WO2015146767A1 - 複合成形品及びその製造方法 - Google Patents

複合成形品及びその製造方法 Download PDF

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Publication number
WO2015146767A1
WO2015146767A1 PCT/JP2015/058203 JP2015058203W WO2015146767A1 WO 2015146767 A1 WO2015146767 A1 WO 2015146767A1 JP 2015058203 W JP2015058203 W JP 2015058203W WO 2015146767 A1 WO2015146767 A1 WO 2015146767A1
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WO
WIPO (PCT)
Prior art keywords
groove
molded product
inorganic filler
fibrous inorganic
resin
Prior art date
Application number
PCT/JP2015/058203
Other languages
English (en)
French (fr)
Inventor
望月　章弘
Original Assignee
ポリプラスチックス株式会社
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.)
Filing date
Publication date
Application filed by ポリプラスチックス株式会社 filed Critical ポリプラスチックス株式会社
Priority to DE112015001385.7T priority Critical patent/DE112015001385B4/de
Priority to JP2015544257A priority patent/JP5918451B2/ja
Priority to CN201580011209.0A priority patent/CN106062052B/zh
Priority to US15/124,440 priority patent/US10232547B2/en
Priority to KR1020167022636A priority patent/KR101734344B1/ko
Publication of WO2015146767A1 publication Critical patent/WO2015146767A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/16—Surface shaping of articles, e.g. embossing; Apparatus therefor by wave energy or particle radiation, e.g. infrared heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/362—Laser etching
    • B23K26/364—Laser etching for making a groove or trench, e.g. for scribing a break initiation groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0078—Measures or configurations for obtaining anchoring effects in the contact areas between layers
    • B29C37/0082—Mechanical anchoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—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
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/005—Surface shaping of articles, e.g. embossing; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024—Thermal pre-treatments
    • B29C66/0246—Cutting or perforating, e.g. burning away by using a laser or using hot air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3034—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/526—Joining bars
    • B29C66/5261—Joining bars for forming coaxial connections, i.e. the bars to be joined forming a zero angle relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/16—Composite materials, e.g. fibre reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/42—Plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/009—Using laser
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING 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
    • B29K2509/00—Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
    • B29K2509/08—Glass

Definitions

  • the present invention relates to a composite molded product and a manufacturing method thereof.
  • Patent Document 1 a filler such as glass fiber is mixed in one resin and molded, and the surface to which the other resin is bonded is treated with chemicals, plasma, flame, etc. It has been proposed that after removing a resin of several ⁇ m to several tens of ⁇ m, the other resin is brought into contact with the other resin to be filled, molded, and bonded. Further, in Patent Document 2, a surface of one resin molded product is irradiated with electromagnetic radiation to form a nanostructure on the surface, and then the other resin molded product is filled and molded in contact with the surface. It has been proposed to integrate.
  • Patent Document 3 proposes to press-bond a base material and a skin material, which have a concavo-convex shape and have hard fibers protruding on the front side.
  • Patent Document 4 it is proposed that the molded members whose metal fibers are exposed on the surface are joined together at the joint.
  • a high-power continuous-wave solid-state laser is used, a composite material such as an FRP member and FRM (fiber reinforced metal) and a composite material plywood or a butt joint, a lap joint of a composite material and a metal dissimilar material joint, Several percent to 80% of reinforcing material including reinforced fiber, tempered glass, and whisker in the joint of edge joint and fillet joint with thermoplastic resin, thermosetting resin, and a mixture of thermoplastic resin and thermosetting resin It has been proposed to laser weld the composite material and the composite material plywood while filling the filler material added in% by weight.
  • the composite molded product is formed by compressing the skin material against the base material on which the fiber protrudes and exists on the surface of the molded product having irregularities, so that the fiber is pierced into the skin material.
  • Patent Document 4 the problem of Patent Document 4 is to achieve mutual conduction between the surfaces of both molded members, and it is sufficient if an inorganic filler is hung on the molded members. In Patent Document 4, there is no disclosure or suggestion about obtaining a high anchor effect.
  • Patent Document 5 only discloses that when carbon fiber reinforced plastic is cut with a conventional CO 2 laser or fiber laser, the carbon fiber is exposed at the cut portion. It does not disclose that it contributes to
  • the present invention has been made in order to solve the above-described problems, and an object of the present invention is to provide a resin molded product that can further increase the strength when bonded to other molded products. is there.
  • the inventors of the present invention have intensively studied to solve the above problems.
  • the resin of the resin molded product containing the fibrous inorganic filler is partially removed and the fibrous inorganic filler is partially removed, and at least the surface side of the groove formed thereby is filled with the fibrous inorganic filler.
  • the groove By forming a groove that is exposed by protruding the end of the agent from the side surface of the groove, the groove can be formed deeper, and the members that make up other molded products can be easily penetrated into the groove.
