JPWO2013099993A1 - Injection molded product using prepreg and its manufacturing method - Google Patents

Abstract

The present invention relates to a low-priced, mass-produced injection molded product in which a synthetic resin is injection molded to a prepreg. When the prepreg 2 is laminated, the coating layer 4 is laminated through an adhesive layer to form a bonded body 5, and the bonded body 5 is inserted into an injection mold and injection molding is performed with a synthetic resin that becomes the mechanical component 7. It is characterized by. That is, in the first step, a laminated body in which a coating layer is laminated via an adhesive layer is formed on the outer surface side of the laminated prepreg, and in the second step, the laminated body is inserted into a mold of an injection molding machine. Hot press molding is performed, and a synthetic resin serving as a mechanical component is injected onto the inner surface side of the prepreg of the bonded body to form an injection molded product.

Description

  The present invention relates to an inexpensive and mass-produced injection-molded product in which a synthetic resin is injection-molded into a prepreg.

An injection molded product using a sheet in which a carbon fiber sheet (CFRP) or a glass fiber reinforced sheet (GFPR) is impregnated with a semi-cured thermosetting resin such as epoxy is known.
Although the injection molded product using this prepreg is lightweight and has high strength and rigidity, the manufacturing process is complicated, time-consuming, and expensive, so its range of use has been limited.
That is, in the manufacturing process, first, in a first step, a prepreg (a sheet in which a carbon fiber fabric is impregnated with a semi-cured thermosetting resin such as epoxy) is laminated.
In the second step, preforming is performed by hot compression pressing using an autoclave.
In the third step, primer treatment is performed on the preformed prepreg.
Next, in the fourth step, the primer-prepared prepreg is inserted into a mold, and a synthetic resin is injection-molded (insert molding) and integrated into a molded product.
Then, in the fifth step, the molded product is printed, and clear coating is performed to complete the molded product.
As described above, normally, five steps are required to produce a prepreg molded product, which is a laborious and complicated operation.
JP-A-9-272134

This invention was invented in view of the above circumstances, and its main problem is
When the prepreg is laminated, the adhesive layer or adhesive replaced with the primer treatment process and the thermoplastic resin layer with the functional coating replaced with the clear coating treatment process are laminated simultaneously and inserted directly into the injection mold. Then, by performing the heat press molding and the injection molding of the synthetic resin at the same time, it is possible to produce a molded product of the prepreg in only two steps.

In order to solve the problem, the invention of claim 1
A coating layer is laminated on one surface side of the laminated prepreg to form a bonded body, the bonded body is inserted into an injection mold and hot press molded, and a mechanical component is formed on the other surface side of the prepreg. It is characterized by being formed by injection molding a synthetic resin.
Here, the lamination of the prepreg and the coating layer may be performed using an adhesive layer or an adhesive, or using the adhesiveness of the prepreg.
In the invention of claim 3,
The bonded body has a coat layer adhered to one surface side of the laminated prepreg, and an adhesive layer or an adhesive or binder layer is adhered to the other surface side of the prepreg,
The bonded body is inserted into an injection mold and hot press molded, and a synthetic resin that is a mechanical component is injection molded on the adhesive layer, adhesive, or binder layer side.
Here, the other surface side of the prepreg and the adhesive layer may be laminated using an adhesive layer or an adhesive.
In the invention of claim 5,
First step of forming a laminated body in which a coat layer is laminated on one surface side of the laminated prepreg and an adhesive layer or an adhesive or a binder layer is laminated on the other surface side of the prepreg via an adhesive layer or an adhesive. When,
The bonded body is inserted into a mold of an injection molding machine and subjected to hot press molding. At the same time, a synthetic resin serving as a mechanical component is injected onto the adhesive layer or adhesive or binder layer side of the bonded body to produce an injection molded product. And a second step to be formed.
The coat layer has a structure in which a coat film is laminated, and the coat film can be printed.

In the present invention, since only two processes are required, the process and the manufacturing time are greatly shortened, and the following effects can be obtained as compared with the conventional molding method.
(1) Cost merit (2) Mass production response (Lot response according to injection molding)
As a result, it is possible to expand the demand range of prepregs that have been used only for high-end products (for example, aviation, space, energy, etc.) to the low-end (for example, mobile phones, portable PCs, etc.). There is.

