, the maximum resin pressure of the kneading zone in the screw is Pkmax (MPa), the full flight zone in the screw When the minimum resin pressure of the resin pressure is Pfmin (MPa),
Pkmax ≧ Pfmin + 0.3
The method of manufacturing by melt-kneading on the conditions satisfying.
(2) The method described in JP-A-2006-347151, that is, a thermoplastic resin (A) and a resin (B) having a reactive functional group, and if necessary, thermoplastic resins other than (A), (B ) Other than rubbers, fillers, and various additives are put into a twin screw extruder having a ratio L / D of screw length L to screw diameter D of 50 or more, and the residence time is 1 minute to 30 minutes, A method of melt-kneading under the condition that the extrusion rate is 0.01 kg / h or more per 1 rpm of the screw rotation.
(3) The method described in International Publication No. 2009/119624, that is, a thermoplastic resin (B) having a reactive functional group and a thermoplastic resin other than (A) if necessary, (B ) Other than rubbers, fillers and various additives are melt kneaded while stretching and flowing.
(4) The method described in JP 2011-063015 A, that is, a thermoplastic resin (B) having a reactive functional group with a thermoplastic resin (A), and if necessary, thermoplastic resins other than (A), (B ) Other than rubbers, fillers, and various additives are melt-kneaded with an extruder and then melt-kneaded with a notched mixing screw.
Among these, the method (4) is preferable from the viewpoint of shock absorption, rigidity, and productivity of the oil pan. L / D is a value obtained by dividing the screw length L by the screw diameter D. The screw length is the length from the upstream end of the screw segment at the position (feed port) where the screw base material is supplied to the screw tip. In the extruder, the side to which raw materials are supplied may be referred to as upstream, and the side from which molten resin is discharged may be referred to as downstream.

When the polyamide resin-rubber polymer composite composition (AB) is produced by the method (4), the inflow effect pressure drop before and after the zone (extension flow zone) in which melt-kneading is performed while stretching and flowing. Is preferably in the range of 100 to 500 kg / cm ² (9.8 to 49 MPa). The inflow effect pressure drop before and after the extension flow zone can be obtained by subtracting the pressure difference (ΔP ₀ ) in the extension flow zone from the pressure difference (ΔP) before the extension flow zone. When the inflow effect pressure drop before and after the extension flow zone is 100 kg / cm ² (9.8 MPa) or more, the ratio of formation of extension flow in the extension flow zone is high, and the pressure distribution is more uniform. Can be. Moreover, when the inflow effect pressure drop before and after the extension flow zone is 500 kg / cm ² (49 MPa) or less, the back pressure in the extruder is suppressed to an appropriate range, and stable production becomes easy.

  Further, when the length of one extension flow zone in the screw of the extruder is Lk and the screw diameter is D, Lk / D = 3 to 8 is preferable from the viewpoints of kneadability and reactivity.

  The extension flow zone is made of a kneading disk, and the helical angle θ, which is the angle between the top of the kneading disk at the front end of the disk and the top of the rear surface, is 0 ° <θ <90 in the half rotation direction of the screw. A twist kneading disk in the range of ° is preferable.

  In FIG. 2, the schematic block diagram of the notch type mixing screw used for this invention is shown. FIG. 2 shows a mixing screw 9 in which the notch 6 is provided in the screw flight 8. Reference numeral 7 denotes a screw pitch of the mixing screw 9, and reference numeral D denotes a screw diameter. A zone (mixing zone) for melting and kneading with a notch mixing screw is a notch type in which the length of a screw pitch is 0.1D to 0.3D and the number of notches is 10 to 15 per pitch. It is preferable that the mixing screw is connected from the viewpoint of improving the cooling efficiency of the molten resin by filling the resin, improving the kneadability, and improving the reactivity. Here, the single thread indicates a screw in which the crest portion of the screw flight advances by one pitch when the screw rotates 360 degrees. The length of the screw pitch indicates the distance between adjacent screw flights in the axial direction. In the case of a single thread, the length of the screw advances in the axial direction when the screw rotates 360 degrees (lead). . Moreover, when the length of one mixing zone in the screw of the extruder is Lm and the screw diameter is D, Lm / D = 5 to 15 is improved in the cooling efficiency of the molten resin due to resin filling and improved kneadability. From the viewpoint of improving the reactivity. In addition, it is preferable to provide mixing zones at two or more locations from the viewpoints of improving the cooling efficiency of the molten resin by filling the resin, improving the kneadability, and improving the reactivity. In addition, 70% or more of the notched mixing screw constituting the mixing zone is in the direction of the screw rotation in the direction opposite to the rotation direction of the screw shaft, improving the cooling efficiency of the molten resin by filling the resin, improving the kneadability, This is preferable from the viewpoint of improving reactivity.

