JP6773824B2 - 複合成形品 - Google Patents
複合成形品 Download PDFInfo
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- JP6773824B2 JP6773824B2 JP2019010821A JP2019010821A JP6773824B2 JP 6773824 B2 JP6773824 B2 JP 6773824B2 JP 2019010821 A JP2019010821 A JP 2019010821A JP 2019010821 A JP2019010821 A JP 2019010821A JP 6773824 B2 JP6773824 B2 JP 6773824B2
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Description
1.少なくとも樹脂、ガラス繊維およびレーザ吸収材を含有し、該ガラス繊維が露出した溝を有する溝付きの第1の樹脂成形品と、
該第1の樹脂成形品の該溝を有する面上に隣接して配置される第2の成形品、
とを備えた複合成形品であって、
該第1の樹脂成形品において、該ガラス繊維は、該樹脂組成物全体に対し12〜45質量%が混合され、
該レーザ吸収材は、該樹脂組成物全体に対し0.25〜10質量%混合されており、かつ、[{第1の樹脂成形品を構成する樹脂組成物に含有されるガラス繊維の量(質量%)×0.9}+{第1の樹脂成形品を構成する樹脂組成物に含有されるレーザ吸収材の量(質量%)×1.4}]×{第2の成形品を構成する材料の溶融粘度(Pa・s)+360}÷{第1の樹脂成形品を構成する樹脂組成物に含有されるガラス繊維の平均直径(μm)×0.8}が、700以上2500以下を満たす、複合成形品。
3.{前記第1の樹脂成形品を構成する樹脂組成物に含有される前記ガラス繊維の量(質量%)×0.9}+{前記第1の樹脂成形品を構成する樹脂組成物に含有される前記レーザ吸収材の量(質量%)×1.4}]×{前記第2の成形品を構成する材料の溶融粘度(Pa・s)+360}÷{前記第1の樹脂成形品を構成する樹脂組成物に含有される前記ガラス繊維の平均直径(μm)×0.8}が1200以上2100以下を満たす、前記1又は2に記載の複合成形品。
本発明の複合成形品は、少なくとも樹脂、ガラス繊維およびレーザ吸収材を含有する樹脂組成物からなり、該ガラス繊維が露出した溝を有する溝付きの第1の樹脂成形品と、該第1の樹脂成形品の該溝を有する面上に隣接して配置される第2の成形品、とを備えた複合成形品であって、該第1の樹脂成形品において、該ガラス繊維は、該樹脂組成物全体に対し12〜45質量%が混合され、該レーザ吸収材は該樹脂組成物全体に対し0.25〜10質量%混合されており、かつ、[{第1の樹脂成形品を構成する樹脂組成物に含有されるガラス繊維の量(質量%)×0.9}+{第1の樹脂成形品を構成する樹脂組成物に含有されるレーザ吸収材の量(質量%)×1.4}]×{第2の成形品を構成する材料の溶融粘度(Pa・s)+360}÷{第1の樹脂成形品を構成する樹脂組成物に含有されるガラス繊維の平均直径(μm)×0.8}が700以上2500以下を満たすことを特徴とする。
図2は、溝付きの第1の樹脂成形品10の概略拡大断面模式図である。溝付きの第1の樹脂成形品10は、ガラス繊維11を含有する。また、溝付きの第1の樹脂成形品10は、ガラス繊維11が側面より突出し露出された溝12を有する。ガラス繊維の一部は、溝に架かっている。
[樹脂]
[ガラス繊維]
[レーザ吸収材]
質量%含有させることにより、レーザ照射時の樹脂の除去しやすさ(溝の形成しやすさ)を適宜調整することができ、接合強度のバラツキを抑制することができる。0.25質量%よりも少ない場合は、ガラス繊維によるレーザの反射や散乱による減衰が発生しやすく、溝の形成状態にバラツキを発生しやすくなり、10質量%を超えた場合は、レーザ吸収材の凝集物が生じたり、またレーザ吸収材が凝集し高濃度となった箇所で、レーザによる過熱が発生し炭化物が生成したりすることで、それらが異物として破壊起点となり、やはり接合強度のバラツキを発生しやすくなる。
[溝]
本明細書では、複合成形品1においてガラス繊維11が露出されていない場合であっても、複合成形品1から第2の成形品20を取り除いた態様において溝12からガラス繊維11が露出していれば、「溝12においてガラス繊維11が露出されている」ものとする。
