JP7288798B2 - Laminate manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a laminate, an automobile part, an automobile wheel, and a method for producing the laminate.

Fiber-reinforced synthetic resins are lightweight and have high mechanical strength. Its use is expanding in fields where

For example, Patent Document 1 discloses a fiber-reinforced composite in which a fiber-reinforced composite material in which fibers are bound to each other with a thermoplastic resin or a cured thermosetting resin is laminated and integrated on the surface of a foam sheet. ing.
Further, in Patent Document 2, a core material containing an expandable resin and a fiber-reinforced resin in which reinforcing fibers are impregnated with a matrix resin, which is a thermosetting resin or a thermoplastic resin, are arranged on both sides of the core material. A fiber reinforced resin sandwich panel is disclosed which is constructed from a skin material comprising
Further, Patent Document 3 discloses a fiber-reinforced composite material in which a core material containing a bead foam molded article containing a thermoplastic resin and a skin material containing fibers and a resin are arranged on at least a part of the surface of the core material. disclosed.

Japanese Patent No. 6067473 Japanese Patent No. 5098132 International Publication No. 2018/186360

However, the fiber-reinforced composites described in Patent Documents 1 to 3 have room for improvement in terms of weight reduction and flexibility in shape.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a lightweight laminate, an automobile part, an automobile wheel, and a method for producing a lightweight laminate having a high degree of freedom in shape.

The present inventors have made intensive studies to solve the above problems, and found that a layer containing a specific fiber-reinforced thermoplastic resin, a layer containing a specific thermoplastic foamed resin, and a specific fiber-reinforced thermoplastic resin. The difference in melting point (or glass transition point if it does not have a melting point) between the fiber-reinforced thermoplastic resin and the thermoplastic foam resin is within a specific range, and in the laminated portion, Including a low density portion where the apparent density of the thermoplastic foam is low and a high density portion where the apparent density is high, the ratio of the apparent density of the thermoplastic foam in the low density portion and the high density portion, and the low density in the laminated portion We have found that the above problems can be solved by forming a laminate having a density portion and a ratio of the high density portion within a specific range, and the laminate of the present invention and automobile parts such as automobile wheels containing the laminate completed.
Further, the present inventors have found that the above problems can be solved by providing an automobile part containing a continuous fiber-reinforced thermoplastic resin and a discontinuous fiber-reinforced thermoplastic resin, and completed the automobile part of the present invention. rice field.

The present invention provides the following laminates, automobile parts, automobile wheels, and methods for producing laminates.

The present invention provides the following.
[ 1 ]
A fiber-reinforced thermoplastic resin (A), a thermoplastic foam resin (B), and a fiber-reinforced thermoplastic resin (C) are laminated in this order and welded to each other to form a laminate precursor,
When the laminate precursor does not have the melting point of the fiber-reinforced thermoplastic resin (A) or the melting point of the fiber-reinforced thermoplastic resin ( _C ) or the melting point of the fiber-reinforced thermoplastic resin (C), which is the glass transition point TA is the glass transition point T _C , which is the higher temperature T _H or higher,
The heated laminate precursor is put into a mold heated to a temperature equal to or lower than _TL , which is the lower temperature of the T _A and the T _C , and the mold is clamped to obtain the thermoplastic foam resin. Forming a laminated portion including a low density portion having a low apparent density of (B) and a high density portion having a high apparent density of the thermoplastic foam resin (B),
The ratio (ρ2/ρ1) of the apparent density (ρ2) of the thermoplastic foamed resin (B) in the high-density portion to the apparent density (ρ1) of the thermoplastic foamed resin (B) in the low-density portion is 1.5 or more ,
When the total area of the laminated portion is taken as 100% in a plan view when viewed from the lamination direction of the laminated portion, the area of the low-density portion is 50 to 90%, and the area of the high-density portion is 10%. 50%.
[ 2 ]
In forming the laminate precursor, further comprising laminating a fiber-reinforced thermoplastic resin (C) between the fiber-reinforced thermoplastic resin (A) and the thermoplastic foam resin (B) [ 1] ] The manufacturing method of the laminated body as described in ].

ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of a lightweight laminated body, a motor vehicle component, the wheel for a motor vehicle, and a lightweight laminated body with high flexibility of a shape can be provided.

An example of a mold for forming a laminate according to the present invention is shown. (A) is a schematic cross-sectional view of the mold in the thickness direction, and (B) is a schematic top view of the lower mold in (A). An example of a mold for forming a laminate according to the present invention is shown. (A) is a schematic cross-sectional view of the mold in the thickness direction, and (B) is a schematic top view of the lower mold in (A).

EMBODIMENT OF THE INVENTION Hereinafter, the form (henceforth "this embodiment") for implementing this invention is demonstrated in detail. The following embodiments are exemplifications for explaining the present invention, and the present invention is not limited to the following embodiments, and various modifications can be made within the scope of the gist thereof.

<Laminate>
As a first aspect of the present invention, the laminate of the present embodiment includes a (A) layer containing a fiber-reinforced thermoplastic resin (A), a (B) layer containing a thermoplastic foam resin (B), and a fiber-reinforced a layer (C) containing a thermoplastic resin (C) and a layer (C) containing the thermoplastic resin ( _C ) in this order; If it does not have the melting point or the melting point of the thermoplastic foam resin (B), the difference from the glass transition point T _B is 50 ° C. or less, and it does not have the melting point or the melting point of the fiber-reinforced thermoplastic resin (C) is a glass transition point T _C and the difference between T _B is 50 ° C. or less, and the laminated portion is a low-density portion having a low apparent density of the thermoplastic foam resin (B) and the thermoplastic The thermoplastic foam resin in the high density portion with respect to the apparent density (ρ1) of the thermoplastic foam resin (B) in the low density portion. The ratio (ρ2/ρ1) of the apparent density (ρ2) of (B) is 1.5 or more, and the total area of the laminated portion is 100% in a plan view when viewed from the lamination direction of the laminated portion. Sometimes characterized in that the area of said low density portion is 50-90% and the area of said high density portion is 10-50%.
By including the above-described laminated portion, the laminate of the present embodiment is lightweight, excellent in impact resistance and rigidity, and has a high degree of thermal insulation, sound absorption, and design freedom.
In the layered product of the present embodiment, portions other than the layered portion may have a single layer structure or a layered structure.
Also, the (C) layer may be further laminated between the (A) layer and the (B) layer.

The thickness of the laminate is preferably 2 to 50 mm. When the thickness of the laminate is within the above range, it is possible to obtain a laminate that is lightweight, has excellent impact resistance and rigidity, and has high heat insulation and sound absorption properties.

<Lamination part>
In the laminated portion included in the laminate of the present embodiment, the (A) layer containing the fiber reinforced thermoplastic resin (A), the (B) layer containing the thermoplastic foam resin (B), and the fiber reinforced thermoplastic resin ( The (C) layer containing C) is included in this order.
The laminated portion of the present embodiment includes the (A) layer, the (B) layer, and the (C) layer in this order, so that it is lightweight, has excellent impact resistance and rigidity, and has heat insulation, sound absorption, and free shape. Excellent degree.

<<(A) layer>>
The (A) layer included in the laminated portion of the present embodiment contains a fiber-reinforced thermoplastic resin (A).

The thickness of the layer (A) is preferably 0.3 to 4.0 mm, more preferably 0.5 to 2.0 mm. When the thickness of the layer (A) is within the above range, it is excellent in impact resistance, rigidity, and moldability.

The ratio of the layer (A) in the lamination portion is preferably 1 to 50%, more preferably 3 to 20%, with the thickness of the low density portion being 100% in the low density portion described later. When the ratio of the (A) layer in the low-density portion is within the above range, excellent impact resistance, rigidity, and moldability are obtained.
In addition, the ratio of the layer (A) in the laminated portion is preferably 5 to 80%, more preferably 20 to 80%, and more preferably 20 to 80%, with the thickness of the high density portion being 100% in the high density portion described later. It is preferably 45 to 80%. When the ratio of the (A) layer in the high-density portion is within the above range, excellent impact resistance, rigidity, and moldability are obtained.

-Fiber-reinforced thermoplastic resin (A)-
The fiber-reinforced thermoplastic resin (A) contained in the layer (A) of the present embodiment is a thermoplastic resin whose strength is increased by containing reinforcing fibers.
The strength and elasticity of layer (A) are adjusted by selecting the type, blending amount, thickness, directionality, etc. of the reinforcing fiber to be used, and the type and blending amount of the thermoplastic resin according to the purpose. be able to.

--Reinforcing fiber--
As the reinforcing fibers contained in the fiber-reinforced thermoplastic resin (A), those used as ordinary fiber-reinforced composite materials can be used, for example, glass fibers, carbon fibers, aramid fibers, ultra-high-strength polyethylene fibers, At least one selected from the group consisting of polybenzazole fibers, liquid crystal polyester fibers, polyketone fibers, metal fibers, and ceramic fibers. Glass fiber is particularly preferable from the viewpoint of improving impact resistance, and carbon fiber is particularly preferable from the viewpoint of improving rigidity.
The reinforcing fibers may be used singly or in combination.

When glass fibers are selected as the reinforcing fibers, a sizing agent may be used, and the sizing agent preferably contains a silane coupling agent, a lubricant, and a sizing agent.
The types of glass fibers and sizing agents used for the glass fibers are not particularly limited, and known ones can be used. Specifically, for example, the one described in JP-A-2015-101794 can be used.

Similarly, when carbon fibers are selected as the reinforcing fibers, a sizing agent may be used, and the sizing agent preferably contains a lubricant and a sizing agent.
The type of sizing agent used for carbon fibers is not particularly limited, and known ones can be used. Specifically, for example, the one described in JP-A-2015-101794 can be used.

Even when other reinforcing fibers are used, the type and amount of sizing agent that can be used for glass fibers and carbon fibers can be appropriately selected and used according to the properties of the reinforcing fibers. It is preferable to set the type and amount of the sizing agent according to the sizing agent.

The reinforcing fiber may be a single yarn, a twisted yarn, or a composite yarn composed of two or more kinds of reinforcing fibers.
In addition, the reinforcing fibers may be in the form of threads, or in the form of strings, braids, sheets (woven fabrics, knitted fabrics, unidirectionally arranged sheets, multiaxial fabrics, non-woven fabrics, etc.). good. Among them, a sheet shape is preferable from the viewpoint of handleability and design flexibility.

Further, the reinforcing fibers may be either discontinuous fibers or continuous fibers, and when the layer (A) is the surface layer on the front side, it is preferably continuous fibers from the viewpoint of improving impact resistance. When the layer (A) is the surface layer on the back side, the layer (A) is preferably made of discontinuous fibers from the viewpoint of improving the rigidity by fluidizing the layer (A) to form ribs and the like during molding.
In the case of discontinuous fibers, the average fiber length of the reinforcing fibers is preferably 3 to 200 mm, more preferably 10 to 150 mm.
The average fiber length of the reinforcing fibers is the average value of the lengths of the reinforcing fibers remaining after incinerating the laminate or automobile parts including the laminate.

