JPH09239760A - Production of composite molded object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To remove a sheet part from the surface of a resin molded object with respect to a part where the sheet is unnecessary simultaneously with the lamination of the sheet to the surface of the resin molded object by constituting the shear parts by both molds at a part cutting a perforated fiber reinforced thermoplastic resin sheet. SOLUTION: A resin molded object 1 integrally provided with a rib-shaped projection 3 along the peripheral edge of an opening part 2 is set to one mold and a mold having the slide member 4 corresponding to the rib-shaped projection 3 provided to the molding surface thereof is set to other mold 6. A perforated sheet 18 is placed on the molding surface of the other molded object 6 while held to a heated state and the resin molded object 1 is arranged on the upper surface thereof so that the rib-shaped projection 3 is opposed to the perforated sheet 18. The outer peripheral surface of the rib-shaped projection 3 and the inner peripheral surface of the slide member 4 become shear surfaces by the mold clamping of both molds 1, 6 and the perforated sheet 18 is cut by the shearing force by the shear surfaces.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing a composite molded body.

[0002]

2. Description of the Related Art Since a porous fiber-reinforced thermoplastic resin sheet is lightweight and excellent in strength, it can be used as a soundproof material for automobile engine covers (Japanese Patent Laid-Open No. 6-156161), a heat insulating member and an interior material. It is widely used for home appliances, building materials, etc., but such a porous fiber reinforced thermoplastic resin sheet is usually used as a composite molded product that is combined with a resin molded product for attachment to other members. in use.

In such a composite molded body, a resin part as a base material and a porous fiber-reinforced thermoplastic resin sheet are usually molded in a desired shape in advance, and then the both are bonded and integrated with an adhesive or the like. Being manufactured. But,
In the case of such a method, a molding die for that is required for each, and the process is lengthened.
There is a problem that the cost becomes high in terms of time and process. In addition, when such a composite molded body is attached to another member, the porous fiber-reinforced thermoplastic resin sheet is only peeled off from the resin molded body which is the base material only in the mounting portion, or the base material itself. In the case where there is an opening, there is a problem that the work efficiency is remarkably inferior because the work such as cutting out the porous fiber-reinforced thermoplastic resin sheet portion covering the opening is required.

[0004]

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention
The present inventors can easily laminate a porous fiber-reinforced thermoplastic resin sheet on the surface of a resin molded body, and at the same time, exclude the sheet portion from the surface of the molded body for the portion where the sheet is unnecessary. Has an opening, it is intended to produce a composite molded body in which a porous fiber-reinforced thermoplastic resin sheet is laminated on a part of the surface of the resin molded body so that the opening is not covered with the sheet portion. As a result of the examination, the present invention has been achieved.

[0005]

According to the present invention, a porous fiber-reinforced thermoplastic resin sheet which is in a softened state by heating is supplied between a pair of molding dies having a resin molded body as one of the dies, Both molds are clamped so that at least a part of the sheet has a thickness not more than the sheet thickness before the supply, and a desired part of the sheet is partially cut, and at the same time, a part of the surface of the resin molded article has a residual porosity. A method for producing a composite molded body, which comprises laminating and integrating a fiber-reinforced thermoplastic resin sheet, wherein a shearing portion is formed by both molding dies at a portion where a porous fiber-reinforced thermoplastic resin sheet is cut, In the shear portion, the shear surfaces of both molds contact each other, or the shear surface of the molding die made of a resin molding overlaps with the shear surface of the other molding die so that the shear surface is scraped off during mold clamping to form the shear. A porous fiber-reinforced thermoplastic resin sheet is formed on a part of the surface of a resin molded body, characterized in that both molding dies are formed and / or arranged, and the sheet is partially cut by the shear portion at the time of mold clamping. It is intended to provide a method for producing a laminated composite molded body.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION A composite molded article for the purpose of the present invention is a molded article in which a porous fiber-reinforced thermoplastic resin sheet is laminated on a part of the surface of the resin molded article. In a composite in which a part or all of the above is laminated with a porous fiber-reinforced thermoplastic resin sheet, for the portion where the sheet is unnecessary in the portion laminated with the sheet, the sheet is a portion from the surface of the molded body. When the resin molded body has an opening in the portion where the sheet is laminated, the composite molded body having a structure in which the sheet is excluded from the opening. Is.

In the method of the present invention, the resin molding itself on which the porous fiber-reinforced thermoplastic resin sheet is to be laminated is used as one molding die, and the resin constituting the resin molding is extruded, Used in injection molding, press molding, etc., such as polyethylene, polypropylene, polystyrene, acrylonitrile / styrene / butadiene copolymer, polyvinyl chloride, polyamide, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, polyphenylene ether, styrene / acrylonitrile copolymer. Polymers, general thermoplastic resins such as acrylic resins, mixtures thereof, polymer alloys using these thermoplastic resins or modified products thereof, and thermosetting resins used for SMC and the like are used. Purpose, Intensity demanded, light weight, be appropriately chosen depending on the heat resistance, bonding between the porous fiber-reinforced thermoplastic resin sheet, molding costs, thermoplastic resin in consideration of formability and the like. The resin may contain organic or inorganic fibers or metal fibers, or may contain a filler such as talc or mica, and, of course, contains various compounding agents usually used. It may have been done.

