JPH0797931A - Resin molded material preparing method and resin-made impeller - Google Patents

Abstract

PURPOSE:To provide a resin molded article, for example, a resinmade impeller, having its strength restrained from being deteriorated to the minimum extent even when the resin is molded by using molding materials compounded with recycle material, and having sufficient strength and durability. CONSTITUTION:A resin-made impeller is made of recycle material obtained by grinding a molded body made of short fiber reinforced composite materials taking thermoplastic resin as a matrix and short fiber reinforced composite materials taking thermoplastic resin equal to the thermoplastic resin as the matrix of the recycle materials, or having same basic molecular structure as it and compatible with it as a matrix. And the impeller is resin-molded by using a preparing method of resin molded materials mixed with the original materials wherein the melt flow rate in the load of 2.16kgf in the molding temperature is larger than that of the load of 2.16kgf in the molding temperature of the recycle materials by 1.5 to 4.7g/10min and the resin molded materials.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention includes a recycled material suitable as a material for an internal combustion engine part used under high temperature and high stress such as a compressor impeller of a turbocharger (turbine type supercharger). The present invention relates to a method for preparing a resin molding material used to obtain a resin molding material, and also to a fiber-reinforced resin impeller made of the resin molding material.

Resin molding materials containing recycled materials include not only fiber reinforced resin materials such as short fiber reinforced composite materials, but also continuous fiber reinforced composite materials such as unidirectional reinforced type, filament winding type, matte or cloth type. Processing such as injection molding, extrusion molding, compression molding, etc. by using recycled material made into a reusable state using a finely pulverizing means such as a crusher or by mixing it with the original material This is a short fiber reinforced composite material type resin molding material that can be shaped by the method.

[0003]

2. Description of the Related Art Conventionally, resin molding materials have been recycled with low-load products and parts in which deterioration of mechanical properties is relatively unlikely to be a problem not only for effective use of resources but also for cost reduction. Has been done. In particular, in the case of a non-reinforced type resin molding material that does not contain a reinforcing material such as glass fiber or carbon fiber, since the deterioration of reliability is small, it is recycled daily.

On the other hand, in a type containing a reinforcing material such as glass fiber or carbon fiber, fiber breakage occurs due to crushing or the like, so that the reinforcing effect of the fiber is lowered, and the heat history increases, so that the resin breaks. Due to the decrease in elongation, there is a different circumstance in which the strength is considerably reduced compared to the original material. For this reason, (1) it is diverted to products or parts whose mechanical properties are less demanding.

(2) Used for other purposes such as a filler.

(3) The compounding ratio of the recycled material is limited to a remarkably small amount.

Either of the above methods is adopted.

[0008] However, the method (1) is the easiest to carry out due to the fact that it is diverted to products and parts in which reliability and durability do not matter. However, in many cases, the result is the use of excessive quality materials, which has the advantage of effective use of resources, but there are many cases in which cheaper materials are diverted to sufficient products and parts, so cost advantages are expected. Hard to do.

Like the method (1), the method (2) is also a method of using a material corresponding to a lower level, and is not a method of using a recycled material, which is accompanied by a particularly advanced technological development. For example, a crushed product of a rear spoiler for an automobile is used as a filler for Class A SMC (Sheet Molding C).
open) and CaC in general SMC for automobiles
Example of recycling by substituting with O ₃ (Abstracts of 36th FRP General Lecture Meeting: 185-189.
There is a 29th to 31st of March (sha) sponsored by the Reinforced Plastics Association.

The method (3) is premised on being used when manufacturing the structural material before being recycled or a structural body which requires the same level of strength, durability and safety. This is the most effective method of using recycled materials, and reuse of PET (polyethylene terephthalate) bottles without fiber reinforcement (molding processing 9
2: 147-148, 1992.7.8-9, sponsored by Japan Society for Plastic Molding Processing) is well known.

However, in a structure requiring a high degree of durability and reliability, a recycled material is blended within a range that does not impair the strength and durability of the structure, so that the amount of recycled material used does not increase easily. There is a point.

[0012]

An internal combustion engine component represented by a compressor impeller of a turbocharger is not easily resinified because it is used in a high temperature and high stress environment and is reinforced with carbon fiber. Currently, it is only applicable to some super heat resistant engineering plastics, so-called super engineering plastics, and the use of very expensive carbon fibers and super engineering plastics makes it difficult to apply them to commercial vehicles.

Therefore, the development of such a recycling technology for super engineering plastics reinforced with carbon fiber has not only the social need to consider the environment but also the cost reduction due to the use of recycled materials and the fiber reinforced resin resulting therefrom. There is a great merit that the internal combustion engine parts made of steel are widely spread.

However, as described above, the internal combustion engine parts represented by the compressor impeller of the turbocharger are
It is only applicable to some super engineering plastics reinforced with carbon fiber, and it was very difficult to secure sufficient strength and durability reliability by using a molding material containing recycled materials.

[0015]

SUMMARY OF THE INVENTION Therefore, the present invention has been made in view of the above-mentioned conventional circumstances, and there is a known reason that the strength reduction observed in a material containing a recycled material is known, for example, (1) It is clarified that the reason is other than the reduction of the fiber length due to the breakage and the accompanying reduction of the reinforcing effect, and (2) the brittleness of the matrix resin due to the increase of the heat history, and the same or the same basic molecular structure or compatibility is possible. A compressor impeller for turbochargers that has sufficient strength and durability by minimizing the deterioration of the strength of the resin molded product by using a molding material that mixes the original material and the recycled material with the thermoplastic resin as the matrix resin. For the purpose of providing a resin molding material containing a recycled material that enables the provision of internal combustion engine parts, and And its object is to provide a fiber-reinforced resin impeller using such resin molding material.

[0016]

A method for preparing a resin molding material containing a recycled material according to the present invention comprises a recycled material obtained by crushing a molded product of a short fiber reinforced composite material using a thermoplastic resin as a matrix, It is made of a short fiber reinforced composite material having the same or the same basic molecular structure or compatible thermoplastic resin as the matrix of the thermoplastic resin as the matrix of the recycled material and has a melt flow rate at a molding temperature of 2.16 kgf. It is characterized in that the recycled material is mixed with an original material having a flow rate of 1.5 to 4.7 g / 10 min which is higher than the melt flow rate of the recycled material at a load of 2.16 kgf at the molding temperature.

The fiber-reinforced resin impeller according to the present invention includes a recycled material obtained by crushing a molded product of a short fiber-reinforced composite material using a thermoplastic resin as a matrix, and a thermoplastic material which is a matrix of the recycled material. It is made of a short fiber reinforced composite material having the same or the same basic molecular structure as the resin or a compatible thermoplastic resin as a matrix, and has a melt flow rate at a molding temperature of 2.16 kgf and a melt flow rate of 2 at the molding temperature of the recycled material. 1.5 ~ than the melt flow rate at 16 kgf
It is characterized in that the resin is molded into an impeller shape with a resin molding material in which an original material having a large size of 4.7 g / 10 min is mixed.

The "original material" referred to in this specification means
It is synonymous with the commonly used "virgin material".

Materials applicable to the fiber-reinforced resin impeller include, for example, carbon fiber reinforced polyetherketone resin (JP-A-1-175972), carbon fiber reinforced polyetherketone resin and polyether. Blend materials with imide resins (Japanese Patent Laid-Open No. 2-269764) and the like are available. In addition, durability reliability is inferior compared to the above two materials, and there are many restrictions on usable temperature and impeller rotation speed. However, super heat-resistant engineering plastics reinforced with carbon fibers (fiber content: about 20% to 45% by weight), such as polyetheretherketone resin, polyallyletherketone resin, polyetherketoneetherketoneketone Resin, polyetherketoneketone resin, polyethernitrile resin, Polyether sulfone resin, polysulfone resin, polyetherimide resin, thermoplastic polyimide resin, polyamide-imide resins.

However, a carbon fiber reinforced polyetherketone resin suitable for a fiber reinforced resin impeller or a blended material of carbon fiber reinforced polyetherketone resin and polyetherimide resin has a weight ratio of 20. %
Even if only the front and rear recycled materials are blended, the instantaneous breaking rotation speed will drop significantly and the continuous service life will decrease.

Therefore, in consideration of the durability and reliability in the market, it can be said that it is practically difficult to use a molding material containing a recycled material.

By the way, as a method of blending the recycled material obtained by crushing with the original material and reusing it, the following three cases can be considered as shown in FIG. In FIG. 1, after the products / parts are crushed by the crusher a, they are sorted by the metal detector b and the sieve c, and the granular crushed material excluding the powdery crushed material is pelletized by the extruder d, and then the oven Injection molding machine f after heating with e
Shows a series of steps of injection molding into test pieces, products and parts.