The number of single yarns of the reinforcing fibers is preferably 30 to 15,000 from the viewpoint of handleability.
Further, the fineness of the reinforcing fiber is preferably 1,000 to 30,000 dtex from the viewpoint of handleability.

The cross-sectional shape of the reinforcing fiber is not particularly limited, and may be circular, elliptical, irregular (for example, Y-shaped, X-shaped, I-shaped, R-shaped, etc.), or hollow. good.
The average cross-sectional diameter of the reinforcing fibers is preferably 3 to 25 μm from the viewpoint of long-term properties.
The average cross-sectional diameter of reinforcing fibers can be measured with an optical microscope, digital microscope, scanning electron microscope (SEM), or the like.

--Thermoplastic resin--
The thermoplastic resin contained in the fiber-reinforced thermoplastic resin (A) may be a crystalline resin or an amorphous resin.
When a mixture of a crystalline resin and an amorphous resin is used, the highest temperature among the melting point of the crystalline resin and the glass transition point of the amorphous resin contained in the thermoplastic resin preferably satisfies the requirements. .
The strength, rigidity, etc. of the layer (A) can be adjusted by selecting the type and blending amount of the thermoplastic resin to be used according to the purpose.

Examples of the thermoplastic resin include, but are not limited to, polyamide-based resins such as polyamide 6, polyamide 66, polyamide 12 and polyamide 46; polyolefin-based resins such as polyethylene and polypropylene; polyethylene terephthalate, polybutylene terephthalate, poly Polyester resin such as trimethylene terephthalate; Polyacetal resin such as polyoxymethylene; Polycarbonate resin; Polyetherketone; Polyetheretherketone; Polyethersulfone; - Thermoplastic fluororesins such as ethylene copolymers; and modified thermoplastic resins obtained by modifying these. Among these thermoplastic resins, polyamide-based resins, polyolefin-based resins, polyphenylene sulfide, thermoplastic polyetherimide, polyamide-imide, and polyetheretherketone are preferable from the viewpoint of heat resistance, strength, and rigidity. , and from the viewpoint of workability, polyamide-based resins are particularly preferred.
The above thermoplastic resins may be used singly or in combination.

(polyamide resin)
A polyamide resin means a polymer compound having a --CO--NH--(amide) bond in its main chain. Examples thereof include polyamides obtained by ring-opening polymerization of lactams, polyamides obtained by self-condensation of ω-aminocarboxylic acids, polyamides obtained by condensation of diamines and dicarboxylic acids, and copolymers thereof. is not limited to
Other details of the lactam, diamine (monomer), and dicarboxylic acid (monomer) described in JP-A-2015-101794 can be used as appropriate.

Specific examples of polyamides include polyamide 4 (polyα-pyrrolidone), polyamide 6 (polycabroamide), polyamide 11 (polyundecaneamide), polyamide 12 (polydodecanamide), polyamide 46 (polytetramethyleneadipane polyamide), polyamide 66 (polyhexamethylene adipamide), polyamide 610, polyamide 612, polyamide 6T (polyhexamethylene terephthalamide), polyamide 9T (polynonanemethylene terephthalamide), and polyamide 6I (polyhexamethylene isophthalamide) , and copolyamides containing these as constituents.

Copolyamides include, for example, a copolymer of hexamethylene adipamide and hexamethylene terephthalamide, a copolymer of hexamethylene adipamide and hexamethylene isophthalamide, and hexamethylene terephthalamide and 2-methylpentanediamine terephthalate. Examples thereof include amide copolymers.

(polyolefin resin)
Examples of polyolefin resins include polypropylene polymerized using a Ziegler catalyst or metallocene catalyst, ethylene-propylene random copolymer, propylene-butene random copolymer, ethylene-propylene block copolymer, ethylene-propylene-butene 3 Polypropylene resin such as original copolymer, low density polyethylene, medium density polyethylene, linear low density polyethylene, linear ultra low density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate Examples include polyethylene resins such as copolymers and ionomer resins.

When the thermoplastic resin contained in the fiber-reinforced thermoplastic resin (A) is a crystalline resin, it preferably has a melting point of 100 to 400°C, more preferably 150 to 300°C.
Further, when the thermoplastic resin contained in the fiber-reinforced thermoplastic resin (A) is an amorphous resin, it preferably has a glass transition point of 0 to 200°C.

The thermoplastic resin contained in the fiber-reinforced thermoplastic resin (A) has a melting point or, if it does not have a melting point (in the case of an amorphous resin), a glass transition point _TA , and a thermoplastic foam resin (B ), or if it does not have the melting point of the thermoplastic resin contained in ) (in the case of an amorphous resin), the difference from T _B , which is the glass transition point, is 50° C. or less. When the difference is 50°C or less, the fiber-reinforced thermoplastic resin (A) and the thermoplastic foamed resin (B) can be easily welded.
Further, the thermoplastic resin contained in the fiber-reinforced thermoplastic resin (A) preferably has _TA equal to or lower than _TB . As a result, when manufacturing the laminate, by setting the molding temperature to TA _or higher and TB or _lower , the thermoplastic resin contained in the fiber-reinforced thermoplastic resin (A) is easily melted, and the thermoplastic foamed resin The thermoplastic resin contained in (B) can be brought into a state in which it is difficult to melt.

The shape of the thermoplastic resin used for producing the fiber-reinforced thermoplastic resin (A) is not particularly limited, and examples thereof include fibrous, string-like, sheet-like (woven fabric, knitted fabric, film, non-woven fabric, etc.), pellet-like, and the like. be done. Among them, a sheet shape is preferable from the viewpoint of handleability and design flexibility.

〈〈(B) layer〉〉
The (B) layer included in the laminated portion of the present embodiment contains a thermoplastic foamed resin (B).

The foaming ratio of the thermoplastic foam resin (B) in the (B) layer is preferably 1.5 to 10 times in the low density portion described later, and 0 to 1.5 in the high density portion described later. Double is preferred. By setting the foaming ratio of the thermoplastic foamed resin (B) in the layer (B) within the above range, it is possible to obtain a laminate having excellent heat insulating performance, sound absorbing performance, and flexibility in shape.

The thickness of the layer (B) and the ratio in the laminated portion are not particularly limited, and may be appropriately adjusted according to the desired rigidity, thermal conductivity, sound absorption coefficient, and the like.

-Thermoplastic foam resin (B)-
The thermoplastic foamed resin (B) contained in the layer (B) of this embodiment may be a crystalline resin or an amorphous resin.
When a mixture of a crystalline resin and an amorphous resin is used, the highest temperature among the melting point of the crystalline resin and the glass transition point of the amorphous resin contained in the thermoplastic resin preferably satisfies the requirements. .
The strength, rigidity, heat insulation, sound absorption, etc. of the layer (B) can be adjusted by selecting the type and blending amount of the thermoplastic resin to be used according to the purpose.

--Thermoplastic resin--
The thermoplastic resin contained in the thermoplastic foam resin (B) includes the same thermoplastic resin as the thermoplastic resin contained in the fiber-reinforced thermoplastic resin (A) described above, and should be excellent in heat resistance, strength, and rigidity. Therefore, polyamide-based resins are particularly preferred.
The above thermoplastic foamed resins may be used singly or in combination.

<<(C) layer>>
The (C) layer included in the laminated portion of the present embodiment contains a fiber-reinforced thermoplastic resin (C).

The preferable range of the thickness of the layer (C) and the ratio in the laminated portion may be the same as those of the layer (A) described above.

-Fiber-reinforced thermoplastic resin (C)-
The fiber-reinforced thermoplastic resin (C) contained in the layer (C) of the present embodiment is a thermoplastic resin whose strength is increased by containing reinforcing fibers.
The fiber-reinforced thermoplastic resin (C) contained in the layer (C) of this embodiment may be a crystalline resin or an amorphous resin.
When a mixture of a crystalline resin and an amorphous resin is used, the highest temperature among the melting point of the crystalline resin and the glass transition point of the amorphous resin contained in the thermoplastic resin preferably satisfies the requirements. .
The strength and elasticity of the (C) layer are adjusted by selecting the type, blending amount, thickness, directionality, etc. of the reinforcing fiber to be used, and the type and blending amount of the thermoplastic resin according to the purpose. be able to.

--Reinforcing fiber--
The reinforcing fibers contained in the fiber-reinforced thermoplastic resin (C) include the same reinforcing fibers as the reinforcing fibers contained in the fiber-reinforced thermoplastic resin (A) described above, and are contained in the fiber-reinforced thermoplastic resin (A). It may be the same as or different from the reinforcing fiber, and from the viewpoint of improving impact resistance, glass fiber is particularly preferred, and from the viewpoint of improving rigidity, carbon fiber is particularly preferred.
The reinforcing fibers may be used singly or in combination.

--Thermoplastic resin--
Examples of the thermoplastic resin contained in the thermoplastic foam resin (C) include the same thermoplastic resins contained in the fiber-reinforced thermoplastic resin (A) described above. It may be the same as or different from the thermoplastic resin used, and polyamide-based resins are particularly preferred because they are excellent in heat resistance, strength, and rigidity.
The above thermoplastic foamed resins may be used singly or in combination.
Thus, in the laminate of the present embodiment, the (A) layer, the (B) layer, and the (C) layer are all layers containing only a thermoplastic resin as a resin, so that the thermosetting foamed resin is included. Unlike laminates, the laminated parts can be melted and the resin can be recovered and reused, so it is highly recyclable. In particular, when the (A) layer, (B) layer, and (C) layer all contain the same type of thermoplastic resin (for example, when containing polyamide 12, polyamide 6, and polyamide 610, respectively), the recovery efficiency is and improve recyclability.

The thermoplastic resin contained in the fiber-reinforced thermoplastic resin (C) has a melting point or, in the case of a non-crystalline resin, a glass transition point T _C , and the difference between the above T _B is 50°C or less. When the difference is 50°C or less, the thermoplastic foamed resin (B) and the fiber-reinforced thermoplastic resin (C) can be easily welded.
Further, the thermoplastic resin contained in the fiber-reinforced thermoplastic resin (C) preferably has a difference of 50° C. or less between T _C and T _A above. When the difference is 50°C or less, the fiber-reinforced thermoplastic resin (A) and the fiber-reinforced thermoplastic resin (C) can be easily welded.
Further, the thermoplastic resin contained in the fiber-reinforced thermoplastic resin (C) preferably has T _C equal to or lower than T _B . As a result, for example, when compression molding an automobile wheel including the laminate of the present embodiment, which will be described later, by setting the molding temperature to T _C or more and T _B or less, the fiber-reinforced thermoplastic resin (C) The thermoplastic resin contained in the fiber-reinforced thermoplastic resin (C) is easily melted, and the thermoplastic resin contained in the thermoplastic foamed resin (B) can be in a state in which it is difficult to melt. It preferentially flows into a mold corresponding to the rim of an automobile wheel, allowing it to be formed into a rim.

