WO2015033980A1 - 繊維強化部材の製造方法 - Google Patents

繊維強化部材の製造方法 Download PDF

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Publication number
WO2015033980A1
WO2015033980A1 PCT/JP2014/073250 JP2014073250W WO2015033980A1 WO 2015033980 A1 WO2015033980 A1 WO 2015033980A1 JP 2014073250 W JP2014073250 W JP 2014073250W WO 2015033980 A1 WO2015033980 A1 WO 2015033980A1
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Prior art keywords
fiber
main body
thermoplastic resin
reinforcing
reinforced member
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PCT/JP2014/073250
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English (en)
French (fr)
Inventor
秋夫 大野
拓也 二山
伊東 宏
西田 正三
Original Assignee
株式会社日本製鋼所
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 株式会社日本製鋼所 filed Critical 株式会社日本製鋼所
Priority to CN201480049341.6A priority Critical patent/CN105531101B/zh
Priority to US14/916,791 priority patent/US10160166B2/en
Priority to EP14842606.7A priority patent/EP3042753B1/en
Publication of WO2015033980A1 publication Critical patent/WO2015033980A1/ja

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/02Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore of moulding techniques only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081Combinations of fibres of continuous or substantial length and short fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/18Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection 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
    • B29C45/14778Injection 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
    • B29C45/14786Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12Thermoplastic materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809Fabrics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0854Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/20Inserts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00Use of elements other than metals as reinforcement
    • B29K2307/04Carbon
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/30Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055Cars
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/34Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3481Housings or casings incorporating or embedding electric or electronic elements

Definitions

  • the present invention relates to a method for manufacturing a fiber reinforced member that is molded by combining a pressure molding method and an injection molding method, which are preferably used for molding a vehicle body component part of an automobile or a casing component part of an electric device.
  • Fiber reinforced resin is excellent in specific strength, moldability, etc., and its application fields are expanding. Specifically, the application of fiber reinforced resin to body components of general automobiles and housing components of electric devices, which are expected to be mass-produced, is being studied.
  • Patent Document 1 discloses an automobile exterior part that is an injection-molded product of a fiber-reinforced thermoplastic resin composition and has a weight average distribution of reinforcing fiber length of 1.5 to 5.0 mm in the molded product of 1 to 50%. Proposed.
  • the reinforcing fiber in the molded product has a weight average distribution of 1 to 50%, preferably 5 to 50%, with a fiber length of 1.5 to 5.0 mm, and the composition used for the automobile exterior part is a thermoplastic resin. It is obtained from 40 to 99% by weight and reinforcing fiber 60 to 1% by weight, preferably 50 to 75% thermoplastic resin and 50 to 25% reinforcing fiber.
  • Patent Document 2 discloses a process (I) of forming a preform by laminating a base material having discontinuous reinforcing fibers and a resin, and placing a preform having a charge rate below 100% in a mold. And the step (II) for press molding, and the step (III) for integrating the thermoplastic resin by injection molding after inserting the planar molded body obtained in the step (II) into an injection mold A method for manufacturing a chemical molded article has been proposed. According to this manufacturing method, a sheet-like molded body formed from discontinuous reinforcing fibers and a resin is used as a primary molded body and integrated with a thermoplastic resin by injection molding, so that heat having high mechanical properties and a complicated shape is obtained. It is said that a plastic resin molded body can be easily obtained.
  • Patent Document 3 a permeable sheet made of a thermoplastic resin and a woven sheet in which the thermoplastic resin filaments are woven into a reinforcing fiber bundle are preliminarily molded by preheating and pressurizing in a preforming mold, and these are integrally molded. After superposing and molding in a mold and molding a decorative preform, the decorative preform is set in an injection mold, and the heat is formed on the back side. There has been proposed a method for molding a textile decorative resin product, in which a thermoplastic resin of the same quality as the plastic resin is injection molded to form a textile decorative resin product.
  • a fabric decorative resin product that is suitably used as a lightweight and highly rigid body component (for example, a cowl) can be trimmed and attached while maintaining the strength and design of the fabric sheet. It is said that it can be formed economically by eliminating all steps such as retrofitting of tools.
  • the present invention can efficiently form a fiber reinforced member having a long average fiber length and a high reinforcing fiber content by combining the pressure molding method and the injection molding method.
  • Another object of the present invention is to provide a method for manufacturing a fiber reinforced member capable of manufacturing a vehicle body component part of an automobile, a casing component part of an electric device, and the like with high productivity.
  • the method for producing a fiber reinforced member according to the present invention includes forming a thermoplastic resin melt in a lower mold, placing a mat-like material formed of reinforcing fibers B on the melt, and After the pressing upper mold is closed and pressed, the matte material impregnated with the thermoplastic resin is cooled and solidified to form a body portion obtained from the fiber reinforced resin, The upper mold for pressure is opened, the upper mold for injection molding is closed on the lower mold to form the injection mold, and then the injection molding is performed to form the additional part, and the additional part is combined with the main body part. A step 2 of forming the fiber-reinforced member.