  If the extruder cylinder set temperature in the extension flow zone is Ck, and the extruder cylinder set temperature in the mixing zone is Cm, melt kneading while satisfying Ck−Cm ≧ 60 can be achieved in addition to greatly improving the cooling efficiency of the molten resin. The kneadability and reactivity can be greatly improved, which is preferable. Further, the ratio of the total length of the extension flow zone to the total length of the screw of the extruder is 10 to 35%, and the ratio of the total length of the mixing zone to the total length of the screw of the extruder is 20 to 35%. It is preferable from the viewpoints of improving the cooling efficiency of the molten resin by filling the resin, improving kneadability, and improving reactivity.

  In the present invention, the polyamide resin-rubber polymer composite composition (AB), which is an intermediate raw material of the fiber reinforced resin composition constituting the molded body (D1), and the non-reinforced resin constituting the molded body (D2) The polyamide resin-rubbery polymer composite composition (AB), which is a composition, is obtained by observing an electron microscope with a polyamide resin as a continuous phase (A) and a rubbery polymer having a reactive functional group as a dispersed phase ( B), and the dispersed phase (B) contains fine particles having a particle diameter of 1 to 100 nm made of a compound formed by the reaction of a polyamide resin and a rubbery polymer having a reactive functional group, and the dispersed phase (B ) Preferably has a morphology in which the area occupied by the fine particles is 10% or more. The compound produced by the reaction of the thermoplastic resin (A) and the rubbery polymer (B) having a reactive functional group is generally present at the interface between the continuous phase (A) and the dispersed phase (B), but is thermoplastic. When the reaction amount of the resin and the rubbery polymer having a reactive functional group increases and the amount of the compound increases, a phenomenon occurs in which the compound is drawn into the continuous phase (A) and / or the dispersed phase (B). The drawn compounds try to exist stably and form micelles, and these micelles are observed as fine particles having a particle diameter of 1 to 100 nm by electron microscope observation. That is, a large area occupied by fine particles having a particle diameter of 1 to 100 nm suggests that the reaction amount of the thermoplastic polymer and the rubbery polymer having a reactive functional group is large. Such morphology is maintained in the molded body (D1) and the molded body (D2). By setting the area occupied by the fine particles in the dispersed phase (B) to 10% or more, the moldability of the fiber reinforced resin composition and the non-reinforced resin composition, the impact absorption of the oil pan, and the rigidity can be further improved. .

  Here, a known technique can be applied to morphology observation. It can be observed directly from the molded body (D1) and the molded body (D2). In general, the morphology in the polyamide resin composition is maintained even after melt molding. Therefore, in the present invention, the morphology can be observed using a molded product obtained by injection molding the polyamide resin composition. That is, the following observation method is mentioned. First, the center part in the cross-section direction of the molded body (D1) or the molded body (D2) or the ISO test piece injection-molded at a cylinder temperature of the melting point of the polyamide resin + 25 ° C. is cut into 1 to 2 mm square, and ruthenium tetroxide The rubbery polymer (B) having a reactive functional group is dyed. From a stained cut piece, an ultrathin section of 0.1 μm or less (about 80 nm) was cut with an ultramicrotome at −196 ° C., first magnified 5,000 times, and observed with a transmission electron microscope for a continuous phase and a dispersed phase. To do. At this time, the thermoplastic resin (A) is observed in black to gray, and the rubbery polymer (B) having a reactive functional group is observed in white. When the continuous phase and the dispersed phase cannot be evaluated at 5,000 times, the magnification is observed up to 35,000 times up to a magnification at which the continuous phase and the dispersed phase can be observed. At this time, a dispersed phase having a maximum diameter in the phase of 10 nm or more can be observed. Next, the magnification is 35,000 times to confirm the presence or absence of fine particles having a particle diameter of 1 to 100 nm in the dispersed phase (B). The particle size and the area occupied by the fine particles in the dispersed phase (B) are calculated using image analysis software “Scion Image” manufactured by Scion Corporation. The particle diameter is the number average value of the particle diameters of 10 particles randomly selected from the obtained image. The particle diameter of each particle is an average value of the maximum diameter and the minimum diameter of each particle.