When the fiber-reinforced thermoplastic resin (A) is a continuous fiber-reinforced thermoplastic resin, the fiber-reinforced thermoplastic resin (C) is preferably a discontinuous fiber-reinforced thermoplastic resin from the viewpoint of design freedom. Depending on the required physical properties, both the fiber-reinforced thermoplastic resin (A) and the fiber-reinforced thermoplastic resin (C) may be continuous fiber-reinforced thermoplastic resins or discontinuous fiber-reinforced thermoplastic resins. .

〈〈Other layers〉〉
The laminated portion of the present embodiment may have other layers in addition to the layers (A), (B), and (C).
Other layers are not particularly limited, and include layers containing thermoplastic resins other than those described above, aluminum plates, general steel plates, high-tensile steel plates, and the like. When non-ferrous metal or iron is included, it is preferable to chemically or laser-treat the surface of the non-ferrous metal or iron in order to improve the bonding strength with the thermoplastic resin.

<<Additive>>
The laminate of the present embodiment may contain additives as necessary. The laminate of the present embodiment includes, for example, an antioxidant, an antioxidant, a weathering agent, a metal deactivator, a light stabilizer, a heat stabilizer, an ultraviolet absorber, an antibacterial/antifungal agent, a deodorant, a conductive Granting agent, dispersant, softening agent, plasticizer, cross-linking agent, co-cross-linking agent, vulcanizing agent, vulcanizing aid, foaming agent, foaming aid, coloring agent, flame retardant, vibration damping agent, nucleating agent, medium Additives, lubricants, antiblocking agents, dispersants, fluidity improvers, release agents, etc. can be added.
The content of the additive is not particularly limited, and can be appropriately set within a range that does not impair the effects of the present invention.

The laminated portion included in the laminate of the present embodiment includes a low-density portion having a low apparent density of the thermoplastic foam resin (B) and a high-density portion having a high apparent density of the thermoplastic foam resin (B). including.
The laminated portion of the present embodiment includes a low-density portion and a high-density portion, so that the low-density portion has excellent heat insulation performance and sound absorption performance, and the high-density portion has strength and rigidity without increasing the number of parts and processing man-hours. It is possible to obtain a laminate that is excellent in bolting, adhesion, and thinning.

<<Low Density Part>>
The laminated portion of this embodiment includes a low-density portion in which the thermoplastic foam resin (B) has a low apparent density. Since the low-density portion is excellent in sound absorption and heat insulation, it is suitable for automobile parts such as roofs, hoods, side doors, back doors, floor panel portions, and the like.

The apparent density (ρ1) of the thermoplastic foam resin (B) in the low-density portion is preferably 0.09-0.8 g/cm ³ , more preferably 0.18-0.8 g/cm ³ . be. When the apparent density (ρ1) is within the above range, it is possible to obtain a laminate having excellent weight reduction, heat insulating properties, and sound absorbing properties.
The apparent density (ρ1) is obtained by cutting out a sheet-like measurement sample from the low-density portion, and using its mass W1 (g) and volume V1 (cm ³ ), the ratio of mass W1 to volume V1 (W1/V1). This is the desired value. More specifically, it can be measured by the method described in Examples below.

The low-density part has an area of 50 to 90%, preferably 60 to 80%, when the total area of the laminated part is 100% in plan view when viewed from the lamination direction of the laminated part. is. When the area of the low-density portion is within the above range, it is excellent in weight reduction.

<<High Density Part>>
The laminated portion of this embodiment includes a high-density portion in which the thermoplastic foamed resin (B) has a high apparent density. Since the high-density portion is excellent in strength, it is suitable for a bolted portion, an adhesive portion, and the like of automobile parts and the like.

The apparent density (ρ2) of the thermoplastic foamed resin (B) in the high-density portion is preferably 0.6-1.2 g/cm ³ . When the apparent density (ρ2) is within the above range, the strength and rigidity are excellent, and therefore, it is suitable for bolted parts, adhesive parts, etc. of automobile parts and the like.
The apparent density (ρ2) is obtained by cutting out a sheet-like measurement sample from the high-density portion, and using the mass W2 (g) and volume V2 (cm ³ ) of the sample, the ratio of mass W2 to volume V2 (W2/V2). This is the desired value. More specifically, it can be measured by the method described in Examples below.

The high-density part has an area of 10 to 50%, preferably 20 to 40%, when the total area of the laminated part is 100% in plan view when viewed from the lamination direction of the laminated part. is. When the area of the high-density portion is within the above range, it is excellent in weight reduction.

Further, the ratio (ρ2/ρ1) of the apparent density (ρ2) of the thermoplastic foam resin (B) in the high density portion to the apparent density (ρ1) of the thermoplastic foam resin (B) in the low density portion is It is 1.5 or more, preferably 2.0 or more, and more preferably 3.0 or more. When ρ2/ρ1 is within the above range, the low-density portion has excellent heat insulation performance and sound absorption performance, and the high-density portion has excellent strength and rigidity.

<Method for manufacturing laminate>
As a fifth aspect of the present invention, the method for producing a laminate of the present embodiment includes laminating a fiber-reinforced thermoplastic resin (A), a thermoplastic foam resin (B), and a fiber-reinforced thermoplastic resin (C) in this order. Then, they are welded together to form a laminate precursor, and the melting point of the fiber-reinforced thermoplastic resin (A) or the glass transition point if it does not have a melting point T _A and the fiber-reinforced thermoplastic resin (C). The laminate precursor is put into a mold heated to a temperature equal to or higher than _TH , which is the higher temperature, and equal to or lower than T plus 50° C. between the melting point or the glass transition point if it does not have a melting point, _{T C .} Then, by clamping the mold, the laminated portion of the laminated body of the above-described embodiment is formed.
According to the above method for manufacturing a laminate, it is possible to manufacture a laminate having a high degree of freedom in shape that allows parts with different performance requirements to be compatible in one laminate. can be improved.
In the method for producing the laminate, as the constituent materials of the laminate, a fiber-reinforced thermoplastic resin (A) prepreg for the layer (A), a thermoplastic foamed resin (B) foam for the layer (B), and It is preferable to use a fiber-reinforced thermoplastic resin (C) prepreg for layer (C).

More specifically, the method for manufacturing the laminate includes, for example, the following steps.
(Welding): A molding machine and a metal mold for a flat plate with spigot structure heated to the above T _H or higher and T _H plus 50° C. or lower are prepared. A fiber-reinforced thermoplastic resin (A) prepreg, a thermoplastic foamed resin (B) foam, and a fiber-reinforced thermoplastic resin (C) prepreg are prepared and laminated in this order in a mold. The mold is clamped so that the pressure applied to the constituent material is 0.1 to 10 MPa, and after holding for 1 to 30 minutes, the mold is cooled to T _H -200°C or more and T _H -10° C. or less, and released. to obtain a laminate precursor in which the constituent materials are welded together.
(Shaping): A mold for a laminate is prepared and heated to a temperature of T _H or higher and T _H plus 50° C. or lower. The laminate precursor is put into a mold, and the mold is clamped at a pressure of 0.1 to 10 MPa for 1 to 10 minutes so that the thermoplastic foam resin (B) is not crushed. Heats and softens the body. Next, the pressure of the molding machine is changed to 1 to 10 MPa and the mold is clamped for 1 to 10 minutes so that the thermoplastic foamed resin (B) is crushed to form a thin portion, thereby turning the laminate precursor into a metal. Shape into a mold shape.
(Cooling): The mold is cooled to T _H minus 200° C. or more and T _H minus 10° C. or less to cool and solidify.
(Mold Release): The mold is opened and the laminate is taken out.

The mold used in the above (shaping) step has a thick cavity for forming the thick portion corresponding to the low density portion and a thin cavity for forming the thin portion corresponding to the high density portion. .
FIG. 1 and FIG. 2 are examples of the above-mentioned mold, and (A) is a schematic cross-sectional view of the mold in the thickness direction, and (B) is a schematic of the lower mold (lower mold) in (A). It is a top view. According to the mold of FIG. 1, a thick portion (500 mm long x 400 mm wide x 10 mm thick) corresponding to the low density portion and two thin portions (500 mm long x 50 mm wide) corresponding to the high density portion at both ends in the horizontal direction. ×thickness 3 mm) can be obtained. Similarly, according to the mold of FIG. ) can be obtained.
The taper angle θ of the side surface of the concave portion of the mold is preferably 1 to 45°. Also, the side surface of the laminate formed by the tapered side surface of the concave portion of the mold is the side surface forming the low density portion (the portion included in the low density portion).

In the above (shaping) step, the mold temperature is T _H or higher and T _H plus 50° C. in order to soften, melt, and shape the fiber-reinforced thermoplastic resin (A) and the fiber-reinforced thermoplastic resin (C). It is below.

In the above (welding) step, a fiber-reinforced thermoplastic resin (C) prepreg is further laminated between the fiber-reinforced thermoplastic resin (A) prepreg and the thermoplastic foam resin (B) foam. good too.

As a sixth aspect of the present invention, the method for producing a laminate of the present embodiment comprises: fiber-reinforced thermoplastic resin (A), thermoplastic foam resin (B), and fiber-reinforced thermoplastic resin (C), in this order. Laminated and welded to each other to form a laminate precursor, and the laminate precursor is combined with the fiber reinforced thermoplastic resin (A) at the melting point or the glass transition point if it does not have a melting point T _A and the fiber Among the melting point of the reinforced thermoplastic resin (C) or T _C which is the glass transition point when it does not have a melting point, it is heated to a temperature equal to or higher than _TH , which is the higher temperature, and the heated laminate precursor is , _TA and _TC , which is the lower temperature of _TL or less. characterized by
According to the above method for manufacturing a laminate, it is possible to manufacture a laminate having a high degree of freedom in shape that allows parts with different performance requirements to be compatible in one laminate. can be improved.
In the method for producing the laminate, as the constituent materials of the laminate, a fiber-reinforced thermoplastic resin (A) prepreg for the layer (A), a thermoplastic foamed resin (B) foam for the layer (B), and It is preferable to use a fiber-reinforced thermoplastic resin (C) prepreg for layer (C).

More specifically, the above manufacturing method includes, for example, the following steps.
(Welding): A laminate precursor is obtained in the same manner as the (welding) step in the method for producing a laminate according to the fifth aspect of the present invention.
(Shaping): Prepare a mold for the laminate. A short wavelength infrared heater is used to preheat the laminate precursor to a temperature of T _H or higher. The mold is heated to a temperature of _TL or less, the preheated laminate precursor is put into the mold, and the pressure is set to 1 to 10.0 MPa and the mold is clamped for 1 to 30 minutes to obtain a laminate precursor. Shape the body into a mold shape.
(Cooling)/(Releasing): The laminate is cooled and solidified in the same manner as the (cooling)/(releasing) steps in the method for manufacturing the laminate according to the fifth aspect of the present invention, and the laminate is taken out.

As the mold used in the (shaping) step, the same mold as that used in the (shaping) step in the method for manufacturing a laminate according to the fifth aspect of the present invention can be used.

