TW201827203A - 一體成形體及其製造方法 - Google Patents
一體成形體及其製造方法 Download PDFInfo
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- TW201827203A TW201827203A TW106143077A TW106143077A TW201827203A TW 201827203 A TW201827203 A TW 201827203A TW 106143077 A TW106143077 A TW 106143077A TW 106143077 A TW106143077 A TW 106143077A TW 201827203 A TW201827203 A TW 201827203A
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- Prior art keywords
- resin
- molded body
- plate
- bonding
- integrated molded
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Classifications
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- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
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Abstract
一種一體成形體,係有接合樹脂(C)介於單側表面為設計面的板材(A)與構件(B)之間的一體成形體,在構件(B)的內側,板材(A)和構件(B)係以分開的方式配置,板材(A)的外周緣部的至少一部分的區域具有與接合樹脂(C)接合的第1接合部,並且在一體成形體的設計面側的表面的至少一部分,具有板材(A)、構件(B)、及接合樹脂(C)露出的區域。複數個構造體係以高接合強度接合,其接合邊界部具有良好的平滑性,即使成形體具有板材的構成構件,也能夠謀求翹曲減少,實現輕量.薄壁化。
Description
本發明係關於可用作例如個人電腦、OA機器、行動電話等的零件、框體部分的適合輕量、高強度.高剛性且要求薄壁化的用途的一體成形體及其製造方法。
現在,隨著個人電腦、OA機器、AV機器、行動電話、電話、傳真機、家電製品、玩具用品等的電氣.電子機器的可攜化發展,逐漸要求更加小型、輕量化。為了達成該要求,在從外部對構成機器的零件,特別是框體,施加荷重的情況下,必須不會使框體大幅度彎曲而與內部零件接觸而造成破壞,因此在達成高強度.高剛性化的同時,也要求薄壁化。
此外,在與包含強化纖維和樹脂的纖維強化樹脂構造體之外的其他構件,例如框架(frame)構件等進行一體化接合成形而小型輕量化的成形構造體方面,要求沒有翹曲的進一步薄壁化、接合強度的可靠性。
專利文獻1中,記載「第一樹脂成形品、和第二樹脂成形品、和將熔融樹脂注入形成在前述第一樹脂成形品與前述第二樹脂成形品之間的接合部所結合的樹脂接合體」,公開了藉由作成「接合部,係將前述 注入流路的下游開口設為約略中心,具有與前述注入流路的熔融樹脂注入方向具有角度並從前述開口中心向外側擴大的部分」的結構,有「無需選擇接合場所,能夠用少量的注入樹脂有效地確保接合強度」的效果。
然而,專利文獻1的結構,係將使用少量的注入樹脂、以簡單的裝置接合2個樹脂成形品作為目標的結構,就應用於形成以實現薄壁輕量化且抑制翹曲為目的的接合複數個構件的成形體來說,仍有改善的餘地,此外,也沒有作出關於此結構的揭示。
此外,專利文獻2中,記載「將合成樹脂進行射出成形而形成的複數個分割片,透過接合部進行一體化而作成一次中空成形品,藉由將此一次中空成形品裝配在成形模具並進一步將合成樹脂進行射出成形而形成的二次成形部,將前述接合部融接而成的合成樹脂中空成形品」,公開了藉由進行「藉由硬插嵌合來形成接合部」,有「樹脂不會漏至接合部的中空部側,而且接合部的破壞強度優異」的效果。
然而,專利文獻2的結構,主要目的在於:藉由硬插嵌合來將接合部構成為彼此很難脫落,從而即使提高二次射出成形時的成形壓力而接合部的嵌合部分變形,也能防止產生間隙而樹脂從此間隙漏至成形品的中空部側,就應用於形成以實現薄壁輕量化且抑制翹曲為目的的複數個構件的接合成形體來說,仍有改善的餘地,此外,也沒有作出關於其結構的揭示。
此外,專利文獻3中,記載「在複數個樹脂製零件的接合部形成通路,將接合用樹脂填充於通路,從而用接合用樹脂接合複數個樹脂製零件的結構」,進一步地公開了藉由「將突起部設在至少一個樹脂製零件」,有「能夠防止接合用樹脂溢出至通路之外,此外,樹脂製品的外觀不會降低,此外,能夠形成很難產生龜裂、破裂及接合不良的樹脂製品」的效果。
然而,專利文獻3的結構,主要目的在於:防止龜裂、破裂及接合不良,進一步地,防止接合用樹脂溢出,就應用於形成以實現薄壁輕量化且抑制翹曲為目的的複數個構件的接合成形體來說,仍有改善的餘地,此外,也沒有作出關於其結構的暗示。
此外,專利文獻4中,記載「包含纖維強化熱塑性樹脂的材料,在前述電波屏蔽材(a)與前述電波透射材(b)的接著界面具有包含熱塑性樹脂的不織布等的熱塑性樹脂接著層,藉由外插(outsert)射出成形,透過該熱塑性樹脂接著層使電波屏蔽材(a)與電波透射材(b)固著的一體成形體」,公開了有「可得到在維持電波遮蔽性的狀態下並未使無線通訊性能劣化,接合部的剝離強度、量產性優異的電子機器框體」的效果。
然而,在專利文獻4的結構方面,係電波透射材為將形成其的材料射出至配置有電波屏蔽材的模具而形成的方法,因此射出樹脂量變多,在一體成形體為面形狀的板材的情況下,對於降低由樹脂的熱收縮所產生的翹曲仍有改善的餘地。
專利文獻1 日本特開2003-236877號公報
專利文獻2 日本特開平11-179758號公報
專利文獻3 日本特開2000-272014號公報
專利文獻4 日本特開2008-34823號公報
本發明有鑑於這樣的先前技術的問題點,目的在於提供一種一體成形體及其製造方法,該一體成形體係以高接合強度接合複數個構造體,其接合邊界部具有良好的平滑性,即使成形體具有板材的構成構件,也能夠謀求翹曲減少,可達成輕量.薄壁化。
為了解決上述課題,本發明採用以下的手段。即:
(1)一種一體成形體,係有接合樹脂(C)介於單側表面為設計面的板材(A)與構件(B)之間的一體成形體,在前述構件(B)的內側,板材(A)和構件(B)係以分開的方式配置,前述板材(A)的外周緣部的至少一部分的區域具有與前述接合樹脂(C)接合的第1接合部,並且在前述一體成形體的設計面側的表面的至少一部分,具有前述板材(A)、前述構件(B)、及前述接合樹脂(C)露出的區域。