In the present invention, the polyamide resin-rubber polymer composite composition (AB), which is an intermediate raw material of the fiber reinforced resin composition constituting the molded body (D1), and the non-reinforced resin constituting the molded body (D2) The polyamide resin-rubber polymer composite composition (AB), which is a composition, has a tensile modulus of E (V1) and E (V2) at tensile speeds V1 and V2 in a tensile test. When V1 <V2, it is preferable that E (V1)> E (V2). By using such a composite composition, the moldability of the fiber reinforced resin composition and the non-reinforced resin composition, the impact absorption of the oil pan, and the rigidity can be further improved. The above relational expression is preferably established for all V1 and V2 in the range of the tensile speed of 10 mm / min to 500 mm / min, and more preferably any V1, V2 in the range of 1 mm / min to 1000 mm / min. It is preferable that The tensile test in this case is performed according to a method specified in the standard, for example, a JIS-5A dumbbell-type test piece obtained by injection molding. The tensile elastic modulus indicates the gradient of the initial straight line portion of the stress-strain curve. When using a JIS-5A dumbbell test piece, the distance between chucks in the tensile test is 50 mm.
Further, assuming that the tensile breaking elongation at the tensile speeds V1 and V2 is ε (V1) and ε (V2), it is preferable that ε (V1) <ε (V2) when V1 <V2. By using such a composite composition, the moldability of the fiber reinforced resin composition and the non-reinforced resin composition, the impact absorption of the oil pan, and the rigidity can be further improved. The tensile elongation at break indicates the elongation at the moment of breaking. The above relational expression is preferably established for all V1 and V2 in the range of the tensile speed of 10 mm / min to 500 mm / min, and more preferably any V1, V2 in the range of 1 mm / min to 1000 mm / min. It is preferable that When using a JIS-5A dumbbell test piece, the distance between chucks in the tensile test is 50 mm.

  The oil pan of the present invention is excellent in moldability, impact absorption, and rigidity, and the molded body (D1) can absorb impact energy received from the outside with a small amount of deformation, and can be applied to components with built-in transmission due to large deformation. Oil leakage due to contact and destruction can be suppressed. In addition, the molded body (D2) absorbs the remaining impact energy, suppresses the scattering of sharp edge fragments of the molded body (D1), and suppresses penetration and breakage. The present invention can be applied to an oil pan for an automobile continuously variable transmission that can suppress leakage.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated in detail, this invention is not limited by a following example. Each evaluation in an Example and a comparative example was implemented with the following method.

<Rigidity>
An ISO test piece was injection molded under the conditions of a cylinder temperature of 260 ° C. and a mold temperature of 80 ° C., and the flexural modulus was measured according to ISO 178.

<Charpy impact strength with notch>
An ISO test piece was injection-molded under the conditions of a cylinder temperature of 260 ° C. and a mold temperature of 80 ° C., and measured according to ISO 179.