  • the melt can be formed from a thermoplastic resin alone or from a thermoplastic resin containing the reinforcing fiber A.
  • the reinforcing fiber A contained in the molded fiber reinforcing member preferably has an average fiber length of 0.1 to 25 mm.
  • the reinforcing fiber B contained in the formed fiber reinforced member preferably has an average fiber length of 1 to 100 mm.
  • the volume content of the reinforcing fiber in the main body portion of the fiber reinforced member is 10 to 70%.
  • the additional portion preferably contains 0 to 50% by volume of reinforcing fibers M having an average fiber length of 0.1 to 25 mm.
  • the member of the shape which protruded from main parts such as a convex part formed in the main part, a boss
  • the melt is preferably formed by applying a thermoplastic resin containing reinforcing fiber A supplied from a plasticizing discharge machine.
  • the method for producing a fiber reinforced member according to the present invention includes forming a thermoplastic resin melt on a lower mold, placing a mat-like material formed of reinforcing fibers on the melt, and After the upper mold is closed and pressed into the mold, the impregnation treatment is performed, and then the main body obtained from the fiber reinforced resin is formed by cooling and solidifying the mat-like material impregnated with the thermoplastic resin, and the main body After the mold is released from the lower mold and the upper mold, the main body portion is disposed in the injection mold and injection molding is performed to form the additional portion, and the additional portion is combined with the main body portion. It may have the process 2 which manufactures the fiber reinforced member.
  • the present invention it is possible to efficiently form a fiber reinforced resin having a long average fiber length and a high content of reinforcing fiber, and it is possible to efficiently produce automotive body components, electrical equipment casing components, and the like. Can be manufactured.
  • FIG. 1 (a) and 1 (b) are drawings showing a fiber reinforced member molded according to the present invention.
  • FIG. 1A is a plan view
  • FIG. 1B is a schematic cross-sectional view.
  • 2 (a) to 2 (c) are drawings showing a process for manufacturing a fiber reinforced member according to the present invention.
  • FIG. 3A and FIG. 3B are diagrams illustrating examples of the adding unit.
  • FIG. 1 (a) and FIG.1 (b) show the fiber reinforcement member shape
  • the present invention provides a fiber reinforced member 50 having a thin plate-like main body 51 having a large area and an additional portion 55 formed in a convex shape on the surface of the main body 51. This is a production method suitably used for molding.
  • thermoplastic resin melt is formed in a lower mold, a mat-like material formed of reinforcing fibers B is placed on the melt, and the upper mold for pressurization is placed on the lower mold.
  • the mat-shaped material impregnated with the thermoplastic resin is cooled and solidified to form a main body obtained from the fiber reinforced resin, and the upper mold for pressurization
  • the upper mold for injection molding is closed to the lower mold to form an injection mold, and then injection molding is performed to form an additional part, and the additional part is combined with the main body part, and the fiber reinforced member Can be carried out by the step 2 of molding.
  • thermoplastic resin melt 511 is formed on the lower mold 10, and a mat formed from the reinforcing fibers B on the melt 511.
  • the material 513 is placed, and the upper mold 20 for pressurization is closed and pressed on the lower mold 10 to perform the impregnation treatment.
  • the lower mold 10 and the pressurizing upper mold 20 are cooled.
  • thermoplastic resin is not particularly limited, and various thermoplastic resins such as polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, polyamide, polycarbonate, and polymethyl methacrylate can be used.
  • the reinforcing fiber B is a base material for the fiber reinforcing member 50 according to the present invention, and a mat-like one is used as described above.
  • the mat shape refers to a fiber bundle made of a mat, woven fabric, or woven fabric.
  • a mat formed from reinforcing fibers having a desired fiber length and fiber density can be easily obtained.
  • a mat-like material 513 formed from the mat-like reinforcing fibers B is placed on the melt 511, and the upper mold 20 for pressing is pressed to impregnate the thermoplastic resin.
  • the reinforcing fiber B constituting the mat-like material 513 hardly flows or is cut during or after the pressing / impregnation process, and thus the fiber reinforcing member 50 having a desired average fiber length is easily manufactured. can do.
  • the average fiber length of the reinforcing fibers B contained in the fiber reinforcing member 50 is preferably 1 to 100 mm, more preferably 2 to 25 mm, and still more preferably 3 to 15 mm. When the average fiber length of the reinforcing fibers B is within the above range, the content of reinforcing fibers in the fiber reinforcing member 50 is increased, and the fiber reinforcing member 50 having high physical properties can be formed.