In the above (shaping) step, the laminate precursor is preheated to a temperature of T _H or higher, and the fiber-reinforced thermoplastic resin (A) and the fiber-reinforced thermoplastic resin (C) are formed before being put into a mold. In order to soften, the molding time can be shortened by keeping the laminate at a low pressure in the mold and heating, softening, and melting the high-density portion, which is necessary in the fifth aspect. There is an advantage. The heating temperature of the laminate precursor is more preferably T _H ° C. or more and T _H plus 50° C. or less.
Further, the mold temperature in the above (shaping) step is more preferably _TL minus 50°C or higher and _{TL or} lower.

In the above (shaping) step, mold clamping is performed only once, unlike the (shaping) step in the method of manufacturing a laminate according to the fifth aspect of the present invention.

In the above (welding) step, a fiber-reinforced thermoplastic resin (C) prepreg is further laminated between the fiber-reinforced thermoplastic resin (A) prepreg and the thermoplastic foam resin (B) foam. good too.

Moreover, you may carry out by the manufacturing method including the following processes.
(Shaping): A mold for a laminate is prepared and heated to T _H or higher and T _H plus 50° C. or lower. A fiber-reinforced thermoplastic resin (A) prepreg and a thermoplastic foamed resin (B) foam are placed in the mold in this order. After heating the fiber-reinforced thermoplastic resin (C) prepreg using a short-wave infrared heater to T _H or more and T _H plus 50° C. or less, immediately laminate it on the thermoplastic foam resin (B) foam in the mold. , and held at 1 to 10 MPa for 1 to 30 minutes to shape into a mold shape.
(Cooling): The mold is cooled to T _H minus 200° C. or more and T _H minus 10° C. or less to cool and solidify.
(Mold release): Open the mold and take out the wheel.

In the above (welding) step, a fiber-reinforced thermoplastic resin (C) prepreg is further laminated between the fiber-reinforced thermoplastic resin (A) prepreg and the thermoplastic foam resin (B) foam. good too.

In addition, as another manufacturing method, a laminate precursor is obtained in the same manner as the (welding) step in the method for manufacturing a laminate according to the fifth aspect of the present invention, and then the mold temperature is set to that of the upper mold. It is also possible to change the apparent density of the thermoplastic foam resin (B) in the thickness direction by changing it with the lower mold.
Specifically, one of the upper mold and the lower mold is heated to T _H or higher and T _H plus 50° C. or lower, and the other is heated to T _H minus 10° C. or lower to obtain a laminate precursor. By sandwiching and pressing the body, it is possible to obtain a laminate having different apparent densities in the thickness direction of the thermoplastic foamed resin (B) and different strength, rigidity, thermal conductivity and sound absorption coefficient in the thickness direction.
In addition, the mold temperature was kept constant between the upper mold and the lower mold, and a short-wave infrared heater was used to heat only one side of the laminate precursor. It is also possible to obtain laminates with different densities.

The fiber-reinforced thermoplastic resin (A) prepreg for the layer (A), the thermoplastic foamed resin (B) foam for the layer (B), and the fiber-reinforced thermoplastic resin (C) prepreg for the layer (C). can be produced, for example, by the following method.

<Method for producing fiber-reinforced thermoplastic resin (A) prepreg>
The fiber-reinforced thermoplastic resin (A) prepreg is, for example, a laminate of a film-like thermoplastic resin and a sheet-like (woven fabric, knitted fabric, unidirectionally arranged sheet, multiaxial woven fabric, non-woven fabric, etc.) reinforced fiber laminate. A method of pressure treatment, a method of heating and pressurizing a sheet (woven fabric, knitted fabric, unidirectionally arranged sheet, multiaxial woven fabric, non-woven fabric, etc.) composed of a fibrous thermoplastic resin (thermoplastic resin fiber) and reinforcing fibers, etc. can be manufactured by A sheet composed of thermoplastic resin fibers and reinforcing fibers may be produced using mixed yarn, coated yarn, impregnated yarn, or the like, of thermoplastic resin fibers and reinforcing fibers.
As the heating and pressure treatment, for example, the material is placed in a mold, the mold is heated to a mold temperature of T _A or more T _A plus 50 ° C. or less, and then the mold is clamped with a clamping force of 1 to 100 MPa. and compression molding. The molding time is 1 to 30 minutes after reaching T _A , and the mold is cooled to T _A -200° C. to T _A -10° C. and then opened to obtain a fiber-reinforced thermoplastic resin (A) prepreg.

The size and shape of the fiber reinforced thermoplastic (A) prepreg can be of various sizes depending on the size and shape of the laminate desired.

<Method for producing thermoplastic foamed resin (B) foam>
As a method for producing the thermoplastic foamed resin (B) foam, a known production method can be used. Among them, from the viewpoint of moldability and economic efficiency, a foamed article is produced by filling a mold with expandable resin particles, heating with steam or the like, expanding the resin particles, and simultaneously heat-bonding the resin particles together. (in-mold foam molding method) is preferred.

Examples of the resin particles used in the in-mold foam molding method include pre-expanded particles. For example, polyamide-based pre-expanded particles can be used when producing a polyamide-based resin foam.
In this specification, the term "pre-expanded particles" refers to resin particles (beads, etc.) with expandability that have not undergone the final stage of expansion.

The pre-expanded particles can be obtained by incorporating (impregnating) a foaming agent into the resin that is the raw material of the foamed resin to cause foaming. For example, the method for incorporating (impregnating) the foaming agent into the polyamide-based resin is not particularly limited, and a generally used method may be used. Among them, it is easy to achieve a high expansion ratio, and the size of the cells in the pre-expanded particles tends to be uniform. Therefore, the gas is brought into a gaseous state with an atmosphere of less than the critical pressure and brought into contact with the resin (gas phase impregnation method). is preferred.

The shape of the resin used in the gas phase impregnation method is not particularly limited, and examples thereof include beads, pellets, spheres, irregular pulverized products, and the like, and the size thereof varies depending on the pre-foaming after foaming. The average diameter is preferably 0.2 to 3 mm from the viewpoints of making the size of the particles appropriate, enhancing the ease of handling of the pre-expanded particles, and making the packing more dense during molding.

The conditions for the gas phase impregnation method are not particularly limited. For example, from the viewpoint of promoting the dissolution of the gas into the resin more efficiently, the atmospheric pressure is preferably 0.5 to 6.0 MPa. The ambient temperature is preferably 5 to 30°C.
Here, the foaming agent used in producing the pre-expanded particles is not particularly limited, but air, carbon dioxide gas (carbon dioxide gas) and the like are used from the viewpoint of solubility in the resin and ease of handling. Especially preferred.
A foaming agent may be used individually by 1 type, and may be used in combination of 2 or more type.

There are no particular restrictions on the method for causing foaming in a resin containing (impregnated with) a foaming agent (foaming agent-impregnated resin). A method of expanding the gas in the foaming agent-impregnated resin to cause foaming is preferred.

The method for molding the pre-expanded particles is not particularly limited. After application, the product can be solidified and shaped by cooling. A method for filling the pre-expanded particles is not particularly limited, and a known manufacturing method can be used.
From the viewpoint of applying a constant gas pressure to the cells of the pre-expanded particles to make the size of the cells inside the particles uniform (cell size), before filling the cavity of the molding die with the pre-expanded particles, It is preferable to pressurize the pre-expanded particles with a gas. The gas used for the pressure treatment is not particularly limited, but air or carbon dioxide gas is preferable from the viewpoint of ease of handling and economy. The method of pressurization is not particularly limited, but a method of filling a pressurized tank with pre-expanded particles and supplying a gas into the tank can be used.

The heat medium used for molding the pre-expanded particles may be a general-purpose heat medium, and from the viewpoint of suppressing oxidative deterioration of the foamed resin, it is preferably saturated steam or superheated steam. From the viewpoint of enabling heating, saturated steam is more preferable.

The method for producing the foamed resin includes, for example, a filling step of filling the pre-expanded particles into the cavity of the mold, and supplying steam having a temperature not higher than the heat-sealing temperature of the pre-expanded particles into the cavity for 5 to 30 seconds. A preheating step of preliminarily heating the pre-expanded particles, and supplying steam having a temperature higher than the heat-sealing temperature of the pre-expanded particles into the cavity for 20 to 120 seconds to expand and heat-seal the pre-expanded particles. , and a fusion step of obtaining a foamed resin.

As described above, the temperature at which the pre-expanded particles are heated is desirably in the vicinity of the heat-sealing temperature of the pre-expanded particles.
In the present specification, the heat fusion temperature refers to the temperature at which the pre-expanded particles are heated in saturated steam and the pre-expanded particles are fused together.

For the structure of the thermoplastic foamed resin (B) foam, heat insulation and sound absorption can be adjusted by selecting open cells or closed cells according to desired parts.
Also, the size and shape of the thermoplastic foam (B) foam can vary depending on the size and shape of the laminate desired.

<Method for producing fiber-reinforced thermoplastic resin (C) prepreg>
The fiber-reinforced thermoplastic resin (C) prepreg can be produced by the same method as the fiber-reinforced thermoplastic resin (A) prepreg described above.

<Thermal conductivity>
The laminate of this embodiment preferably has a thermal conductivity of 0.02 to 0.15 W/m·K in the low-density portion, and a more preferable upper limit is 0.1 W/m·K or less. Since the thermal conductivity of the low-density portion is within the above range, the laminate can be used as a heat insulating material.
The thermal conductivity is a value measured according to ISO22007-6, and can be specifically measured by the method described in Examples below.

<Vertical incident sound absorption coefficient at frequency 1000 Hz>
In the laminate of the present embodiment, the normal incident sound absorption coefficient at a frequency of 1000 Hz is preferably 5% or more, more preferably 10% or more, in the low density portion. Since the normal incidence sound absorption coefficient at a frequency of 1000 Hz in the low density portion is within the above range, the laminate can be suitably used as a sound absorbing material.
The normal incident sound absorption coefficient is a value measured at 20° C. in accordance with JIS A1405-2, and can be specifically measured by the method described in Examples below.

<Bending rigidity>
The laminate of the present embodiment preferably has a flexural rigidity of 1 GPa or more in the low-density portion. When the bending rigidity of the low-density portion is within the above range, the weight can be reduced by thinning.
Moreover, it is preferable that the laminate of the present embodiment has a bending rigidity of 8 GPa or more in the high-density portion. By setting the flexural rigidity in the high-density portion within the above range, the weight can be reduced by thinning.
The flexural rigidity is a value measured at 23° C. in accordance with ISO178, and can be specifically measured by the method described in Examples below.

<Automotive parts>
As a second aspect of the present invention, an automobile component of the present embodiment is characterized by including the laminate described above. By including the above-described laminate, the automobile part of the present embodiment is lighter than conventional automobile parts containing metals such as iron and aluminum, and has excellent impact resistance and rigidity, heat insulation, and sound absorption. and a high degree of freedom in design.

Examples of automotive parts include, but are not limited to, roofs, side doors, back doors, hoods, fenders, and wheels.