(Case 1): A method in which a recycled material, which is a granular crushed material obtained by crushing products / parts and then sorting, is mixed with the original material without being pelletized, and injection molding is performed.

(Case 2): A method of mixing resin powder, reinforcing material, and recycled material obtained by crushing at the stage of manufacturing pellets of the original material, feeding the mixture into the extruder d, and pelletizing again.

(Case 3): A method in which recycled materials obtained by crushing products / parts are individually pelletized, and then mixed with pellets of original materials and injection-molded.

The advantages and disadvantages of the three methods are summarized in Table 1 above.

[0027]

[Table 1]

That is, in the case 1 method, the thermal history is one less and the number of extrusions is one less than in the case of pelletizing again, so that the fiber is less damaged. Therefore, it should be most advantageous in terms of physical properties. In addition, since it can be reused only by crushing, it has an advantage of low recycling cost.

In the case 2 method, since the crushed material is simply mixed at the time of manufacturing the original material pellets, the recycling cost is low as in the case 1. The biggest problem with this method is that the crushed material (recycled material) is mixed during the production of the original pellets. There is a risk that the pellets will be difficult to use.

On the other hand, in the case 3 method, since the recycled material obtained by crushing is pelletized independently, the mixing ratio of the recycled material may be changed according to the fluidity and the physical properties.
In other words, the physical property value of recycled material pellets is insufficient,
If the fluidity is poor, the ratio of the original material may be increased. The biggest problem with this method is the cost of pelletizing the recycled material alone.

When the molding material containing the recycled material is applied to the fiber-reinforced resin impeller, Case 2 of the above three recycling methods has many problems in terms of quality stability. I examined the method.

However, the impeller molded using the molding material containing the recycled material is not only significantly inferior to the instantaneous breaking rotational speed and continuous durability life of the impeller molded using only the original material, but also has a thermal history. Since the resin is less deteriorated because it is less than 1 time, and the fiber is less damaged because the number of times of extrusion is less than once, it is better to adopt the method of Case 1 which is considered to be advantageous in terms of physical properties. The result is incomprehensible in that there are cases inferior to Case 3. Further, in Case 1, there is no correlation between the instantaneous breaking rotation speed / continuous durable life and the blending ratio of the recycled material, which causes a problem that the blendable upper limit of the recycled material cannot be determined. However,
In any case, it is true that the use of a molding material containing recycled materials will result in a significant decrease in the instantaneous breaking rotation speed and continuous durable life, and it is difficult to apply such molding material to mass-produced industrial products. .

In order to solve such a problem, the inventor of the present invention firstly proposes the blending ratio of the recycled material and the instantaneous breaking rotation speed.
We decided to elucidate the relationship between continuous durable lives. This is because the behavior as described above cannot be explained by the deterioration of the resin due to the increase of the heat history and the breakage of the fiber due to the increase of the number of times of extrusion.

From a common sense, the strength and durability reliability should decrease as the blending ratio of recycled materials increases, but with such an idea, the blending ratio of recycled materials, instantaneous breaking rotation speed, and continuous durability should be considered. Unable to reasonably explain the relationship between lifespans.

As a reason for exhibiting such a behavior, the present inventor has found that the recycled material and the original material are not sufficiently uniformly mixed in the cylinder of the injection molding machine, and therefore the recycled material and the original material are not sufficiently adhered. It is estimated that the fracture may occur from the interface with the material, which may cause a large decrease in strength even when the blending ratio of the recycled material is small.

If this assumption is correct, the recycled material and the original material are relatively uniformly mixed in the cylinder of the injection molding machine by using the re-pelletized product in which the particle diameter of the recycled material is almost uniform. Although the strength should be improved to some extent, in practice, by using the re-pelletized product, even if a correlation can be found between the strength of the test piece and the blending ratio of the recycled material, the crushing Repelletized product (1
Since the strength of (00%) itself is small, if the restriction that the strength and durability of the product is not impaired is set, the recycled material to be blended with the original material must be significantly reduced, which is a practical limitation. I don't get.

As described above, it has been found that the use of recycled materials has the following problems.

(1) Although it is inexpensive when used in a pulverized state, a high degree of strength and durability are required because no clear relationship can be found between the physical properties of the molding material containing the recycled material and the mixing ratio. Difficult to use for the products and parts that are used.
In addition, even if the blending ratio of the recycled material is relatively small, a large decrease in strength occurs.
It is difficult to expect the same level of strength and durability as when using%.

(2) When the recycled material is pelletized, the mixed state with the original material is slightly improved, but since fiber breakage and resin deterioration occur during pelletization, the strength of the pelletized recycled material is increased. It itself drops significantly. For this reason, if the same strength and reliability as when using a material containing no recycled material is required, almost no recycled material can be blended.

An object of the present invention is to solve the problems (1) and (2), that is, in the case where "the original material is 100% even if a pellet is not required and a considerable amount of recycled material is blended. It is a resin molding material containing recycled materials, which provides strength and durability reliability comparable to those of the above, and whose physical properties can be predicted from the blending ratio of recycled materials.

By the way, in the case of a short fiber reinforced composite material using a reinforcing material having a fiber length of more than 300 μm in a pellet or a molded article such as glass fiber, the length of the fiber is shortened by pulverization. In many cases, the flow properties of recycled materials are rather improved. However, when a reinforcing material having a fiber length of less than 200 μm, such as carbon fiber, is used, the fiber length does not extremely decrease even when crushed, so that the influence of the deterioration of the resin is conspicuous and the flow characteristics deteriorate. It's easy to do.

The deterioration of fluidity greatly deteriorates the physical properties of the molding material containing the recycled material, such as deterioration of the resin due to the temperature rise of the resin in the injection molding machine due to shearing and reduction of the length of the reinforcing material. Also, as a matter of course, it makes it difficult to uniformly mix the original material and the recycled material. Therefore,
It is considered that the problems (1) and (2) can be solved by finding a molding material that covers the deterioration of the resin, the decrease of the fiber length and the deterioration of the mixed state due to the deterioration of the fluidity without pelletizing the pulverized material. .

As a resin molding material that solves such a problem, the present inventor has stated that "a recycled material obtained by pulverization and a matrix resin having the same or the same basic molecular structure as or compatible with the recycled material are compatible with each other. Use a molding material that is a mixture of the original materials consisting of the short fiber reinforced composite materials used, and that has greater flow characteristics of the original material than when using the original material alone (that is, when the recycled material is not mixed) The present invention has led to the invention of a resin molding material characterized in that

FIG. 2 shows the MFR (melt flow rate) of a blended material of a polyetherketone resin and a polyetherimide resin reinforced with 30% by weight of short carbon fibers described later.
And the relationship between tensile strength and tensile strength.

Here, MFR (melt flow rate)
Is a flow rate when the melt is extruded from a piston under a fixed condition, and is an index showing the ease of flow of the melt, and is also called MI (melt index) or MFI (melt flow index). There is something. The smaller the MFR of the pellet used for molding, the better the physical properties of the molded product.

Regarding the physical properties of the short fiber reinforced composite material, the greater the elongation of the matrix resin and the longer the fiber length, the more excellent the values obtained. The fluidity of the pellet becomes smaller as the elongation of the matrix resin increases (the molecular weight increases) and the fiber length of the reinforcing material increases.

By the way, since the MFR of the recycled material obtained by crushing the product molded by using the original material having a small MFR alone is further lowered due to the deterioration of the resin, it is different from the original material having a small MFR. If the recycled materials are mixed and used, the fluidity will drop drastically, the temperature inside the cylinder of the injection molding machine will become excessive relative to the set value, and resin deterioration and reinforcement due to the temperature rise of the resin in the injection molding machine due to shearing will occur. As a result, the fiber length is reduced, and the physical property value is greatly reduced.

Despite these reasons, a molding material obtained by mixing an original material having a large MFR, which is originally disadvantageous in terms of physical properties, with a recycled material in which resin deterioration and fiber length decrease occur, as in the present invention. It is thought that it is impossible at all to obtain the strength and durability equivalent to a product formed by using an original material having a small MFR alone, but it was presumed to be practical for the following reasons.

For example, considering the formability, as shown in FIG. 3B, a case where an original material having a medium MFR is used alone and M as shown in FIG.
Compared with the case of using a molding material that has a medium MFR by mixing an original material with a large FR and a recycled material with a small MFR, the latter has a smaller temperature rise in the cylinder, so the resin Less deterioration and less fiber breakage.

The reason why such a difference occurs is that, in the latter case, the original material having a small melt viscosity is melted first, so that the recycled material having a large melt viscosity can be gradually melted in the molten resin. However, in the former case, a very large amount of shearing heat is generated due to melting, and as a result, the temperature inside the cylinder rises.