The porous fiber-reinforced thermoplastic resin sheet of the present invention is not particularly limited as long as it is a porous sheet having a large number of continuous voids in the fiber-reinforced thermoplastic resin sheet reinforced with reinforcing fibers. However, for example, (1) piercing a plurality of strand-shaped reinforcing fibers with a needle,
A sheet-shaped molding material obtained by laminating a thermoplastic resin on a mat-like strand reinforcing fiber in which the fibers are entangled with each other, and heating and pressurizing this. (2) A sheet-shaped molding material obtained by applying a molten thermoplastic resin to a reinforcing fiber bundle and applying pressure. (3) Disperse the powdered resin in the reinforcing fiber, heat it,
Sheet-shaped molding material obtained by pressing. (4) Sheet-like molding material obtained by heating and pressurizing a nonwoven material obtained by papermaking from a suspension obtained by uniformly dispersing and mixing reinforcing fibers and thermoplastic resin powder in water (papermaking method fiber-reinforced thermoplastic Resin sheet). By heating various sheet-shaped molding materials such as
This can be expanded in the thickness direction of the raw material sheet to obtain a porous sheet having a high porosity, but in addition to the dispersibility of the resin and the reinforcing fibers and the freedom of the mixing ratio, the expansion ratio is high and the porosity is higher. A porous fiber-reinforced thermoplastic resin sheet obtained from the fiber-reinforced thermoplastic resin sheet produced by the papermaking method is suitable because a highly porous fiber-reinforced thermoplastic resin sheet can be easily obtained.

Examples of the reinforcing fibers used in such a fiber-reinforced thermoplastic resin sheet include metal fibers such as stainless steel fibers, inorganic fibers such as glass fibers and carbon fibers, organic fibers such as aramid fibers, and mixed fibers thereof. Is selected according to the required characteristics,
In particular, glass fibers are most preferably used because they are low in cost, and have high soundproofing, high heat insulating performance and reinforcing effect.
In such reinforcing fibers, fibers having a fiber diameter of 1 to 50 μm and a length of 3 to 50 mm, particularly 5 mm or more are preferably used. Further, the reinforcing fiber content in the fiber-reinforced thermoplastic resin sheet is appropriately selected according to each purpose, but generally, as the reinforcing fiber content decreases, the expansion ratio decreases and the porosity is low. A reinforced thermoplastic resin sheet can be obtained, and when the reinforcing fiber content increases, the expansion ratio increases and a porous fiber reinforced thermoplastic resin sheet with a high porosity can be obtained, but if the content is too large, the mechanical strength decreases. Or the shape retention of itself decreases, so that it is usually in the range of 10 to 70% by weight.
Such a reinforcing fiber may be subjected to a sizing treatment on the fiber surface in order to improve the adhesiveness with the matrix resin at the time of manufacturing the fiber-reinforced thermoplastic resin sheet.

As the matrix resin of the fiber reinforced thermoplastic resin sheet, thermoplastic resins usually used in extrusion molding, injection molding, press molding and the like, for example, polyolefin resins such as polyethylene and polypropylene, polystyrene, acrylonitrile / styrene / butadiene copolymer are used. Polymer, polyvinyl chloride, polyamide, polycarbonate,
General thermoplastic resins such as polyethylene terephthalate, polybutylene terephthalate, polyphenylene ether, styrene-acrylonitrile copolymers, thermoplastic elastomers, mixtures thereof, polymer alloys using these thermoplastic resins, and modified products thereof The thermoplastic resin in the present invention includes all of them. Such a thermoplastic resin may optionally contain various compounding agents that are usually compounded, such as a stabilizer, a pigment, and a filler.

Such a fiber-reinforced thermoplastic resin sheet may be used as it is as a raw material of the present invention, or a thermoplastic resin film may be laminated on its surface, preferably one surface. In this case, the effect of preventing absorption of oil and water when used as a composite, preventing deterioration of properties such as soundproofing and heat insulation, and improving sound absorbing properties of low frequency sound when used as a sound absorbing material, for example. Is high. The material of the thermoplastic resin film used for such purpose is preferably a resin having the same or similar structure as the matrix resin of the sheet in consideration of the adhesiveness with the fiber-reinforced thermoplastic resin sheet, but the adhesiveness is Other resin materials may be used as long as they are good, or a multilayer film in which these are appropriately laminated may be used. The thickness of the film may be sufficient as long as the above effects can be obtained, and is usually 20 to 100 μm.
The range is about m. The fiber-reinforced thermoplastic resin sheet obtained by laminating such a thermoplastic resin film on one surface thereof is usually used in the method of the present invention described later such that the non-film side is the resin molded product surface side.