  • the fibrous inorganic filler exposed in the groove serves as an anchor that suppresses breakage at the joint between the resin molded product with groove and other molded products, resulting in composite molding. It has been found that the strength of the body can be significantly increased. Specifically, the present invention provides the following.
  • This invention has the said groove
  • This is a composite molded product in which other materials are integrated on the surface.
  • the present invention is the composite molded article according to (1), wherein the exposure of the end of the fibrous inorganic filler and the formation of the groove are performed by laser irradiation.
  • this invention is a composite molded product in any one of (1) or (2) whose depth of the said groove
  • this invention is a composite molded article as described in (4) from which the edge part of the said fibrous inorganic filler protrudes and exposes on a coaxial line from the both sides
  • the molded product made of the other material is disposed so as to surround the fibrous inorganic filler inside the groove.
  • the present invention is a composite molded article according to any one of (1) to (6), which is integrated by injection molding.
  • a composite molded article comprising: a groove forming process for forming an exposed groove protruding in a side surface direction; and a composite molding process for manufacturing a composite molded article by integrating the surface having the groove with another material as a contact surface It is a manufacturing method.
  • this invention is a manufacturing method of the composite molded product as described in (8) by which partial removal of the said resin is performed by laser irradiation.
  • the present invention is the method for producing a composite molded product according to (9), wherein the laser irradiation is performed from a direction other than perpendicular to the surface of the molded product.
  • the partial removal of the resin is performed until the depth of the groove is 200 ⁇ m or more. It is.
  • the groove forming step partially removes the resin from the resin molded product, and at least the ends of the fibrous inorganic filler are opposed to both sides of the groove on the surface side inside the groove. It is a manufacturing method of the composite molded product according to any one of (8) to (11), which is a step of forming an exposed groove protruding in the side surface direction.
  • the present invention provides the composite molded article according to any one of (8) to (12), wherein the groove forming step is a step in which part of the fibrous inorganic filler is removed. It is a manufacturing method.
  • the groove forming step is a step of exposing and exposing the end portions of the fibrous inorganic filler so as to face both side surfaces of the groove by partially removing the fibrous inorganic filler.
  • the composite molding step is a step of manufacturing a composite injection molded product by integrating the surface having the groove with another material by injection molding using the surface having the groove as a contact surface. 14) The method for producing a composite molded article according to any one of 14).
  • the fibrous inorganic filler exposed in the groove serves as an anchor that suppresses the destruction of the grooved resin molded product and other molded products.
  • the strength of the composite molded body can be significantly increased.
  • FIG. 1 is a schematic enlarged cross-sectional schematic view of a grooved resin molded product 10 which is a component of the composite molded product 1 (FIG. 2) of the present invention.
  • the grooved resin molded product 10 contains a fibrous inorganic filler 11.
  • channel has the groove
  • the surface side means the side close to the surface of the molded product in the depth direction of the groove.
  • the type of the resin is not particularly limited as long as it can be removed by laser irradiation and can form the groove 12 as a result.
  • the laser absorption is adjusted, and not only the resin is removed by laser irradiation, but also the laser irradiation.
  • the end of the fibrous inorganic filler 11 can be suitably exposed at least on the surface side of the groove formed in the grooved resin molded product 10. .
  • adjusting the absorption rate of the laser adjusting the type and amount of the compounding agent that absorbs the laser in the resin can be mentioned.
  • a compounding agent pigments and dyes are used, and carbon black is effective.
  • the resin may be thermoplastic or thermosetting.
  • suitable materials for the resin include polyphenylene sulfide (PPS), liquid crystal polymer (LCP), polybutylene terephthalate (PBT), and polyacetal (POM).
  • Fibrous inorganic filler 11 When the fibrous inorganic filler 11 forms the groove 12 by removing a part of the resin of the resin molded product, at least a part of the fibrous inorganic filler 11 is partially removed, and the fibrous inorganic filler 11 There is no particular limitation as long as the end of 11 protrudes from the side surface of the groove and is exposed at least on the surface side of the groove formed in the resin molded product 10 with the groove.
  • the fibrous inorganic filler 11 examples include glass fiber, carbon fiber, whisker fiber, and the like, and they can be used alone or in combination. If it is fibrous, the fibrous inorganic filler 11 is prevented from falling off from the composite molded product (1 in FIG. 2), and the fibrous inorganic filler 11 is formed into the grooved resin molded product 10 and other molded products (FIG. 2) 20) It serves as an anchor that suppresses separation.
  • glass fiber is preferably used in the present invention.
  • inorganic fillers such as glass flakes other than fibrous, mica, talc, and glass beads, and other additives and modifiers may be blended to such an extent that the effects of the present invention are not hindered. .