Therefore, even if the physical properties of the pellets are inferior (that is, the elongation of the resin is small and the fiber length is small), if the resin deterioration and the fiber breakage occurring at the injection molding stage can be reduced, as a result, May improve the strength and durability of the product. Therefore, it is not impossible to obtain the same physical property value as the original material having a low MFR excellent in strength by mixing the recycled material having a large decrease in physical properties with the original material having a large MFR which is disadvantageous in strength.

The present invention is very effective as is clear from the examples and comparative examples shown below.

In the present invention, applicable matrix resins include, for example, polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, nylon 66, nylon 6, nylon 12, nylon 46, Polyamide resins such as nylon 11 and nylon 610, general-purpose resins such as AS resin, ABS resin and polycarbonate, and polyphenylene sulfide, polyether sulfone, polysulfone, polyetherimide,
Polyamideimide, polyetherketone, polyetheretherketone, polyetherketoneketone, polyetherketoneetherketoneketone, polyallyletherketone, polyethernitrile, thermoplastic polyimide,
Heat resistant engineering plastics such as polyketone sulfide and super heat resistant engineering plastics can be used, and heat resistant engineering plastics and super heat resistant engineering plastics that are prone to resin deterioration due to high molding temperature are particularly suitable. .

It is desirable that the recycled material and the original material have the same or the same basic molecular structure from the viewpoint of compatibility, but if the resin is compatible with the recycled material, the original material mixed with the recycled material is the recycled material. It is not necessary that the materials have the same or the same basic molecular structure. If you use an original material that is incompatible with the recycled material, the resin strength is likely to decrease.
The effect of the present invention cannot be sufficiently obtained.

As the reinforcing fibers, for example, inorganic fibers such as glass fibers, carbon fibers, ceramics fibers and mineral fibers, metal fibers such as stainless steel, brass and nickel,
Organic fibers such as polyacrylonitrile fiber, cellulosic fiber, polyphenylene benzothiazole fiber, polyethylene terephthalate fiber, liquid crystal aromatic polyester fiber, polyvinyl alcohol fiber, aromatic polyamide (aramid) fiber, etc. can be mentioned. A fiber having a small decrease and a fiber length in the pellet of 200 μm or less, such as carbon fiber, is suitable.

In addition, various stabilizers and fillers such as flame retardants, antioxidants, ultraviolet absorbers, lubricants, colorants, and heat stabilizers are added within a range that does not impair moldability and mechanical properties. May be.

More specifically, as the filler, calcium carbonate, zinc oxide, magnesium oxide, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, talc, silicic acid, calcium silicate, mica, glass, glass balloon, quartz balloon , Graphite, boron, alumina, silicon carbide, boron carbide, boria, boron nitride, silicon nitride,
Inorganic powder of aluminum nitride, silica, beryllium, beryllium oxide, asbestos, potassium titanate, carbon, graphite, boron, alumina, silicon carbide, boron carbide, boria, quartz, silica, beryllium, boron nitride and other inorganic whiskers, aramid pipe , Microcellulose, thermosetting resin powder, and the like, and as the release agent and the inorganic filler,
There are lower alcohol esters of higher fatty acids, polyhydric alcohol esters of fatty acids, liquid paraffin, barium sulfate, shirasu, antimony oxide, etc. Other crystallization accelerators are alkylene glycol derivatives, polyalkylene glycol derivatives, ionomers, mica, titanium dioxide. Etc.

There is no particular restriction on the blending ratio of the recycled material, but as the fiber length becomes longer, advantageous properties such as the deflection temperature under load and the creep life will be described below. Within the range of less than 100%, a peculiar phenomenon in which the fiber length becomes larger than in the case of 100% of the original material is observed, so use of this range is desirable.

As described above, in the present invention, by using a material having a large MFR as the original material mixed with the recycled material (crushed material), fiber damage and resin deterioration in the cylinder are reduced, and the recycled material is dispersed. It has become possible not only to improve the condition and greatly reduce the decrease in static strength, but also to obtain elastic modulus, deflection temperature under load, and creep life that exceed those of the original material.

In the present invention, as the original material, one whose MFR at a molding temperature of a load of 2.16 kgf is larger than that of the recycled material at a molding temperature of a load of 2.16 kgf by 1.5 to 4.7 g / 10 min is used. However, since the difference in MFR between the original material and the recycled material appears in the difference between the two peaks observed in the fiber length distribution in the molded product,
It can also be shown by the difference between the two peaks.

That is, as shown in FIGS. 4A and 4B, when the difference in MFR is large, the difference between the two peaks is large.
If the difference in MFR is small, the difference between the two peaks will be small,
The peak with the larger fiber length is due to the original material, and the peak with the smaller fiber length is due to the recycled material.

There is a proportional relationship between the difference between the two peak values relating to the fiber length in the molded product and the difference in MFR between the recycled material and the original material, and such a relationship is present in the fiber reinforced grade. In the commonly used fiber content, that is, in the range of more than 10% by weight, it is substantially established regardless of the type of matrix resin.

Therefore, the area in which the present invention is applicable: 1.
The peak-to-peak distance of the fiber length distribution in the molded product is 5 to 4.7 g / 10 min, which is 27 to 64 μm.

The MFRs in this specification are all values at a molding temperature of each material under a load of 2.16 kgf, and the unit is g / 10 min.

[0065]

The relationship between the MFR of the original material and the fiber length and the principle of the present invention will be described together with the operation as follows.

First, the relationship between the MFR of the original material and the fiber breakage and the fiber length in the molded product is as shown in Table 2.

[0067]

[Table 2]

The breakage of the fiber occurs in two cases, inside the cylinder of the injection molding machine and during the mold filling. When a grade having a large MFR is used, the frequency of fiber breakage is reduced because the shearing heat generated by the rotation of the screw in the cylinder is reduced due to the low melt viscosity. However, since a material having a high MFR tends to be filled in the mold in a turbulent state, the frequency of fiber breakage at the time of filling the mold increases.

On the other hand, when a grade having a small MFR is used, the melt viscosity is large, so that the shear heat generation due to the rotation of the screw in the cylinder becomes large, so that the frequency of fiber breakage increases. However, since a material having a low MFR tends to be filled in the mold in a laminar flow state, the frequency of fiber breakage at the time of filling the mold is reduced.

The fiber length in the recycled material is not large because the recycled material itself already has an injection history. However, when mixed with a high MFR original material, the MFR of the original material itself is large, so there is little fiber damage in the cylinder of the original material, and the original material melts relatively early, so it is protected by the molten original material. Therefore, the damage of recycled materials will be extremely reduced. The fiber breakage at the time of mold filling was a defect of the high MFR original material, but the apparent MFR becomes small by mixing the recycled material, and the fiber breakage at the time of mold filling is reduced. With such a mechanism, a large fiber length can be obtained as a result despite the use of recycled materials.

For this reason, the creep life and the deflection temperature under load, which are likely to reflect the effect of increasing the fiber length, have a specific effect in that they are larger when used in combination with a recycled material than when the original material is used alone.

The relationship between the ratio of recycled material and the deflection temperature under load is shown in FIG. 5. When a molding material containing 50% recycled material is used, the deflection temperature under load is higher than that of the original material. ing.

Further, as shown in FIG. 6, the creep life of the original material is longer than that of the original material when 25% of the recycled material is mixed.

Further, looking at the relationship between the shape of the resin and the melting, as shown in FIG. 7, in the case of a crushed material such as a recycled material, the thermal conductivity of the resin is inferior, so it is relatively large. The spherical pulverized material only melts on the surface and does not easily completely melt. On the other hand, as shown in FIG. 8, in the case of pellets, since the distance from the pellet surface to the center is small, the temperature easily rises and melts. And
When the crushed material and the pellets are mixed, as shown in FIG. 9, the pellets are first melted in the vicinity of the crushed material, so that the viscosity becomes smaller than that when the crushed material is used alone, and the fiber breakage is reduced. Since the melting finishes earlier, it becomes easier to uniformly mix the crushed material and the original material. In addition, the rise in the resin temperature is reduced and the resin deterioration is reduced.

Furthermore, the upper mold 1 having the sprue 1a as shown in FIGS. 10 and 11, the assembly mold 2 forming the cavity 2a, the lower mold 3 having the resin reservoir 3a, and the center of the cavity 2a are penetrated. MF of the molding material in the case of injection molding with a molding die equipped with
When R is large, as shown in FIG. 10, the resin is filled in a turbulent state, so that the fibers are likely to be damaged, and when MFR is small, as shown in FIG.
Since the resin is filled in a laminar flow state, the damage to the fibers is small, and this also applies to the crushed material (recycled material) and the high MFR original material.