The method of the present invention will be described below with reference to the drawings. The resin molded body (1) in the present invention serves as a base material of a composite molded body which is a product, and its shape is arbitrary, for example, as shown in FIG. It may be provided, or the main parts may be stepwise as shown in FIGS. 2 and 3, and the openings (2) may be appropriately provided in these main parts.
Here, an opening is provided such that the opening direction is the same as the opening / closing direction of the molding die in the subsequent molding step, and the opening is a porous fiber-reinforced thermoplastic resin sheet (hereinafter, simply referred to as porous). In some cases, it is necessary to provide rib-shaped projections (3) along the peripheral edge of the opening for the purpose of producing a composite molded body that is not covered with the (. (FIGS. 1 and 2) Further, as shown in FIGS. 2 and 3, a resin molding having a vertical wall portion (15) whose surface is perpendicular to the opening / closing direction of the molding die in the molding process. In the case of, by adjusting the shape of the mold vertical wall portion (19) corresponding to this vertical wall portion of the other mold that slides with the vertical wall portion, the porosity in the vertical wall portion of the resin molded body is adjusted. The cut portion of the sheet can be adjusted, and when cutting all or part of the vertical wall portion of the resin molded body, it is not necessary to provide rib-shaped projections on the vertical wall portion of the resin molded body.

When a resin molded body is provided with an opening which is in the same direction as the opening and closing direction of the molding die, and the opening is not covered with a porous sheet, the above-mentioned method is used. The rib-shaped protrusions (3) are usually formed integrally with the resin molded body which is a base material continuously in a plate shape along the periphery so as to surround the opening (2).
This rib-shaped projection serves as a cutting member for cutting the porous sheet between the rib-shaped projection provided on another mold described later and the sliding member (4) forming the shear surface. Required for cutting depending on material properties such as compressive strength and hardness of the resin forming the rib-like projections, type of reinforcing fiber in the porous sheet to be cut, content thereof, type of matrix resin, etc. Thickness (A) and protruding height (B)
It is adjusted to. If the thickness (A) of the rib-shaped protrusions is too thin, the porous sheet cannot withstand the heat and shearing force during cutting,
On the other hand, if the resin molding is too thick, sink marks are likely to be formed on the back surface side (design side) of the rib during the production of the resin molded product, which causes a problem of appearance and a problem of weight increase.
Therefore, the thickness (A) of the rib-like protrusion is generally 1 to
It is preferably about 10 mm. Further, the protruding height (B) of the rib-shaped projection is also related to the sliding length (C) between the rib-shaped projection and the sliding member (4) provided on the other molding die at the time of cutting, and sufficient sliding is achieved. It is decided that the length can be taken. Here, the sliding length (C) is also appropriately selected depending on the physical properties of the material resin, etc. Generally, the harder the material, the shorter the sliding length may be, but it is usually 1 mm or more, preferably 3 mm or more. is there.
(FIG. 4)

When a rib-shaped projection (3) is provided on a resin molding (1) used as one of the molding dies, the rib-shaped projection is provided on the other molding die at a position facing the rib-shaped projection. A sliding member (4) that slides on the outer peripheral surface of the object is provided. (FIG. 5) This sliding member is provided, for example, as a ring-shaped projection so as to surround the outer peripheral surface of the rib-shaped projection in correspondence with the shape of the rib-shaped projection. The inner peripheral surface of the member may be provided so that the gap between the two surfaces becomes zero when the mold is clamped, that is, the both surfaces are in complete contact with each other. In order to reduce the inner peripheral shape, for example, the inner peripheral diameter of the sliding member is smaller than the outer peripheral diameter of the rib-shaped projection,
The rib-shaped projections may be provided so that the outer peripheral surface and the inner peripheral surface of the sliding member partially overlap with each other. In the method of the present invention, when the molds are clamped together, the outer peripheral surface of the rib-shaped projection and the inner peripheral surface of the sliding member serve as shear surfaces, respectively, and shears are formed. Therefore, the edges of the rib-like protrusions, especially the outer peripheral surface tip and the sliding member tip portion, especially the inner peripheral surface tip, are formed at right angles or acute angles with respect to their respective height directions. It is preferable to keep it in advance, and when each of the leading ends is rounded, the porous sheet becomes difficult to cut. In particular, the edge portion of the sliding member is always kept in a sharp state, and for this reason, it is preferable that the sliding member is made of a material having high hardness, such as steel or ceramic.

Here, when the sliding member in the other molding die is made of a material having a very high hardness as described above, and the material of the rib-shaped projection is also relatively hard, the rib-shaped projection is used. Since the porous sheet is relatively easily cut due to the shear formed by the outer peripheral surface of and the inner peripheral surface of the sliding member, the gap between both surfaces should be as small as possible, preferably zero. The rib-shaped protrusions and the sliding member are provided so that they completely contact each other. However, if the rib-shaped protrusion material has low compressive strength and is easily deformed,
The rib-shaped protrusion is provided so that the outer peripheral surface thereof and the inner peripheral surface of the sliding member partially overlap with each other. In this case, the porous sheet is cut while the inner peripheral surface of the sliding member scrapes off the overlapping portion of the outer peripheral surface of the rib-shaped projection as the molding dies are compressed. The overlapping width at this time is usually 5 mm or less, although it varies depending on the material characteristics of the rib-like protrusions and the sliding member and their thickness.