<Ratio of fine particles in dispersed phase (B)>
The center part in the cross-sectional direction of the ISO test piece obtained by injection molding was cut into 1 to 2 mm square, and a rubbery polymer having a reactive functional group was dyed with ruthenium tetroxide. An ultra-thin section of 0.1 μm or less (about 80 nm) is cut from a stained cut piece with an ultramicrotome at −196 ° C., first magnified 5,000 times, and evaluated for a continuous phase and a dispersed phase with a transmission electron microscope. did. At this time, the thermoplastic resin (A) is observed in black to gray, and the rubbery polymer (B) having a reactive functional group is observed in white. When the continuous phase and the dispersed phase could not be evaluated at 5,000 times, the magnification was observed up to 35,000 times up to a magnification at which the continuous phase and the dispersed phase could be observed. At this time, a dispersed phase having a maximum diameter in the phase of 10 nm or more can be observed. Next, this was magnified 35,000 times, and the presence or absence of fine particles having a particle diameter of 1 to 100 nm in the dispersed phase (B) of the rubbery polymer having a reactive functional group was observed. The area occupied by the fine particles in the dispersed phase (B) of the rubbery polymer having a reactive functional group was calculated using image analysis software “Scion Image” manufactured by Scion Corporation. As for the particle diameter, ten particles are randomly selected from the obtained image, and the average value is obtained by measuring the maximum diameter and the minimum diameter of each particle, and then the number average value of these ten average values. Was calculated by calculating.

<Shock absorption>
Using the INSTRON 9250HV dynaup test machine, the oil pan produced in each example and comparative example was subjected to a high-speed falling weight impact test in which a weight-shaped φ12.64 weight, a mass of 24 kg, and a height of 0.1 m were freely dropped. The form (presence / absence of molded body destruction) was visually observed. Moreover, oil was put into the oil pan after a test, and it visually observed whether the oil leaked from the opposite surface. The surface morphology and oil leakage of the molded body (D1) and molded body (D2) were determined according to the following criteria. Further, the maximum deformation after the test was measured.
(Surface morphology)
Molded body (D1); undestructed: A, crack: B, brittle fracture: C
Molded body (D2); Undestructed: A, penetration or brittle fracture: C
(Oil leak)
No: A, Yes: C

  The materials used in Examples and Comparative Examples are shown below.

Polyamide resin (A)
A-1: Polyamide 6 resin (viscosity number VN 135 ml / g, crystal melting temperature 170 ° C., amino end group concentration 5.8 × 10 ⁻⁵ mol / g)
The amount of amino end groups was measured by dissolving a polyamide resin in an 85 wt% phenol-ethanol solution and titrating with an aqueous hydrochloric acid solution using thymol blue as an indicator. Moreover, the crystal melting temperature was measured using a differential scanning calorimeter (DSC) at a temperature rising / falling rate of 20 ° C./min.

Rubbery polymer having a reactive functional group (B)
B-1: Ethylene / methyl acrylate / glycidyl methacrylate copolymer (BF-7L, manufactured by Sumitomo Chemical Co., Ltd.)
Copolymerization component weight ratio: ethylene / methyl acrylate / glycidyl methacrylate copolymer = 70/27/3 (wt%)
B-2: Maleic anhydride-modified ethylene-1-butene copolymer (MH7010 manufactured by Mitsui Chemicals)

Fibrous inorganic filler (C)
C-1: Glass fiber (T-249 manufactured by Nippon Electric Glass Co., Ltd.)

Other resins Resin R10: Fiber reinforced resin not containing a rubbery polymer (B) having a reactive functional group (CM1011G30 manufactured by Toray)
Resin R11: Non-reinforced resin not containing a rubbery polymer (B) having a reactive functional group (CM1021 manufactured by Toray)