[0076]

EXAMPLE An upper mold 1 having a sprue 1a as shown in FIG. 12 and an assembly mold 2 for forming a cavity 2a will be described below.
And a lower mold 3 having a resin reservoir (slag well) 3a
Then, an example and a comparative example in the case of molding the fiber-reinforced resin impeller 11 having the shape shown in FIG. 13 by the molding die 10 having the pin 4 penetrating the center of the cavity 2a will be described.

When the MFR of the original material is different Comparative Example 1 Polyetherketone resin "VICTR" made by ICI of England
EX PEK 220P "and polyetherimide resin" ULTEM 1000 "manufactured by GE USA were mixed so that the weight ratio of the polyetherketone resin and the polyetherimide resin was 80:20, and then Toho Rayon Co., Ltd. ) Made of Vesphite HTA carbon fiber (fiber length:
6 mm) was dry blended so that the weight fraction of the carbon fiber was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fiber), and the cylinder temperature was 40 using an extruder.
It was extruded under the condition of 0 ° C. to obtain a pellet-shaped molding material.
The MFR of this pellet-shaped molding material was 2.4.

Next, using this pellet-shaped molding material, cylinder temperature: 400 ° C., screw rotation speed: 85
rpm. , Mold temperature: 220 ° C., Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) injection molding machine and the molding die 10 shown in FIG. 12 were used, and the resin impeller 1 shown in FIG. 13 was used.
A molded product of No. 1 was obtained.

The resin impeller 1 thus obtained
The molded product of No. 1 was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.), and a powdery or granular recycled material with a particle size of 8 mm or less (M
FR: 2.2) was obtained. This recycled material was inspected for foreign matter using a metal detector (KD801AW manufactured by Anritsu Corporation).

Next, the recycled material obtained by the above method and the original material made of the above-mentioned pelletized molding material and having an MFR of 2.4 were mixed in a weight ratio of the recycled material and the original material of 25:75. Then, the resin impeller was molded again using the above molding conditions, molding die and injection molding machine. After that, the sprue of the impeller molded body and the resin pool are cut off, shaft hole processing, internal defect inspection (ultrasonic flaw detection), single balancing are performed, and a burst test is carried out using a spin tester after being incorporated into a turbocharger. The breaking rotation speed was measured. The result is shown in FIG.

Example 1 As in Comparative Example 1, a polyetherketone resin "VICTREX PEK 220P" manufactured by ICI of the United Kingdom and US G
Polyetherimide resin "ULTEM100" manufactured by E
0 ″ was mixed so that the weight ratio of the polyetherketone resin and the polyetherimide resin was 80:20, and then Vesphite HTA carbon fiber (fiber length: 6 mm) manufactured by Toho Rayon Co., Ltd. was mixed. Dry blend so that the weight fraction of carbon fiber is 30% with respect to the total weight (the sum of the weight of resin and carbon fiber), and then extrude using an extruder at a cylinder temperature of 400 ° C to form pellets. As a result, the pellet-shaped molding material had an MFR of 2.4.

Next, using this pellet-shaped molding material, cylinder temperature: 400 ° C., screw rotation speed: 85
rpm. , Mold temperature: 220 ° C., Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) injection molding machine and the molding die 10 shown in FIG. 12 were used, and the resin impeller 1 shown in FIG. 13 was used.
A molded product of No. 1 was obtained.

Resin impeller 1 thus obtained
The molded product of No. 1 was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.) in the same manner as in Comparative Example 1 to obtain a powdery / granular recycled material (MFR: 2.2) having a particle diameter of 8 mm or less. . This recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the recycled material obtained by the above method and the original material obtained by changing the molecular weight of the matrix resin in the pelletized molding material so that the MFR was 3.7 were compared. Similarly, the recycled material and the original material were mixed so that the weight ratio was 25:75, and the resin impeller was molded again using the molding conditions, the molding die and the injection molding machine described above. After that, the sprue of the impeller molded body and the resin pool are cut off, shaft hole processing, internal defect inspection (ultrasonic flaw detection), single balancing are performed, and a burst test is carried out using a spin tester after being incorporated into a turbocharger. The breaking rotation speed was measured. The result is shown in FIG.

Example 2 A pellet-shaped molding material having an MFR of 2.4 was obtained in the same manner as in Example 1, and then molded into a molded body of a resin impeller 11 under the same conditions as in Example 1, and further carried out. By grinding in the same manner as in Example 1, a powdery / granular recycled material (MFR: 2.2) having a particle diameter of 8 mm or less was obtained. This recycled material was inspected for foreign matter using a metal detector as in Example 1.

Next, the recycled material obtained by the above method and the original material obtained by changing the molecular weight of the matrix resin in the pellet-shaped molding material so that the MFR was 4.3 were used as recycled materials. The mixture was mixed so that the weight ratio with the original material was 25:75, and the resin impeller was molded again under the same conditions as in Example 1. After this, Example 1
A burst test was carried out in the same manner as above, and the instantaneous breaking rotation speed was measured. The result is shown in FIG.

Example 3 A pellet-shaped molding material having an MFR of 2.4 was obtained in the same manner as in Example 1, and then molded into a molded body of a resin impeller 11 under the same conditions as in Example 1, and further carried out. By grinding in the same manner as in Example 1, a powdery / granular recycled material (MFR: 2.2) having a particle diameter of 8 mm or less was obtained. This recycled material was inspected for foreign matter using a metal detector as in Example 1.

Next, the recycled material obtained by the above method and the original material obtained by changing the molecular weight of the matrix resin in the pelletized molding material so that the MFR was 5.6 were used as recycled materials. The mixture was mixed so that the weight ratio with the original material was 25:75, and the resin impeller was molded again under the same conditions as in Example 1. After this, Example 1
A burst test was carried out in the same manner as above, and the instantaneous breaking rotation speed was measured. The result is shown in FIG.

Example 4 A pellet-shaped molding material having an MFR of 2.4 was obtained in the same manner as in Example 1, and then molded into a molded article of a resin impeller 11 under the same conditions as in Example 1, and further carried out. By grinding in the same manner as in Example 1, a powdery / granular recycled material (MFR: 2.2) having a particle diameter of 8 mm or less was obtained. This recycled material was inspected for foreign matter using a metal detector as in Example 1.

Next, the recycled material obtained by the above method and the original material obtained by changing the molecular weight of the matrix resin in the pelletized molding material so that the MFR was 6.7 were used as the recycled material. The mixture was mixed so that the weight ratio with the original material was 25:75, and the resin impeller was molded again under the same conditions as in Example 1. After this, Example 1
A burst test was carried out in the same manner as above, and the instantaneous breaking rotation speed was measured. The result is shown in FIG.

Comparative Example 2 A pellet-like molding material having an MFR of 2.4 was obtained in the same manner as in Comparative Example 1, and then molded into a molded article of a resin impeller 11 under the same conditions as in Comparative Example 1 and further compared. By grinding in the same manner as in Example 1, a powdery / granular recycled material (MFR: 2.2) having a particle diameter of 8 mm or less was obtained. This recycled material was inspected for foreign matter using a metal detector as in Comparative Example 1.

Next, the recycled material obtained by the above method and the original material obtained by changing the molecular weight of the matrix resin in the pelletized molding material so that the MFR was 7.5 were used as recycled materials. The mixture was mixed so that the weight ratio with the original material was 25:75, and the resin impeller was molded again under the same conditions as in Comparative Example 1. After this, Comparative Example 1
A burst test was carried out in the same manner as above, and the instantaneous breaking rotation speed was measured. The result is shown in FIG.

Evaluation Example 1 As shown in FIG. 14, when the MFR of the recycled material is 2.2 and the MFR of the original material is in the range of 3.7 to 6.9, that is, the MFR of the original material is 1.5-4.7g / 10mi compared with MFR of recycled material
When it was large within the range of n, it was possible to obtain a resin impeller having excellent characteristics of large instantaneous breaking rotation speed.

When pelletizing the recycled material alone
(Comparative Example 3), recycle when manufacturing original material pellets
When a resin material is mixed (Comparative Example 4), Comparative Example 3 A pellet-shaped molding material having an MFR of 2.4 is obtained in the same manner as in Comparative Example 1, and then the resin impeller 11 of Comparative Example 1 is prepared under the same conditions. It was molded into a molded body and further pulverized in the same manner as in Comparative Example 1 to obtain a powdery / granular recycled material (MFR: 2.2) having a particle diameter of 8 mm or less. This recycled material was subjected to foreign matter inspection using a metal detector in the same manner as in Comparative Example 1, and then pelletized again under the above conditions to obtain a recycled molding material (MFR: 1.9).