  • Reinforcing fiber B can be obtained only from reinforcing fibers, such as those coated with a thermoplastic resin around the reinforcing fiber, those containing a thermoplastic resin in the form of yarn, powder or sheet, etc. Can be used. The above impregnation treatment can be facilitated and accelerated by the coating of the thermoplastic resin or the like. In order to heat the reinforcing fiber B quickly, the thermoplastic resin content by coating or the like is desirably 30 vol% or less of the reinforcing fiber.
  • the melt 511 may be formed only from a thermoplastic resin, or may be formed from a thermoplastic resin containing the reinforcing fiber A.
  • the thermoplastic resin containing the reinforcing fiber A is used, the reinforcing fiber A can be mixed in the reinforcing fiber B, and the content of the reinforcing fiber in the fiber reinforcing member 50 can be increased.
  • the volume content of the reinforcing fibers contained in the main body 51 of the fiber reinforced member 50 is preferably 10 to 70%, more preferably 20 to 65%, and still more preferably 30 to 60%. .
  • the fiber reinforced member 50 having high physical properties can be formed.
  • the melt 511 is preferably formed by applying a thermoplastic resin containing the reinforcing fiber A supplied from an extruder.
  • a thermoplastic resin containing the reinforcing fiber A supplied from an extruder it is preferable to use a twin-screw extruder that supplies roving-like reinforcing fibers, cuts the reinforcing fibers with a screw, and further cuts the cut reinforcing fibers while kneading with a thermoplastic resin.
  • a twin-screw extruder that supplies roving-like reinforcing fibers, cuts the reinforcing fibers with a screw, and further cuts the cut reinforcing fibers while kneading with a thermoplastic resin.
  • the average fiber length of the reinforcing fibers A contained in the main body 51 of the fiber reinforced member 50 is preferably 0.1 to 25 mm, more preferably 1 to 15 mm, and still more preferably 6 to 10 mm.
  • the average fiber length of the reinforcing fibers A is within the above range, the content of reinforcing fibers in the fiber reinforcing member 50 is increased, and the fiber reinforcing member 50 having high physical properties can be formed.
  • a high-temperature thermoplastic resin containing the reinforcing fiber A can be supplied, production with high energy efficiency can be performed.
  • the reinforcing fiber B and the reinforcing fiber A can be the same or different (for example, the same filament material and different sizes).
  • the extruder may be an injection machine, and the present invention can be widely used for plasticizing discharge machines.
  • the lower mold 10 and the upper mold 20 for pressurization are cooled.
  • a solid body 51 is formed by cooling the lower mold 10 and the upper mold 20 for pressurization.
  • the pressurizing upper mold 20 is opened, and the injection molding upper mold 30 is disposed as shown in FIG. Is closed to the lower mold 10 to form an injection mold.
  • injection molding is performed to form the additional portion 55 as shown in FIG. 2C, and the fiber reinforced member 50 in which the additional portion 55 is combined with the main body portion 51 is molded.
  • stacked on or integrated with the main-body part 51 by injection molding are formed.
  • the sprue 560 is cut off to form the fiber reinforced member 50.
  • the lower mold 10 in this example has a flat shape without irregularities, but may have irregularities.
  • the injection molding is performed after the main body 51 is in a solidified state, that is, it is performed after the thermoplastic resin impregnated in the reinforcing fibers of the main body 51 is already solidified. There is no problem of fiber orientation and bias. According to the present invention, it is possible to solve a problem related to a conventional insert molding method in which a prepreg is laminated or a prepreg and a resin sheet laminated are heated and pressure-molded.
  • thermoplastic resin or a thermoplastic resin containing the reinforcing fiber M can be used as the resin used for the injection molding.
  • this thermoplastic resin the same or different one from the thermoplastic resin forming the melt 511 can be used.
  • the reinforcing fiber M the same material (the material and size of the filament) as the reinforcing fiber B or the reinforcing fiber A can be used. Further, as the reinforcing fiber M, a material different from the reinforcing fiber B or the reinforcing fiber A can be used.
  • the average length of the reinforcing fiber M contained in the additional portion 55 is preferably 0.1 to 25 mm, more preferably 2 to 15 mm, and further preferably 3 to 6 mm.
  • the content of reinforcing fibers in the fiber reinforcing member 50 is increased, and the fiber reinforcing member 50 having high physical properties can be formed.
  • the volume content of the reinforcing fiber M in the additional portion 55 can be 0 to 50%.
  • the volume content of the reinforcing fiber M contained in the additional portion 55 is more preferably 10 to 40%.
  • the additional portion 55 formed by injection molding includes a boss 553, a rib 554, a hinge 555, a flange 556, a claw 557, and a side wall. 558 etc. are included.
  • the additional portion includes the above-described runner function portion 559, but includes a convex portion having a convex shape in a broad sense not included in the above category.
  • the volume content of the reinforced fiber A contained in the fiber reinforced member 50 is preferably 20 to 70%, more preferably 30 to 70%.