The sliding member (4) is provided, for example, as a ring-shaped projection so as to surround the outer peripheral surface thereof in accordance with the shape of the rib-shaped projection as described above. The length is not particularly limited as long as the cut porous sheet end material (5) is not extremely compressed at the hole bottom, but the shape of the hole from a position deeper than the sliding position of the rib-shaped projection with the outer peripheral surface. If the hole is made large and processed so that the hole is communicated with the outside of the mold, the cut porous sheet end material can be easily taken out of the mold. When the sliding member is provided as a ring-shaped protrusion, the width of the sliding member is such that the inner peripheral surface of the sliding member forms a share with the outer peripheral surface of the rib-shaped protrusion and the porous sheet is cut. There is no limitation as long as it does not bend or break. In this sense, the inner peripheral surface may be provided with a recess corresponding to this without providing a ring-shaped projection as the sliding member. In this case, the ring-shaped projection is provided. The protruding length of the rib-shaped projections may be adjusted appropriately as compared with the case where the rib-shaped projections are provided.

Hereinafter, in the case of producing a composite molded body in which an opening is provided in the resin molded body in the same direction as the opening and closing direction of the molding die and the opening is not covered with the porous sheet (18). Will be specifically described. 5 to FIG.
The resin molded body (1) integrally provided with the rib-shaped projections (3) along the peripheral edge of the opening (2) is used as one molding die, and a sliding member corresponding to the rib-shaped projections ( Composite molding in which a porous sheet is laminated on a part of the surface of the resin molded body (1) using a pair of molding dies in which the molding dies 4) provided on the molding surface are other molding dies (6) This is an example of manufacturing the body (7). On the molding surface of another molding die (6), a porous sheet expanded in the thickness direction of the raw material sheet by heating is placed while maintaining a heated state, and a resin molding is provided with rib-shaped projections on the upper surface thereof. Place it so that it faces the seat.
(FIG. 5) The heating of the raw material sheet at this time is performed at a temperature not lower than the melting temperature of the thermoplastic resin that is the matrix resin to such an extent that the sheet shape can be maintained. However, the porous sheet expands in the thickness direction up to about 2 to 10 times. When supplying the porous sheet, the rib-shaped projections (3) provided on the resin molded body (1) and the sliding member (4) provided on the other molding die (6) should not be displaced. It is necessary to ensure the positions of the resin molded body and other molding dies, and in particular, to bring them close to each other and to slide the outer peripheral surface of the rib-shaped projection and the inner peripheral surface of the sliding member without causing positional displacement. In order to move and cut the porous sheet at the shear surface, a resin molded body is fixed to a holding member (8) corresponding to its shape, and this holding member is movable in the opening / closing direction of the molding die. It is preferably attached to a device or the like.

The holding member (8) is not particularly limited in its holding method as long as it can hold the resin molded body. For example, a method of vacuum suction, a method of holding the outer periphery with an air cylinder or the like can be used. A simple method of simply fitting the body with frictional resistance or the like may be used. If the resin molded body has an opening, a protrusion that can be closely fitted to the opening is provided on the holding member so that the rib-shaped protrusion has an outer peripheral surface and a sliding member of another molding die. The rib-shaped projections may be prevented from falling or breaking inside the opening due to sliding with the peripheral surface, or the cut porous sheet end material (5) may be prevented from entering the opening. . After supplying the porous sheet that is in a softened state by heating, the outer peripheral surface of the rib-shaped projections of the resin molded body is a sliding member of another molding die as soon as possible in order to reduce the temperature drop of the sheet. While rubbing against the inner peripheral surface of the rib-shaped projection, or scraping off the outer peripheral surface of the rib-shaped projection at the inner peripheral surface of the sliding member, and at that time Either or both molds are moved in the mold clamping direction and compressed so that the porous sheet is cut at the contact points on the peripheral surface. (FIG. 6) The pressing force (compressive force) at this time varies depending on the porosity of the porous sheet in the desired composite molded body, the presence or absence of a hollow portion between the resin molded body and the porous sheet, the gap, and the like. However, it is necessary that at least the porous sheet is cut, and that a part or all of the porous sheet is in close contact with and firmly bonded to the resin molded body. Therefore, the pressing force of the entire porous sheet is weakened to keep the porosity of the porous sheet high, and the main part of the porous sheet is a hollow portion between the resin molded body and the porous sheet without exerting a compressive force. When it is desired to form a groove, for example, the height of the protrusion of the sliding member is increased, and the residual porous sheet surrounding the outer peripheral surface of the rib-shaped protrusion is compressed into a resin molded body at the tip of the sliding member. The porous sheet may be firmly joined to the resin molded body at this portion, or in the case of a box-shaped molded body, the side wall inner wall (9 ) And the outer peripheral portion (10) of another molding die, the shear clearance between the molding dies is made narrower than the thickness of the supplied porous sheet, and the porous sheet is sandwiched and compressed at the clearance portion to form a resin. Body side wall inner wall (9)
You may join by a part. (FIG. 6)