Next, the recycled material obtained by the above-mentioned method (recycled material pelletized again) and MFR of 3.
The original material of Example 1 which is No. 7 was mixed so that the weight ratio of the recycled material and the original material was 25:75, and the resin impeller was molded again under the same conditions as in Comparative Example 1. Thereafter, a burst test was carried out in the same manner as in Comparative Example 1, and the instantaneous breaking rotation speed was measured. The results are shown in FIG. 14, but the instantaneous breaking rotation speed was inferior to that in the case of Example 1.

Comparative Example 4 A pellet-shaped molding material having an MFR of 2.4 was obtained in the same manner as in Comparative Example 1, and then molded into a molded article of a resin impeller 11 under the same conditions as in Comparative Example 1 and further compared. By grinding in the same manner as in Example 1, a powdery / granular recycled material (MFR: 2.2) having a particle diameter of 8 mm or less was obtained. This recycled material was subjected to foreign matter inspection using a metal detector in the same manner as in Comparative Example 1.

Next, the recycled material obtained by the above method and the polyetherketone resin "VIC" manufactured by ICI of England
TREX PEK 220P ", polyetherimide resin" ULTEM 1000 "manufactured by GE, USA, Vesphite HTA manufactured by Toho Rayon Co., Ltd., carbon fiber (fiber length: 6 mm), polyetherketone resin and polyetherimide resin And carbon fiber weight ratio is 56:14:30
And the original material mixed so that the weight ratio of the recycled material is 25%, dry blending is performed, and the cylinder temperature is 400 using an extruder.
Extruded under conditions of ℃, molding material (pellet state MF
R: 1.9) was obtained. Incidentally, polyether Kent resin,
Polyetherimide resin and carbon fiber are the above-mentioned MFR
The same lot as that used for manufacturing the original material pellet of 2.4 was used.

Using this molding material, a resin impeller was molded again in the same manner as in Comparative Example 1. Thereafter, a burst test was carried out in the same manner as in Comparative Example 1, and the instantaneous breaking rotation speed was measured. As a result, 205,000 rpm. However, it was inferior to Examples 1 to 4.

Original material MFR and recycled material M
Difference with FR Comparative Example 5 Polyetherketone resin "VICTR" manufactured by British ICI
EX PEK 220P "and Vesphite HTA carbon fiber (fiber length: 6 mm) manufactured by Toho Rayon Co., Ltd. were dry-blended so that the carbon fiber content was 30% by weight, and then the cylinder temperature was adjusted using an extruder. : 390 ° C
It was extruded under the conditions described above to obtain a pellet-shaped molding material.

Then, using this pellet-shaped molding material, cylinder temperature: 390 ° C., screw rotation speed: 85 r
pm. Mold temperature: 200 ° C., manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) injection molding machine and molding die 10 shown in FIG. 12 were used to mold the resin impeller 11 shown in FIG. Got the body

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the molecular weight of the matrix resin of the recycled material obtained by the above method and the pelletized molding material was changed so that the MFR was 1.1 larger than the MFR of the recycled material. Original material,
The weight ratio of recycled material to original material is 25:75
Then, the resin impeller was molded again using the above molding conditions, molding die and injection molding machine. After this,
The sprue of the impeller molded body, resin puddle are cut off, axial hole processing, internal defect inspection (ultrasonic flaw detection), single balance balancing, burst test using a spin tester incorporated into a turbocharger, and instantaneous breaking rotation speed Was measured. The results are shown in FIG.

Example 5 As in Comparative Example 5, a polyetherketone resin "VICTREXPEK 220P" manufactured by ICI, UK, and Vesphite HTA carbon fiber (fiber length: 6 mm) manufactured by Toho Rayon Co., Ltd. were used as a carbon fiber-containing material. After dry-blending so that the ratio would be 30% by weight, it was extruded using an extruder under the conditions of cylinder temperature: 390 ° C. to obtain a pellet-shaped molding material.

Next, using the pelletized molding material, the cylinder temperature was 390 ° C. and the screw rotation speed was 85 r.
pm. Mold temperature: 200 ° C., manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) injection molding machine and molding die 10 shown in FIG. 12 were used to mold the resin impeller 11 shown in FIG. Got the body

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, by changing the molecular weight of the matrix resin of the recycled material obtained by the above method and the above pelletized molding material, the MF is higher than the MFR of the recycled material.
The weight ratio of the recycled material to the original material is 25:
The resin impeller was molded again using the above molding conditions, a molding die, and an injection molding machine by mixing so as to be 75. After this, remove the sprue and resin pool of the impeller molded body,
Shaft hole processing, internal defect inspection (ultrasonic flaw detection), single balance balancing, and incorporation into a turbocharger were carried out burst test using a spin tester to measure instantaneous breaking rotation speed. The results are shown in FIG.

Example 6 A pellet-shaped molding material was obtained in the same manner as in Example 5, and this molding material was injection-molded under the same conditions as in Example 5 to obtain a molded body of the resin impeller 11. Next, the resin impeller thus obtained was crushed in the same manner as in Example 5 to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less, and then foreign matter inspection was performed in the same manner as in Example 5. .

Next, by changing the molecular weight of the recycled resin obtained by the above method and the pellet-shaped molding material of the matrix resin, the MF is higher than the MFR of the recycled material.
The weight ratio of recycled material to original material is 25:
The resin impeller was molded again using the above molding conditions, a molding die, and an injection molding machine by mixing so as to be 75. Thereafter, a burst test was carried out in the same manner as in Example 5, and the instantaneous breaking rotation speed was measured. The results are shown in FIG.

Example 7 A pellet-shaped molding material was obtained in the same manner as in Example 5, and this molding material was injection-molded under the same conditions as in Example 5 to obtain a molded body of the resin impeller 11. Next, the resin impeller thus obtained was crushed in the same manner as in Example 5 to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less, and then foreign matter inspection was performed in the same manner as in Example 5. .

Next, by changing the molecular weight of the matrix resin of the recycled material obtained by the above method and the pelletized molding material, the MF is higher than the MFR of the recycled material.
The weight ratio of recycled material and original material is 25:
The resin impeller was molded again using the above molding conditions, a molding die, and an injection molding machine by mixing so as to be 75. Thereafter, a burst test was carried out in the same manner as in Example 5, and the instantaneous breaking rotation speed was measured. The results are shown in FIG.

Example 8 A pellet-like molding material was obtained in the same manner as in Example 5, and this molding material was injection-molded under the same conditions as in Example 5 to obtain a molded body of the resin impeller 11. Next, the resin impeller thus obtained was crushed in the same manner as in Example 5 to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less, and then foreign matter inspection was performed in the same manner as in Example 5. .

Next, by changing the molecular weight of the recycled resin obtained by the above method and the matrix resin of the pelletized molding material, the MF is higher than the MFR of the recycled material.
The weight ratio of the recycled material and the original material is 25:
The resin impeller was molded again using the above molding conditions, a molding die, and an injection molding machine by mixing so as to be 75. Thereafter, a burst test was carried out in the same manner as in Example 5, and the instantaneous breaking rotation speed was measured. The results are shown in FIG.

Comparative Example 6 A pellet-like molding material was obtained in the same manner as in Comparative Example 5, and this molding material was injection-molded under the same conditions as in Comparative Example 5 to obtain a molded body of the resin impeller 11. Then, the resin impeller thus obtained was crushed in the same manner as in Comparative Example 5 to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less, and then foreign matter inspection was performed in the same manner as in Comparative Example 5. .

Next, by changing the molecular weight of the matrix resin of the recycled material obtained by the above method and the pelletized molding material, the MF is higher than the MFR of the recycled material.
The weight ratio of the recycled material to the original material is 25:
The resin impeller was molded again using the above molding conditions, a molding die, and an injection molding machine by mixing so as to be 75. Thereafter, a burst test was carried out in the same manner as in Comparative Example 5, and the instantaneous breaking rotation speed was measured. The results are shown in FIG.

Evaluation Example 2 As shown in FIG. 15, the MFR of the original material is larger than that of the recycled material, and the difference between them is 1.5 to 4.
When it was within the range of 7 g / 10 min, the instantaneous breaking rotation speed increased, and it was possible to obtain a resin impeller having excellent characteristics.

Mixing ratio of recycled materials Examples 9 to 11 Polyetherketone resin "VICTR" manufactured by ICI, UK
EX PEK 220P "and polyetherimide resin" ULTEM 1000 "manufactured by GE USA were mixed so that the weight ratio of the polyetherketone resin and the polyetherimide resin was 80:20, and then Toho Rayon Co., Ltd. ) Made of Vesphite HTA carbon fiber (fiber length:
6 mm) was dry blended so that the weight fraction of the carbon fiber was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fiber), and the cylinder temperature was 40 using an extruder.
It was extruded under the condition of 0 ° C. to obtain a pellet-shaped molding material.
The MFR of this pellet-shaped molding material was 2.4.