  • the fibrous inorganic filler 11 is not particularly limited as long as the end of the fibrous inorganic filler 11 protrudes and is exposed in the side surface direction opposed to the side surface of the groove on the surface side of the groove. It is preferable that at least the surface side inside the groove protrudes from both side surfaces of the groove and is exposed, and more preferably protrudes from both side surfaces of the groove so as to face the coaxial line.
  • the inorganic filler 11 exposed in the groove 12 serves as an anchor that suppresses the breakage of the grooved resin molded product 10 and other molded products 20, a part of the resin is removed in the deep portion of the groove 12. It is preferable that the fibrous inorganic filler 11 is suitably bridged between the uneven peaks 13 to be formed.
  • the content of the fibrous inorganic filler 11 is not particularly limited, but is preferably 5 parts by weight or more and 80 parts by weight or less with respect to 100 parts by weight of the resin. If it is less than 5 parts by weight, even if the fibrous inorganic filler 11 is exposed in the groove 12, the fibrous inorganic filler 11 serves as an anchor that suppresses the destruction of the grooved resin molded product 10 and other molded products 20. May not be sufficient. If it exceeds 80 parts by weight, it is not preferable in that the effect of locking the fibrous inorganic filler 11 and the other molded product provided with the groove 12 may not be sufficiently exhibited.
  • resin material containing fibrous inorganic filler 11 Commercially available resin materials containing fibrous inorganic filler 11 include PPS with glass fiber (product name: Durafide PPS 1140A1, manufactured by Polyplastics), PPS with glass fiber (product name: Durafide PPS 1140A7, poly Plastics), PPS with glass fiber / inorganic filler (product name: Durafide PPS 6165A7, manufactured by Polyplastics), LCP with glass fiber (Product name: Vectra LCP E130i, manufactured by Polyplastics), etc. be able to.
  • PPS with glass fiber product name: Durafide PPS 1140A1, manufactured by Polyplastics
  • PPS with glass fiber product name: Durafide PPS 1140A7, poly Plastics
  • PPS with glass fiber / inorganic filler product name: Durafide PPS 6165A7, manufactured by Polyplastics
  • LCP with glass fiber Product name: Vectra LCP E130i, manufactured by Polyplastics
  • Grooves 12 are formed on the surface of the resin molded product 10. In the groove 12, the fibrous inorganic filler 11 is exposed. Then, the groove 12 is formed by forming a groove 12 by removing a part of the resin and removing a part of the fibrous inorganic filler that partially exposes the laser that is exposed from the side surface and irradiated to the groove at least on the surface side of the groove. The end portions of the fibrous inorganic filler 11 can be exposed from the side surfaces 12a of the twelve sides while protruding from the side surfaces of the grooves.
  • the laser shielding effect by the fibrous inorganic filler exposed in the groove 12 is reduced, so that the laser can be effectively irradiated deep into the groove. Can be made deeper, and this can enhance the anchor effect when composite molding with other resin molded products.
  • at least the surface of the fibrous filler exposed at the surface side is partly removed, and in particular the fibrous inorganic filling at the center of the groove.
  • the present invention produces a composite molded product (1 in FIG. 2) by integrating the surface having the groove 12 of the grooved resin molded product 10 with another molded product (20 in FIG. 2) as a contact surface.
  • this composite molded article 1 the fibrous inorganic filler 11 is not exposed.
  • the fibrous inorganic filler is removed from the groove 12 in a mode in which the other molded product 20 is removed from the composite molded product 1. If 11 is exposed, it is assumed that "the fibrous inorganic filler 11 is exposed in the plurality of grooves 12".
  • the longitudinal direction of the groove 12 is a fiber in that a sufficient anchor effect can be obtained more effectively by projecting and exposing the end portion of the inorganic filler from the side surface of the groove when composite molding with another resin molded product is performed. It is preferably different from the longitudinal direction of the fibrous inorganic filler 11.
  • the groove 12 formed on the surface of the resin molded product 10 is provided with a plurality of grooves 12 to enhance the anchor effect.
  • each of the plurality of grooves 12 may be formed individually, or a groove formed of a plurality of concaves and convexes at a time in the manner of one-stroke writing. It may be.
  • the plurality of grooves 12 may be formed by arranging the grooves 12 connected at both ends like contour lines, or may be formed in a stripe shape that does not intersect, or may be formed in a lattice shape in which the grooves 12 intersect.
  • the longitudinal direction of the grooves 12 is preferably formed in an oblique lattice shape that is different from the longitudinal direction of the fibrous inorganic filler.
  • channel 12 may be a rhombus shape.
  • the length of the groove 12 is not particularly limited, and when the groove 12 is short, the shape of the opening may be square, round, or oval. In order to obtain the anchor effect, the groove 12 is preferably long.
  • the depth D of the groove 12 is not particularly limited, but the depth of the groove 12 is preferably deeper in that a higher anchor effect can be obtained.