In any of these cases,
As shown in FIG. 6, when it is desired to further increase the bonding strength of the porous sheet to the resin molded body, a pin-shaped protrusion (1
1) is provided, and the pin-shaped projections are pierced into the porous sheet at the time of molding, so that the porous sheet is clung to the projections or partially heat-sealed, and the bonding strength is provided through the pin-shaped projections. May be improved. When the pin-shaped protrusions (11) are provided, the length thereof is such that at least a length capable of being pierced into the porous sheet at the time of molding, preferably at least half the thickness of the porous sheet, and depending on the case Providing a pin-shaped protrusion with a length longer than the distance between the inner surface of the resin molded body and the outer surface of the porous sheet when molding is completed, the tip of the extra pin-shaped protrusion is crushed by a compressive force at the time of molding to make it porous. Alternatively, the porous sheet may be embedded in the resin sheet, and the porous sheet may be more firmly bonded to the resin molded body via the pin-shaped protrusions.

By such a method, the clearance between the lower surface of the resin molded body and the molding surface of the molding die is set to be equal to or less than the thickness of the porous sheet which is in a softened state by the supplied heating, and thus the resin molded body is formed. A composite in which the porous sheet and the porous sheet are closely adhered to each other is obtained, and the clearance between the two is made equal to or larger than the thickness of the porous sheet in a softened state by the supplied heating, thereby forming an air layer between the resin molded body and the porous sheet. (Hollow part) (12) can be provided. Further, the clearance may be partially changed, or the molding surface of the resin molded body or the molding die may be provided with irregularities, whereby the thickness of the porous sheet may be partially changed or an air layer may be provided.
When the hollow part (12) is provided, in order to maintain the space between the surface of the porous sheet on the hollow part side and the surface of the resin molded product,
It is effective to preliminarily provide the resin molded body with a raised gap-holding material (13) having a relatively flat tip end portion that comes into contact with the porous sheet. In this case, the gap retaining material (13) may have a continuous plate-like protrusion, or may have a circular or angular pedestal shape. In addition, such a pedestal is provided at the base of the resin molded body of the pin-shaped protrusion (11), and as a pin-shaped protrusion with a pedestal, the portion from the tip of the pin-shaped protrusion to the pedestal is pierced into the porous sheet to make it porous. The adhesiveness with the flexible sheet may be improved, and the pedestal portion may act as a gap holding material.

The above description is directed to an example of manufacturing a composite molded body in which an opening is provided in the resin molded body so as to be in the same direction as the opening / closing direction of the molding die, and the opening is not covered with the porous sheet. However, as shown in FIG. 8, the main part has a staircase shape, and the horizontal part (14) of the staircase part is formed.
In the above, the porous sheet is laminated, but the composite molded body in which the laminated sheet is excluded from the vertical wall portion (15) can be basically manufactured in the same manner as above.

In this case, the vertical wall portion (15) of the resin molded body as the base material corresponds to the rib-shaped projection described above,
The mold vertical wall portion (19) of another mold corresponding to the vertical wall portion corresponds to the sliding member. Therefore, also in this case, the clearance between the vertical wall portion (15) of the resin molded body and the mold vertical wall portion (19) of the other molding die is as small as possible, preferably zero, or depending on the resin molded body. Is designed so that the vertical wall of the resin molding partially covers the mold vertical wall of the other molding die, and the mold vertical wall of the other molding die scrapes the surface of the vertical wall of the resin molding during mold clamping. The porous sheet is cut. still,
The vertical wall portion of the resin molded body is not limited to the one located inside the resin molded body, and may be the outermost wall of the resin molded body. In this case, the other mold outer peripheral portion (10) corresponds to the mold vertical wall portion (19) of the above other mold.

In this method, in order to improve the cuttability of the porous sheet or to enhance the bondability of the porous sheet to the resin molded body in the horizontal portion continuous with the vertical wall portion, the mold opening / closing direction is changed. A continuous rib-shaped or discontinuous pin-shaped projection (16) is provided in the lower part of the vertical wall portion, and the projection enhances contact with the mold vertical wall portion of another molding die, or the tip of the projection is porous. The sheet can be pierced or compressed to firmly bond the porous sheet to the resin molding through the protrusion. Similarly, a continuous rib-shaped projection or a discontinuous pin-shaped projection (17) is provided on the molding surface side of the end of the vertical wall portion of another molding die, and the porous sheet is resin-molded at the tip of the projection. It can also be compressed more strongly to the body than elsewhere, for a stronger bond. Of course, both such protrusions (16, 17) may be provided, or only one of them may be provided. The thickness and height of such a protrusion are the same as those of the rib-like protrusion (3) and the sliding member (4) described above, but the protrusion (16) is formed on the lower portion of the vertical wall portion (15) of the resin molded body. In the case of providing, the thickness of the protrusion is usually the same as the thickness of the vertical wall portion, and is often provided as an extension of the vertical wall. In this case, an opening may be provided in the vertical wall portion of the resin molded body.