(2)如(1)的一體成形體,其中前述第1接合部係形成為涵蓋前述板材(A)的外周緣部整周。
(3)如(1)的一體成形體,其包含前述板材(A)和前述構件(B)透過前述接合樹脂(C)重疊的區域。
(4)如(1)的一體成形體,其中前述接合樹脂(C)係熱塑性樹脂。
(5)如(1)的一體成形體,其中前述構件(B)係金屬製框架。
(6)如(1)的一體成形體,其中前述構件(B)係包含強化纖維及樹脂的纖維強化樹脂。
(7)如(1)的一體成形體,其中前述構件(B)係在前述構件(B)的至少一部分具有立壁形狀部的框架構件。
(8)如(1)~(7)中任一項的一體成形體,其中前述板材(A)具有由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少一個所構成的構件。
(9)如(8)的一體成形體,其中前述板材(A)具有用包含由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少任一個所構成的構件的皮層包夾芯層的兩表面的夾芯(sandwich)構造,前述芯層係從熱塑性樹脂、發泡體、及包含不連續纖維和熱塑性樹脂的多孔質基材中的任一者中選出。
(10)如(8)的一體成形體,其中進一步在前述板材(A)的外表面設有熱塑性樹脂層(D),並且前述板材(A)和接合樹脂(C)係透過前述熱塑性樹脂層(D)接合。
(11)如(9)的一體成形體,其中在包含前述發泡體、及包含不連續纖維和熱塑性樹脂的多孔質基材中的任一者的前述芯層的一部分,具有前述接合樹脂(C)進入的嵌入部。
(12)如(9)的一體成形體,其中在前述芯層為前述多孔質基材的前述板材(A)的前述第1接合部、與該第1接合部以外的區域之間具有階差部,前述階差部具有相對於前述板材(A)的面內方向10°~90°的傾斜面。
(13)如(12)的一體成形體,其中前述第1接合部中的前述多孔質基材的空隙率比前述第1接合部以外的區域中的前述多孔質基材的空隙率低。
(14)一種一體成形體的製造方法,至少具有以下的步驟[1]及步驟[2]:[1]在具有框架形狀的構件(B)的內側,使至少一部分與前述構件(B)分開地將單側表面為設計面的板材(A)配置在模具內的步驟;[2]將接合樹脂(C)射出成形在前述板材(A)與前述構件(B)的空隙,從而在至少前述板材(A)的外周緣部使前述板材(A)和前述構件(B)接合而一體化的步驟。
(15)如(14)的一體成形體的製造方法,其中從與前述設計面相反的側將接合樹脂(C)射出成形在前述空隙,從而將前述設計面側的一體成形體表面的至少一部分作為前述板材(A)、前述構件(B)及前述接合樹脂(C)露出的區域。
根據本發明的一體成形體及其製造方法的話,則複數個構造體係以高接合強度接合,其接合邊界部具有良好的平滑性,即使成形體具有板材的構成構件,也能夠謀求翹曲減少,實現輕量.薄壁化。
1‧‧‧一體成形體
2‧‧‧板材(A)
3‧‧‧構件(B)
4‧‧‧接合樹脂(C)
5‧‧‧外周緣部
6‧‧‧接合邊界部
7‧‧‧重疊的區域
8‧‧‧立壁形狀部
9‧‧‧熱塑性樹脂層(D)
10‧‧‧皮層
11‧‧‧芯層
12‧‧‧第1接合部
13‧‧‧第1接合部以外的區域
14‧‧‧階差部
15‧‧‧下模具
16‧‧‧上模具
17‧‧‧嵌入部
圖1係顯示本發明的一體成形體的構成構件的板材(A)的一例的斜視圖。
圖2係顯示本發明的一體成形體的構成構件的構件(B)的一例的斜視圖。
圖3係顯示本發明的一體成形體的一例的斜視圖。
圖4係顯示本發明的一體成形體的厚度方向上的剖面的一例的斜視圖。
圖5係顯示本發明的一體成形體的外周緣部附近的接合狀態的一例的放大剖面圖。
圖6係顯示板材(A)係由皮層及芯層所構成的夾芯構造體的情況的本發明的一體成形體的厚度方向上的剖面的一例的斜視圖。
圖7係顯示圖6所示的一體成形體的外周緣部附近的接合狀態的放大剖面圖。
圖8係顯示在板材(A)的單面設有熱塑性樹脂層(D)的本發明的一體成形體的外周緣部附近的接合狀態的一例的剖面圖。
圖9係顯示板材(A)係由皮層及包含發泡體的芯層所構成的夾芯構造體的情況的本發明的一體成形體的厚度方向上的剖面的一例的斜視圖。
圖10係顯示圖9所示的一體成形體的外周緣部附近的接合狀態的放大剖面圖。
圖11係顯示板材(A)係具有階差部的夾芯構造體的情況的本發明的一體成形體的厚度方向上的剖面的一例的斜視圖。
圖12係顯示圖11所示的一體成形體的外周緣部附近的接合狀態的放大剖面圖。
圖13係顯示本發明的一體成形體的製造方法的一例的概略構成圖。
圖14係顯示本發明的一體成形體的構成構件的構件(B)的另一形態的一例的斜視圖。
圖15係顯示本發明的一體成形體的另一形態的一例的斜視圖。
圖16係顯示在板材(A)的單面設有熱塑性樹脂層(D)的本發明的一體成形體的外周緣部附近的接合狀態的一例的剖面圖。
圖17係顯示本發明的一體成形體的另一形態的一例的厚度方向上的剖面的一例的斜視圖。
圖18係顯示本發明的一體成形體的另一形態的一例的斜視示意圖。
圖19係本發明的一體成形體的另一形態的一例的厚度方向上的放大剖面圖。
圖20係先前技術的一體成形體的接合部的概略剖面圖。
以下,針對本發明的實施形態,一邊參照圖式一邊進行說明。又,本發明完全不限於圖式、實施例。
本發明的一體成形體的結構,係有接合樹脂(C)介於單側表面為設計面的板材(A)與構件(B)之間的一體成形體,在前述構件(B)的內側,前述板材(A)和前述構件(B)係以分開的方式配置,前述板材(A)的外周緣部的至少一部分的區域具有與前述接合樹脂(C)接合的第1接合部,並且在前述一體成形體的設計面側的表面的至少一部分,具有前述板材(A)、前述構件(B)、及前述接合樹脂(C)露出的區域的構造。
如圖1~圖3所示,本發明的一體成形體1係分別預先準備好板材(A)2及構件(B)3,藉由接合樹脂(C)4將兩者接合的結構。例如如圖3~圖5所示,配置成以下的結構:接合樹脂(C)4係接合於板材(A)2的外周緣部5的側面部和平面部(稱為第1接合部),進一步地,接合樹脂(C)4和構件(B)3接合(稱為第2接合部),接合樹脂(C)4介於兩者之間。
藉由此結構,即使接合樹脂量減少,也能夠確保接合強度,進一步而言,與以往的在構件(B)的區域射出接合樹脂(C)而與板材(A)一體化的成形方法相 比,能夠大幅地減少樹脂量,可以謀求由樹脂的熱收縮所產生的翹曲的減少。
此外,在本發明中,係使板材(A)2分開地配置在構件(B)3的內側。如將一體成形體1的外周緣部5放大的圖5所示,在構件(B)3的內側配置板材(A)2,例如,板材(A)2和構件(B)3係不具有彼此相接的部位,以隔著接合樹脂(C)4而相向的形式配置。藉此,所射出的接合樹脂(C)4變得容易插入板材(A)2與構件(B)3之間,能夠用較少的接合樹脂量謀求一體成形體1的接合強度的提升,進一步而言,可以藉由減少接合樹脂量來謀求由樹脂的熱收縮所產生的翹曲的減少。