  • the fibrous inorganic filler exposed in the groove By removing a part, shielding of the laser irradiated to the groove is reduced, and a deeper groove can be easily formed.
  • the groove can be formed even if the depth is 200 ⁇ m or more.
  • the depth D is shallow, when the composite molded product 1 is formed by joining with the other molded product 20 in the groove 12, it is between the fibrous inorganic filler 11 exposed in the groove 12 and the other molded product 20. Since a sufficient anchor effect is not generated, the grooved resin molded product 10 and the other molded product 20 may not be firmly adhered to each other.
  • the grooved resin molded product 10 removes the resin partially by irradiating the resin molded product containing the fibrous inorganic filler 11 with a laser, and at least the end of the fibrous inorganic filler 11 on the surface side. Is obtained by forming a groove 12 exposed from the side surface.
  • Laser irradiation is set based on the type of material to be irradiated and the output of the laser device.
  • the laser irradiation conditions are not particularly limited as long as the resin is partially removed, but the resin is partially removed by performing from a direction other than perpendicular to the surface of the molded product. At the same time, it is preferable to remove a part of the fibrous inorganic filler. By removing both part of the resin and part of the fibrous inorganic filler, the end of the fibrous inorganic filler 11 protrudes in the direction of the side facing the both sides of the groove on the surface side of the groove and is exposed. More specifically, it can be exposed by projecting on the same axis from both side surfaces of the groove.
  • FIG. 2 is a schematic enlarged cross-sectional view of the composite molded article 1 of the present invention.
  • another molded product 20 is adjacent to the surface having the groove 12 of the grooved resin molded product 10.
  • the form of the other molded product 20 inside the groove 12 is not particularly limited, but the other molded product 20 surrounds the fibrous inorganic filler 11 inside the groove 12 in order to obtain a high anchor effect. It is preferable to arrange
  • the other molded product 20 is not particularly limited as long as it can enter the groove 12 in which the fibrous inorganic filler 11 is exposed in an uncured state, and is not limited to a thermoplastic resin or a curable resin. Any of resin (thermosetting resin, photocurable resin, radiation curable resin, etc.), rubber, adhesive, metal and the like may be used.
  • the composite molded product 1 is obtained not only by multiple molding but also by heat melting of a resin molded product such as ultrasonic welding, laser welding, high frequency induction heating welding, and the like.
  • FIG. 3 is a schematic explanatory diagram when the composite molded article 1 is obtained by multiple molding.
  • primary resin is primary-molded and grooved resin molded product preliminary body 10 'is produced.
  • the resin is partially removed from at least a part of the surface of the preliminary body 10 ′ to form the grooves 12.
  • the grooved resin molded product 10 is produced.
  • the grooved resin molded product 10 is put into a mold (not shown), and the surface having the grooves 12 is used as a contact surface inside the mold. Resin (uncured material constituting the other molded article 20) is enclosed, and this material is cured. By passing through the said process, the composite molded product 1 with curable resin by multiple shaping
  • the type of mold is not particularly limited, but the grooved resin molded product 10 is inserted into an injection mold with a surface having a groove formed by laser irradiation as a contact surface, and the other molded product 20 is inserted. It is preferable to integrate the materials according to the above by injection molding to obtain a composite molded product. Injection molding is performed by injecting another uncured molded product 20 into a mold containing the grooved resin molded product 10 under high pressure, so that the fibrous inorganic filler 11 is exposed to the groove 12 exposed. It is possible to easily obtain an integrated composite molded product that is effectively inserted.
  • the grooved molded product 10 has the groove 11 and the other molded product 20 does not have the groove.
  • the present invention is not limited to this.
  • Also has a groove puts the grooved molded product 10 on one side of the mold, puts the other molded product 20 on the other side, and then attaches the adhesive between the grooved molded product 10 and the other molded product 20.
  • the composition may be put so that the adhesive composition enters the groove 11 of the grooved molded article 10 and the groove of the other molded article 20.
  • the adhesive composition may not be suitable for interlayer adhesion between the grooved molded article 10 and the other molded article 20.
  • the grooved molded product 10 and the other molded product 20 can be firmly joined.
  • a glass fiber-containing PPS product name: Durafide PPS 1140A1, manufactured by Polyplastics Co., Ltd.
  • a laser with a spot diameter of 50 ⁇ m is applied 10 times to 25 ⁇ m.
  • the irradiation was repeated 3 times, and the irradiation was performed 30 times in total so that the irradiation width became 100 ⁇ m.
  • the laser one is irradiated perpendicularly to the surface of the injection molded product as shown in FIG. 4 (1), and the other is injected as shown in (2) in FIG.
  • the laser oscillation wavelength was 1.064 ⁇ m, the maximum rated output was 13 W (average), the output was 90%, the frequency was 40 kHz, and the scanning speed was 1000 mm / s.