(Manufacturing method P1)
While mixing each component with the composition shown in Table 1 and carrying out nitrogen flow, the screw diameter is 65 mm, the screw is two screws with two threads, L / D = 31.5 in the same direction rotation complete meshing Using a type twin screw extruder (manufactured by Nippon Steel Works, TEX-65αII), melt kneading was performed at a cylinder temperature of 230 ° C., a screw rotation speed of 220 rpm, and an extrusion rate of 300 kg / h, and a discharge port (L / D = 31. 5) Strand-like molten resin was discharged. In this case, the screw configuration is a twist in which the helical angle θ, which is the angle between the apex on the kneading disc tip side and the apex on the rear side, is 20 ° from the position of L / D = 10 in the half rotation direction of the screw. The kneading disks were connected at Lk / D = 4.0 minutes to form a zone (extension flow zone) in which the kneading disks melt and knead while being extended and flowed. Further, a reverse screw zone of L / D = 0.5 was provided on the downstream side of the extension flow zone. When the ratio (%) of the total length of the extension flow zone to the total length of the screw was calculated by (total length of extension flow zone) ÷ (total length of screw) × 100, it was 13%. Further, by subtracting the pressure difference (ΔP ₀ ) in the extension flow zone from the pressure difference (ΔP) in front of the twist kneading disc, the inflow effect pressure drop before and after the extension flow zone was obtained. cm ² (14.7 MPa). Further, from the positions of L / D = 16 and 21, a notch type mixing screw having a single thread and a screw pitch of 0.25D and a number of notches of 12 per pitch is connected to Lm / D = 4.0 minutes respectively. Thus, two mixing zones were formed. When the ratio (%) of the total length of the mixing zone to the total length of the screw was calculated by (total length of the mixing zone) / (total length of the screw) × 100, it was 25%. In the notch mixing screw constituting the mixing zone, the ratio (%) of the screw in the direction of screw rotation in the direction opposite to the rotation direction of the screw shaft was set to 75%. The vent vacuum zone was provided at a position of L / D = 27, and volatile components were removed at a gauge pressure of −0.1 MPa. The molten resin discharged from the 4 mmφ × 23 hole passing through the die head was drawn into a strand shape, passed through a cooling bath, cooled, and cut while being taken out by a pelletizer to obtain a pellet-shaped sample of resin R1 .

(Manufacturing method P2)
While mixing each component with the composition shown in Table 1 and performing nitrogen flow, the screw diameter is two screws of 65 mm and the screw is a double thread, L / D = 35, the same direction rotation complete mesh type 2 Using a shaft extruder (manufactured by Nippon Steel Co., Ltd., TEX-65αII), melt kneading is performed at the cylinder temperature, screw rotation speed 220 rpm, extrusion rate 300 kg / h shown in Table 1, discharge port (L / D = 35) More strand-like molten resin was discharged. The screw configuration at that time is provided with three kneading zones starting from the positions of L / D = 7, 16, 25, and the length Lk / D of each kneading zone is Lk / D = 3.0 in order. 3.0 and 3.0. Furthermore, the reverse screw zone was provided in the downstream of each kneading zone, and length Lr / D of each reverse screw zone was Lr / D = 0.5, 0.5, 0.5 in order. Further, the ratio (%) of the total length of the kneading zone to the total length of the screw was calculated by (total length of kneading zone) / (total length of screw) × 100, and was 26%. The vent vacuum zone was provided at a position of L / D = 30, and volatile components were removed at a gauge pressure of −0.1 MPa. The molten resin discharged from the 4 mmφ × 23 hole passing through the die head is drawn in a strand shape, cooled by passing through a cooling bath, and cut while being taken out by a pelletizer, whereby a pellet-like sample of the resins R2 to R3 is obtained. Obtained.