Examples of the method for manufacturing the automobile part include a method of press molding in the same manner as the method for manufacturing the laminate described above. By installing the constituent materials of the laminate, the automobile part can be obtained. By press molding, the degree of freedom in designing automobile parts can be improved and the number of parts can be reduced.

<Automotive wheels>
As a third aspect of the present invention, the automobile wheel of the present embodiment is characterized by comprising spokes and/or hubs containing the laminate described above.
The automobile wheel of the present embodiment is provided with spokes and/or hubs containing the above-described laminate, so that it is lighter and more impact resistant than conventional automobile wheels containing metals such as iron and aluminum. And it has excellent rigidity, heat insulation, sound absorption, and a high degree of freedom in design.

Further, the automotive wheel of the present embodiment includes a rim having a layer containing a unidirectional fiber-reinforced thermoplastic resin, and the reinforcing fibers contained in the unidirectional fiber-reinforced thermoplastic resin are arranged in the circumferential direction of the rim. Orientation at a constant angle is preferred. Since the rim has a layer containing a unidirectional fiber-reinforced thermoplastic resin, the strength of the rim is increased, and it is possible to suppress the bending of the rim due to impact and load.

The types of reinforcing fibers contained in the unidirectional fiber-reinforced thermoplastic resin include the same reinforcing fibers as those contained in the above-mentioned fiber-reinforced thermoplastic resin (A), and the viewpoint of improving impact resistance and economic efficiency. Glass fiber is particularly preferable from the viewpoint of improving rigidity, and carbon fiber is particularly preferable.
Examples of the thermoplastic resin contained in the unidirectional fiber-reinforced thermoplastic resin include those similar to the thermoplastic resin contained in the above-mentioned fiber-reinforced thermoplastic resin (A). Polyamide-based resins are particularly preferred because they are excellent.

The unidirectional fiber-reinforced thermoplastic resin is preferably laminated such that the reinforcing fibers contained in the resin are oriented at a constant angle with respect to the circumferential direction of the rim.
The angle of the reinforcing fibers with respect to the circumferential direction of the rim is preferably 0 to 45 degrees. When the angle of the reinforcing fibers with respect to the circumferential direction of the rim is within the above range, it is possible to effectively suppress bending of the rim due to impact or load.

<Manufacturing method of automobile wheel>
Examples of the method for manufacturing the automobile wheel include a method of press molding, as in the method for manufacturing the laminate described above. By press molding, the degree of freedom in designing the automobile wheel can be improved and the number of parts can be reduced.
In press molding, an automotive wheel having spokes and/or hubs containing the laminate is placed in a cavity portion for forming the spokes and/or hub in a wheel mold, thereby forming the laminate. can be obtained. At this time, the molten fiber-reinforced thermoplastic resin (A) and/or (C) flows into the cavity portion for forming the rim, thereby forming a rim containing the fiber-reinforced thermoplastic resin (A) and/or (C). can be formed.

In addition, as a method for producing a rim having a layer containing the unidirectional fiber-reinforced thermoplastic resin, a rim is formed by heating and pressurizing a tape or sheet of the unidirectional fiber-reinforced thermoplastic resin with ultrasonic waves or heat. A method of winding a tape on a rim (automated tape laying), and a method of placing a unidirectional fiber-reinforced thermoplastic resin prepreg in a cavity portion for forming a rim when press-molding an automobile wheel.
A unidirectional fiber-reinforced thermoplastic resin prepreg can be produced, for example, by the following method.
<<Method for producing unidirectional fiber-reinforced thermoplastic resin prepreg>>
Cut the unidirectional fiber-reinforced thermoplastic resin into a tape shape, overlap one end and the other end of the unidirectional fiber-reinforced thermoplastic resin cut into a tape shape, and measure the melting point of the unidirectional fiber-reinforced thermoplastic resin As described above, a hollow columnar unidirectional fiber-reinforced thermoplastic resin prepreg is manufactured by heat-sealing with a pressure of 0.1 to 100 MPa.
The thickness of the unidirectional fiber-reinforced thermoplastic resin prepreg can be adjusted by stacking tape-shaped cut pieces and heat-sealing them.
In addition, when cutting the unidirectional fiber reinforced thermoplastic resin into a tape shape, by adjusting the angle of the reinforcing fiber with respect to the length direction of the tape, the angle of the reinforcing fiber with respect to the circumferential direction of the rim in the wheel after molding is adjusted. can do.
Furthermore, a unidirectional fiber-reinforced thermoplastic resin prepreg can also be produced by a thermoplastic resin 3D printer that uses filaments in which continuous reinforcing fibers are impregnated with a thermoplastic resin.

<Automotive parts>
As a fourth aspect of the present invention, the automobile component of this embodiment is characterized by containing a continuous fiber-reinforced thermoplastic resin (D) and a discontinuous fiber-reinforced thermoplastic resin (E).
The automobile part of the present embodiment contains the continuous fiber-reinforced thermoplastic resin (D) and the discontinuous fiber-reinforced thermoplastic resin (E), so that it is compared with conventional automobile parts containing metals such as iron and aluminum. , while being lightweight, it has excellent impact resistance and rigidity, and has a high degree of heat insulation, sound absorption, and design freedom.
In addition, the automobile part of the present embodiment uses a thermoplastic resin as the resin, so that the automobile part can be melted and the resin can be recovered and reused. Excellent recyclability. In particular, when all the thermoplastic resins contained in the automobile parts of the present embodiment are of the same type (for example, when polyamide 6 and polyamide 12 are included, respectively), the recovery efficiency is increased, and the recyclability is further improved. do.

<Continuous fiber reinforced thermoplastic resin (D)>
The continuous fiber-reinforced thermoplastic resin (D) contained in the automobile component of the present embodiment is a thermoplastic resin whose strength is increased by containing continuous reinforcing fibers.
The strength of the continuous fiber reinforced thermoplastic resin (D) can be increased by selecting the type, blending amount, thickness, directionality, etc. of the continuous reinforcing fiber to be used, and the type and blending amount of the thermoplastic resin according to the purpose. and elasticity can be adjusted.

－Continuous reinforcing fiber－
Examples of the type of continuous reinforcing fibers contained in the continuous fiber-reinforced thermoplastic resin (D) include the same reinforcing fibers as those contained in the above-described fiber-reinforced thermoplastic resin (A), from the viewpoint of improving impact resistance. Glass fiber is particularly preferable from the viewpoint of improving rigidity, and carbon fiber is particularly preferable.
The continuous reinforcing fibers may be used singly or in combination.

-Thermoplastic resin-
Examples of the thermoplastic resin contained in the continuous fiber-reinforced thermoplastic resin (D) include the same thermoplastic resins contained in the above-mentioned fiber-reinforced thermoplastic resin (A). Polyamide-based resins are particularly preferred because of their excellent rigidity.
The above thermoplastic resins may be used singly or in combination.

<Discontinuous fiber reinforced thermoplastic resin (E)>
The discontinuous fiber-reinforced thermoplastic resin (E) contained in the automobile component of the present embodiment is a thermoplastic resin whose strength is increased by containing discontinuous reinforcing fibers.
Discontinuous fiber-reinforced thermoplastic resin (E) is obtained by selecting the type, blending amount, thickness, directionality, etc. of the discontinuous reinforcing fiber to be used, and the type and blending amount of the thermoplastic resin according to the purpose. It is possible to adjust the strength, elasticity, etc. of the

- Discontinuous reinforcing fiber -
The discontinuous reinforcing fibers contained in the discontinuous fiber-reinforced thermoplastic resin (E) may be randomly dispersed in the thermoplastic resin, or randomly oriented materials having randomly oriented discontinuous fibers (such as nonwoven fabrics ) may be configured as

The average fiber length of the discontinuous reinforcing fibers is preferably 3-200 mm, more preferably 10-150 mm. When the average fiber length of the discontinuous reinforcing fibers is 3 mm or more, the strength can be increased, and when the average fiber length is 200 mm or less, the fibers themselves can flow to the periphery during press molding of automobile parts. .
The average fiber length of the discontinuous reinforcing fibers is the average value of the lengths of the reinforcing fibers remaining after incinerating the laminate or automobile parts including the laminate.

The types of the discontinuous reinforcing fibers include the same reinforcing fibers as those included in the fiber-reinforced thermoplastic resin (A), and the same as the continuous reinforcing fibers included in the continuous fiber-reinforced thermoplastic resin (D). Glass fiber is particularly preferable from the viewpoint of improving impact resistance, and carbon fiber is particularly preferable from the viewpoint of improving rigidity.
The discontinuous reinforcing fibers may be used singly or in combination.

-Thermoplastic resin-
Examples of the thermoplastic resin contained in the discontinuous fiber-reinforced thermoplastic resin (E) include the same thermoplastic resins contained in the fiber-reinforced thermoplastic resin (A) described above. It may be the same as or different from the thermoplastic resin contained in the resin (D), and is particularly preferably a polyamide-based resin because it is excellent in heat resistance, strength and rigidity.
The above thermoplastic resins may be used singly or in combination.

<<Additive>>
The automobile part of the present embodiment may contain additives as necessary. Automotive parts of the present embodiment include, for example, antioxidants, antioxidants, weathering agents, metal deactivators, light stabilizers, heat stabilizers, ultraviolet absorbers, antibacterial/antifungal agents, deodorants, conductive Granting agent, dispersant, softening agent, plasticizer, cross-linking agent, co-cross-linking agent, vulcanizing agent, vulcanizing aid, foaming agent, foaming aid, coloring agent, flame retardant, vibration damping agent, nucleating agent, medium Additives, lubricants, antiblocking agents, dispersants, fluidity improvers, release agents, etc. can be added.
The content of the additive is not particularly limited, and can be appropriately set within a range that does not impair the effects of the present invention.

<Lamination part>
The automobile part of the present embodiment preferably includes a laminated portion having a surface layer containing the above-described continuous fiber-reinforced thermoplastic resin (D) and a base layer containing the above-described discontinuous fiber-reinforced thermoplastic resin (E).
By including the above-described laminated portion, the automobile part of the present embodiment is lighter than conventional automobile parts containing metals such as iron and aluminum, and has excellent impact resistance and rigidity, heat insulation, and sound absorption. , and a high degree of design freedom.

<<surface>>
The surface layer of the laminated portion contains the above-described continuous fiber-reinforced thermoplastic resin (D).
Since the surface layer contains the continuous fiber-reinforced thermoplastic resin (D), it has excellent strength, rigidity, and impact resistance. In particular, when the surface layer contains a glass fiber-reinforced thermoplastic resin as the continuous fiber-reinforced thermoplastic resin (D), the impact resistance of the laminated portion is improved.

The thickness of the surface layer and the ratio in the laminated portion are not particularly limited, and may be appropriately adjusted according to the required physical properties.

〈〈Base layer〉〉
The base layer of the laminated portion contains the discontinuous fiber-reinforced thermoplastic resin (E) described above.
The base layer contains the discontinuous fiber-reinforced thermoplastic resin (E), and by allowing the discontinuous fiber-reinforced thermoplastic resin (E) to flow in the mold during molding, it has excellent shape flexibility. In particular, when the base layer contains a carbon fiber-reinforced thermoplastic resin as the discontinuous fiber-reinforced thermoplastic resin (E), the rigidity of the laminated portion is improved.