  • the grooved resin molded product according to Example 1 is obtained by removing part of the fibrous inorganic filler when part of the resin is removed by laser irradiation. As a result, it was confirmed that the ends of the fibrous inorganic filler protruded from the side surface of the groove and exposed at least on the surface side. Moreover, it was confirmed that the depth of the groove can be made deeper than in the preliminary test, and as a result, a high anchor effect can be obtained.
  • Example 2 Partial removal of glass fiber (comparison of resin materials) Subsequently, suitable resin materials were verified.
  • the material of the resin in the resin molded product is as follows. (PPS 1140 A1 CB with glass fiber 0.2%: Durafide PPS 1140A1, carbon black 0.2%, manufactured by Polyplastics) PPS 1140 A1 CB with glass fiber 0.01%: Durafide PPS 1140A1 carbon black 0.01%, manufactured by Polyplastics) POM: Duracon POM M450-44, manufactured by Polyplastics
  • the breaking load of the composite molded product was measured.
  • the breaking load was measured as follows. Tensilon UTA-50kN (Orientec Co., Ltd.) was used as a measuring instrument, and the composite molded body (120 mm length, 12 mm width, 6 mm thickness) was pulled and peeled off at a crosshead speed of 1 mm / min. The results are shown in FIG. About the comparative example, it destroyed by weak force and the intensity
  • the grooved resin molded product according to Examples 2 and 3 is obtained by removing part of the fibrous inorganic filler when part of the resin is removed by laser irradiation. As a result, it was confirmed that the ends of the fibrous inorganic filler protruded from the side surface of the groove and exposed at least on the surface side. Further, it was confirmed that the depth of the groove can be easily increased as compared with the case where a part of the fibrous inorganic filler is not removed, and as a result, a high anchor effect can be obtained.
  • the composite molded product 1 When measuring the bonding strength, the composite molded product 1 was not simply peeled, but was destroyed by the base material destruction in which the other molded product was damaged while a part of the other molded product remained in the groove. This is considered because the edge part of a fibrous inorganic filler protrudes in the side surface direction which opposes from the both sides