(Manufacturing method P3)
While mixing each component with the composition shown in Table 2 and performing nitrogen flow, the screw diameter is two screws of 65 mm and the screw is a double thread, L / D = 45, the same direction rotation complete mesh type 2 Using a shaft extruder (manufactured by Nippon Steel Works, TEX-65αII), melt kneading at a cylinder temperature of 230 ° C., a screw rotation speed of 350 rpm, and an extrusion rate of 200 kg / h, and strands from the discharge port (L / D = 45) The molten resin was discharged. In this case, the screw configuration is a twist in which the helical angle θ, which is the angle between the apex on the kneading disc tip side and the apex on the rear side, is 20 ° from the position of L / D = 10 in the half rotation direction of the screw. The kneading disks were connected at Lk / D = 4.0 minutes to form a zone (extension flow zone) in which the kneading disks melt and knead while being extended and flowed. Further, a reverse screw zone of L / D = 0.5 was provided on the downstream side of the extension flow zone. When the ratio (%) of the total length of the extension flow zone to the total length of the screw was calculated by (total length of extension flow zone) ÷ (total length of screw) × 100, it was 9%. Further, by subtracting the pressure difference (ΔP ₀ ) in the extension flow zone from the pressure difference (ΔP) in front of the twist kneading disc, the inflow effect pressure drop before and after the extension flow zone was obtained. cm ² (14.7 MPa). Further, from the positions of L / D = 16 and 21, a notch type mixing screw having a single thread and a screw pitch of 0.25D and a number of notches of 12 per pitch is connected to Lm / D = 4.0 minutes respectively. Thus, two mixing zones were formed. When the ratio (%) of the total length of the mixing zone to the total length of the screw was calculated by (total length of the mixing zone) / (total length of the screw) × 100, it was 18%. In the notch mixing screw constituting the mixing zone, the ratio (%) of the screw in the direction of screw rotation in the direction opposite to the rotation direction of the screw shaft was set to 75%. Further, a kneading zone of Lk / D = 3.0 was provided at a position of L / D = 35, and a reverse screw zone of Lr / D = 0.5 was provided downstream thereof. A side feeder is installed at the position of L / D = 33, and raw materials other than the fibrous inorganic filler (C) are from the root of the extruder (position of L / D = 1), and the fibrous inorganic filler (C) is In the middle of the extruder (position of L / D = 33), it was charged according to Table 2. The vent vacuum zone was provided at a position of L / D = 40, and volatile components were removed at a gauge pressure of −0.1 MPa. The molten resin discharged from the 4 mmφ × 23 hole through the die head was drawn in a strand shape, passed through a cooling bath, cooled, and cut while being taken out by a pelletizer to obtain a pellet-shaped sample of resin R4 .

(Manufacturing method P4)
While mixing each component with the formulation shown in Table 2 and carrying out nitrogen flow, the screw diameter is 65 mm and the screw is two screws with two threads, L / D = 35 in the same direction rotation fully meshing type 2 Using a shaft extruder (manufactured by Nippon Steel Works, TEX-65αII), melt kneading is performed at the cylinder temperature shown in Table 2, screw rotation speed 200 rpm, extrusion rate 300 kg / h, and discharge port (L / D = 35) More strand-like molten resin was discharged. The screw configuration at that time is provided with three kneading zones starting from the positions of L / D = 7, 16, 25, and the length Lk / D of each kneading zone is Lk / D = 3.0 in order. 3.0 and 3.0. Furthermore, the reverse screw zone was provided in the downstream of each kneading zone, and length Lr / D of each reverse screw zone was Lr / D = 0.5, 0.5, 0.5 in order. Further, the ratio (%) of the total length of the kneading zone to the total length of the screw was calculated by (total length of kneading zone) / (total length of screw) × 100, and was 26%. Furthermore, a side feeder is installed at a position of L / D = 23, and raw materials other than the fibrous inorganic filler (C) are from the root of the extruder (position of L / D = 1), and the fibrous inorganic filler (C) is From the middle of the extruder (position of L / D = 23), it was charged according to Table 2. The vent vacuum zone was provided at a position of L / D = 30, and volatile components were removed at a gauge pressure of −0.1 MPa. The molten resin discharged from the 4 mmφ × 23 hole passing through the die head is drawn into a strand shape, cooled by passing through a cooling bath, and cut while being taken out by a pelletizer, whereby pellets of resin R5 to R9 are obtained. Obtained.

Resins R1 to R9
The pellets obtained by the above-described manufacturing method were vacuum dried, and then a predetermined test piece for property evaluation was obtained using an injection molding machine. About the obtained test piece, the rigidity (bending elastic modulus), the notched Charpy impact strength, and the proportion of fine particles in the dispersed phase (B) were measured by the above-described methods. The results are shown in Tables 1-2. In the morphology observation, it was confirmed that the polyamide resin formed the continuous phase (A) and the rubbery polymer having a reactive functional group formed the dispersed phase (B). In addition, when a tensile test was performed with Autograph AG100 kNG (manufactured by Shimadzu Corporation) on a JIS-5A dumbbell obtained by molding resin R1 with SE30D manufactured by Sumitomo Heavy Industries, Ltd., the tensile speeds were V1 and V2. Assuming that the tensile modulus of elasticity is E (V1) and E (V2), when V1 <V2, it was E (V1)> E (V2). The tensile test was performed under three conditions of a chuck distance of 50 mm and a tensile speed of 100 mm / min, 500 mm / min, and 1000 mm / min.