接合樹脂(C)4與板材(A)2及構件(B)3的接合係將接合樹脂(C)4射出成形在板材(A)2與構件(B)3之間,從而隔著接合樹脂(C)4進行接合一體化。對此進行後述。
此外,板材(A)2和接合樹脂(C)4係在板材(A)2的外周緣部5接合。板材(A)2的外周緣部5較佳為設為相對於板材(A)2的一邊長度,從板端部起0.1~15%的長度範圍。更佳為0.5~10%的範圍,進一步較佳為1~5%的範圍。若小於0.1%,則有接合強度降低的情況,若超過15%,則樹脂量增大,有成形時的翹曲惡化的情況。
此外,板材(A)2係側面部面積比底面積小的面形狀,在底面積為50~10000cm2的範圍內,側面部的高度的板材(A)2的板厚較佳為在0.2~20mm的範圍內。更佳為底面積在100~2500cm2的範圍內,板厚在 0.4~10mm的範圍內,進一步較佳為底面積在300~1000cm2的範圍內,板厚在0.6~2mm的範圍內。例如,在如個人電腦的框體,側面部面積比底面積小,所謂的薄壁型直方體形狀中,側面部的面積窄,為了將構件(B)3接合於該部分,需要高接合強度。即使是這樣的形態,藉由採取本發明的接合結構,則即使是窄面積的接合部,也能夠具有高強度,將構件(B)3進行接合。
此外,在本發明中,作成以下的結構:在一體成形體1的設計面側的表面的至少一部分,具有板材(A)2、構件(B)3、及接合樹脂(C)4露出的區域。
先前技術的使用接著劑進行接合的形態,有接著劑滲出的情況,若發生那樣的情況,便不得不將滲出的接著劑除去,此外,對接合的構件間的對位要求非常高的尺寸精度。
相對於此,本發明中,如圖5所示,藉由接合樹脂(C)4位於接合的板材(A)2與構件(B)3之間,以接合樹脂(C)4在那些構件之間露出的方式成形,只要具備一定的尺寸精度的話,便能夠藉由接合樹脂(C)4來容易地進行板材(A)2與構件(B)3之間的接合。圖5中係上方作為設計面側。此外,成為在成形時,在設計面,板材(A)2、接合樹脂(C)4及構件(B)3係在模具的成形面,排列在同平面上的形態,接合邊界部6的平滑性提升。
此外,在本發明中,較佳為前述第1接合部係形成為涵蓋前述板材(A)2的外周緣部5的整周而成。如圖3或圖4所示,涵蓋板材(A)2的外周緣部整周 地形成接合部,與接合樹脂(C)4接合,從而作為一體成形體1整體,能夠實現高接合強度和薄壁化。
此外,在本發明中,較佳為包含板材(A)2和構件(B)3透過接合樹脂(C)4重疊的區域7(圖5)的結構。如圖5所示,構件(B)3係透過接合樹脂(C)4,以平行地重疊的方式配置在板材(A)2的下方,從而能夠形成重疊的區域7而使一體成形體1的接合強度提升。
此外,在本發明中,較佳為接合樹脂(C)4係熱塑性樹脂。藉此,藉由射出成形,能夠容易地使接合樹脂(C)4插入板材(A)2與構件(B)3之間,能夠使一體成形體1的接合強度提升。
此外,在本發明中,能夠合適地使用金屬製框架作為構件(B)3。在使用金屬製框架作為構件(B)3的情況下,接合樹脂(C)4熔融而能夠與金屬製框架的構件(B)3的表面接合。
作為金屬製框架,能夠使用熱延鋼板、不銹鋼板(SUS)、將鎳、鋅、銅等的金屬進行單層鍍覆而成的單層鍍覆鋼板、將這些金屬中的2種以上進行多層鍍覆而成的多層鍍覆鋼板等的各種鋼板、鋁板、鋁合金板等的各種金屬板。金屬板的表面可以進行使包含鉻水合氧化物的單層皮膜形成的重鉻酸溶液中的電解處理、使包含上層為鉻水合氧化物且下層為金屬鉻的2層皮膜形成的電解鉻酸處理、浸漬鉻酸處理、磷酸鉻酸處理,另外,利用鹼溶液或酸溶液的蝕刻處理、陽極氧化處理等的各種轉化處理。此外,為了提高與接合樹脂(C)4的緊 貼性,除了將金屬板的表面進行利用如上所述的藥液的蝕刻處理的方法外,也能夠較佳地使用以下方法:藉由雷射加工、砂紙等的方法來使微細的凹凸形成在金屬表面,使其進行由樹脂進入所產生的定錨接合。
此外,金屬板的表面,也能夠基於使金屬板和接合樹脂(C)4的緊貼性提升為目的,有各種底漆、接著劑存在。底漆、接著劑,能夠舉出以往已知的鋁系、鈦系、矽烷系等的偶合劑、丙烯酸樹脂系接著劑、胺基甲酸酯樹脂系接著劑、環氧樹脂系接著劑、聚酯樹脂系接著劑等。
此外,在本發明中,能夠合適地使用由強化纖維及樹脂所構成的纖維強化樹脂作為構件(B)3。
在構件(B)3係包含熱硬化性樹脂的纖維強化樹脂的情況下,成為與接合樹脂(C)4接合的構造。
此外,在構件(B)3係包含熱塑性樹脂的纖維強化樹脂的情況下,成為構件(B)3的熱塑性樹脂係與接合樹脂(C)4熔融固著的接合構造。藉此,作為一體成形體1,能夠實現更高的接合強度。熔融固著的接合構造係指構件因熱而彼此熔融,冷卻而固著的狀態的接合構造。
此外,在本發明中,較佳為構件(B)3係在構件(B)3的至少一部分具有立壁形狀部的框架構件。例如,如圖5所示,藉由具備在構件(B)3的下方延伸的立壁形狀部8,能夠將一體成形體1作成箱型形狀體。
此外,在本發明中,就板材(A)2來說,能夠合適地使用由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少一個所構成的構件。
成為接合樹脂(C)熔融,而與由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少一個所構成的板材(A)2的表面接合的形態。又,能夠基於使板材(A)的輕量化和高剛性化等特性提升為目的、或者使板材(A)與接合樹脂(C)的接合強度提升為目的,對板材(A)追加其他構件。作為其他構件的金屬製構件,能夠使用與前述的構件(B)3的金屬製框架相同的材料及表面處理方法。
此外,在本發明中,較佳為板材(A)具有用包含由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少任一個所構成的構件的皮層包夾芯層的兩表面的夾芯構造,芯層係從熱塑性樹脂、發泡體、及包含不連續纖維和熱塑性樹脂的多孔質基材中的任一者選出。
例如如圖6及圖7所示,作成利用包含由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少任一個所構成的構件的皮層10,將包含熱塑性樹脂或發泡體的芯層11夾在中間的結構,從而能夠實現板材(A)2的輕量化和高剛性化。
此外,能夠將藉由加熱包含不連續纖維和熱塑性樹脂的芯層前驅物來使其因回彈(spring-back)而在厚度方向上膨脹並形成空間而成的多孔質基材用於芯 層11。將構成芯層11的含有不連續纖維和熱塑性樹脂的成形體加熱至熱塑性樹脂的軟化點或熔點以上並進行加壓後,解除加壓,藉由在不連續纖維的殘留應力解放時回復原狀的復原力(所謂的回彈)來使其膨脹,從而能夠在芯層11內形成所要的空間。藉此,能夠實現一體成形體1的輕量化和高剛性。