  • the fibrous inorganic filling It is expected that the agent can effectively engage with the other molded article and prevent the other molded article 20 from being pulled out of the groove.

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Abstract

　他の成形品と接合したときの強度をよりいっそう高める。　本発明の複合成形品１は、繊維状無機充填剤１１の端部が少なくとも溝内部の表面側において溝の側面より突出し露出された溝１２を有する溝付き樹脂成形品１０の溝１２を有する面上に他の材料が一体化されている。繊維状無機充填剤１１の端部の露出及び溝１２の形成は、レーザの照射によってなされることが好ましく、溝１２の深さは２００μｍ以上であることが好ましい。他の材料からなる他の成形品２０は、溝１２の内部において、繊維状無機充填剤１１を囲んで配されている。

Description

複合成形品及びその製造方法
　本発明は、複合成形品、及びその製造方法に関する。
　近年、自動車、電気製品、産業機器等をはじめとした分野では、二酸化炭素の排出量削減、製造コストの削減等の要請に応えるため、金属成形品の一部を樹脂成形品に置き換える動きが広がっている。これに伴い、樹脂成形品と金属成形品とを一体化した複合成形品が広く普及している。これに限らず、同種又は異種の材料からなる成形品を一体化した複合成形品も広く普及している。
　一の成形品と他の成形品とを一体化した複合成形品の製造方法として、例えば、次のようなものが提案されている。特許文献１には、一方の樹脂にガラスファイバー等の充填剤を混入して成形し、他方の樹脂を接着する面に薬品、プラズマ、炎等の処理を施して厚さ０．数μｍ～数１０μｍの樹脂を除去した後、前記他方の樹脂を接着する面に前記他方の樹脂を接して充填、成形し、接着させることが提案されている。また、特許文献２には、一方の樹脂成形品の表面に電磁放射線を照射することで該表面にナノ構造を形成し、その後、該表面に他方の樹脂成形品を接して充填、成形し、一体化させることが提案されている。
　また、特許文献３には、凹凸形状を有し、表見に硬質繊維が突出する基材と表皮材とをプレス接合することが提案されている。特許文献４には、表面に金属繊維が露出する成型部材どうしを接合部で接合することが提案されている。特許文献５には、高出力連続発振固体レーザを用いて、ＦＲＰ部材及びＦＲＭ（繊維強化金属）等の複合材料及び複合材料合板同志または複合材料と金属の異種材料継手の突合せ継手、重ね継手、へり継手、すみ肉継手の接合部に熱可塑性樹脂、熱硬化性樹脂、及び熱可塑性樹脂と熱硬化性樹脂の混合したものに、強化繊維、強化ガラス、ウイスカーを含む強化材を数％～８０％重量％添加した溶加材を充填しつつ、複合材料及び複合材料合板とをレーザ溶接することが提案されている。
特開平０１－１２６３３９号公報 特表２０１１－５２９４０４号公報 特開２０００－３５１１８９号公報 特開平３－２０３２９１号公報 特開２０１０－２４７２０６号公報
　しかしながら、一の成形品と他の成形品とを接合したときの強度に関し、さらなる改良の余地がある。例えば、特許文献３に記載の手法では、複合成形品は、凹凸を有する成形品表面に繊維が突出し存在する基材に対し、表皮材を圧縮成形することになるため、繊維を表皮材に突き刺すことだけでなく、表皮材を繊維から引き抜くことも容易となる。表示材が外れることを防ぐためには、基材と表皮材との間を接着剤で接合することを要する。
　また、特許文献４の課題は、両成型部材の表面の相互の導通をはかることであり、相互の成形部材に無機充填剤が架かっていれば足りる。特許文献４において、高いアンカー効果を得ることについては開示も示唆もない。
　また、特許文献５においても、従来のＣＯ２レーザやファイバレーザで炭素繊維強化プラスチックを切断すると、切断部において炭素繊維のむき出しが見られることを開示するにとどまり、この炭素繊維が部材の接合強度に寄与することを開示するものではない。
　本発明は、以上のような課題を解決するためになされたものであり、その目的は、他の成形品と接合したときの強度をよりいっそう高めることの可能な樹脂成形品を提供することである。
　本発明者らは、上記のような課題を解決するために鋭意研究を重ねた。その結果、繊維状無機充填剤を含有する樹脂成形品の樹脂を一部除去するとともに、繊維状無機充填剤の一部除去を行い、これにより形成される溝の少なくとも表面側において繊維状無機充填剤の端部が溝の側面から突出して露出された溝を形成することで、溝をより深く形成したり、溝に他の成形品を構成する部材の侵入を容易に出来、溝付き樹脂成形品と他の成形品とを接合した際に、溝で露出する繊維状無機充填剤が溝付き樹脂成形品及び他の成形品の接合部における破壊を抑えるアンカーの役割を果たし、結果として複合成形体の強度を著しく高められることを見出した。具体的に、本発明は以下のものを提供する。
　（１）本発明は、繊維状無機充填剤の端部が溝内部の少なくとも表面側において溝の側面より対向する側面方向に突出して露出された溝を有する溝付き樹脂成形品の前記溝を有する面上に他の材料が一体化された複合成形品である。