Examples 1-10
A box having the minimum thickness shown in Table 3 under the conditions of a cylinder temperature of 260 ° C. and a mold temperature of 80 ° C. using an injection molding machine after the pellets (resins R1 to R9) obtained by the above-described manufacturing method are vacuum dried. Shaped compact (D1) and compact (D2) were obtained. An oil pan was produced by placing the molded body (D1) and the molded body (D2) shown in Table 3 on top of each other. In the present invention, when one surface of the molded body (D1) formed by molding the fiber reinforced resin composition is used as an impact receiving surface (a surface that directly receives impact force), the impact receiving surface of the molded body (D1). And the impact force are preferably in the range of 30 ° to 150 °, more preferably 87 ° to 93 °. The side on which the molded body (D1) is disposed is the side that receives impact force, and the side on which the molded body (D2) is disposed is the opposite side. did. The results are shown in Table 3. The oil pan obtained here is excellent in shock absorption and rigidity, and even when subjected to external impact, it can suppress oil leakage due to contact with and destruction of transmission built-in parts due to large deformation. As bread, it was highly practical.

Examples 11-14
An oil pan was produced in the same manner as in Example 2 except that the molded body (D1) and the molded body (D2) shown in Table 4 were molded in two colors, and the impact absorbability was evaluated. The results are shown in Table 4. The oil pan obtained here is excellent in shock absorption and rigidity, and even when subjected to external impact, it can suppress oil leakage due to contact with and destruction of transmission built-in parts due to large deformation. As bread, it was highly practical.

Comparative Example 1
An oil pan was produced in the same manner as in Example 2 except that the single molded body (D2) shown in Table 5 was used, and the impact absorbability was evaluated. The results are shown in Table 5. When the oil pan obtained here was subjected to a high-speed drop weight impact test, the amount of deformation was too large to penetrate. Further, this oil pan penetrated to the opposite side to the side receiving the impact force at the time of impact, and oil leakage occurred, so that it was not sufficient as an oil pan.

Comparative Example 2
An oil pan was produced in the same manner as in Example 2 except that the single molded body (D1) shown in Table 5 was used, and the impact absorbability was evaluated. The results are shown in Table 5. When the oil pan obtained here was subjected to a high-speed falling weight impact test, cracks occurred. Also, this oil pan was not sufficient as an oil pan because cracks occurred on the side opposite to the side receiving the impact force at the time of impact and oil leakage occurred.

Comparative Examples 3-4
An oil pan was produced in the same manner as in Example 7 except that the molded body (D2) shown in Table 5 was subjected to impact force, and the impact absorbability was evaluated. The results are shown in Table 5. When the oil pan obtained here was subjected to a high-speed falling weight impact test, the molded body (D2) on the side receiving the impact force penetrated, and cracks occurred in the molded body (D1) on the opposite side. Further, these oil pans were not sufficient as oil pans because cracks occurred on the side opposite to the side receiving impact force at the time of impact and oil leakage occurred.

Comparative Example 5
The molded body (D1) shown in Table 5 formed by molding a fiber reinforced resin R10 (Toray CM1011G30) not blended with a rubbery polymer (B) having a reactive functional group was used as a side receiving impact force. Except for the above, an oil pan was produced in the same manner as in Example 2, and the impact absorbability was evaluated. The results are shown in Table 5. When the oil pan obtained here was subjected to a high-speed drop weight impact test, the molded body (D1) formed by molding the fiber reinforced resin R10 disposed on the side receiving the impact force was destroyed, and the molding on the opposite side was performed. Body (D2) broke through. Further, this oil pan was not sufficient as an oil pan because the side opposite to the side receiving the impact force at the time of impact penetrated and an oil leak occurred.