作為芯層11中所使用的具有空孔的發泡體,能夠合適地使用:聚胺基甲酸酯樹脂、酚樹脂、三聚氰胺樹脂、丙烯酸樹脂、聚乙烯樹脂、聚丙烯樹脂、聚氯乙烯樹脂、聚苯乙烯樹脂、丙烯腈-丁二烯-苯乙烯(ABS)樹脂、聚醚醯亞胺樹脂或聚甲基丙烯酸基醯亞胺樹脂。具體而言,為了確保輕量性,較佳為使用表觀密度比皮層小的樹脂,特別是,能夠較佳地使用聚胺基甲酸酯樹脂、丙烯酸樹脂、聚乙烯樹脂、聚丙烯樹脂、聚醚醯亞胺樹脂或聚甲基丙烯酸基醯亞胺樹脂。
此外,在本發明中,亦較佳為進一步在上述板材(A)的外表面設有熱塑性樹脂層(D),並且上述板材(A)和接合樹脂(C)係透過熱塑性樹脂層(D)接合的形態。
例如如圖8所示,先使熱塑性樹脂層(D)9附著在板材(A)2的與接合樹脂(C)4接合的側的面,之後將接合樹脂(C)4射出成形。藉此,板材(A)2係透過熱塑性樹脂層(D)9而與熔融的接合樹脂(C)4接合,從而作為一體成形體,能夠實現高接合強度。作為熱塑性樹脂層(D)9,能夠適當使用熱塑性樹脂薄膜、熱塑性樹脂的不織布。
此外,在本發明中,較佳為作為以下結構:在包含發泡體、及包含不連續纖維和熱塑性樹脂的多孔質基材中的任一者的芯層11的一部分,具有接合樹脂(C)4進入的嵌入部。
例如如圖9及圖10所示,若使接合樹脂(C)4射出成形,則接合樹脂(C)4和板材(A)2的皮層10的平面部或側面部接合,並且接合樹脂(C)4因射出成形壓力而從板材(A)2的側面部進入芯層11內的一部分的區域。這是因為芯層11內的區域係空孔率高,成為熔融的接合樹脂(C)4容易進入的構造的緣故。此外,將包含不連續纖維和熱塑性樹脂的多孔質基材用於芯層11,從而能夠藉由接合樹脂(C)4進入芯層11的內部的定錨效果來進一步提高接合強度。
此外,在本發明中,亦較佳為例如如圖11及圖12所示,在芯層11為多孔質基材的板材(A)2的第1接合部12、與第1接合部以外的區域13之間具有階差部14,階差部14具有相對於板材(A)2的面內方向角度θ:10°~90°的傾斜面的結構。
位於板材(A)2的外周緣部的第1接合部12,係作成設置與本體部的面內方向約略平行的壁厚不同的區域,下側的皮層10具有具有角度θ的傾斜的階差部14的結構。藉此,第1接合部12的接合面積增加,與單純將其他構造體接合在夾芯構造體的側面平坦部的情況相比,能夠擴大其接合面積,得到提高接合強度的效果。另外,能夠將板材(A)2的厚度和接合樹脂(C)4的 厚度設為相同的厚度,能夠同時實現高接合強度和構造體的薄壁化。
此處,皮層10相對於板材(A)2的面內方向的傾斜角度θ(°)較佳為10~90°,更佳為30~90°,進一步較佳為45~90°。垂直的階差部的角度θ成為90°。
此外,在本發明中,較佳為第1接合部12中的多孔質基材的空隙率比第1接合部以外的區域13中的多孔質基材的空隙率低。
例如如圖11或圖12的剖面圖所示,芯層11係由不連續纖維和熱塑性樹脂構成,在芯層11形成某種大小的空隙。夾芯構造體的板材(A)2包含形成在外周緣部的至少一部分的第1接合部12、和第1接合部以外的區域13,第1接合部以外的區域13中的芯層11的空隙率和第1接合部12中的芯層11的空隙率具備有不同的空隙率。
作為構成板材(A)2、構件(B)3及接合樹脂(C)4的熱塑性樹脂的種類,沒有特別的限制,能夠使用以下所例示的熱塑性樹脂中的任何樹脂。例如,可舉出從以下所選出的熱塑性樹脂:聚對苯二甲酸乙二酯(PET)樹脂、聚對苯二甲酸丁二酯(PBT)樹脂、聚對苯二甲酸丙二酯(PTT)樹脂、聚對萘二甲酸乙二酯(PEN樹脂)、液晶聚酯樹脂等的聚酯樹脂,聚乙烯(PE樹脂)、聚丙烯(PP樹脂)、聚丁烯樹脂等的聚烯烴樹脂,聚甲醛(POM)樹脂、聚醯胺(PA)樹脂、聚苯硫醚(PPS)樹脂等的聚伸芳基硫醚樹脂、聚酮(PK)樹脂、聚醚酮(PEK)樹脂、聚醚醚酮(PEEK) 樹脂、聚醚酮酮(PEKK)樹脂、聚醚腈(PEN)樹脂、聚四氟乙烯樹脂等的氟系樹脂、液晶聚合物(LCP)等的結晶性樹脂、苯乙烯系樹脂,此外,聚碳酸酯(PC)樹脂、聚甲基丙烯酸甲酯(PMMA)樹脂、聚氯乙烯(PVC)樹脂、聚苯醚(PPE)樹脂、聚醯亞胺(PI)樹脂、聚醯胺醯亞胺(PAI)樹脂、聚醚醯亞胺(PEI)樹脂、聚碸(PSU)樹脂、聚醚碸樹脂、聚芳香酯(PAR)樹脂等的非晶性樹脂,此外,酚系樹脂、苯氧基樹脂,另外,聚苯乙烯系樹脂、聚烯烴系樹脂、聚胺基甲酸酯系樹脂、聚酯系樹脂、聚醯胺系樹脂、聚丁二烯系樹脂、聚異戊二烯系樹脂、氟系樹脂、及丙烯腈系樹脂等的熱塑性彈性體等、或它們的共聚物及改性物。其中,從所得到的成形品的輕量性的觀點出發,可較佳地使用聚烯烴樹脂,從強度的觀點出發,可較佳地使用聚醯胺樹脂,從表面外觀的觀點出發,可較佳地使用如聚碳酸酯樹脂、苯乙烯系樹脂、改性聚苯醚系樹脂的非晶性樹脂,從耐熱性的觀點出發,可較佳地使用聚伸芳基硫醚樹脂,從連續使用溫度的觀點出發,可較佳地使用聚醚醚酮樹脂。
此外,作為強化纖維,可舉出:聚丙烯腈(PAN)系、嫘縈系、木質素系、瀝青系的碳纖維,石墨纖維,玻璃等的絕緣性纖維,聚芳醯胺樹脂、聚苯硫醚樹脂、聚酯樹脂、丙烯酸樹脂、尼龍樹脂、聚乙烯樹脂等的有機纖維,碳化矽、氮化矽等的無機纖維。這些強化纖維可以單獨使用一種,也可以併用兩種以上。其中,從輕量化效果的觀點出發,可較佳地使用比強度、比剛 性優異的PAN系、瀝青系、嫘縈系等碳纖維。此外,從提高所得到的成形品的經濟性的觀點出發,可較佳地使用玻璃纖維,特別是,考慮力學特性和經濟性的均衡,較佳為併用碳纖維和玻璃纖維。另外,從提高所得到的成形品的衝擊吸收性、賦形性的觀點出發,可較佳地使用聚芳醯胺纖維,特別是,考慮力學特性和衝擊吸收性的均衡,較佳為併用碳纖維和聚芳醯胺纖維。此外,從提高所得到的成形品的導電性的觀點出發,也能使用被覆了鎳、銅、鐿等金屬的強化纖維。其中,能更佳地使用強度和彈性模數等力學特性優異的PAN系的碳纖維。
此外,作為熱硬化性樹脂的例示,能夠較佳地使用:不飽和聚酯樹脂、乙烯基酯樹脂、環氧樹脂、酚(可溶性酚醛(resol)型)樹脂、脲.三聚氰胺樹脂、聚醯亞胺樹脂、馬來醯亞胺樹脂、苯并樹脂等的熱硬化性樹脂等。這些熱硬化性樹脂,可以應用掺混2種以上的樹脂等。其中,特別是從成形體的力學特性、耐熱性的觀點出發,較佳為環氧樹脂。環氧樹脂,為了展現其優異的力學特性,較佳為作為使用的樹脂的主要成分包含,具體而言,較佳為每個樹脂組成物包含60重量%以上。
接著,針對本發明的一體成形體的製造方法,一邊參照圖式一邊進行說明。
本發明係至少具有以下的步驟[1]及步驟[2]的一體成形體1的製造方法。
[1]在具有框架形狀的構件(B)3的內側,使至少一部分與前述構件(B)3分開地將單側表面為設計面的板材(A)2配置在模具內的步驟;[2]將接合樹脂(C)4射出成形在前述板材(A)2與前述構件(B)3的空隙,從而在至少前述板材(A)2的外周緣部使前述板材(A)和前述構件(B)3接合而一體化的步驟。
使用圖13說明本發明的製造方法的一例。
首先,將圖1所示的板材(A)2、和圖2所示的作成四角框形狀的構件(B)3分別預先成形。