The thickness of the base layer and the ratio in the laminated portion are not particularly limited, and may be appropriately adjusted according to the required physical properties.

〈〈Other layers〉〉
The laminated portion may have other layers in addition to the surface layer and the base layer.
Other layers are not particularly limited, and include layers containing thermoplastic resins other than those described above, aluminum plates, general steel plates, high-strength steel plates, and the like. When non-ferrous metal or iron is included, it is preferable to chemically or laser-treat the surface of the non-ferrous metal or iron in order to improve the bonding strength with the thermoplastic resin.

Automobile parts of the present embodiment are not particularly limited, but include, for example, roofs, side doors, back doors, hoods, fenders, wheels, and the like. Among them, wheels are preferable.

<Automotive wheels>
The automotive component of this embodiment is preferably an automotive wheel comprising spokes and/or hubs containing the above-described laminated portion.
The automotive wheel of the present embodiment includes the above-described laminated portion in the spoke and/or hub, so that it is lighter, impact resistant and more durable than conventional automotive wheels containing metals such as iron and aluminum. It has excellent rigidity, heat insulation, sound absorption, and a high degree of freedom in design. In particular, when the surface layer of the laminated portion contains a glass fiber reinforced thermoplastic resin as the continuous fiber reinforced thermoplastic resin (D), the impact resistance is improved, and the base layer of the laminated portion contains the discontinuous fiber reinforced thermoplastic resin (E). When carbon fiber reinforced thermoplastic resin is included, rigidity is improved.

Further, in the automotive wheel of the present embodiment, the rim preferably contains the discontinuous fiber-reinforced thermoplastic resin (E). Since the rim of the automobile wheel of this embodiment contains the discontinuous fiber-reinforced thermoplastic resin (E), it is lighter than conventional automobile wheels containing metals such as iron and aluminum. Moreover, especially when the discontinuous fiber-reinforced thermoplastic resin (E) is a carbon fiber-reinforced thermoplastic resin, the rigidity is improved.

Further, in the automotive wheel of the present embodiment, the rim has a layer containing a unidirectional fiber-reinforced thermoplastic resin, and the reinforcing fibers contained in the unidirectional fiber-reinforced thermoplastic resin are uniform in the circumferential direction of the rim. Angular orientation is preferred. Since the rim has a layer containing a unidirectional fiber-reinforced thermoplastic resin, the strength of the rim is increased, and it is possible to suppress the bending of the rim due to impact and load.
The unidirectional fiber-reinforced thermoplastic resin may be the same as the unidirectional fiber-reinforced thermoplastic resin used for the automotive wheel according to the third aspect of the present invention.

<Manufacturing method for automobile parts>
The automobile part as the fourth aspect of the present invention is preferably manufactured by press molding. Constituent materials for automobile parts include continuous fiber-reinforced thermoplastic resin (D) prepreg and discontinuous fiber-reinforced thermoplastic resin ( E) It is preferable to use prepreg.

More specifically, the manufacturing method of the automobile part includes the following steps. A case where the automobile part is an automobile wheel will be described as an example.
(Shaping): A wheel mold is prepared, and the melting point of the continuous fiber-reinforced thermoplastic resin (D) or, if it does not have a melting point, the glass transition point T _D and the discontinuous fiber-reinforced thermoplastic resin (E). If it does not have a melting point or does not have a melting point, it is heated to a temperature higher than T _{H '} , which is the higher temperature of T E which is the glass transition point, and T _{H '} plus 50° C. or lower. A continuous fiber reinforced thermoplastic (D) prepreg is placed in the cavity portions for forming the spokes and hub. After heating the discontinuous fiber-reinforced thermoplastic resin (E) prepreg using a short wavelength infrared heater to T _E or more and T _E plus 50 ° C or less, immediately on the continuous fiber-reinforced thermoplastic resin (D) prepreg in the mold , and clamped at 1 to 100 MPa and held for 1 to 30 minutes to shape into a mold shape.
(Cooling): The mold is cooled to 0 to 100° C. to cool and solidify.
(Mold release): Open the mold and take out the wheel.
In the above manufacturing method, the molten discontinuous fiber-reinforced thermoplastic resin (E) flows into the cavity portion for forming the rim, thereby forming a rim containing the discontinuous fiber-reinforced thermoplastic resin (E).

EXAMPLES The present invention will be described below based on Examples , Reference Examples and Comparative Examples, but the present invention is not limited to these.

<Measurement method>
The measurement methods used in Examples , Reference Examples and Comparative Examples are as follows.

(1) Apparent Density Sheet-like measurement samples were cut out from the laminates obtained in Examples , Reference Examples , and Comparative Examples, and the mass W (g) and volume V (cm ³ ) were determined. The volume V was calculated by measuring three sides of the sheet-like measurement sample with a vernier caliper. The ratio of mass W to volume V (W/V) was defined as apparent density (g/cm ³ ). As for the laminate having the low-density portion and the high-density portion, a measurement sample was cut out from each portion and measured.

(2) Thermal conductivity A test piece (30 mm × 30 mm × thickness of each example , reference example and comparative example) was prepared from the laminates obtained in Examples, Reference Examples and Comparative Examples, and based on ISO22007-6, Thermal conductivity (W/m·K) in the thickness direction of the test piece was measured using a thermal conductivity measuring device (“Mobile-10” manufactured by iPhase). As for the laminate having the low-density portion and the high-density portion, test pieces for each portion were prepared and measured.

(3) Normal Incidence Sound Absorption Coefficient The normal incidence sound absorption coefficient (%) at a frequency of 160 to 5000 Hz was measured at 20° C. for the laminates obtained in Examples , Reference Examples and Comparative Examples based on JIS A1405-2. A test piece (disk-shaped with a diameter of 41.5 mm) was prepared from each laminate, and measured using a vertical incident sound absorption coefficient measurement system (“WinZac MTX type” manufactured by Nippon Onkyo Engineering Co., Ltd.). The test piece was arranged so that the sound was incident from the surface layer 1 side. As a measurement result, the average normal incident sound absorption coefficient (%) in the 1/3 octave band is shown. As for the laminate having the low-density portion and the high-density portion, test pieces for each portion were prepared and measured.

(4) Bending Rigidity The bending stiffness (GPa) of the laminates obtained in Examples , Reference Examples and Comparative Examples was measured under the following conditions based on ISO178. The average value of the measured values at three locations was used as the measurement result. As for the laminate having the low-density portion and the high-density portion, test pieces for each portion were prepared and measured. In addition, for laminates with different laminate structures on the front and back, a bending test was performed with the front facing and the back facing, respectively, and the higher rigidity value was entered in the table.
・Flexural modulus: tangent method ・Test environment: 23°C, 50RH%
・Test piece: Strip shape of length 200 mm×width 10 mm×thickness of each example , reference example and comparative example ・Test speed: strain rate of 1%/min.・Between spans: Test piece thickness x 16mm
・ Equipment used: Instron 50kN (manufactured by Instron)

<Raw materials>
Raw materials used in Examples , Reference Examples and Comparative Examples are as follows.

<Thermoplastic resin>
・ Polyamide 12 resin (“UBESTA3014U” manufactured by Ube Industries, Ltd., melting point 175 ° C.)
・ Polyamide 12 staple fiber (single fiber fineness: 1.7 dtex, number of crimps: 12 crimps/25 mm, degree of crimp: 13%, cut length: 51 mm, melting point: 175 ° C.)
・Polyamide 6 resin (melting point 225°C)
・ Polyamide 66 resin ("1300S" manufactured by Asahi Kasei Corporation, melting point 265 ° C.)

<Reinforcing fiber>
・Glass fiber (fineness: 11500dtex, number of single yarns: 2000)
・ Carbon fiber (“T-300” manufactured by Toray Industries, Inc., amount of epoxy resin-based sizing agent attached: 1.0 to 1.2% by mass)

<Sizing agent>
- Glass fiber sizing agent An aqueous solution having the following composition was prepared as a glass fiber sizing agent by preparing with deionized water.
・Silane coupling agent: γ-aminopropyltriethoxysilane (“KBE-903” manufactured by Shin-Etsu Chemical Co., Ltd.) 0.5% by mass
・ Lubricant: Wax ("Carnauba wax" manufactured by Kato Yoko Co., Ltd.) 1% by mass
・ Polyurethane resin ("Y65-55" manufactured by ADEKA Co., Ltd.): 2% by mass
- Binding agent: 3% by mass of a copolymer (weight average molecular weight: 20000) of maleic anhydride (40% by mass), methyl acrylate (50% by mass), and methyl methacrylate (10% by mass)

<metal>
・ 5000 series aluminum (“A5052” manufactured by Hakudo Co., Ltd.)

The materials of the prepregs produced in Examples , Reference Examples and Comparative Examples are as follows.

<Resin film>
Polyamide 12 resin film: A resin film (thickness: 150 μm, basis weight: 170 g/m ² ) was produced using a polyamide 12 resin with a T-die extruder (manufactured by Soken Co., Ltd.).
Polyamide 66 resin film: A resin film (thickness: 150 μm, basis weight: 170 g/m ² ) was produced using a polyamide 66 resin with a T-die extruder (manufactured by Soken Co., Ltd.).

<Glass cloth>
A glass fiber to which 0.45% by mass of a glass fiber sizing agent was attached was produced. The winding form was DWR, and the average single yarn diameter was 17 μm. A glass cloth (plain weave, weaving density: 6.5 threads/25 mm, basis weight: 600 g/m ² ) was produced by weaving the obtained glass fibers as warp and weft using a rapier loom (weaving width: 2 m).

<Nonwoven fabric>
A blend of 50% by mass of chopped carbon fiber (average fiber length 50 mm) and 50% by mass of polyamide 12 short fiber is passed through each step of opener, roller card, crosslayer, roller card, and needle punching to obtain discontinuous carbon. A nonwoven fabric (basis weight: 400 g/m ² ) was produced from the fibers and polyamide 12 short fibers.

<Unidirectional glass fiber reinforced polyamide resin>
Unidirectional glass fiber reinforced polyamide resin in which unidirectional glass fiber is impregnated with polyamide 6 ("CETEX TC910" manufactured by TENCATE, glass content 40% by mass, density 1.46 g/cm ³ , width 166 mm, thickness 0.25 mm)

[ Reference Example 1: Laminate]
A continuous glass fiber reinforced polyamide prepreg A1, a discontinuous carbon fiber reinforced polyamide prepreg C1, and a polyamide foam B1 for use in producing laminates were produced by the following method.
<Production of continuous glass fiber reinforced polyamide prepreg A1>
A molding machine ("S100V-8A" manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a flat plate mold (500 mm long x 500 mm wide x 0.4 mm thick) with a spigot structure were prepared.
The polyamide 12 resin film and the glass cloth were cut according to the shape of the mold, and one polyamide 12 resin film, one glass cloth, and one polyamide 12 resin film were laminated in this order and placed in the mold.
The mold was heated to a mold temperature of 200° C. and then clamped with a mold clamping force of 5 MPa for compression molding. The molding time was 15 minutes after reaching 175 ° C., the melting point of polyamide 12, and the mold was cooled to 100 ° C. and then opened to form a continuous glass fiber reinforced polyamide prepreg A1 (length 500 mm × width 500 mm × thickness 0 .4 mm, volume fraction (resin/reinforcing fiber) 58/42, density 1.73 g/cm ³ ).