  • the main body 51 formed in the step 1 can perform the next step 2 if its shape is fixed by cooling. For this reason, since the main-body part 51 can perform the process 2 when it is still in a heating state, manufacture of the fiber reinforced member 50 with high productivity and energy efficiency can be performed.
  • a method of heating and pressure molding the laminated prepreg Unlike, there are few shape restrictions. For this reason, in the shape design of the main-body part 51, such as the shape or size of an edge surrounding wall, a cross-sectional shape, or thickness, a comparatively free design can be performed. Further, by appropriately selecting the material, form (average fiber length, density, coating treatment, etc.) or content of the reinforcing fiber or thermoplastic resin forming the mat-like material or the melt, the impregnation treatment is promoted. A fiber reinforced member having a long average fiber length and a high content of reinforcing fibers can be formed.
  • the manufacturing method of this fiber reinforced member was demonstrated.
  • the manufacturing method of the fiber reinforced member which concerns on this invention is not restricted to said embodiment.
  • injection molding is performed with a new injection mold rather than the injection mold composed of the lower mold 10 and the upper mold 30 for injection molding. It may be preferable to do so.
  • the present invention can be applied even in such a case. That is, in the method for manufacturing a fiber reinforced member according to the present invention, a thermoplastic resin melt is formed on a lower mold, a mat-like material made of reinforcing fibers is placed on the melt, and the lower mold is placed on the lower mold.
  • the mat-shaped material is cooled and solidified to form a main body made of fiber-reinforced resin, and the molded main body is formed into the lower and upper molds.
  • the main body part is disposed in the injection mold and injection molding is performed to form the additional part, and the fiber reinforced member in which the additional part is combined with the main body part is manufactured in step 2 It may be a method to be implemented. Also in this manufacturing method, the process 2 can be performed when the main body 51 is still in a heated state, so that the fiber-reinforced member 50 with high productivity and energy efficiency can be manufactured.