本発明の第2の成形品20を形成する材料は、未硬化の流動状態であって、ガラス繊維11が露出された溝12に入ることが可能な樹脂であれば特に限定されるものでなく、熱可塑性樹脂、硬化性樹脂(熱硬化性樹脂、光硬化性樹脂、放射線硬化性樹脂等)、ゴム、接着剤等のいずれからなるものであってもよいが、加工性の点から、射出成形で賦形することができる熱可塑性樹脂、熱硬化性樹脂、ゴムを含む樹脂組成物が好ましく、熱可塑性樹脂を含む熱可塑性樹脂組成物であることがより好ましい。第1の樹脂成形品を構成する樹脂と同種の樹脂または異種の樹脂を使用することもできる。ここで異種とは、第1の樹脂成形品を構成する樹脂を、一部含む場合も含んでいる。本発明では、異種の場合に特に効果が発揮される。
第1の樹脂成形品に第2の成形品が射出成形、トランスファ成形、溶着等の方法により積層されることにより、本発明の複合成形品が形成される。
本発明では、溝付きの第1の樹脂成形品を構成する樹脂組成物に含有されるガラス繊維の含有量と平均直径、レーザ吸収材の含有量、および第2の成形品を構成する材料の溶融粘度が、得られる複合成形品の接合強度に相互に影響を及ぼす。
ポリプラスチックス株式会社製、融点280℃、ISO11443に準拠し310℃で測定した1000sec−1における溶融粘度45Pa・sの液晶ポリマー(以下「LCP」とも記載)に、日本電気硝子株式会社製ガラス繊維ECS03T−786H(平均繊維長3mm、平均直径10.5μm、以下「GF10.5」とも記載)およびレーザ吸収材として三菱化学株式会社製カーボンブラック#3030B(以下「CB」とも記載)を表1に記載の量(LCPをベースとした樹脂組成物全体に対し、GF10.5を5〜50質量%、CBを0.01〜10.00質量%)混合し、下記条件で65mm×13mm×6.5mmの棒状成形品を射出成形した。この射出成形品の13mm×6.5mmの面に、照射回数が10回になるように、射出成形品の表面に対して垂直方向から斜格子状にレーザを照射した。
予備乾燥:140℃、3時間
シリンダ温度:290℃
金型温度:80℃
射出速度:100mm/sec
保圧:80MPa(800kg/cm2)
上記溝付きの第1の樹脂成形品について、レーザの照射によって形成された溝を有する面を接触面として130mm×13mm×6.5mmのキャビティの射出成形用金型にインサートし、第2の成形品を構成する材料を射出成形し、キャビティ内の残りの65mm×13mm×6.5mmの空間に充填することで第2の成形品を積層し、130mm×13mm×6.5mmの複合成形品の試料を得た。なお、第2の成形品を構成する材料は、第1の樹脂成形品を構成する樹脂組成物と同じ材料を用い、第1の樹脂成形品と同じ成形条件で射出成形した。
上記試料について各10サンプルを取り出し、23℃50%RHの雰囲気下、オリエンテック社製テンシロンUTA−50kN(クロスヘッド速度10mm/分)にて引張試験を行い、複合成形品の接合強度及びそのバラツキを評価した。評価基準は下記の通りとした。B以上であれば、実用上の問題は発生しないレベルである。
A:10個のうち10個が接合強度12MPa以上
B:10個のうち10個が接合強度10MPa以上12MPa未満
C:10個のうち8〜9個が接合強度10MPa以上、他が10MPa未満
D:10個のうち3個以上が接合強度10MPa未満
予備乾燥:140℃、3時間
シリンダ温度:320℃
金型温度:140℃
射出速度:30mm/sec
保圧:80MPa(800kg/cm2)
上記試料について各10サンプルを取り出し、23℃50%RHの雰囲気下、オリエンテック社製テンシロンUTA−50kN(クロスヘッド速度10mm/分)にて引張試験を行い複合成形品の接合強度及びそのバラツキを評価した。評価基準は下記の通りとした。B以上であれば、実用上の問題は発生しないレベルである。
A:10個のうち10個が接合強度40MPa以上
B:10個のうち10個が接合強度30MPa以上40MPa未満
C:10個のうち8〜9個が接合強度30MPa以上、1〜2個が30MPa未満
D:10個のうち3個以上が接合強度30MPa未満
予備乾燥:80℃、3時間
シリンダ温度:195℃
金型温度:80℃
射出速度:16mm/sec
保圧:80MPa(800kg/cm2)