<Production of discontinuous carbon fiber reinforced polyamide prepreg C1>
A molding machine (“S100V-8A” manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a flat plate mold (500 mm long×500 mm wide×0.3 mm thick) with spigot structure were prepared.
The nonwoven fabric was cut according to the shape of the mold, and one piece was placed in the mold.
The mold was heated to a mold temperature of 200° C. and then clamped with a mold clamping force of 5 MPa for compression molding. The molding time was 15 minutes after reaching 175 ° C., the melting point of polyamide 12, and the mold was cooled to 100 ° C. and then opened. 0.3 mm, volume fraction (resin/reinforcing fiber) 40/60, density 1.4 g/cm ³ ).

<Production of polyamide foam B1>
A polyamide 6 resin was melt-kneaded by a single-screw extruder under heating conditions, extruded into a strand shape, cooled with water in a cold water tank, and cut to obtain a pellet-shaped base resin.
In addition, according to the method described in the examples of JP-A-2011-105879, the base resin is made to contain carbon dioxide as a foaming agent, and the base resin containing carbon dioxide is heated to cause foaming. induced to obtain pre-expanded particles. The obtained pre-expanded particles are enclosed in an autoclave, compressed air is introduced until the pressure inside the autoclave reaches 0.5 MPa, and then the pre-expanded particles are pressurized by maintaining the pressure for 24 hours. was applied.
After clamping the mold attached to the in-mold foam molding machine, pressurized pre-expanded particles are filled, then saturated steam at 135° C. is supplied into the cavity for 10 seconds (first stage heating), Furthermore, saturated steam at 144 ° C. was supplied into the cavity for 30 seconds (second stage heating) to expand and heat-seal the pre-expanded particles, thereby producing a polyamide foam B1 (thickness: 10 mm, density: 228 kg). /m ³ , expansion ratio: 5 times).

Using the continuous glass fiber-reinforced polyamide prepreg A1, the discontinuous carbon fiber-reinforced polyamide prepreg C1, and the polyamide foam B1 obtained above, a laminate was produced by the following method.
<Production of laminate>
(Welding): A molding machine ("S100V-8A" manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a flat plate mold with a spigot structure heated to 220 ° C. (length 500 mm × width 500 mm) were prepared. . One sheet of continuous glass fiber reinforced polyamide prepreg A1, one sheet of polyamide foam B1 and one sheet of discontinuous carbon fiber reinforced polyamide prepreg C1 were prepared and laminated in this order in a mold. The mold was clamped so that the pressure applied to the constituent materials was 0.1 MPa, held for 1 minute, cooled to 100° C., and released to obtain a laminate precursor in which the constituent materials were welded together. Obtained.
(Shaping): As shown in Fig. 1, a laminate having a thick portion (500 mm long x 400 mm wide x 10 mm thick) and two thin portions (500 mm long x 50 mm wide x 3 mm thick) at both ends in the horizontal direction. A mold (the taper angle θ of the side surface of the recess is 10°) was prepared and heated to 220°C. The laminate precursor was put into a mold and clamped at a pressure of 0.1 MPa for 2 minutes to heat and soften the laminate precursor. Then, the laminate precursor was shaped into a mold shape by clamping the mold for 1 minute at a pressure of 1.0 MPa.
(Cooling): The mold was cooled to 100°C and solidified by cooling.
(Mold Release): The mold was opened and the laminate was taken out.

By the above-described manufacturing method, a laminate having a low-density portion (thick portion) with a low apparent density of the polyamide foam B1 and a high-density portion (thin portion) with a high apparent density of the polyamide foam B1 was obtained. . Table 1 shows the structure and physical properties of the obtained laminate.
A drilled hole with a diameter of 8 mm was provided in the high density part of the obtained laminate, a nut was attached through an M6 bolt, and tightened with a torque of 9.2 N m, the laminate was damaged and the thickness of the high density part did not change.

[ Reference Example 2: Laminate]
A laminate was produced in the same manner as in Reference Example 1, except that an intermediate layer was produced by further laminating a discontinuous carbon fiber reinforced polyamide prepreg C1 between the continuous glass fiber reinforced polyamide prepreg A1 and the polyamide foam B1. bottom.
Table 1 shows the structure and physical properties of the obtained laminate.
A drilled hole with a diameter of 8 mm was provided in the high density part of the obtained laminate, a nut was attached through an M6 bolt, and tightened with a torque of 9.2 N m, the laminate was damaged and the thickness of the high density part did not change.

[Example 3: Laminate]
A laminate was produced in the same manner as in Reference Example 2, except that the laminate precursor was preheated in the shaping step.
<Production of laminate>
(Shaping): Using a short wavelength infrared heater (manufactured by Heraeus), the laminate precursor was preheated until the surface layers 1 and 2 of the laminate precursor reached 200°C. A preheated laminate precursor is put into a mold heated to 150 ° C., the pressure is set to 1.0 MPa, and the mold is clamped for 1 minute to crush the thin portion of the polyamide foam B1, thereby shaping it into a mold shape. let me
Table 1 shows the structure and physical properties of the obtained laminate.
A drilled hole with a diameter of 8 mm was provided in the high density part of the obtained laminate, a nut was attached through an M6 bolt, and tightened with a torque of 9.2 N m, the laminate was damaged and the thickness of the high density part did not change.

[Example 4: Laminate]
A discontinuous carbon fiber reinforced polyamide prepreg C2 having a thickness of 2.0 mm was used for the surface layer 2, and a laminate was produced in the same manner as in Example 3, except that the mold used in the shaping step was changed.
<Production of discontinuous carbon fiber reinforced polyamide prepreg C2>
A molding machine ("S100V-8A" manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a mold for a flat plate (500 mm long x 500 mm wide x 2.0 mm thick) with a spigot structure were prepared.
The nonwoven fabric was cut according to the shape of the mold, and 7 pieces were placed in the mold.
The mold was heated to a mold temperature of 200° C. and then clamped with a mold clamping force of 15 MPa for compression molding. The molding time was 15 minutes after reaching 175 ° C., the melting point of polyamide 12, and the mold was cooled to 100 ° C. and then opened. 2.0 mm, volume fraction (resin/reinforcing fiber) 37/63, density 1.38 g/cm ³ ).
<Production of laminate>
(Shaping): Using a short wavelength infrared heater (manufactured by Heraeus), the laminate precursor was preheated until the surface layers 1 and 2 of the laminate precursor reached 200°C. As shown in FIG. 2, a laminate having a thick portion (500 mm long × 400 mm wide × 5.7 mm deep) and two thin cavities (500 mm long × 50 mm wide × 4.7 mm deep) at both ends in the horizontal direction A mold (the taper angle θ of the side surface of the recess was 10°) for obtaining the body was prepared and heated to 150°C. A preheated laminate precursor was put into a mold, and the mold was clamped at a pressure of 1.0 MPa for 1 minute to shape the laminate precursor into a mold shape.
Table 1 shows the structure and physical properties of the obtained laminate.
A drilled hole with a diameter of 8 mm was provided in the high density part of the obtained laminate, a nut was attached through an M6 bolt, and tightened with a torque of 9.2 N m, the laminate was damaged and the thickness of the high density part did not change.

[ Reference Example 5: Wheel]
Continuous glass fiber reinforced polyamide prepreg A2 and discontinuous carbon fiber reinforced polyamide prepreg C3 for use in manufacturing wheels were produced in the following manner.
<Production of continuous glass fiber reinforced polyamide prepreg A2>
A disc having a diameter of 415 mm was cut from the continuous glass fiber-reinforced polyamide prepreg A1 produced as described above to obtain a continuous glass fiber-reinforced polyamide prepreg A2.

<Production of discontinuous carbon fiber reinforced polyamide prepreg C3>
A molding machine ("S100V-8A" manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a mold for a flat plate (500 mm long x 500 mm wide x 5.1 mm thick) with a fitting structure were prepared.
The nonwoven fabric was cut according to the shape of the mold, and 17 sheets were placed in the mold.
The mold was heated to a mold temperature of 200° C. and then clamped with a mold clamping force of 15 MPa for compression molding. The molding time was 15 minutes after reaching 175 ° C., the melting point of polyamide 12, and the mold was cooled to 100 ° C. and then opened to form a flat discontinuous carbon fiber reinforced polyamide prepreg (500 mm long x 500 mm wide). x thickness 5.1 mm, volume fraction (resin/reinforcing fiber) 40/60, density 1.4 g/cm ³ ).
Next, the obtained flat discontinuous carbon fiber reinforced polyamide prepreg was cut into discs with a diameter of 415 mm to obtain discontinuous carbon fiber reinforced polyamide prepreg C3.

Using the continuous glass fiber reinforced polyamide prepreg A2 and the discontinuous carbon fiber reinforced polyamide prepreg C3 obtained above, a wheel was produced by the following method.
<Wheel manufacturing>
(Shaping): A mold capable of molding a 15-inch wheel (5 spokes, 4 holes) was prepared and heated to 180°C. A piece of continuous glass fiber reinforced polyamide prepreg A2 was placed in the cavity portion for forming the spokes and hub. Next, five discontinuous carbon fiber reinforced polyamide prepregs C3 are heated with a short wavelength infrared heater (manufactured by Heraeus) until the surface layer reaches 200 ° C., and immediately placed on the continuous glass fiber reinforced polyamide prepreg A2 in the mold. It was formed into a mold shape by stacking, clamping the mold at 10 MPa and holding for 1 minute.
(Cooling): The mold was cooled to 100°C and solidified by cooling.
(Mold release): The mold was opened and the wheel was taken out.
A wheel having spokes and a hub composed of a surface layer of continuous glass fiber reinforced polyamide, a body of discontinuous carbon fiber reinforced polyamide, and a rim formed by flowing the discontinuous carbon fiber reinforced polyamide in a mold. was gotten. Note that 720 g of discontinuous carbon fiber reinforced polyamide flowed out of the mold as burrs. Table 1 shows the configuration and physical properties of the obtained wheel.

[ Reference Example 6: Wheel]
A wheel was produced in the same manner as in Reference Example 5, except that the polyamide foam B2 was used as the base layer.
<Production of polyamide foam B2>
A polyamide foam (thickness: 15 mm, density: 228 kg/m ³ , expansion ratio: 5 times) produced in the same manner as the above polyamide foam B1 was cut into discs with a diameter of 415 mm to obtain polyamide foam B2.