It is a schematic diagram which shows the manufacturing process of the injection molded product using a prepreg, (a) shows an independent prepreg and a coating layer, (b) is the process of forming a bonding body, (c) is hot press molding, The process of simultaneously performing injection molding of synthetic resin is shown. It is a schematic diagram which shows the manufacturing process of the injection molded product using a prepreg, (a) shows an independent coat layer, a prepreg, and an adhesive layer or an adhesive agent, (b) is the process of forming a bonding body, (c ) Shows a process of simultaneously performing hot press molding and synthetic resin injection molding.

DESCRIPTION OF SYMBOLS 1 Injection molded product 2 Prepreg 3 Adhesive layer 4 Coat layer 5 Bonding body 6 2nd adhesive layer 7 Synthetic resin used as a mechanism component

  In this invention, a coat layer and an adhesive layer or an adhesive are laminated on a prepreg, and the prepreg is cured into a predetermined shape by simultaneously performing hot press molding and injection molding of a synthetic resin as a mechanical component using an injection mold. The injection molded products using carbon fiber sheets with high strength can be manufactured at low cost and with few manufacturing processes.

Hereinafter, Example 1 of an injection molded product 1 using a prepreg will be described with reference to FIG.
The prepreg 2 is a sheet obtained by impregnating a carbon fiber fabric with a semi-cured thermosetting resin (such as epoxy).
The prepreg 2 is appropriately laminated in accordance with the application.
In this embodiment, a CFRP prepreg is used, but the prepreg is not particularly limited to CFRP.

On one surface side of the laminated prepreg 2, a bonding coat 5 is formed by laminating a functional coat film that provides the adhesive layer 3 and becomes the coat layer 4.
Here, the adhesive layer 3 may be formed by applying an adhesive or by laminating a thermoplastic resin layer.
In this example, PET was used as the functional coat film, but in the present invention, a known coat film or hard coat film can be used.

In this invention, you may use the coat film which consists of prepreg and resin with favorable adhesiveness as a raw material of the coating layer 4, without using the said adhesive layer or an adhesive agent, for example.
In that case, the use of the adhesive layer or the adhesive can be omitted.

The bonded body 5 thus formed is inserted into a mold of an injection molding machine (not shown).
Under the present circumstances, one surface side (coat film sticking side) of the said bonding body 5 is arrange | positioned at the inner wall surface of the side by which the resin of a metal mold | die is not inject | emitted.

And the synthetic resin 7 used as a mechanism component is inject | poured and integrated with the said bonding body 5 by the other surface side (side opposite to the coating film sticking side) of the said bonding body 5 with an injection molding machine.
That is, in the mold, simultaneously with the injection molding of the synthetic resin, the bonding body 5 is hot press-molded by a hot press process, and is integrated with the synthetic resin 7 which is injection-molded simultaneously with the pressing of the bonding body 5. .

Thereby, the injection-molded product 1 having a desired shape using the prepreg can be manufactured.
In this embodiment, the mold temperature used for hot press molding was in the range of 100 ° C. to 150 ° C., but it can be set to an appropriate temperature even if it is outside the above range depending on the type of resin to be injected.
The condition for curing the prepreg was 3 minutes and 40 kgf, but this condition is only an example, and is not particularly limited in the present invention.

As described above, in this example, an adhesive is applied to the laminated prepreg (an adhesive layer is interposed), or a coat film is laminated using the adhesive property of the prepreg to form a bonded body, By inserting and pressing the bonded body into the mold of an injection molding machine, and simultaneously injection molding the synthetic resin, which is a mechanical component, into a desired shape, an injection molded product using a carbon fiber sheet can be obtained in a short time by two processes. Can be produced.
In the illustrated example, the synthetic resin as the mechanical component is illustrated as being bonded to the entire area along the other surface of the prepreg 2. However, in the present invention, the injection molding is performed beyond the other surface of the prepreg 2. Or may be formed by injection molding on a part of the other surface of the prepreg 2.