　（２）また、本発明は、前記繊維状無機充填剤の端部の露出及び前記溝の形成は、レーザの照射によってなされる、（１）に記載の複合成形品である。
　（３）また、本発明は、前記溝の深さが２００μｍ以上である、（１）又は（２）のいずれかに記載の複合成形品である。
　（４）また、本発明は、前記繊維状無機充填剤の端部は、前記溝内部の少なくとも表面側において溝の両側面より突出して露出されている、（１）から（３）のいずれかに記載の複合成形品である。
　（５）また、本発明は、前記繊維状無機充填剤の端部は、前記溝の両側面より同軸線上に対向して突出して露出されている、（４）に記載の複合成形品である。
　（６）また、本発明は、前記他の材料からなる成形品は、前記溝の内部において、前記繊維状無機充填剤を囲んで配されている、（１）から（５）のいずれかに記載の複合成形品である。
　（７）また、本発明は、射出成形により一体化されている、（１）から（６）のいずれかに記載の複合成形品である。
　（８）また、本発明は、繊維状無機充填剤を含有する樹脂成形品に樹脂の一部除去を行い、少なくとも溝内部の表面側において繊維状無機充填剤の端部が溝の側面より対向する側面方向に突出して露出された溝を形成する溝形成工程と、前記溝を有する面を接触面として他の材料と一体化して複合成形品を製造する複合成形工程とを含む、複合成形品の製造方法である。
　（９）また、本発明は、前記樹脂の一部除去がレーザの照射により行われる、（８）に記載の複合成形品の製造方法である。
　（１０）また、本発明は、前記レーザの照射を、成形品の表面に対して垂直以外の方向から行う、（９）に記載の複合成形品の製造方法である。
　（１１）また、本発明は、前記樹脂の一部除去が、前記溝の深さが２００μｍ以上になるまで行われる、（８）から（１０）のいずれかに記載の複合成形品の製造方法である。
　（１２）また、本発明は、前記溝形成工程が、前記樹脂成形品に樹脂の一部除去を行い、少なくとも溝内部の表面側において繊維状無機充填剤の端部が溝の両側面より対向する側面方向に突出して露出された溝を形成する工程である、（８）から（１１）のいずれかに記載の複合成形品の製造方法である。
　（１３）また、本発明は、前記溝形成工程が、前記繊維状無機充填剤の一部除去を併せて行う工程である、（８）から（１２）のいずれかに記載の複合成形品の製造方法である。
　（１４）また、本発明は、前記溝形成工程が、前記繊維状無機充填剤の一部除去により、前記繊維状無機充填剤の端部を溝の両側面より対向して突出して露出させる工程である、（８）から（１３）のいずれかに記載の複合成形品の製造方法である。
　（１５）また、本発明は、前記複合成形工程が、前記溝を有する面を接触面として他の材料と射出成形により一体化して複合射出成形品を製造する工程である、（８）から（１４）のいずれかに記載の複合成形品の製造方法である。
　本発明によると、溝付き樹脂成形品を他の成形品と接合した際に、溝で露出する繊維状無機充填剤が溝付き樹脂成形品及び他の成形品の破壊を抑えるアンカーの役割を果たし、結果として複合成形体の強度を著しく高めることができる。
本発明の複合成形品１の構成要素である溝付き樹脂成形品１０の概略拡大断面の模式図である。 本発明の複合成形品１の概略拡大断面の模式図である。 多重成形によって複合成形品１を得るときの概略説明図である。 実施例１（レーザの照射角度の比較）における照射角度を説明するための図である。 実施例１（レーザの照射角度の比較）に係る溝付き樹脂成形品のＳＥＭ写真である。 実施例２（樹脂材料の比較）に係る溝付き樹脂成形品のＳＥＭ写真である。
　以下、本発明の実施形態について詳細に説明するが、本発明は、以下の実施形態に何ら限定されるものではなく、本発明の目的の範囲内において、適宜変更を加えて実施することができる。なお、説明が重複する箇所については、適宜説明を省略する場合があるが、発明の要旨を限定するものではない。
＜溝付き樹脂成形品１０＞
　図１は、本発明の複合成形品１（図２）の構成要素である溝付き樹脂成形品１０の概略拡大断面模式図である。溝付き樹脂成形品１０は、繊維状無機充填剤１１を含有する。また、溝付き樹脂成形品１０は、繊維状無機充填剤１１の端部が少なくとも表面側において側面より対向する側面方向に突出し露出された溝１２を有する。表面側とは溝の深さ方向において成形品表面に近い側のことを意味する。
［樹脂］
　樹脂の種類は、レーザの照射により除去され、結果として溝１２を形成できるものであれば特に限定されず、レーザの吸収を調整し、レーザの照射により樹脂を除去するだけでなく、レーザの照射により繊維状無機充填剤１１の一部を除去し、繊維状無機充填剤１１の端部を少なくとも溝付き樹脂成形品１０に形成される溝の表面側において好適に露出できるものであれば構わない。
　レーザの吸収率を調整する手法として、樹脂にレーザを吸収する配合剤の種類や添加量を調整することが挙げられる。このような配合剤としては、顔料や染料といったものが用いられ、カーボンブラックが効果的である。
　樹脂は、熱可塑性であってもよいし、熱硬化性であってもよい。樹脂の好適な材質として、例えば、ポリフェニレンスルフィド（ＰＰＳ）、液晶ポリマー（ＬＣＰ）、ポリブチレンテレフタレート（ＰＢＴ）、ポリアセタール（ＰＯＭ）等が挙げられる。
［繊維状無機充填剤１１］
　繊維状無機充填剤１１は、樹脂成形品の樹脂の一部を除去することにより溝１２を形成する際に、少なくとも一部の繊維状無機充填剤１１が一部除去され、繊維状無機充填剤１１の端部が少なくとも溝付き樹脂成形品１０に形成される溝の表面側において溝の側面より突出し露出されるものであれば、特に限定されない。