將它們如在圖13[1]所示般,在構件(B)3的內側,在前述構件(B)3與至少一部分分開的狀態下,將板材(A)2的設計面側設在下模具15側,進行對位及配置。
之後,如圖13[2]所示,安裝(set)上模具16,將熔融的接合樹脂(C)4射出成形於形成在板材(A)2及構件(B)3之間的空隙部。藉此,以在板材(A)2的外周緣部有接合樹脂(C)4介於其與構件(B)3之間的形式接合而予以一體化。可較佳地使用插入射出成形、外插射出成形。
此外,在本發明的製造方法中,較佳為從與設計面相反的側將接合樹脂(C)4射出成形在空隙,從而設計面側的一體成形體1的表面的至少一部分成為板材(A)2、構件(B)3及接合樹脂(C)4露出的區域。
如圖13[2]所示,在表面位在同平面上的狀態下將板材(A)2及構件(B)3配置在下模具15,將熔融的 接合樹脂(C)4射出成形於形成在板材(A)2及構件(B)3之間的空隙部,從而在模具的底面,三構件的表面係位在同平面上地露出,能夠使一體成形體的接合部的表面設計性提升。
此外,使用圖14及圖15說明使用了另一形態的構件(B)3的實施形態。圖14中,顯示四邊獨立的形態的構件(B)3的一個部位。如圖15所示,在板材(A)2的四邊的外側分別設置一定空隙地配置構件(B)3,之後藉由將接合樹脂(C)4射出成形,板材(A)2和四邊獨立的構件(B)3係以有接合樹脂(C)4隔著的形式接合並一體化。
藉由將構件(B)3設為四邊獨立的形態,一體成形體的成形的自由度擴大,並且藉由在四角的位置配置接合樹脂(C)4,能夠提高接合強度。
以下,藉由實施例,針對本發明的一體成形體及其製造方法具體地進行說明,但下述的實施例並非限制本發明。首先,以下敘述實施例中使用的測定方法。
在將箱型形狀的一體成形體的設計面側朝上的狀態下,如下所述測定頂板(板材(A))的厚度方向的位移(mm)。測定點係頂板(板材(A))的中央部、一體成形體的4個角部、和各長邊、短邊的中央部的4點(合計9點)。又,頂板(板材(A))中央部以外的測定地方係分別距長邊、短邊2mm的內側。測定係使用3維測定器。
長邊、短邊的翹曲量,係不含頂板(板材(A))的中央部的位移(mm),從剩下的8點的位移(mm)導出。長邊的翹曲量,首先求出從一個長邊得到的3個位移(mm)當中,連結端部2點的直線和中央的點的距離。接著,同樣地操作而求出從另一長邊算出的連結端部2點的直線和中央的點的距離,將從2個長邊算出的距離的平均值作為長邊的翹曲量。同樣地操作,導出短邊的翹曲量。
對角線的翹曲量,係從頂板(板材(A))的中央部的位移(mm)、和4個角部的位移(mm)導出。與長邊的翹曲量的導出方法同樣地操作,針對2條對角線,求出連結一體成形體的作為對角的角部的2點的直線和頂板(板材(A))的中央部的點的距離,將那些距離的平均值作為對角線的翹曲量。
進一步地,將所得到的各翹曲量加以合計的值依以下的基準評價。A、B為合格,C、D為不合格。
A:各翹曲量的合計小於2.5mm
B:各翹曲量的合計為2.5mm以上小於3.0mm
C:各翹曲量的合計為3.0mm以上小於3.5mm
D:各翹曲量的合計為3.5mm以上
在一體成形體的接合部中,使用表面粗糙度測定器,以垂直地越過接合部的方式將表面粗糙度計測定頭對接合邊界線進行掃描,測定一體成形體表面的粗糙度(測定方法係根據JISB0633(2001))。從板材(A)的 厚度方向的位移(設為Y方向,單位:μm)和測定衝程(單位:mm)求出粗糙度曲線。作為測定條件,選擇測定衝程係20mm,測定速度0.3mm/s,截止(cut-off)值0.3mm,濾波器(filter)類別係高斯,無傾斜補正。將接合部設在測定衝程的中間點的10mm的部分。此處,將所得到的粗糙度曲線中的最大的山頂的Y方向位移和最小的谷底的Y方向位移的差作為接合部的階差。又,在本實施例中,使用東京精密(股)製的Surfcom480A作為表面粗糙度測定器。藉由上述的方法,求出板材(A)和接合樹脂(C)、板材(A)和構件(B)及構件(B)和接合樹脂(C)的各接合部的階差。又,各測定地方係針對一體成形體的2個長邊的各自中央部進行測定,將其平均值作為接合部的階差。
用以下的基準評價所得到的接合部的階差。此外,基於各接合部的階差的判定結果,用以下的基準進行綜合評價。A、B皆為合格的,C是不合格的。
A:接合部的階差小於8.0μm
B:接合部的階差為8.0μm以上小於1.2μm
C:接合部的階差為1.2μm以上
A:全部為A判定的情況
B:不含C判定,至少一個為B判定的情況
C:至少一個為C判定的情況
基於一體成形體的翹曲量、及一體成形體接合邊界線的平滑性的2個綜合評價的判定結果,用以下的基準判定一體成形體的綜合評價。A、B是合格的,C、D是不合格的。
A:2個綜合評價皆為A判定的情況
B:2個綜合評價當中,不含C、D判定,至少一個為B判定的情況
C:2個綜合評價當中,不含D判定,至少一個為C判定的情況
D:2個綜合評價當中,至少一個為D判定的情況
由以聚丙烯腈作為主要成分的聚合物進行紡紗、燒成處理,得到總絲數12000條的碳纖維連續束。利用浸漬法將上漿劑賦予此碳纖維連續束,在加熱空氣中進行乾燥得到PAN系碳纖維束。此PAN系碳纖維束的特性如下。
單纖維徑:7μm
每單位長度的質量:0.83g/m
密度:1.8g/cm3
拉伸強度:4.0GPa
拉伸彈性模數:235GPa
使用刀式塗布機將環氧樹脂(基底樹脂:二氰二醯胺/二氯苯基甲基尿素硬化系環氧樹脂)塗布在脫模紙上得到環氧樹脂薄膜。
使在材料組成例1得到的PAN系碳纖維束在單方向上排列成薄片狀,從碳纖維的兩面重疊2片在材料組成例2製作的環氧樹脂薄膜,利用加熱加壓使其含浸樹脂,製作碳纖維的重量含有率係70%,厚度0.15mm的單方向預浸物。
將聚醯胺樹脂(Toray(股)製的CM8000,4元共聚聚醯胺6/66/610/12,熔點130℃)的粒料進行壓製(press)成形,得到厚度0.05mm的熱塑接著薄膜。將其用作熱塑性樹脂層(D)。
將玻璃纖維強化尼龍樹脂CM1011G-30(Toray(股)製,尼龍6樹脂基質(martix),纖維重量含有率30%,熔點225℃)用作接合樹脂(C)。
聚丙烯樹脂基底(base)的發泡薄片係厚度0.65mm,密度0.5g/cm3。
使用匣式切割機(cartridge cutter)切割材料組成例1的PAN系碳纖維束,得到纖維長度6mm的短切碳纖維束。
攪拌界面活性劑(和光純藥工業(股)公司製,「正十二烷基苯磺酸鈉」(製品名))的1.5wt%水溶液 100公升,製作預先起泡的分散液。在此分散液中,投入在材料組成例7所得到的短切碳纖維束1,攪拌10分鐘後,流入具有長度400mm×寬度400mm的抄紙面的抄紙機,利用抽吸脫水後,在150℃的溫度下進行2小時乾燥,得到包含碳纖維的碳纖維墊片。所得到的墊片係良好的分散狀態。