Next, using this pellet-shaped molding material, cylinder temperature: 400 ° C., screw rotation speed: 85 rp
m. A mold made of a resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and a molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.), and a powdery / granular recycled material having a particle size of 8 mm or less (MFR: 2.
2) was obtained. The recycled material was inspected for foreign matter using a metal detector (KD801AW manufactured by Anritsu Corporation).

Next, the recycled material obtained by the above method and the original material obtained by changing the molecular weight of the matrix resin in the pelletized molding material so that the MFR was 5.6 were used as recycled materials. The weight ratio with the original material is 25:75 (Example 9), 50:50 (Example 1)
0) and 75:25 (Example 11) were mixed, and the resin impeller was molded again using the molding conditions, the molding die and the injection molding machine described above. After that, the sprue of the impeller molded body and the resin pool are cut off, shaft hole processing, internal defect inspection (ultrasonic flaw detection), single balancing are performed, and a burst test is carried out using a spin tester after being incorporated into a turbocharger. The breaking rotation speed was measured. The result is shown in FIG.

Comparative Examples 7 to 9 Polyetherketone resin "VICTR" manufactured by British ICI
EX PEK 220P "and polyetherimide resin" ULTEM 1000 "manufactured by GE USA were mixed so that the weight ratio of the polyetherketone resin and the polyetherimide resin was 80:20, and then Toho Rayon Co., Ltd. ) Made of Vesphite HTA carbon fiber (fiber length:
6 mm) was dry blended so that the weight fraction of the carbon fiber was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fiber), and the cylinder temperature was 40 using an extruder.
It was extruded under the condition of 0 ° C. to obtain a pellet-shaped molding material.
The MFR of this pellet-shaped molding material was 2.4.

Next, using this pellet-shaped molding material, cylinder temperature: 400 ° C., screw rotation speed: 85 rp
m. A mold made of a resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and a molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.), and a powdery / granular recycled material having a particle size of 8 mm or less (MFR: 2.
2) was obtained. This recycled material was subjected to foreign matter inspection using a metal detector (KD801AW manufactured by Anritsu Corporation), and then pelletized again under the above conditions to obtain a recycled molding material (MFR: 1.9).

Next, a recycled material (re-pelletized) obtained by the above method and an original material obtained by changing the molecular weight of the matrix resin in the pelletized molding material so that the MFR was 2.4. The weight ratio of recycled material to original material is 25:75 (Comparative Example 7), 5
The resin impeller was molded again using the molding conditions, the molding die and the injection molding machine described above by mixing so as to be 0:50 (Comparative Example 8) and 75:25 (Comparative Example 9). After this, the sprue of the impeller molded body and the resin pool are cut off and the shaft hole is machined.
An internal defect inspection (ultrasonic flaw detection), a single balance adjustment, a built-in turbocharger, and a burst test using a spin tester were performed to measure the instantaneous breaking rotation speed. The result is shown in FIG.

Evaluation Example 3 In order to confirm the durability of each resin impeller, a representative example, a comparative example, and four examples each (that is, Examples 1, 5, 9,
For 10 and Comparative Examples 1, 6, 7, and 9), a continuous durability test for 200 hours was performed. Experimental conditions were: compressor outlet temperature: 150 ° C. (compressor inlet temperature was controlled so that the compressor outlet temperature was 150 ° C.), turbine speed: 110,000 rpm. And The inline 6-cylinder 2500cc engine was used for the experiment, and the maximum diameter of the impeller was 6
The thing of 6.6 mm was used. The results are shown in Table 3.

[0125]

[Table 3]

As shown in Table 3, the resin impellers of the examples of the present invention were extremely excellent in durability.

Physical property test and molding using molded product (test piece)
Measurement of fiber length in product (test piece) Comparative Examples 10 to 14 Polyetherketone resin “VICTR” manufactured by British ICI
EX PEK 220P "and polyetherimide resin" ULTEM 1000 "manufactured by GE USA were mixed so that the weight ratio of the polyetherketone resin and the polyetherimide resin was 80:20, and then Toho Rayon Co., Ltd. ) Made of Vesphite HTA carbon fiber (fiber length:
6 mm) was dry blended so that the weight fraction of the carbon fiber was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fiber), and the cylinder temperature was 40 using an extruder.
It was extruded under the condition of 0 ° C. to obtain a pellet-shaped molding material.
The MFR of this pellet-shaped molding material was 2.4.

Next, using this pellet-shaped molding material, cylinder temperature: 400 ° C., screw rotation speed: 85 rp
m. A mold made of a resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and a molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Tomoki Iron Works Co., Ltd.), and a powdery / granular recycled material having a particle size of 8 mm or less (MFR: 2.
2) was obtained. This recycled material was subjected to foreign matter inspection using a metal detector (KD801AW manufactured by Anritsu Corporation), and then pelletized again under the above conditions to obtain a recycled molding material (MFR: 1.9). .

Next, the recycled material (re-pelletized) obtained by the above method and the original material in which the MFR was 2.4 by changing the molecular weight of the matrix resin in the above pelletized molding material. The weight ratio of recycled material to original material is 100: 0 (Comparative Example 10), 2
5:75 (Comparative Example 11), 50:50 (Comparative Example 12),
75:25 (Comparative Example 13), 0: 100 (Comparative Example 14)
To obtain a cylinder temperature of 400 ° C. and a screw rotation speed of 85 rpm. A No. 1 dumbbell-shaped test piece according to ASTM D638 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) under the condition of mold temperature: 220 ° C. Then, the tensile strength was measured using this test piece, the test piece was dissolved using concentrated sulfuric acid, and the fiber length in the test piece was measured. The results are shown in FIGS. 17 and 18.

Comparative Examples 15 to 19 Polyetherketone resin "VICTR" manufactured by ICI of England
EX PEK 220P "and polyetherimide resin" ULTEM 1000 "manufactured by GE USA were mixed so that the weight ratio of the polyetherketone resin and the polyetherimide resin was 80:20, and then Toho Rayon Co., Ltd. ) Made of Vesphite HTA carbon fiber (fiber length:
6 mm) was dry blended so that the weight fraction of the carbon fiber was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fiber), and the cylinder temperature was 40 using an extruder.
It was extruded under the condition of 0 ° C. to obtain a pellet-shaped molding material.
The MFR of this pellet-shaped molding material was 2.4.

Next, using this pellet-shaped molding material, cylinder temperature: 400 ° C., screw rotation speed: 85 rp
m. A mold made of a resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and a molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Tomoki Iron Works Co., Ltd.), and a powdery / granular recycled material having a particle diameter of 8 mm or less (MFR: 2.
2) was obtained. The recycled material was inspected for foreign matter using a metal detector (KD801AW manufactured by Anritsu Corporation).

Next, the recycled material obtained by the above method and the polyetherketone resin "VIC" manufactured by ICI of England
TREX PEK 220P ", polyetherimide resin" ULTEM 1000 "manufactured by GE, USA, Vesphite HTA carbon fiber (fiber length: 6 mm) manufactured by Toho Rayon Co., Ltd. Carbon fiber weight ratio is 56:14:30
The original material mixed so that the weight ratio of the recycled material is 0% (Comparative Example 15) and 25% (Comparative Example 1).
6), 50% (Comparative Example 17), 75% (Comparative Example 18),
100% (Comparative Example 19), and the mixture was dry-blended, and a cylinder temperature was measured using an extruder:
Extruded molding material at 400 ° C (pellet state
MFR: 1.9) was obtained. The polyetherketone resin, polyetherimide resin, and carbon fiber are the above-mentioned MF.
The same lot as that used for manufacturing the R2.4 original material pellets was used.

Cylinder temperature: 40 using this molding material
0 ° C., screw rotation speed: 85 rpm. , Mold temperature: 2
A No. 1 dumbbell-shaped test piece according to ASTM D638 was obtained using a 75 ton (mold clamping pressure) injection molding machine manufactured by Japan Steel Works, Ltd. under the condition of 20 ° C. Then, the tensile strength was measured using this test piece, the test piece was dissolved using concentrated sulfuric acid, and the fiber length in the test piece was measured. 17 and 1
The result is shown in FIG.