  • the manufacturing method of the fiber reinforced member concerning this invention does not necessarily need to perform the said process 1 and the process 2 in the order. That is, first, the upper mold for injection molding is closed on the lower mold to form the injection mold, then injection molding is performed to form the additional portion, and then the additional portion formed by the injection molding is cooled. Then, the upper mold for injection molding is opened, a thermoplastic resin is applied to the lower mold to form a melt with the additional portion protruding, and the reinforcing fiber B is formed on the melt. After placing the mat-like material, the upper die for pressurization is closed and pressed on the lower die and subjected to impregnation treatment, and then cooled and solidified to form a fiber reinforced member from which the additional portion protrudes.
  • the manufacturing method of a fiber reinforced member may be sufficient.

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Abstract

 本発明に係る繊維強化部材の製造方法は、下金型に熱可塑性樹脂の溶融体を形成し、溶融体上に強化繊維Bから形成されたマット状素材を載置し、下金型に加圧用上金型を閉じて押圧し含浸処理を行った後、樹脂が含浸したマット状素材を冷却・固化して繊維強化樹脂から形成される本体部を成形する工程1と、加圧用上金型を開き、下金型に射出成形用上金型を閉じて射出成形金型を形成した後に射出成形を行って付加部を形成し、付加部が本体部に複合された繊維強化部材を成形する工程2を有する。

Description

繊維強化部材の製造方法
 本発明は、自動車の車体構成部品や電気機器の筐体構成部品などの成形に好適に使用される加圧成形法と射出成形法を組み合わせて成形する繊維強化部材の製造方法に関する。
 繊維強化樹脂は、比強度、成形性などに優れ、その適用分野が拡大している。具体的には、繊維強化樹脂は、大量生産が期待される一般の自動車の車体構成部品や電気機器の筐体構成部品などへの適用が検討されている。
 繊維強化樹脂の一般自動車部品や電気機器部品への適用においては、熱可塑性樹脂をマトリックスとしたガラス繊維又は炭素繊維による繊維強化樹脂の開発が進められており、成形品中に含まれる強化繊維の繊維長を長くすること、強化繊維の含有率を高めることが求められている。例えば、特許文献1に、繊維強化熱可塑性樹脂組成物の射出成形品であって、成形品中の強化用繊維長さ1.5~5.0mmの重量平均分布が1~50%である自動車外装部品が提案されている。そして、成形品中の強化用繊維は、繊維長1.5~5.0mmの重量平均分布が1~50%、好ましくは5~50%であり、自動車外装部品に使用される組成物は、熱可塑性樹脂40~99重量%および強化用繊維60~1重量%から得られ、好ましくは熱可塑性樹脂50~75%、強化用繊維50~25%であるとされる。
 このような繊維強化樹脂からなる一般自動車部品や電気機器部品は、平板状部に各種部品の取付用ボスやリブなどが設けられた形状をしており、一般に本体部を形成する平板状部は薄肉で大面積であり、ボスやリブなどの付加部を形成する部分は複雑な形状をしているものが多い。このため、長繊維の強化繊維を高体積含有率で含有させることができ、等方性で強度の高い繊維強樹脂性部品の製造に好適に使用される加圧成形法と、複雑な形状物の大量生産に好適に使用される射出成形法を組み合わせた製造方法が提案されている。
 例えば、特許文献2に、不連続の強化繊維と樹脂を有してなる基材を積層してプリフォームを作製する工程(I)、下記チャージ率が100%より大きなプリフォームを金型に配置してプレス成形する工程(II)、工程(II)で得られた面状成形体を射出成形の金型にインサートした後に熱可塑性樹脂を射出成形して一体化する工程(III)を有する一体化成形品の製造方法が提案されている。この製造方法によると、不連続な強化繊維と樹脂から形成された面状成形体を一次成形体とし、射出成形で熱可塑樹脂と一体化することにより、高い力学的特性および複雑形状を有する熱可塑性樹脂成形体を容易に得ることができるとされる。
 特許文献3には、熱可塑性樹脂からなる透過シート及びその熱可塑性樹脂フィラメントを強化繊維束に織り込んだ織物シートをそれぞれ予備成形金型内で余熱・加圧して予備成形し、それらを一体成形金型内に重ね合わせて熱加圧成形して、それらが一体化した加飾予備成形品を成形した後、前記加飾予備成形品を射出成型用金型内にセットし、裏面側に前記熱可塑性樹脂と同質の熱可塑樹脂を射出成形して織物加飾樹脂製品を成形する織物加飾樹脂製品の成形方法が提案されている。この成形方法によれば、軽量で高剛性の車体構成部品(例えばカウルなど)として好適に使用される織物加飾樹脂製品を、織物シートが持つ強度と意匠性をそのまま保持し、トリミング作業や取付具の後付け作業等の工程を一切削除して経済的に成形できるとされる。