準備未改性聚丙烯樹脂(Prime Polymer(股)公司製,”PrimePolypro”(註冊商標)J105G,熔點160℃)90質量%、和酸改性聚丙烯樹脂(三井化學(股)公司製,”ADMER”(註冊商標)QE510,熔點160℃)10質量%,將它們進行乾式掺混。從雙軸擠出機的送料斗投入此乾式掺混品,以擠出機進行熔融混練後,從400mm寬的T字模擠出。之後,藉由用60℃的冷卻輥牽引來使其冷卻固化,得到聚丙烯樹脂薄膜。
與材料組成例9同樣地操作,準備未改性聚丙烯樹脂(Prime Polymer(股)公司製,”PrimePolypro”(註冊商標)J105G,熔點160℃)80質量%、和酸改性聚丙烯樹脂(三井化學(股)公司製,”ADMER”(註冊商標)QE510,熔點160℃)20質量%,將它們進行乾式掺混。從雙軸擠出機的送料斗投入此乾式掺混品,以擠出機進行熔融混練後,從400mm寬的T字模擠出。之後,藉由用60℃的冷卻輥牽引來使其冷卻固化,得到聚丙烯樹脂薄片。
使用鋁板(AL5052,厚度1.25mm)作為板材(A)2的金屬製構件。
使用擠出成形機,得到使材料組成例1的PAN系碳纖維束含浸酚樹脂的作成圖14的形狀的CFRP製框架材。將其用作構件(B)的CFRP製框架構件。
將AL5052的角材進行CNC加工,得到作成圖14的形狀的鋁製框架。將其用作構件(B)的鋁製框架構件。
使用在材料組成例3得到的單方向預浸物、和在材料組成例4得到的熱塑接著薄膜,分別調整成400mm見方的尺寸後,以[單方向預浸物0°/單方向預浸物90°/單方向預浸物0°/單方向預浸物90°/單方向預浸物90°/單方向預浸物0°/單方向預浸物90°/單方向預浸物0°/接著薄膜]的順序進行積層。用脫模薄膜包夾此積層體,進一步用工具板包夾。此處,在工具板間插入厚度1.25mm的間隔物(spacer)作為厚度調整。在盤面溫度150℃的盤面上配置工具板後,關閉盤面,在3MPa下進行加熱壓製。從加壓起經過5分鐘後,打開盤面,得到作成厚度1.25mm的平板形狀的附熱塑接著薄膜的熱硬化CFRP板。將其作為有熱塑性樹脂層(D)附著的板材(A)2。
接著,使用材料組成例5的玻璃纖維強化尼龍樹脂進行射出成形,得到圖2所示的作成四角框形狀的框架構件。將其作為構件(B)3。
接著,如圖13所示,在框架構件(構件(B)3)的內側,在與前述框架構件(構件(B)3)分開的狀態下,將加工成300mm×200mm尺寸的附熱塑接著薄膜的CFRP板(板材(A)2)的設計面側設在下模具15側,進行對位及配置。安裝上模具16後,進行合模後,將材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4)射出成形,製造圖3所示的由頂板(板材(A)2)、和4邊的立壁(構件(B)3)所構成的一體成形體1。將所得到的一體成形體1的包含接合部及立壁的剖面顯示在圖16。又,圖3及圖16係將圖的上方作為設計面側。
在一體成形體的設計面中,一體成形體的附熱塑接著薄膜的CFRP板(板材(A)2)與接合樹脂(C)4的接合邊界部、和接合樹脂(C)4與框架構件(構件(B)3)的接合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。將一體成形體的特性整理並顯示在(表1)。
使用在實施例1得到的300mm×200mm×厚度1.25mm的附熱塑接著薄膜的CFRP板(板材(A)2)、和材料組成例12的圖14所示的CFRP製框架(構件(B)3)。省略熱塑接著薄膜的圖示。將CFRP製框架的接著區域的表面用砂紙粗糙化。接著,如圖13所示,將附熱塑接 著薄膜的CFRP板(板材(A)2)的設計面側朝下地配置在下模具15的中央,在該附熱塑接著薄膜的CFRP板(板材(A)2)的四邊的外側分別設置一定空隙地配置4根CFRP製框架構件(B)3,進行合模後,將材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4)射出成形,製造圖15所示的由頂板和4邊的立壁所構成的一體成形體1。將所得到的一體成形體1的包含接合部及立壁的剖面顯示在圖17。又,圖15及圖17係將圖的上方作為設計面側。
在一體成形體的設計面中,一體成形體的附熱塑接著薄膜的CFRP板(板材(A)2)與接合樹脂(C)4的接合邊界部、和接合樹脂(C)4與CFRP製框架(構件(B)3)的接合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。
使用在材料組成例3得到的單方向預浸物、和在材料組成例6得到的發泡聚丙烯樹脂薄片,分別調整成400mm見方的尺寸後,以[單方向預浸物0°/單方向預浸物90°/發泡聚丙烯樹脂薄片/單方向預浸物90°/單方向預浸物0°]的順序進行積層。用脫模薄膜包夾此積層體,進一步用工具板包夾。此處,在工具板間插入厚度1.25mm的間隔物作為厚度調整。在盤面溫度150℃的盤面上配置工具板後,關閉盤面,在3MPa下進行加熱壓製。從加壓起經過5分鐘後,打開盤面,得到作成厚度1.25mm的平板形狀的發泡芯層夾芯構造體(板材(A)2)。
接著,將在實施例1得到的玻璃纖維強化尼龍樹脂製的作成四角框形狀的框架構件(構件(B)3)、和加工成300mm×200mm的尺寸的發泡芯層夾芯構造體與實施例1同樣地操作並安裝在射出成形模具內,進行合模後,射出材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4),製造圖3所示的由頂板和4邊的立壁所構成的一體成形體。將所得到的一體成形體的包含接合部及立壁的剖面顯示在圖9及圖10。又,圖3、圖9及圖10係將圖的上方作為設計面側。
在一體成形體的設計面中,一體成形體的發泡芯層夾芯構造體(板材(A)2)與接合樹脂(C)4的接合邊界部、和接合樹脂(C)4與框架構件(構件(B)3)的接合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。
使用在材料組成例3得到的單方向預浸物、在材料組成例4得到的熱塑接著薄膜、和在材料組成例10得到的聚丙烯樹脂薄片,分別調整成400mm見方的尺寸後,以[單方向預浸物0°/單方向預浸物90°/聚丙烯樹脂薄片/單方向預浸物90°/單方向預浸物0°/接著薄膜]的順序進行積層。用脫模薄膜包夾此積層體,進一步用工具板包夾。此處,在工具板間插入厚度1.25mm的間隔物作為厚度調整。在盤面溫度160℃的盤面上配置工具板後,關閉盤面,在3MPa下進行加熱壓製。從加壓起經過5分鐘後,打開盤面,得到作成厚度1.25mm的平板形狀的聚丙烯樹脂芯層夾芯構造體(板材(A)2)。
接著,將在實施例1得到的玻璃纖維強化尼龍樹脂製的作成四角框形狀的框架構件(構件(B)3)、和加工成300mm×200mm的尺寸的聚丙烯樹脂芯層夾芯構造體與實施例1同樣地操作並安裝在射出成形模具內,進行合模後,射出材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4),製造圖3所示的由頂板和4邊的立壁所構成的一體成形體。將所得到的一體成形體的包含接合部及立壁的剖面顯示在圖8。又,圖3及圖8係將圖的上方作為設計面側。