[0024]

According to the method of the present invention, a porous fiber-reinforced thermoplastic resin sheet is easily laminated on the surface of a resin molded body, and at the same time, the sheet portion is removed from the surface of the molded body for the portion where the sheet is unnecessary. If the resin molding has an opening, the porous fiber-reinforced thermoplastic resin sheet is laminated on a part of the surface of the resin molding so that the opening is not covered by the sheet portion. It is possible to manufacture a composite molded body.

[0025]

EXAMPLES The present invention will be described in more detail with reference to the following examples, but it goes without saying that the present invention is not limited thereto.

Example 1 Using glass fiber reinforced polypropylene resin (GHH43: manufactured by Sumitomo Chemical Co., Ltd.), a box-shaped resin molded body having a thickness of 3 mm was obtained by an injection molding method. This resin molding has a circular opening with a diameter of 80 mm in its flat surface and a wall thickness of 4 mm and a height of 8 mm along the periphery of the opening as shown in FIG.
mm ring-shaped rib-like protrusions (outer diameter 88 mm) are provided, and a flat surface between the side wall and the opening has a diameter of 6 mm.
mm, height 10 mm, and two pin-shaped protrusions having conical tips. This resin molded body is held by a holding member having a protrusion that can be closely fitted to the opening of the resin molded body as shown in FIG. 5 to form a molding die. At a position corresponding to the ring-shaped rib-shaped projection of the resin molding on the molding surface of the other molding die that is arranged opposite to this, a wall thickness of 2 mm that surrounds the outer peripheral surface of the rib-shaped projection. , Inner diameter 86m
m, a sliding member made of steel, which is a ring-shaped protrusion having a height of 8 mm from the molding surface, is provided. Fabrication method fiber-reinforced thermoplastic resin sheet with a basis weight of 2000 g / m ² in which a nylon film is laminated on one surface (Capilla Sheet Co., Ltd., matrix resin: polypropylene, reinforcing fiber: glass fiber, glass fiber content: 62% by weight, Thickness 1.8m
m) is heated with a far-infrared heater until the surface temperature reaches 210 ° C., and the porous sheet that has been softened and expanded to a thickness of about 12 mm is in an open state so that the nylon film side is the molding surface side. It was placed on the molding surface of the other mold between the resin molded body and the other mold (lower mold in the figure). (FIG. 5) Immediately after that, the resin molded body held by the holding member is lowered to bring the resin molded body and the porous sheet close to each other, and the clearance between the pin-shaped projection side surface of the resin molded body and the molding surface of the molding die is made. The descent of the resin molding is stopped at a position of 10 mm, the outer peripheral surface of the rib-shaped projection is scraped off by the inner circumference of the ring-shaped rib-shaped projection of another molding die, and the opening sandwiched between them is formed. The porous sheet was cut, and at the same time, the pin-shaped projection was pierced into the porous sheet, and the conical portion at the tip of the pin-shaped projection was crushed and embedded in the porous sheet. (FIG. 6) At this time, the shear clearance formed by the inner surface of the vertical wall (side wall) of the resin molded body and the outer peripheral surface of the other molding die was set to 5 mm. While maintaining this state, the porous member was cooled and then the holding member was raised to obtain a composite molded body. (FIG. 7) The thickness of the porous sheet of the obtained composite molded article was 10 mm, the porous sheet was cut completely through the opening of the resin molded article, and the porous sheet was made of resin. It was also joined to the molded body.