日本国特開2005-298664号公報 日本国特開2010-253938号公報 日本国特開2009-51080号公報
 特許文献2又は3に提案された方法は、先ず強化繊維から形成されたシート状のプリプレグを作製した後に、このプリプレグを積層、又はプリプレグと樹脂シートを積層したものを加圧成形して本体部を成形し、この成形された予備成形体を射出成形金型に移して射出成形する方法が採用される。このため、工程数が多くなり、エネルギー効率もよくなく、高生産性の射出成形法の利点が生かされていないという問題がある。
 本発明は、このような従来の問題点に鑑み、加圧成形法と射出成形法を組み合わせて、平均繊維長が長く強化繊維の含有率の高い繊維強化部材を効率的に成形することができ、自動車の車体構成部品や電気機器の筐体構成部品などを高生産性で製造することができる繊維強化部材の製造方法を提供することを目的とする。
 本発明に係る繊維強化部材の製造方法は、下金型に熱可塑性樹脂の溶融体を形成し、この溶融体上に強化繊維Bから形成されたマット状素材を載置し、前記下金型に加圧用上金型を閉じて押圧し含浸処理を行った後、熱可塑性樹脂が含浸したマット状素材を冷却・固化して繊維強化樹脂から得られる本体部を成形する工程1と、前記加圧用上金型を開き、前記下金型に射出成形用上金型を閉じて射出成形金型を形成した後に射出成形を行って付加部を形成し、前記付加部が前記本体部に複合された繊維強化部材を成形する工程2を有する。
 上記発明において、溶融体は、熱可塑性樹脂のみから形成するもの、または強化繊維Aを含有する熱可塑性樹脂から形成するものとすることができる。そして、成形された繊維強化部材に含まれる強化繊維Aは、平均繊維長が0.1~25mmであることが好ましい。また、成形された繊維強化部材に含まれる強化繊維Bは、平均繊維長が1~100mmであることが好ましい。
 また、繊維強化部材の本体部における強化繊維の体積含有率が10~70%であることが好ましい。
 付加部は、平均繊維長が0.1~25mmの強化繊維Mを体積含有率で0~50%含有することが好ましい。そして、付加部としては、本体部に形成された凸状部、ボス、リブ、ヒンジ、フランジ、ツメ又は側壁部などの本体部から突出した形状の部材を成形することができる。
 溶融体は、可塑化吐出機から供給される強化繊維Aを含有した熱可塑性樹脂の塗布により形成するのがよい。
 また、本発明に係る繊維強化部材の製造方法は、下金型に熱可塑性樹脂の溶融体を形成し、前記溶融体上に強化繊維から形成されたマット状素材を載置し、前記下金型に上金型を閉じて押圧し含浸処理を行った後、熱可塑性樹脂が含浸したマット状素材を冷却・固化して繊維強化樹脂から得られる本体部を成形する工程1と、前記本体部を前記下金型及び前記上金型から離型した後に、前記本体部を射出成形金型に配設して射出成形を行って付加部を形成し、前記付加部が前記本体部に複合された繊維強化部材を製造する工程2を有するものであってもよい。
 本発明によれば、平均繊維長が長く強化繊維の含有率の高い繊維強化樹脂を効率的に成形することができ、自動車の車体構成部品や電気機器の筐体構成部品などを高生産性で製造することができる。
図1(a)および図1(b)は、本発明により成形される繊維強化部材を示す図面である。図1(a)は平面図、図1(b)は模式化した断面図である。 図2(a)~図2(c)は、本発明に係る繊維強化部材の製造工程を示す図面である。 図3(a)および図3(b)は、付加部の各例を示す図面である。
 以下、本発明を実施するための形態について図面を基に説明する。図1(a)及び図1(b)は、本発明により成形される繊維強化部材を示す。本発明は、図1(b)に示すように、薄肉で広い面積の平板状の本体部51と、この本体部51の表面に凸状に形成される付加部55を有する繊維強化部材50の成形に好適に使用される製造方法である。
 本発明に係る製造方法は、下金型に熱可塑性樹脂の溶融体を形成し、この溶融体上に強化繊維Bから形成されたマット状素材を載置し、前記下金型に加圧用上金型を閉じて押圧し含浸処理を行った後、熱可塑性樹脂が含浸したマット状素材を冷却・固化して繊維強化樹脂から得られる本体部を成形する工程1と、前記加圧用上金型を開き、前記下金型に射出成形用上金型を閉じて射出成形金型を形成した後に射出成形を行って付加部を形成し、その付加部が前記本体部に複合された繊維強化部材を成形する工程2により実施することができる。
 すなわち、本製造方法は、先ず、図2(a)に示すように、下金型10に熱可塑性樹脂の溶融体511を形成し、この溶融体511の上に強化繊維Bから形成されたマット状素材513を載置し、下金型10に加圧用上金型20を閉じて押圧し含浸処理を行う。そして、下金型10及び加圧用上金型20の冷却を行う。
 本製造方法において、熱可塑性樹脂は、特に限定されず、ポリエチレン、ポリプロピレン、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリアミド、ポリカーボネート、ポリメチルメタクリレートなど各種の熱可塑性樹脂を使用することができる。
 強化繊維は、炭素繊維、ガラス繊維などを使用することができるが、軽量化及び強度の点からは炭素繊維が好ましい。強化繊維Bは、本発明に係る繊維強化部材50の基材となるものであり、上述のようにマット状のものが使用される。マット状とは、繊維束をマット、織物、織布にしたものをいい、所望の繊維長、繊維密度の強化繊維から形成されたものを容易に入手することができる。このマット状の強化繊維Bから形成されるマット状素材513を溶融体511の上に載置し、加圧用上金型20を押圧して熱可塑性樹脂を含浸させる。マット状素材513を構成する強化繊維Bは、この押圧・含浸処理中およびそれ以降において流動したり、切断されることがほとんどないので、所望の平均繊維長を有する繊維強化部材50を容易に製造することができる。繊維強化部材50に含まれる強化繊維Bの平均繊維長を1~100mmにすることが好ましく、より好ましくは2~25mm、さらに好ましくは3~15mmである。強化繊維Bの平均繊維長が前記範囲であると、繊維強化部材50中の強化繊維の含有率が高くなり、高物性な繊維強化部材50を成形することができる。