在一體成形體的設計面中,一體成形體的聚丙烯樹脂芯層夾芯構造體(板材(A)2)與接合樹脂(C)4的接合邊界部、和接合樹脂(C)4與框架構件(構件(B)3)的接合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。
使用材料組成例3的單方向預浸物、材料組成例4的熱塑接著薄膜、材料組成例8的碳纖維墊片、和材料組成例9的聚丙烯樹脂薄膜。將它們調整成400mm見方的尺寸後,以[單方向預浸物0°/單方向預浸物90°/聚丙烯樹脂薄膜/碳纖維墊片/聚丙烯樹脂薄膜/單方向預浸物90°/單方向預浸物0°/接著薄膜]的順序進行積層。
用脫模薄膜包夾此積層體,進一步用工具板包夾。在盤面溫度為180℃的壓製成形機的盤面上配置工具板後,關閉盤面,在3MPa下進行加熱壓製。從加 壓起經過5分鐘後,打開盤面,將工具板迅速地配置在盤面溫度為40℃的壓製成形機的盤面上,在3MPa下進行冷卻壓製。在5分鐘後從壓製成形機取出工具板,得到聚丙烯樹脂含浸於芯層的板厚0.85mm的附熱塑接著薄膜的夾芯構造體(板材(A)2)。接著,在包夾所得到的附熱塑接著薄膜的夾芯構造體的工具板之間插入厚度1.25mm的間隔物,進一步僅在前述附熱塑接著薄膜的夾芯構造體的接著區域配置厚度0.4mm的間隔物,再度用同樣的操作順序、條件進行加熱壓製及冷卻壓製。僅使附熱塑接著薄膜的夾芯構造體的中央部的芯層回彈,從而得到接著區域的外周部被調整為厚度0.85mm而其他區域被調整為厚度1.25mm的經階差賦形的附熱塑接著薄膜的夾芯構造體。此處,皮層10相對於附熱塑接著薄膜的夾芯構造體(板材(A)2)的面內方向的傾斜角度θ(°)為45°。
接著,將在實施例1得到的玻璃纖維強化尼龍樹脂製的作成四角框形狀的框架構件(構件(B)3)、和加工成300mm×200mm的尺寸的經階差賦形的附熱塑接著薄膜的CFRP板與實施例1同樣地操作並安裝在射出成形模具內,進行合模後,將材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4)射出成形,製造圖3所示的由頂板和4邊的立壁所構成的一體成形體。將所得到的一體成形體的包含接合部及立壁的剖面顯示在圖11及圖12。又,圖3、圖11及圖12係將圖的上方作為設計面側。
在一體成形體的設計面中,一體成形體的經階差賦形的附熱塑接著薄膜的夾芯構造體(板材(A)2)與接合樹脂(C)4的接合邊界部、和接合樹脂(C)4與框架構件(構件(B)3)的接合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。
僅將材料組成例11的鋁板(板材(A)2)的接著面側的表面用砂紙粗糙化後,調整為300mm×200mm的尺寸。接著,將在實施例1得到的玻璃纖維強化尼龍樹脂製的作成四角框形狀的框架構件(構件(B)3)、和鋁板(板材(A)2)與實施例1同樣地操作並安裝在射出成形模具內,進行合模後,將材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4)射出成形,製造圖3所示的由頂板和4邊的立壁所構成的一體成形體。將所得到的一體成形體的包含接合部及立壁的剖面顯示在圖4及圖5。又,圖3、圖4及圖5係將圖的上方作為設計面側。
在一體成形體的設計面中,鋁板(板材(A)2)與接合樹脂(C)4的接合邊界部、和接合樹脂(C)4與框架構件(構件(B)3)的接合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。
使用在實施例1得到的300mm×200mm×厚度1.25mm的附熱塑接著薄膜(本發明中的熱塑性樹脂層(D))的CFRP板(板材(A)2)、和材料組成例13的鋁製框架(構件(B)3)。將鋁製框架的接著區域的表面用砂紙粗糙 化。接著,將附熱塑接著薄膜的CFRP板、和4根鋁製框架與實施例2同樣地操作並安裝在射出成形模具內,進行合模後,將材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4)射出成形,製造圖15所示的由頂板和4邊的立壁所構成的一體成形體。將所得到的一體成形體的包含接合部及立壁的剖面顯示在圖16。又,圖15及圖16係將圖的上方作為設計面側。
在一體成形體的設計面中,一體成形體的附接著層的CFRP板(板材(A)2)與接合樹脂(C)4的接合邊界部、和接合樹脂(C)4與鋁製框架(構件(B)3)的接合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。
將在實施例1得到的301mm×201mm×厚度1.25mm的附熱塑接著薄膜的CFRP板(板材(A)2)、和在實施例1得到的玻璃纖維強化尼龍樹脂製的作成四角框形狀的框架構件(構件(B)3)與實施例1同樣地操作並安裝在射出成形模具內,進行合模後,射出材料組成例5的玻璃纖維強化尼龍樹脂(接合樹脂(C)4),製造圖18所示的由頂板和4邊的立壁所構成的一體成形體。將所得到的一體成形體的包含接合部及立壁的剖面顯示在圖19。又,圖18及圖19係將圖的下方作為設計面側。
在一體成形體的設計面中,一體成形體的附熱塑接著薄膜的CFRP板(板材(A)2)與接合樹脂(C)4的邊界部、和接合樹脂(C)4與框架構件(構件(B)3)的接 合邊界部皆具有良好的平滑性。此外,一體成形體的翹曲量也是小而良好的。
使用在材料組成例3得到的單方向預浸物,調整成400mm見方的尺寸後,以[單方向預浸物0°/單方向預浸物90°/單方向預浸物0°/單方向預浸物90°/單方向預浸物90°/單方向預浸物0°/單方向預浸物90°/單方向預浸物0°]的順序進行積層。用脫模薄膜包夾此積層體,進一步用工具板包夾。此處,在工具板間插入厚度1.2mm的間隔物作為厚度調整。在盤面溫度150℃的盤面上配置工具板後,關閉盤面,在3MPa下進行加熱壓製。從加壓起經過5分鐘後,打開盤面,得到作成厚度1.2mm的平板形狀的CFRP板(板材(A)2)。
接著,僅在加工成301mm×201mm尺寸的CFRP板(板材(A)2)的接著區域塗布接著劑,將塗布了接著劑的CFRP板(板材(A)2)安裝在射出成形模具內,進行合模後,將材料組成例5的玻璃纖維強化尼龍樹脂射出成形,製造圖18所示的由頂板和4邊的立壁所構成的一體成形體。將所得到的一體成形體的包含接合部及立壁的剖面顯示在圖20。又,圖18及圖20係將圖的上方作為設計面側。
在一體成形體的設計面中,一體成形體的附接著層的CFRP板(板材(A)2)與射出樹脂的接合邊界部具有良好的平滑性。但是,一體成形體的翹曲量大而不佳。將一體成形體的特性整理並顯示在(表1)。