上記試料について各10サンプルを取り出し、23℃50%RHの雰囲気下、オリエンテック社製テンシロンUTA−50kN(クロスヘッド速度10mm/分)にて引張試験を行い複合成形品の接合強度及びそのバラツキを評価した。評価基準は下記の通りとした。B以上であれば、実用上の問題は発生しないレベルである。
A:10個のうち10個が接合強度10MPa以上
B:10個のうち10個が接合強度7MPa以上10MPa未満
C:10個のうち8〜9個が接合強度7MPa以上、1〜2個が7MPa未満
D:10個のうち3個以上が接合強度7MPa未満
10 溝付きの第1の樹脂成形品
11 無機充填剤
12 溝
12a 溝の側壁
13 山
20 第2の成形品
D 溝の深さ
W 山の幅
Claims (4)
- 少なくとも樹脂、ガラス繊維およびレーザ吸収材を含有し、該ガラス繊維が露出した溝を有する溝付きの第1の樹脂成形品と、
該第1の樹脂成形品の該溝を有する面上に隣接して配置される第2の樹脂成形品、
とを備えた射出成形インサート成形品である複合成形品であって、
該第1の樹脂成形品において、該ガラス繊維は、該樹脂組成物全体に対し15〜40質量%が混合され、
該レーザ吸収材は該樹脂組成物全体に対し0.30〜10質量%混合されており、かつ、[{第1の樹脂成形品を構成する樹脂組成物に含有されるガラス繊維の量(質量%)×0.9}+{第1の樹脂成形品を構成する樹脂組成物に含有されるレーザ吸収材の量(質量%)×1.4}]×{第2の成形品を構成する材料の溶融粘度(Pa・s)+360}÷{第1の樹脂成形品を構成する樹脂組成物に含有されるガラス繊維の平均直径(μm)×0.8}が、700以上2500以下を満たす、複合成形品。
ただし溶融粘度とは、ISO11443に準拠して測定した1000sec−1における溶融粘度を指し、測定温度は、樹脂成形品を構成する材料に主に含まれる樹脂が融点を持つものである場合はその融点+30℃、融点を持たないものである場合はガラス転移温度+120℃にて測定するものである。 - 前記ガラス繊維が、前記第1の樹脂成形品を構成する樹脂組成物全体に対し20〜35質量%混合され、前記レーザ吸収材が、前記第1の樹脂成形品を構成する樹脂組成物全体に対し0.35〜7.5質量%混合されている、請求項1に記載の複合成形品。
- {前記第1の樹脂成形品を構成する樹脂組成物に含有される前記ガラス繊維の量(質量%)×0.9}+{前記第1の樹脂成形品を構成する樹脂組成物に含有される前記レーザ吸収材の量(質量%)×1.4}]×{前記第2の樹脂成形品を構成する材料の溶融粘度(Pa・s)+360}÷{前記第1の樹脂成形品を構成する樹脂組成物に含有される前記ガラス繊維の平均直径(μm)×0.8}が1200以上2100以下を満たす、請求項1又は2に記載の複合成形品。
- 前記第1の樹脂成形品を構成する樹脂と前記第2の樹脂成形品を構成する樹脂が、異種である請求項1〜3いずれかに記載の複合成形品。
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US11705641B2 (en) | 2019-08-21 | 2023-07-18 | Ticoan Llc | Antenna system including a polymer composition having a low dissipation factor |
US11555113B2 (en) | 2019-09-10 | 2023-01-17 | Ticona Llc | Liquid crystalline polymer composition |
US11912817B2 (en) | 2019-09-10 | 2024-02-27 | Ticona Llc | Polymer composition for laser direct structuring |
US11646760B2 (en) | 2019-09-23 | 2023-05-09 | Ticona Llc | RF filter for use at 5G frequencies |
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US11728559B2 (en) | 2021-02-18 | 2023-08-15 | Ticona Llc | Polymer composition for use in an antenna system |
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