Examples 12 to 14 and Comparative Examples 20 to 21 Polyetherketone resin "VICTR" manufactured by ICI of England
EX PEK 220P "and polyetherimide resin" ULTEM 1000 "manufactured by GE USA were mixed so that the weight ratio of the polyetherketone resin and the polyetherimide resin was 80:20, and then Toho Rayon Co., Ltd. ) Made of Vesphite HTA carbon fiber (fiber length:
6 mm) was dry blended so that the weight fraction of the carbon fiber was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fiber), and the cylinder temperature was 40 using an extruder.
It was extruded under the condition of 0 ° C. to obtain a pellet-shaped molding material.
The MFR of this pellet-shaped molding material was 2.4.

Next, using this pellet-shaped molding material, cylinder temperature: 400 ° C., screw rotation speed: 85 rp
m. A mold made of a resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and a molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Tomoki Iron Works Co., Ltd.), and a powdery / granular recycled material having a particle size of 8 mm or less (MFR: 2.
2) was obtained. The recycled material was inspected for foreign matter using a metal detector (KD801AW manufactured by Anritsu Corporation).

Next, the recycled material obtained by the above method and the original material obtained by changing the molecular weight of the matrix resin in the pelletized molding material so that the MFR was 4.9 were used as recycled materials. The weight ratio with the original material is 0: 100 (Comparative Example 20), 25:75 (Example 1)
2), 50:50 (Example 13), 75:25 (Example 14) and 100: 0 (Comparative Example 21) were mixed, and the cylinder temperature was 400 ° C and the screw rotation speed was 85.
rpm. Mold temperature: 220 ° C, manufactured by Japan Steel Works, Ltd .: 75 tons (clamping pressure) using an injection molding machine, ASTM
A No. 1 dumbbell-shaped test piece conforming to D638 was obtained. The tensile strength was measured using this test piece, the test piece was dissolved using concentrated sulfuric acid, and the fiber length in the test piece was measured. The results are shown in FIGS.

Evaluation Example 4 As is clear from a comparison between FIG. 17 and FIG. 19, Examples 12 to 14 show a large tensile strength when a recycled material is blended. It can be seen that the reduction in strength is greatly reduced. Further, as can be seen by comparing FIG. 18 and FIG. 20, Examples 12 to 14
It can be seen that the fiber length rather increases by blending recycled materials. In FIG. 20, the fiber length is longer than in the case of 100% of the original material, and the behavior seems incomprehensible, but this is because the molding conditions described in Examples and Comparative Examples are targeted for materials with relatively small MFR. This is because there is a circumstance that it cannot be said that it is optimal for an original material having a large MFR, but in any case, it is still possible to reduce the strength reduction by mixing a high MFR material, which is disadvantageous in strength.

Original materials and recycled materials are compatible
Examples, Incompatible Examples In the above-mentioned Examples and Comparative Examples, the same material was used as the recycled material and the original material, but if the both are compatible, the recycled material and the original material need not be the same material. Examples 15 and Comparative Example 22 show examples in which the recycled material and the original material are compatible, and Comparative Examples 23 and 24 show examples in which the recycled material and the original material are incompatible.

Comparative Example 22 Polyetherimide resin "ULTEM" manufactured by GE USA
1000 "and Beth Fight HT manufactured by Toho Rayon Co., Ltd.
A Carbon fiber (fiber length: 6 mm) and the total weight (the sum of the weight of resin and carbon fiber) of the carbon fiber weight fraction is 3
Dry blending was performed so as to be 0%, and the mixture was further extruded using an extruder at a cylinder temperature of 360 ° C. to obtain a pellet-shaped molding material.

Next, using this pellet-shaped molding material, cylinder temperature: 370 ° C., screw rotation speed: 85 rp
m. A mold of resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and the molding die 10 shown in FIG. .

The resin impeller thus obtained was pulverized using a pulverizer (manufactured by Homura Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the recycled material obtained by the above method, polyetherketoneetherketoneketone "ULTRA PEK A3000" manufactured by BASF Germany, and Besfight HTA carbon fiber manufactured by Toho Rayon Co., Ltd. (fiber length) : 6 mm) and the total weight (the sum of the weight of the resin and the carbon fiber) of the carbon fiber is 30% dry blended, and further using an extruder, the cylinder temperature: 400 ℃ conditions Was extruded to obtain a pellet-shaped molding material. At this time, the difference in MFR between the recycled material and the original material was 0.8 (recycled material <
Original material).

Next, the recycled material and the original material were mixed so that the weight ratio was 25:75, and the resin impeller was molded again using the molding conditions, the molding die and the injection molding machine. After that, the sprue of the impeller molded body and the resin pool are cut off, axial hole processing, internal defect inspection (ultrasonic flaw detection), single balancing is performed, and a burst test is performed using a spin tester by incorporating it into a turbocharger.
When the instantaneous breaking rotation speed was measured, it was 197,000 rp
m. Met.

Example 15 Polyetherimide resin "ULTEM" manufactured by GE, USA
1000 "and Beth Fight HT manufactured by Toho Rayon Co., Ltd.
A Carbon fiber (fiber length: 6 mm) and the total weight (the sum of the weight of resin and carbon fiber) of the carbon fiber weight fraction is 3
Dry blending was performed so as to be 0%, and the mixture was further extruded using an extruder at a cylinder temperature of 360 ° C. to obtain a pellet-shaped molding material.

Next, using this pellet-shaped molding material, cylinder temperature: 370 ° C., screw rotation speed: 85 rp
m. A mold of resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and the molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the recycled material obtained by the above-mentioned method, polyetherketoneetherketoneketone "ULTRA PEK A1000" manufactured by BASF Germany, and Vesphite HTA carbon fiber manufactured by Toho Rayon Co., Ltd. (fiber length) : 6 mm) and the total weight (the sum of the weight of the resin and the carbon fiber) of the carbon fiber is 30% dry blended, and further using an extruder, the cylinder temperature: 400 ℃ conditions Was extruded to obtain a pellet-shaped molding material. At this time, the difference in MFR between the recycled material and the original material was 2.5 (recycled material <
Original material).

Next, the recycled material and the original material were mixed so that the weight ratio was 25:75, and the resin impeller was molded again using the molding conditions, the molding die and the injection molding machine. After that, the sprue of the impeller molded body and the resin pool are cut off, axial hole processing, internal defect inspection (ultrasonic flaw detection), single balancing is performed, and a burst test is performed using a spin tester by incorporating it into a turbocharger.
When the instantaneous breaking rotation speed was measured, it was 232,000 rp
m. Met.

Comparative Example 23 Polyethersulfone resin "VICT" manufactured by ICI of England
REX PES 3600P "and Vesphite HTA carbon fiber manufactured by Toho Rayon Co., Ltd. (fiber length: 6 mm)
And were dry-blended so that the weight fraction of the carbon fibers was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fibers), and the cylinder temperature was 360 ° C using an extruder.
It was extruded under the conditions described above to obtain a pellet-shaped molding material.

Next, using this pellet-shaped molding material, cylinder temperature: 350 ° C., screw rotation speed: 85 rp
m. A mold of resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and the molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the recycled material obtained by the above method, polyetherketoneetherketoneketone "ULTRA PEK A3000" manufactured by BASF Germany, and Besfight HTA carbon fiber manufactured by Toho Rayon Co., Ltd. (fiber length) : 6 mm) and the total weight (the sum of the weight of the resin and the carbon fiber) of the carbon fiber is 30% dry blended, and further using an extruder, the cylinder temperature: 400 ℃ conditions Was extruded to obtain a pellet-shaped molding material. At this time, the difference in MFR between the recycled material and the original material was 1.1 (recycled material <original material).

Next, the recycled material and the original material were mixed so that the weight ratio was 25:75, and the resin impeller was molded again using the molding conditions, the molding die and the injection molding machine. After that, the sprue of the impeller molded body and the resin pool are cut off, axial hole processing, internal defect inspection (ultrasonic flaw detection), single balancing is performed, and a burst test is performed using a spin tester by incorporating it into a turbocharger.
When the instantaneous breaking rotation speed was measured, it was 175,000 rp
m. Met.

Comparative Example 24 Polyethersulfone resin "VICT" manufactured by British ICI
REX PES 3600P "and Vesphite HTA carbon fiber manufactured by Toho Rayon Co., Ltd. (fiber length: 6 mm)
And were dry-blended so that the weight fraction of the carbon fibers was 30% with respect to the total weight (the sum of the weight of the resin and the carbon fibers), and the cylinder temperature was 360 ° C using an extruder.
It was extruded under the conditions described above to obtain a pellet-shaped molding material.