 強化繊維Bは、強化繊維のみから得られるものを使用することができ、強化繊維の回りに熱可塑性樹脂をコーティングしたもの、糸、粉体またはシート状の熱可塑性樹脂を間に含んだもの等を使用することができる。上記の含浸処理は、この熱可塑性樹脂のコーティングなどにより容易になり、また促進されるようにすることができる。なお、強化繊維Bの迅速な加熱を図るために、コーティングなどによる熱可塑性樹脂の含有量は、強化繊維の30vol%以下が望ましい。
 溶融体511は、熱可塑性樹脂のみから形成されるものであってもよく、または強化繊維Aを含有する熱可塑性樹脂から形成されるものであってもよい。強化繊維Aを含有する熱可塑性樹脂を使用すると、この強化繊維Aを強化繊維Bに混在させることができ、繊維強化部材50の強化繊維の含有率を高くすることができる。本発明においては、繊維強化部材50の本体部51に含まれる強化繊維の体積含有率を10~70%にすることが好ましく、より好ましくは20~65%、さらに好ましくは30~60%である。本体部51に含まれる強化繊維の体積含有率が前記範囲であると、高物性な繊維強化部材50を成形することができる。
 溶融体511は、押出機から供給される強化繊維Aを含有した熱可塑性樹脂の塗布により形成するのがよい。特にロービング状の強化繊維を供給し、スクリューによりその強化繊維を分断しさらに熱可塑性樹脂と混練を行いつつ分断された強化繊維をさらに切断することができる二軸押出機を使用するのがよい。これにより、所望の長繊維の強化繊維Aが熱可塑性樹脂に含有された溶融体511を形成することができる。そして、繊維強化部材50の本体部51に含まれる強化繊維Aの平均繊維長を0.1~25mmにすることが好ましく、より好ましくは1~15mm、さらに好ましくは6~10mmである。強化繊維Aの平均繊維長が前記範囲であると、繊維強化部材50中の強化繊維の含有率が高くなり、高物性な繊維強化部材50を成形することができる。また、強化繊維Aを含有した高温状態の熱可塑性樹脂を供給することができるので、エネルギー効率の高い生産を行うことができる。
 なお、強化繊維Bと強化繊維Aは、その構成するフィラメントの材質、サイズ等が同一のもの、あるいは異なる(例えば、フィラメントの材質が同じでサイズが異なる)ものとすることができる。また、押出機は射出機であってもよく、本発明は広く可塑化吐出機に使用することができる。
 上述のように、含浸処理の後は下金型10及び加圧用上金型20の冷却が行われる。下金型10及び加圧用上金型20の冷却により固体状の本体部51が成形される。固体状の本体部51が成形されると、加圧用上金型20を開き、図2(b)に示すように射出成形用上金型30を配設し、この射出成形用上金型30を下金型10に閉じて射出成形金型を形成する。そして、射出成形を行って、図2(c)に示すように付加部55を形成し、その付加部55が本体部51に複合された繊維強化部材50を成形する。なお、射出成形により本体部51に積層された又は一体になったランナー機能部559、スプルー560が形成される。スプルー560は切除されて繊維強化部材50が成形される。本例の下金型10は、凹凸の無い平面状になっているが、凹凸の有るものであってもよい。
 本発明においては、射出成形は本体部51が固化した状態になってから行われる、すなわち、本体部51の強化繊維に含浸した熱可塑性樹脂がすでに固化した状態になってから行われるので、強化繊維の配向や偏りの問題が無い。本発明により、プリプレグを積層、又はプリプレグと樹脂シートを積層したものを加熱して加圧成形するような従来のインサート成形法に係る問題を解決することができる。
 この射出成形に供される樹脂は、熱可塑性樹脂又は強化繊維Mを含有する熱可塑性樹脂を使用することができる。この熱可塑性樹脂は、溶融体511を形成する熱可塑性樹脂と同一のもの又は異なるものを使用することができる。そして、強化繊維Mは、強化繊維B又は強化繊維Aと同一の素材(フィラメントの材質、サイズ)を使用することができる。また、強化繊維Mは、強化繊維B又は強化繊維Aと異なる素材を使用することができる。
 付加部55に含まれる強化繊維Mは、平均繊維長が0.1~25mmとすることが好ましく、より好ましくは2~15mm、さらに好ましくは3~6mmである。強化繊維Mの平均繊維長が前記範囲であると、繊維強化部材50中の強化繊維の含有率が高くなり、高物性な繊維強化部材50を成形することができる。また、付加部55における強化繊維Mの体積含有率は0~50%とすることができる。そして、付加部55に含まれる強化繊維Mの体積含有率は、10~40%がより好ましい。
 射出成形により形成される付加部55には、図1(a)、図3(a)および図3(b)に示すように、ボス553、リブ554、ヒンジ555、フランジ556、ツメ557、側壁558などが含まれる。また、付加部には、上述のランナー機能部559も含まれるが、上記の範疇に含まれない広い意味で凸形状の凸状部が含まれる。
 なお、繊維強化部材50の強度向上を図るためには、繊維強化部材50に含まれる強化繊維Aの体積含有率は、20~70%が好ましく、30~70%がより好ましい。
 上記繊維強化部材の製造方法においては、工程1により形成された本体部51は、冷却によりその形状が固定化されれば次の工程2を行うことをできる。このため、本体部51は未だ加熱状態にあるときに工程2を行うことができるので、生産性及びエネルギー効率の高い繊維強化部材50の製造を行うことができる。