Example 2 of an injection molded product 1 using a prepreg will be described with reference to FIG.
The point of laminating the functional coat film to be the coat layer 4 on the one surface side of the laminated prepreg 2 is the same as that of the first embodiment, and the description thereof is omitted.
Further, a second adhesive layer 6 is integrally formed on the other surface side of the prepreg 2 to form a bonded body 5.
The adhesive layer 3 and the second adhesive layer 6 may be applied with an adhesive or may be formed by laminating a thermoplastic resin layer.
Further, a known binder layer may be provided in place of the second adhesive layer 6.

In Example 2, a resin compatible with the molding material was used for the adhesive layers 3 and 6.
The bonded body 5 thus formed is inserted into a mold of an injection molding machine (not shown).

At this time, the coated film application side of the bonded body 5 is arranged on the inner wall surface on the side where the resin of the mold is not injected, and the synthetic resin 7 serving as a mechanical component is injected on the second adhesive layer 6 side, and the bonded body 5 is injected. And integrated.
That is, in the mold, simultaneously with the injection molding of the synthetic resin, the bonded body 5 is hot press molded by a hot press process, and the synthetic resin 7 that is injection molded simultaneously with the pressing of the bonded body 5 is integrated. Is called.

As described above, in this embodiment, the coat film 4 is adhered to one surface side of the laminated prepreg 2 via the adhesive layer 3, and the adhesive layer 3 or adhesive is adhered to the other surface side via the second adhesive layer 6. The step of laminating the agent to form the bonded body 5, and inserting and pressing the bonded body 5 into the mold of the injection molding machine, and at the same time, injection molding the synthetic resin to be a mechanical part into a desired shape 2 An injection molded product using a carbon fiber sheet can be manufactured in a short time by the process.
Since other configurations are the same as those of the first embodiment, the description thereof is omitted.

In any of the embodiments, printing on a molded product can be performed by printing on the hard coat film or the coat film in advance, so that the step of printing after molding can be omitted.
Although the gravure printing is used as the printing method, the method is not particularly limited, such as offset printing, screen printing, and digital printing.
Thereby, it is not necessary to perform the printing process independently.
In addition, the present invention is not limited to the above-described embodiments, and various design changes can be made without departing from the scope of the invention.

Claims (7)

  A coating layer is laminated on one surface side of the laminated prepreg to form a bonded body, and the bonded body is inserted into an injection mold and subjected to hot press molding, and a mechanical component is mounted on the other surface side of the prepreg. An injection-molded product using a prepreg, which is obtained by injection molding a synthetic resin.   The injection-molded article using the prepreg according to claim 1, wherein the lamination of one surface side of the prepreg and the coat layer is performed by using an adhesive layer or an adhesive. The bonded body has a coat layer bonded to one surface side of the laminated prepreg, and an adhesive layer or an adhesive or binder layer is bonded to the other surface side of the prepreg,
The bonded body is inserted into an injection mold and hot press-molded, and a synthetic resin to be a mechanical component is injection-molded on the adhesive layer, the adhesive, or the binder layer side. An injection molded article using the prepreg according to Item 1.   The injection molded product using the prepreg according to claim 1, wherein the other surface side of the prepreg and the adhesive layer are laminated using an adhesive layer or an adhesive.   The injection-molded product using the prepreg according to any one of claims 1 to 4, wherein the coat layer is made of a coat film, and the coat film is provided with a printing layer and a functional coat layer. A first step of laminating a coat layer on one surface side of the laminated prepreg and forming a bonded body in which an adhesive layer or an adhesive or a binder layer is laminated on the other surface side of the prepreg;
The bonded body is inserted into a mold of an injection molding machine and subjected to hot press molding. At the same time, a synthetic resin serving as a mechanical component is injected onto the adhesive layer or adhesive or binder layer side of the bonded body to produce an injection molded product. The manufacturing method of the injection molded product using the prepreg characterized by including the 2nd process to form.   The method for producing an injection-molded product using a prepreg according to claim 6, wherein the coat layer is made of a coat film, and the coat film is printed.

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