Example 2 Using the same glass fiber reinforced polypropylene resin (GHH43 manufactured by Sumitomo Chemical Co., Ltd.) used in Example 1, a thickness of 3 was used.
A step-shaped box-shaped resin molded body of mm was obtained. This resin molding has a two-stage structure as shown in the cross section of FIG. 2, and the distance between the outer surfaces of the upper surface flat portion and the lower surface flat portion is 18 mm. A circular opening having a diameter of 80 mm and a ring-shaped rib-shaped projection (outer diameter 88 mm) having a thickness of 4 mm and a height of 8 mm along the periphery of the opening are formed on the flat portion on the lower surface. Diameter 6
mm, height 10 mm, and one pin-shaped protrusion having a conical tip. Further, on the vertical wall surface between the upper surface and the lower surface, a width of 10 mm at a position 10 mm from the upper end of the vertical wall,
A rectangular opening with a length of 50 mm is provided on the vertical wall,
A plate-shaped continuous protrusion having a width equal to the thickness of the molded body and a height of 8 mm is provided as an extension of the vertical wall. The other molding die (lower mold in the figure) arranged opposite to this also has a two-stage structure on the molding surface corresponding to the resin molding,
At the position corresponding to the ring-shaped rib-shaped projection of the resin molding on the upper molding surface, the thickness is 2 mm, the inner diameter is 86 mm, and the height from the molding surface is 8 mm so as to surround the outer peripheral surface of the rib-shaped projection.
A sliding member made of steel, which is a ring-shaped protrusion of mm, is provided. Further, along the upper edge of the vertical wall of the other mold, a steel plate-like protrusion having a thickness of 2 mm and a height of 8 mm is provided upward, and the outer peripheral surface of the protrusion is formed by molding of the mold. At times, it comes into close contact with the inner surface of the vertical wall portion of the resin molded body. A fiber-reinforced thermoplastic resin sheet having a basis weight of 2000 g / m ² in which a nylon film is laminated on the same side as that used in Example 1 is heated with a far infrared heater until the surface temperature reaches 210 ° C. to be softened. About 12m thick
The porous sheet expanded to m was placed on the molding surface of the other molding die between the resin molding in the open state and the other molding die so that the nylon film side was the molding surface side.
(FIG. 8) Immediately after that, the resin molded body held by the holding member is lowered to bring the resin molded body and the porous sheet close to each other, and the upper and lower flat surface portions of the resin molded body and the upper and lower molding surfaces of other molding dies, respectively. The lowering of the resin molded body is stopped at a position where the clearance becomes 10 mm, and the outer peripheral surface of the rib-shaped projection is scraped off by the inner periphery of the ring-shaped rib-shaped projection of another molding die on the upper surface of the resin molded body. In this way, the porous sheet of the opening sandwiched between them is cut, the pin-shaped projection is pierced into the porous sheet at the lower surface of the resin molded body, and,
The conical portion at the tip of the pin-shaped projection is crushed and embedded in the porous sheet, and further, in the vertical wall portion of the resin molded body, the plate-shaped projection portion provided on another mold is the lower portion of the vertical wall portion. The porous sheet was cut at this portion by sliding closely on the protrusions. (FIG. 9) In this case, the shear clearance formed by the inner surface of the outermost wall of the resin molded body and the outer peripheral surface of another molding die was set to 5 mm. While maintaining this state, the porous member was cooled and then the holding member was raised to obtain a composite molded body. (FIG. 10) The thickness of the porous sheet of the obtained composite molded body was 10 mm, and the porous sheet was cut to completely penetrate the opening portion provided in the flat surface portion of the upper surface of the resin molded body, Further, the porous sheet was not joined to the central vertical wall portion, and the opening portion was also penetrated.

Example 3 Using the same glass fiber reinforced polypropylene resin (GHH43 manufactured by Sumitomo Chemical Co., Ltd.) used in Example 1, a thickness of 3 was used.
A step-shaped box-shaped resin molded body of mm was obtained. As shown in the cross section of FIG. 3, this resin molded body has a two-step structure, and the distance between the outer surfaces of the flat surface portion of the upper surface and the flat surface portion of the lower surface is 23 mm. A circular pedestal having a diameter of 30 mm and a height of 10 mm and a pin-shaped protrusion having a conical tip with a diameter of 6 mm and a height of 10 mm are provided in the center, and the pedestal and the central vertical wall portion are provided. A plate-shaped gap holding material having a thickness of 2 mm and a height of 10 mm is provided between them. In addition, the flat surface of the lower surface has a diameter of 6 m.
m, height 10 mm, and one pin-shaped protrusion with a conical tip, and on the vertical wall between the upper surface and the lower surface, a width of 10 mm and a length of 50 mm at a position 10 mm from the upper end of the vertical wall. A rectangular opening is provided, and the vertical wall is provided with a plate-shaped continuous protrusion having the same width as the thickness of the molded body and a height of 8 mm as an extension of the vertical wall. The other molding die (lower mold in the figure) arranged opposite to this also has a two-step structure on the molding surface corresponding to the resin molding, and the molding wall of the other molding die Along the periphery of the upper edge, the thickness is 3 mm upward,
A plate-like protrusion made of steel having a height of 13 mm is provided, and the outer peripheral surface of the protrusion comes into close contact with the inner surface of the vertical wall portion of the resin molded body during molding of the molding die. Incidentally, the other molding die at this time is designed so that the cavity clearances between the two flat surface portions of the resin molding die and the corresponding two molding surfaces of the other molding die are different when the molding is completed. . .
A papermaking method fiber reinforced thermoplastic resin sheet having a basis weight of 2000 g / m ² in which a nylon film is laminated on the same side as that used in Example 1 is heated by a far infrared heater until the surface temperature reaches 210 ° C. and softened. And the thickness is about 12 mm
The expanded porous sheet was placed on the molding surface of the other molding die between the resin molding in the open state and the other molding die so that the nylon film side was the molding surface side.
(FIG. 11) Immediately thereafter, the resin molded body held by the holding member is lowered to bring the resin molded body and the porous sheet close to each other,
The cavity clearance between the flat surface portion of the upper surface of the resin molded body and the molding surface of another molding die corresponding thereto becomes 20 mm, and the flat surface portion of the lower surface of the resin molded body and the molding surface of another molding die corresponding thereto At the position where the cavity clearance is 10 mm, the resin molded body is stopped from descending, and a porous sheet having a thickness of about 10 mm is provided on the upper surface of the resin molded body with a gap of about 10 mm due to the gap holding material and the pedestal of the pin-shaped projection. To form a hollow portion, and at the bottom surface of the resin molded body, the porous sheet is compressed to a thickness of 10 mm to be in close contact with the resin molded body, and the pin-shaped protrusions pierce the porous sheet and pin-shaped. The conical portion at the tip of the protrusion is crushed and embedded in the porous sheet, and further, in the vertical wall portion of the resin molded body, the plate-shaped protrusion portion provided on another molding die is located at the lower portion of the vertical wall portion. It was cut porous sheet in the moiety in close sliding contact with the force. (FIG. 12) At this time, the shear clearance formed between the innermost surface of the outermost wall of the resin molded body and the outer peripheral surface of another molding die was set to 5 mm. While maintaining this state, the porous member was cooled and then the holding member was raised to obtain a composite molded body. (FIG. 13) The obtained composite molded article was bonded to a porous sheet having a thickness of about 10 mm on one surface through hollow portions having a distance of about 10 mm,
The other surface was in close contact with the surface of the resin molded body and joined with a porous sheet having a thickness of 10 mm, and the central vertical wall portion separating both surfaces was not joined with the porous sheet, and the opening portion was also penetrated.