 また、本発明の繊維強化部材の製造方法においては、上述のように本体部51の成形において強化繊維からなるマット状素材に含浸処理を行うので、積層されたプリプレグを加熱・加圧成形する方法とは異なり、形状的な制限が少ない。このため、縁周壁の形状又はサイズ、断面形状又は肉厚など本体部51の形状設計において、比較的自由な設計を行うことができる。また、マット状素材又は溶融体を形成する強化繊維や熱可塑性樹脂の材質、形態(平均繊維長、密度、コーティング処理等)又は含有量などを適宜選択することにより、含浸処理を促進させ、また、平均繊維長が長く高い含有量の強化繊維を含む繊維強化部材を成形することができる。
 以上、本繊維強化部材の製造方法について説明した。本発明に係る繊維強化部材の製造方法は、上記の実施形態に限らない。例えば、繊維強化部材50の付加部55を成形するのに、上記下金型10と射出成形用上金型30から構成される射出成形金型よりも、新たな射出成形金型で射出成形を行うのが好ましい場合がある。本発明は、このような場合でも適用することができる。すなわち、本発明に係る繊維強化部材の製造方法は、下金型に熱可塑性樹脂の溶融体を形成し、この溶融体上に強化繊維からなるマット状素材を載置し、前記下金型に上金型を閉じて押圧し含浸処理を行った後、マット状素材を冷却・固化して繊維強化樹脂からなる本体部を成形する工程1と、前記成形された本体部を前記下及び上金型から離型した後に、本体部を射出成形金型に配設して射出成形を行って付加部を形成し、その付加部が前記本体部に複合された繊維強化部材を製造する工程2により実施される方法であってもよい。この製造方法においても、本体部51は未だ加熱状態にあるときに工程2を行うことができるので、生産性及びエネルギー効率の高い繊維強化部材50の製造を行うことができる。
 また、本発明に係る繊維強化部材の製造方法は、上記工程1と工程2を必ずしもその順序に行うものでなくてもよい。すなわち、先ず、下金型に射出成形用上金型を閉じて射出成形金型を形成した後に射出成形を行って付加部を形成し、次に、前記射出成形により形成された付加部を冷却して固化させた後、射出成形用上金型を開き、前記下金型に熱可塑性樹脂を塗布して前記付加部が突出した溶融体を形成し、この溶融体上に強化繊維Bからなるマット状素材を載置した後、前記下金型に加圧用上金型を閉じて押圧し含浸処理を行った後、これを冷却・固化して前記付加部が突出した繊維強化部材を成形する繊維強化部材の製造方法であってもよい。
 本発明を詳細にまた特定の実施形態を参照して説明したが、本発明の精神と範囲を逸脱することなく様々な変更や修正を加えることができることは当業者にとって明らかである。本出願は、2013年9月6日出願の日本特許出願(特願2013-185771)に基づくものであり、その内容はここに参照として取り込まれる。
 10  下金型
 20  加圧用上金型
 30  射出成形用上金型
 50  繊維強化部材
  51 本体部
   511 溶融体
   513 マット状素材
  55 付加部
   553 ボス
   554 リブ
   555 ヒンジ
   556 フランジ
   557 ツメ
   558 側壁
   559 ランナー機能部
   560 スプルー

Claims (9)

  1.  下金型に熱可塑性樹脂の溶融体を形成し、前記溶融体上に強化繊維Bから形成されたマット状素材を載置し、前記下金型に加圧用上金型を閉じて押圧し含浸処理を行った後、熱可塑性樹脂が含浸したマット状素材を冷却・固化して繊維強化樹脂から得られる本体部を成形する工程1と、
     前記加圧用上金型を開き、前記下金型に射出成形用上金型を閉じて射出成形金型を形成した後に射出成形を行って付加部を形成し、前記付加部が前記本体部に複合された繊維強化部材を成形する工程2を有する繊維強化部材の製造方法。
  2.  前記溶融体は、熱可塑性樹脂のみから形成するもの、または強化繊維Aを含有する熱可塑性樹脂から形成するものである、請求項1に記載の繊維強化部材の製造方法。
  3.  前記強化繊維Aは、平均繊維長が0.1~25mmである、請求項2に記載の繊維強化部材の製造方法。
  4.  前記強化繊維Bは、平均繊維長が1~100mmである、請求項1~請求項3の何れか一項に記載の繊維強化部材の製造方法。
  5.  前記繊維強化部材の前記本体部における強化繊維の体積含有率が10~70%である、請求項1~請求項4の何れか一項に記載の繊維強化部材の製造方法。
  6.  前記付加部は、平均繊維長が0.1~25mmの強化繊維Mを体積含有率で0~50%含有する、請求項1~請求項5の何れか一項に記載する繊維強化部材の製造方法。
  7.  前記付加部は、前記本体部に形成された凸状部、ボス、リブ、ヒンジ、フランジ、ツメ又は側壁部である、請求項1~請求項6の何れか一項に記載する繊維強化部材の製造方法。
  8.  前記溶融体は、可塑化吐出機から供給される前記強化繊維Aを含有する前記熱可塑性樹脂の塗布により形成される、請求項2~請求項7の何れか一項に記載する繊維強化部材の製造方法。
  9.  下金型に熱可塑性樹脂の溶融体を形成し、前記溶融体上に強化繊維から形成されたマット状素材を載置し、前記下金型に上金型を閉じて押圧し含浸処理を行った後、熱可塑性樹脂が含浸したマット状素材を冷却・固化して繊維強化樹脂から得られる本体部を成形する工程1と、
     前記本体部を前記下金型及び前記上金型から離型した後に、前記本体部を射出成形金型に配設して射出成形を行って付加部を形成し、前記付加部が前記本体部に複合された繊維強化部材を製造する工程2を有する繊維強化部材の製造方法。
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