Comparative Example 6
A molded body (D2) shown in Table 5 formed by molding a non-reinforced resin R11 (Toray CM1021) not blended with a rubbery polymer (B) having a reactive functional group, and a molded body shown in Table 5 ( Except that D1) was used, an oil pan was produced in the same manner as in Example 2, and the impact absorption was evaluated. The results are shown in Table 5. When the oil pan obtained here was subjected to a high-speed drop weight impact test, a crack was generated in the molded body (D1) on the side receiving the impact force, and the non-strengthened material placed on the side opposite to the side subjected to the impact force The molded body (D2) formed by molding the resin R11 was brittlely broken. In addition, this oil pan was not sufficient as an oil pan because the side opposite to the side receiving the impact force at the time of impact was brittlely broken and an oil leak occurred.

  In FIG. 3, the schematic block diagram of the oil pan used in the above-mentioned Example and comparative example is shown. FIG. 3A shows an oil pan in which a molded body (D1) 4 formed by molding a fiber-reinforced resin composition and a molded body (D2) 5 formed by molding a non-reinforced resin composition are stacked. FIG. 3B is a schematic longitudinal sectional view of the mission case 105 observed along the section AA ′ of FIG. 3A. Also in the oil pan 10 shown in FIG. 3, as in FIG. 1, the side on which the molded body (D1) 4 is arranged becomes the side 11 that receives the impact force 1, and the molded body (D2) 5 formed by molding the non-reinforced resin composition. Since the respective molded bodies are arranged so that the side on which the oil is placed becomes the opposite side 12, the oil pan 10 becomes a built-in component of the transmission (for example, control valve 103, oil strainer 104, etc.) due to large deformation of the oil pan 10 body. ) And the oil leakage due to the damage of the oil pan 10 main body can be more effectively suppressed. Since other configurations are the same as those in FIG. 1, the same reference numerals as those in FIG.

DESCRIPTION OF SYMBOLS 1 Impact force 2 Impact receiving surface 3 Opposite surface 4 Molded object (D1)
5 Molded body (D2)
6 Notch 7 Screw pitch 8 Screw flight 9 Mixing screw 10 Oil pan 11 Impact receiving side 12 Opposite side 100 Automobile 101 Transmission 102 Built-in parts 103 Control valve 104 Oil strainer 105 Mission case 110 Curbstone D Screw diameter

Claims (5)

  A molded body (D1) formed by molding a fiber reinforced resin composition comprising a polyamide resin, a rubbery polymer having a reactive functional group, and a fibrous inorganic filler, and a polyamide resin and a reactive functional group The side on which the molded body (D1) is placed is placed on the side that receives the impact force. The molded body (D2) formed by molding a non-reinforced resin composition containing a rubber polymer Oil pan for transmission.   The minimum thickness (d1) of the molded body (D1) is 1.0 to 10.0 mm, and the minimum thickness (d2) of the molded body (D2) is 0.5 to 5.0 mm. Oil pan for transmission as described. The transmission according to claim 1 or 2, wherein a minimum thickness (d1) of the molded body (D1) and a minimum thickness (d2) of the molded body (D2) satisfy the following formulas (I) and (II): Oil pan.
(I) 2.3 mm ≦ (d1) + (d2) ≦ 9.0 mm
(II) 0.8 ≦ (d1) / (d2) ≦ 8.0   The reactive functional group of the rubbery polymer having the reactive functional group is at least one selected from the group consisting of an epoxy group, an acid anhydride group, an amino group, a carboxyl group, a carboxyl metal salt, and an oxazoline group. The oil pan for transmission according to any one of claims 1 to 3.   When the molded body (D1) and the molded body (D2) are observed with an electron microscope, the polyamide resin forms a continuous phase (A), the rubbery polymer having a reactive functional group forms a dispersed phase (B), and The dispersed phase (B) contains fine particles having a particle diameter of 1 to 100 nm made of a compound formed by the reaction of a polyamide resin and a rubbery polymer having a reactive functional group, and the fine particles in the dispersed phase (B) The oil pan for a transmission according to any one of claims 1 to 4, which has a morphology in which an area occupied by is 10% or more.

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