[Brief description of drawings]

FIG. 1 is a schematic sectional view of an example of a resin molded body applied to the method of the present invention.

FIG. 2 is a schematic sectional view of an example of a resin molded body applied to the method of the present invention.

FIG. 3 is a schematic sectional view of an example of a resin molded body applied to the method of the present invention.

FIG. 4 is a schematic cross-sectional view showing the relationship between the rib-shaped protrusion and the sliding member in the present invention.

FIG. 5 is a schematic cross-sectional view showing a manufacturing process in the method of Example 1.

FIG. 6 is a schematic cross-sectional view showing a manufacturing process in the method of Example 1.

7 is a schematic cross-sectional view of a composite molded body obtained by the method of Example 1. FIG.

FIG. 8 is a schematic cross-sectional view showing a manufacturing process in the method of Example 2.

FIG. 9 is a schematic cross-sectional view showing a manufacturing process in the method of Example 2.

10 is a schematic cross-sectional view of a composite molded body obtained by the method of Example 2. FIG.

FIG. 11 is a schematic cross-sectional view showing the manufacturing process in the method of Example 3.

FIG. 12 is a schematic cross-sectional view showing the manufacturing process in the method of Example 3.

13 is a schematic cross-sectional view of a composite molded body obtained by the method of Example 3. FIG.

[Explanation of symbols]

 1: Resin molded product 2: Opening part 3: Rib-shaped projections 4: Sliding member 5: Porous sheet end material 6: Other molding die 7: Composite molded product 8: Holding member 9: Side wall inner wall 10: Other Molding die outer peripheral portion 11: Pin-shaped protrusions 12: Hollow portion 13: Gap holding material 14: Resin molded body horizontal portion 15: Resin molded body vertical wall portion 16: Resin molded body protrusion 17: Molded body protrusion 18: Porous sheet 19: Mold vertical wall portion of another molding die A: Thickness of pin-shaped projection B: Length of pin-shaped projection C: Sliding length of pin-shaped projection

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number in the agency FI Technical display location B29L 9:00 (72) Inventor Masuhei Masui 2-27-1, Shinkawa, Chuo-ku, Tokyo Sumitomo Chemical Industrial Co., Ltd. (72) Inventor Satoshi Funakoshi 2-10-1, Tsukahara, Takatsuki City, Osaka Prefecture Sumitomo Chemical Co., Ltd.

Claims (4)

[Claims] 1. A porous fiber-reinforced thermoplastic resin sheet which is in a softened state by heating is fed between a pair of molding dies having a resin molded body as one of the dies, and at least a part of the sheet is fed before feeding. Both molds are clamped so that the sheet thickness becomes equal to or less than the sheet thickness, and a desired portion of the sheet is partially cut, and at the same time, the remaining porous fiber-reinforced thermoplastic resin sheet is laminated on a part of the surface of the resin molded body. A method for producing a composite molded body, which comprises integrating, wherein a shear portion by both molding dies is formed in a portion where a porous fiber-reinforced thermoplastic resin sheet is cut, and the shear portion of both molding dies is formed in the shear portion. Form both molds so that the surfaces are in contact with each other or the shear surface of the molding die made of a resin molding overlaps with the shear surface of the other molding die to form the shear while being scraped off during mold clamping. Of the composite molded body in which a porous fiber-reinforced thermoplastic resin sheet is laminated on a part of the surface of the resin molded body, characterized in that the sheet is partially cut by the shear portion at the time of mold clamping. Production method. 2. A protrusion that forms a shear surface in the mold clamping direction is provided at a position corresponding to the sheet cutting portion of the resin molded body, and the other molding die is provided with the shear surface corresponding to the protrusion. The method for producing a composite molded body according to claim 1, wherein: 3. The method for producing a composite molded article according to claim 1, wherein the overlapping width of the shear surfaces is 5 mm or less. 4. The method for producing a composite molded body according to claim 1, wherein the resin molded body has an opening corresponding to the cut sheet portion.