本發明的一體成形體,能有效地用於汽車內外裝飾、電氣.電子機器框體、腳踏車、運動用品用構造材料、航空器內部裝飾材料、輸送用箱體等。
Claims (15)
- 一種一體成形體,其係有接合樹脂(C)介於單側表面為設計面的板材(A)與構件(B)之間的一體成形體,在該構件(B)的內側,該板材(A)和該構件(B)係以分開的方式配置,該板材(A)的外周緣部的至少一部分的區域具有與該接合樹脂(C)接合的第1接合部,並且在該一體成形體的設計面側的表面的至少一部分,具有該板材(A)、該構件(B)、及該接合樹脂(C)露出的區域。
- 如請求項1的一體成形體,其中該第1接合部係形成為涵蓋該板材(A)的外周緣部整周。
- 如請求項1的一體成形體,其包含該板材(A)和該構件(B)透過該接合樹脂(C)重疊的區域。
- 如請求項1的一體成形體,其中該接合樹脂(C)係熱塑性樹脂。
- 如請求項1的一體成形體,其中該構件(B)係金屬製框架。
- 如請求項1的一體成形體,其中該構件(B)係包含強化纖維及樹脂的纖維強化樹脂。
- 如請求項1的一體成形體,其中該構件(B)係在該構件(B)的至少一部分具有立壁形狀部的框架構件。
- 如請求項1至7中任一項的一體成形體,其中該板材(A)具有由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少一個所構成的構件。
- 如請求項8的一體成形體,其中該板材(A)具有用包含由包含強化纖維和熱硬化性樹脂的纖維強化樹脂構件及金屬製構件中的至少任一個所構成的構件的皮層包夾芯層的兩表面的夾芯(sandwich)構造,該芯層係從熱塑性樹脂、發泡體、及包含不連續纖維和熱塑性樹脂的多孔質基材中的任一者選出。
- 如請求項8的一體成形體,其中進一步在該板材(A)的外表面設有熱塑性樹脂層(D),並且該板材(A)和接合樹脂(C)係透過該熱塑性樹脂層(D)接合。
- 如請求項9的一體成形體,其中在包含該發泡體、及包含不連續纖維和熱塑性樹脂的多孔質基材中的任一者的該芯層的一部分,具有該接合樹脂(C)進入的嵌入部。
- 如請求項9的一體成形體,其中在該芯層為該多孔質基材的該板材(A)的該第1接合部、與該第1接合部以外的區域之間具有階差部,該階差部具有相對於該板材(A)的面內方向10°~90°的傾斜面。
- 如請求項12的一體成形體,其中該第1接合部中的該多孔質基材的空隙率比該第1接合部以外的區域中的該多孔質基材的空隙率低。
- 一種一體成形體的製造方法,至少具有以下的步驟[1]及步驟[2]:[1]在具有框架形狀的構件(B)的內側,使至少一部分與該構件(B)分開地將單側表面為設計面的板材(A)配置在模具內的步驟; [2]將接合樹脂(C)射出成形在該板材(A)與該構件(B)的空隙,從而在至少該板材(A)的外周緣部使該板材(A)和該構件(B)接合而一體化的步驟。
- 如請求項14的一體成形體的製造方法,其中從與該設計面相反的側將接合樹脂(C)射出成形在該空隙,從而將該設計面側的一體成形體表面的至少一部分作為該板材(A)、該構件(B)及該接合樹脂(C)露出的區域。
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JP7249544B2 (ja) * | 2018-05-23 | 2023-03-31 | パナソニックIpマネジメント株式会社 | 樹脂部品保持部材および画像表示装置 |
MX2020011720A (es) * | 2018-06-07 | 2021-01-08 | Toray Industries | Cuerpo moldeado integrado y metodo para manufacturar el mismo. |
US11945378B2 (en) * | 2019-03-05 | 2024-04-02 | Agc Glass Europe | Method for manufacturing a molded vehicle trim element |
WO2020202903A1 (ja) * | 2019-03-29 | 2020-10-08 | 東レ株式会社 | 繊維強化プラスチック成形体 |
EP3825116A1 (en) * | 2019-11-19 | 2021-05-26 | SABIC Global Technologies B.V. | Portable electronic device housings having laminate plates and sidewalls and methods of making the same |
US20230294340A1 (en) | 2020-03-18 | 2023-09-21 | Toray Industries, Inc. | Integrally molded body and method of manufacturing same |
CN115298021A (zh) * | 2020-03-31 | 2022-11-04 | 东丽株式会社 | 纤维增强塑料成型体 |
DE102020117430A1 (de) | 2020-07-02 | 2022-01-05 | Audi Ag | Sandwichbauteil für ein Interieur eines Kraftfahrzeuges |
KR20220029973A (ko) * | 2020-09-02 | 2022-03-10 | 현대자동차주식회사 | 자동차용 샌드위치 판넬 제조 방법 및 자동차용 샌드위치 판넬 |
JP7512919B2 (ja) * | 2021-02-02 | 2024-07-09 | トヨタ自動車株式会社 | ハイブリッド成形体、成形装置、及び成形方法 |
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JP7187653B1 (ja) | 2021-12-21 | 2022-12-12 | 株式会社サカイヤ | クッション性を備え、加飾された成形樹脂製品およびその製造方法 |
CN114734576A (zh) * | 2022-03-08 | 2022-07-12 | 厦门市中鸿宇创科技有限公司 | 一种金属-塑胶复合的产品外壳及其制作方法 |
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EP3552794A1 (en) | 2019-10-16 |
JP6992512B2 (ja) | 2022-01-13 |
KR20190093566A (ko) | 2019-08-09 |
TWI781970B (zh) | 2022-11-01 |
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