Next, using this pellet-shaped molding material, cylinder temperature: 350 ° C., screw rotation speed: 85 rp
m. A mold of resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and the molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the recycled material obtained by the above method, polyetherketoneetherketoneketone "ULTRA PEK A1000" manufactured by BASF Germany, and Besfight HTA carbon fiber manufactured by Toho Rayon Co., Ltd. (fiber length) : 6 mm) and the total weight (the sum of the weight of the resin and the carbon fiber) of the carbon fiber is 30% dry blended, and further using an extruder, the cylinder temperature: 400 ℃ conditions Was extruded to obtain a pellet-shaped molding material. At this time, the difference in MFR between the recycled material and the original material was 2.8 (recycled material <original material).

Next, the recycled material and the original material were mixed so that the weight ratio was 25:75, and the resin impeller was molded again using the molding conditions, the molding die and the injection molding machine. After that, the sprue of the impeller molded body and the resin pool are cut off, axial hole processing, internal defect inspection (ultrasonic flaw detection), single balancing is performed, and a burst test is performed using a spin tester by incorporating it into a turbocharger.
When the instantaneous breaking rotation speed was measured, it was 176,000 rp
m. Met.

Evaluation Example 5 As can be seen by comparing Example 15 and Comparative Example 22,
The present invention is applicable even if the original material and the recycled material are not the same material. However, as is clear from Comparative Example 23 and Comparative Example 24, even if there is a sufficient difference in MFR, the present invention is hard to be realized unless the two are compatible with each other.

When other resin materials are used Example 16 Thermoplastic polyimide "Aurum PL400C" manufactured by Mitsui Toatsu Chemicals, Inc. and Vesphite HTA carbon fiber manufactured by Toho Rayon Co., Ltd. (fiber length: 6 mm) And were dry-blended so that the weight fraction of carbon fiber was 30% with respect to the total weight (the sum of the weight of resin and carbon fiber), and further extruded using an extruder at a cylinder temperature of 420 ° C. A pelletized molding material was obtained.

Next, using this pellet-shaped molding material, cylinder temperature: 420 ° C., screw rotation speed: 85 rp
m. A mold made of a resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and a molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Tomoki Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the recycled material obtained by the above method and the original material having an MFR of 2.2 larger than the MFR of the recycled material (the original material manufactured by the above method using "Aurum PL500C") are used. The recycled material and the original material were mixed so that the weight ratio was 25:75, and the resin impeller was molded again using the molding conditions, the molding die, and the injection molding machine. After that, the sprue of the impeller molded body and the resin pool are cut off, shaft hole processing, internal defect inspection (ultrasonic flaw detection), single balancing are performed, and a burst test is carried out using a spin tester after being incorporated into a turbocharger. When the breaking speed was measured, it was 21
9,000 rpm. Met.

Comparative Example 25 Thermoplastic polyimide “Aurum PL400C” manufactured by Mitsui Toatsu Chemicals, Inc. and Vesphite HTA carbon fiber (fiber length: 6 mm) manufactured by Toho Rayon Co., Ltd. were used as the total weight (resin and carbon). Dry blending so that the weight fraction of the carbon fibers is 30% with respect to the sum of the weight of the fibers), and the mixture was extruded using an extruder at a cylinder temperature of 420 ° C. to obtain a pelletized molding material. .

Next, using this pellet-shaped molding material, cylinder temperature: 420 ° C., screw rotation speed: 85 rp
m. A mold made of a resin impeller 11 was obtained by using an injection molding machine manufactured by Japan Steel Works, Ltd .: 75 tons (mold clamping pressure) and a molding die 10 shown in FIG. .

The resin impeller thus obtained was crushed using a crusher (manufactured by Homura Iron Works Co., Ltd.) to obtain a powdery / granular recycled material having a particle diameter of 8 mm or less. Recycled material is a metal detector (made by Anritsu Corporation: KD801A
Foreign matter inspection was performed using W).

Next, the recycled material obtained by the above method and the original material made of a pelletized molding material are
The weight ratio of recycled material to original material is 25:75
Then, the resin impeller was molded again using the above molding conditions, a molding die and an injection molding machine. After that, the sprue of the impeller molded body and the resin pool are cut off, shaft hole processing, internal defect inspection (ultrasonic flaw detection), single balancing are performed, and a burst test is carried out using a spin tester after being incorporated into a turbocharger. When the breaking rotation speed was measured, it was 189,000 rpm. Met.

Evaluation Example 6 As can be seen from Example 16 and Comparative Example 25, it can be seen that the method of the present invention is also effective for a short fiber reinforced composite material using thermoplastic polyimide as a matrix.

[0172]

As described above, according to the present invention,
A recycled material obtained by crushing a molded product of a short fiber reinforced composite material using a thermoplastic resin as a matrix, and a thermoplastic resin having the same or the same basic molecular structure as or compatible with the thermoplastic resin as the matrix of the recycled material. And a melt flow rate at a molding temperature of 2.16 kgf at a molding temperature of 2.16 kg.
1.5-4.7g than the melt flow rate in kgf
Since a resin molding material is prepared by mixing an original material having a large size of / 10 min, it is possible to obtain a resin molded product having a remarkably small strength decrease by resin molding using such a resin molding material. In particular, a remarkably excellent effect that a resin impeller used under high temperature and high stress can be molded with a molding material containing a recycled material is brought about.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing steps of a typical recycling method.

FIG. 2 is a graph showing the relationship between the MFR of original material pellets and the tensile strength of test pieces molded using the same.

FIG. 3 is an explanatory diagram showing the basic principle of the present invention.

FIG. 4 is an explanatory diagram showing the relationship between the fiber length and the frequency when there are many recycled materials (FIG. 4A) and when there are many original materials (FIG. 4B).

FIG. 5 is a graph showing the relationship between the ratio of recycled materials and the deflection temperature under load.

FIG. 6 is a graph showing the relationship between the load stress and the time required until breakage in the case of 25% recycled material and 100% original material.

FIG. 7 is an explanatory diagram showing a molten state of a pulverized material.

FIG. 8 is an explanatory diagram showing a molten state of pellet material.

FIG. 9 is an explanatory diagram showing a molten state of a mixed material of a pulverized material and a pellet material.

FIG. 10 is an explanatory diagram showing a fiber breakage condition when a molding material having a large MFR is filled in a mold.

FIG. 11 is an explanatory diagram showing a fiber breakage condition at the time of filling a mold with a molding material having a small MFR.

FIG. 12 is a cross sectional explanatory view showing an example of a molding die for injection molding of a resin impeller.

FIG. 13 is a perspective view of a resin impeller.

Figure 14: MF of original material mixed with recycled material
It is a graph which illustrates the relationship between R and the instantaneous breaking rotation speed of a resin impeller.

FIG. 15 is a graph illustrating the relationship between the difference between the MFR of a recycled material and the MFR of an original material mixed with this recycled material, and the instantaneous breaking rotation speed of a resin impeller.

FIG. 16 is a graph illustrating the relationship between the blending ratio of recycled material and the instantaneous breaking rotation speed of a resin impeller.

FIG. 17: Mixing ratio of recycled materials and molded products (test pieces)
3 is a graph illustrating the relationship with the tensile strength of the.

FIG. 18: Mixing ratio of recycled materials and molded products (test pieces)
It is a graph which illustrates the relationship with the average fiber length in the inside.

FIG. 19: Recycled material mixture ratio and molded product (test piece)
3 is a graph illustrating the relationship with the tensile strength of the.

FIG. 20: Mixing ratio of recycled materials and molded products (test pieces)
It is a graph which illustrates the relationship with the average fiber length in the inside.

[Explanation of symbols]

 11 Resin impeller

Claims (2)

[Claims] 1. A recycled material obtained by crushing a molded product of a short fiber reinforced composite material using a thermoplastic resin as a matrix, and the same or the same basic molecular structure or compatibility as the thermoplastic resin as the matrix of the recycled material. It is composed of a short fiber reinforced composite material using a possible thermoplastic resin as a matrix, and has a melt flow rate at a molding temperature of 2.16 kgf under a load of 2.16 kgf than that of the recycled material at a molding temperature of 2.16 kgf. A method for preparing a resin molding material, which comprises mixing an original material having a large size of 5 to 4.7 g / 10 min. 2. A recycled material obtained by crushing a molded product of a short fiber reinforced composite material using a thermoplastic resin as a matrix, and the same or the same basic molecular structure or compatibility as the thermoplastic resin as the matrix of the recycled material. It is composed of a short fiber reinforced composite material using a possible thermoplastic resin as a matrix, and has a melt flow rate at a molding temperature of 2.16 kgf under a load of 2.16 kgf than that of the recycled material at a molding temperature of 2.16 kgf. A fiber-reinforced resin impeller characterized by being molded into an impeller shape with a resin molding material in which a large original material of 5 to 4.7 g / 10 min is mixed.