<Wheel manufacturing>
(Shaping): A mold capable of molding a 15-inch wheel (5 spokes, 4 holes) was prepared and heated to 180°C. One sheet of continuous glass fiber reinforced polyamide prepreg A2 and one sheet of polyamide foam B2 were placed and laminated in this order in a cavity portion for forming spokes and a hub. Next, after heating three discontinuous carbon fiber reinforced polyamide prepregs C3 with a short wavelength infrared heater (manufactured by Heraeus) until the surface layer reaches 200 ° C., immediately laminate on the polyamide foam B2 in the mold, By clamping the mold at 10 MPa and holding for 1 minute, it was formed into a mold shape.
(Cooling) (Releasing): Performed in the same manner as in Reference Example 5.
Spokes and hubs composed of a laminate having a low density portion and a high density portion (continuous glass fiber reinforced polyamide, polyamide foam, discontinuous carbon fiber reinforced polyamide laminated in order from the surface), and discontinuous carbon fiber reinforcement A wheel was obtained having a rim formed by the polyamide flowing in a mold. Table 1 shows the configuration and physical properties of the obtained wheel.

[ Reference Example 7: Wheel]
A wheel was produced in the same manner as in Reference Example 6, except that a unidirectional glass fiber reinforced polyamide prepreg was produced and the wheel contained a layer of unidirectional glass fiber reinforced polyamide on the surface of the rim.
<Production of unidirectional glass fiber reinforced polyamide prepreg>
A unidirectional glass fiber reinforced polyamide resin was cut to prepare two pieces of unidirectional glass fiber reinforced polyamide resin (the glass fiber direction is the longitudinal direction) each having a size of 1310 mm in length×15 mm in width×0.25 mm in thickness. Two sheets of unidirectional glass fiber reinforced polyamide resin were superimposed and heat-sealed at a temperature of 250° C. and a pressure of 5 MPa to obtain a unidirectional glass fiber reinforced polyamide resin with a size of 1310 mm in length×15 mm in width×0.5 mm in thickness. . Furthermore, one end (length 3.5 mm) and the other end (length 3.5 mm) of this unidirectional glass fiber reinforced polyamide resin are overlapped and heat-sealed at a temperature of 250 ° C. and a pressure of 5 MPa. A unidirectional glass fiber reinforced polyamide prepreg having a hollow cylindrical shape (415 mm in diameter, 15 mm in width, and 0.5 mm in thickness) was obtained.

<Wheel manufacturing>
(Shaping): A mold capable of molding a 15-inch wheel (5 spokes, 4 holes) was prepared and heated to 180°C. One piece of continuous glass fiber reinforced polyamide prepreg A2 and one piece of polyamide foam B2 are placed and laminated in this order in the cavity portion for forming the spokes and the hub, and a hollow circle is placed in the cavity portion for forming the rim. A columnar unidirectional fiber reinforced thermoplastic resin prepreg was installed. Next, after heating three discontinuous carbon fiber reinforced polyamide prepregs C3 with a short wavelength infrared heater (manufactured by Heraeus) until the surface layer reaches 200 ° C., immediately laminate on the polyamide foam B2 in the mold, By clamping the mold at 10 MPa and holding for 1 minute, it was formed into a mold shape.
(Cooling) (Releasing): Performed in the same manner as in Reference Example 6.
Spokes and hubs composed of a laminate having a low-density portion and a high-density portion (continuous glass fiber reinforced polyamide, polyamide foam, discontinuous carbon fiber reinforced polyamide laminated in order from the surface), and unidirectional glass fiber reinforcement A wheel was obtained having a rim consisting of a rim surface layer of polyamide and a rim body formed by flowing discontinuous carbon fiber reinforced polyamide in a mold. Table 1 shows the configuration and physical properties of the obtained wheel.

[Comparative Example 1: Monolayer]
A polyamide foam B1 was produced and made into a monolayer. Table 2 shows the structure and physical properties of the obtained monolayer.
A drilled hole with a diameter of 8 mm was provided in the obtained single layer body, a nut was attached through an M6 bolt, and tightened with a torque of 9.2 Nm. sunk in the thickness direction and could not be fastened.

[Comparative Example 2: Monolayer]
Polyamide foam B1 is produced, then a molding machine ("S100V-8A" manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a flat plate with a spigot structure (length 500 mm × width 500 mm × thickness 2 mm) metal A mold was prepared and polyamide foam B1 was placed in the mold.
The mold was heated to a mold temperature of 250° C. and then clamped with a mold clamping force of 15 MPa for compression molding. The molding time was set to 15 minutes after reaching 225°C, which is the melting point of polyamide 6, and the mold was cooled to 100°C and then opened to obtain a single layer (thickness: 2 mm, apparent density: 1.14 g/cm ^{3 )} . ). Table 2 shows the structure and physical properties of the obtained monolayer.
A drilled hole with a diameter of 8 mm was provided in the obtained single layer body, a nut was attached through an M6 bolt, and tightened with a torque of 9.2 Nm. There was no

[Comparative Example 3: Monolayer]
A continuous glass fiber reinforced polyamide prepreg A3 was produced as a single layer as follows.
<Production of continuous glass fiber reinforced polyamide prepreg A3>
Same as the production of continuous glass fiber reinforced polyamide prepreg A1, except that 13 sets of 1 polyamide 12 resin film, 1 glass cloth, and 1 polyamide 12 resin film were laminated and placed in the mold. A continuous glass fiber reinforced polyamide prepreg A3 (length 500 mm x width 500 mm x thickness 5.2 mm, volume fraction (resin/reinforcement fiber) 58/42, density 1.73 g/cm ³ ) is produced by Obtained. Table 2 shows the structure and physical properties of the obtained monolayer.
A drilled hole with a diameter of 8 mm was provided in the obtained single layer body, a nut was attached through an M6 bolt, and tightened with a torque of 9.2 Nm. There was no

[Comparative Example 4: Monolayer]
A single layer of aluminum having a length of 500 mm, a width of 500 mm, and a thickness of 10 mm was used. Table 2 shows the structure and physical properties of the obtained monolayer.

[Comparative Example 5: Laminate]
A laminate was produced in the same manner as in Reference Example 1, except that continuous glass fiber reinforced polyamide prepreg A4 was used for the surface layers 1 and 2.
<Production of continuous fiber reinforced thermoplastic resin prepreg A4>
A molding machine ("S100V-8A" manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a flat plate mold (500 mm long x 500 mm wide x 0.4 mm thick) with a spigot structure were prepared.
The polyamide 66 resin film and the glass cloth were cut according to the shape of the mold, and one polyamide 66 resin film, one glass cloth, and one polyamide 66 resin film were laminated in this order and placed in the mold.
The mold was heated to a mold temperature of 300° C. and then clamped with a mold clamping force of 5 MPa for compression molding. The molding time was 15 minutes after reaching 265°C, the melting point of polyamide 66, and the mold was cooled to 150°C and then opened to form a continuous glass fiber reinforced polyamide prepreg A4 (length 500mm x width 500mm x thickness 0 .4 mm, volume fraction (resin/reinforcing fiber) 58/42, density 1.73 g/cm ³ ).
<Production of laminate>
(Welding): A molding machine ("S100V-8A" manufactured by Toshiba Machine Co., Ltd. with a maximum clamping force of 300 tons) and a flat plate mold (500 mm long x 500 mm wide) with a spigot structure heated to 300 ° C. were prepared. . One sheet of continuous glass fiber reinforced polyamide prepreg A4, one sheet of polyamide foam B1 and one sheet of continuous glass fiber reinforced polyamide prepreg A4 were prepared and stacked in this order in a mold. The mold was clamped so that the pressure applied to the constituent materials was 0.1 MPa, held for 1 minute, cooled to 100° C., and released to obtain a laminate precursor in which the constituent materials were welded together. Obtained.
(Shaping): The laminate precursor was shaped into a mold in the same manner as in Reference Example 1, except that the mold was heated to 300°C.
(Cooling)/(Mold release): Performed in the same manner as in Reference Example 1.
The polyamide foam was totally crushed during shaping, and a good laminate that conformed to the shape of the mold was not obtained. Table 2 shows the structure and physical properties of the obtained laminate.

[Comparative Example 6: Wheel]
A 15-inch aluminum wheel (5 spokes, 4 holes, mass 8.4 kg) having the same shape as the wheel manufactured in Reference Example 5 was used. Table 2 shows the composition and physical properties of the wheel.

[Comparative Example 7: Wheel]
Wheels were manufactured using only continuous glass fiber reinforced polyamide prepreg A5.
<Production of continuous glass fiber reinforced polyamide prepreg A5>
A disc having a diameter of 415 mm was cut from the continuous glass fiber reinforced polyamide prepreg A3 to obtain a continuous glass fiber reinforced polyamide prepreg A5.
<Wheel manufacturing>
(Shaping): A mold capable of molding a 15-inch wheel (5 spokes, 4 holes) was prepared and heated to 180°C. Five sheets of continuous glass fiber reinforced polyamide prepreg A5 are heated with a short wavelength infrared heater (manufactured by Heraeus) until the surface layer reaches 200 ° C., immediately stacked in a mold, clamped at 10 MPa and held for 1 minute. By this, it was formed into a mold shape.
(Cooling) (Releasing): Performed in the same manner as in Reference Example 5.
The continuous glass fiber reinforced polyamide prepreg A5 had poor fluidity, and a good wheel conforming to the shape of the mold could not be obtained. Table 2 shows the configuration and physical properties of the obtained wheel.

Since the laminate, automobile part, and automobile wheel of the present invention are lightweight, they can be suitably used for various automobile parts.

Claims (2)

A fiber-reinforced thermoplastic resin (A), a thermoplastic foam resin (B), and a fiber-reinforced thermoplastic resin (C) are laminated in this order and welded to each other to form a laminate precursor,
When the laminate precursor does not have the melting point of the fiber-reinforced thermoplastic resin (A) or the melting point of the fiber-reinforced thermoplastic resin ( _C ) or the melting point of the fiber-reinforced thermoplastic resin (C), which is the glass transition point TA is the glass transition point T _C , which is the higher temperature T _H or higher,
The heated laminate precursor is put into a mold heated to a temperature equal to or lower than _TL , which is the lower temperature of the T _A and the T _C , and the mold is clamped to obtain the thermoplastic foam resin. Forming a laminated portion including a low density portion having a low apparent density of (B) and a high density portion having a high apparent density of the thermoplastic foam resin (B),
The ratio (ρ2/ρ1) of the apparent density (ρ2) of the thermoplastic foamed resin (B) in the high-density portion to the apparent density (ρ1) of the thermoplastic foamed resin (B) in the low-density portion is 1.5 or more ,
When the total area of the laminated portion is taken as 100% in a plan view when viewed from the lamination direction of the laminated portion, the area of the low-density portion is 50 to 90%, and the area of the high-density portion is 10%. 50%. 4. The method of forming the laminate precursor further comprising laminating a fiber-reinforced thermoplastic resin (C) between the fiber-reinforced thermoplastic resin (A) and the thermoplastic foam resin (B). 2. The method for manufacturing the laminate according to 1 .

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