　繊維状無機充填剤１１として、ガラス繊維、炭素繊維、ウィスカー繊維、等を挙げることができ、単独もしくは混合して用いることが出来る。繊維状であれば、繊維状無機充填剤１１が複合成形品（図２の１）から脱落することを防止し、繊維状無機充填剤１１が溝付き樹脂成形品１０及び他の成形品（図２の２０）の分離を抑えるアンカーの役割を果たす。中でもガラス繊維が本願発明においては好適に用いられる。また、繊維状以外のガラスフレーク、マイカ、タルク、ガラスビーズなどの無機充填剤やその他の添加剤や改質剤などが、本発明の効果の発現を妨げない程度に配合されていても構わない。
　上述したとおり、繊維状無機充填剤１１は、繊維状無機充填剤１１の端部が溝の表面側において溝の側面より対向する側面方向に突出し露出されるものであれば、特に限定されないが、溝内部の少なくとも表面側において溝の両側面より突出して露出されることが好ましく、溝の両側面より同軸線上に対向して突出して露出されることがより好ましい。溝付き樹脂成形品１０と他の成形品（図２の２０）とが一体化された複合成形品１において、接合強度を測定すると、複合成形品１は、単なる剥離ではなく、溝に他の成形品２０の一部が残った状態で他の成形品２０が破損する母材破壊によって破壊される。このことから、溝の両側面より対向する側面方向に突出して露出されることで、溝付き樹脂成形品１０と他の成形品（図２の２０）とが一体化された複合成形品１において、溝付き樹脂成形品１０と他の成形品２０とを引きはがす力が加わる際、繊維状無機充填剤１１が他の成形品２０と効果的に係合し、溝から他の成形品２０が引き出されることを防止できるといえる。
　溝１２で露出する無機充填剤１１が溝付き樹脂成形品１０及び他の成形品２０の破壊を抑えるアンカーの役割を果たすにあたり、溝１２の深部においては、樹脂の一部が除去されることにより形成される凹凸の山１３どうしを繊維状無機充填剤１１が好適に架けていることが好ましい。
　繊維状無機充填剤１１の含有量は特に限定されるものでないが、樹脂１００重量部に対して５重量部以上８０重量部以下であることが好ましい。５重量部未満であると、繊維状無機充填剤１１が溝１２で露出したとしても、この繊維状無機充填剤１１が溝付き樹脂成形品１０及び他の成形品２０の破壊を抑えるアンカーの役割を十分に果たせない可能性がある。８０重量部を超えると、繊維状無機充填剤１１と溝１２がに配された他の成形品との係止効果が十分に発揮できない場合がある点で好ましくない。
［繊維状無機充填剤１１を含有する樹脂材料の好適な市販品］
　繊維状無機充填剤１１を含有する樹脂材料の市販品として、ガラス繊維入りＰＰＳ（製品名：ジュラファイドＰＰＳ　１１４０Ａ１，ポリプラスチックス社製）、ガラス繊維入りＰＰＳ（製品名：ジュラファイドＰＰＳ　１１４０Ａ７，ポリプラスチックス社製）、ガラス繊維・無機フィラー入りＰＰＳ（製品名：ジュラファイドＰＰＳ　６１６５Ａ７，ポリプラスチックス社製）、ガラス繊維入りＬＣＰ（製品名：ベクトラＬＣＰ　Ｅ１３０ｉ、ポリプラスチックス社製）等を挙げることができる。
［溝１２］
　樹脂成形品１０の表面には溝１２が形成されている。溝１２では、繊維状無機充填剤１１が露出されている。そして、樹脂の一部除去により溝１２を形成するとともに溝の少なくとも表面側において側面から露出し溝に照射されるレーザを一部遮蔽する繊維状無機充填剤の一部を除去することにより、溝１２の側面１２ａから繊維状無機充填剤１１の端部を溝側面より突出した状態で露出させることができる。繊維状無機充填剤１１の少なくとも一部を除去することで、溝１２に露出する繊維状無機充填剤によるレーザの遮蔽効果が減ることで、溝の深くまでレーザが効果的に照射出来るため、溝をより深くすることができ、これにより、他の樹脂成形品と複合成形したときのアンカー効果を高めることができる。また、他の成形品と一体化して複合成形品を得る際、少なくとも表面側において露出する繊維状充填剤の端部を突出する状態で一部を除去しとりわけ溝の中央部の繊維状無機充填剤を除去することで、流動状態にある他の成形品の溝への入り込みを容易にし、溝が深くとも高いアンカー効果を得ることが出来る。
　ところで、本発明は、溝付き樹脂成形品１０の溝１２を有する面を接触面として他の成形品（図２の２０）と一体化して複合成形品（図２の１）を製造するところ、この複合成形品１において繊維状無機充填剤１１は露出されていない。本明細書では、複合成形品１において繊維状無機充填剤１１が露出していない場合であっても、複合成形品１から他の成形品２０を取り除いた態様において溝１２から繊維状無機充填剤１１が露出していれば、「複数の溝１２において繊維状無機充填剤１１が露出されている」ものとする。
　他の樹脂成形品と複合成形したときに溝の側面から無機充填剤の端部が突出して露出することで十分なアンカー効果がより効果的に得られる点で、溝１２の長手方向は、繊維状無機充填剤１１の長手方向とは異なることが好ましい。
　樹脂成形品１０の表面に形成される溝１２は、複数の溝１２を設けることにより、アンカーの効果がより高まる。溝１２を複数形成する際、これら複数の溝１２は、各々の溝が個別に形成されたものであってもよいし、一筆書きの要領で複数の凹凸からなる溝が一度に形成されたものであってもよい。
　複数の溝１２は両端が繋がった溝１２を等高線のように並べて設けても良いし、交差しない縞状に形成されても、溝１２が交差する格子状に形成されてもよい。溝１２を格子状に形成する場合は、溝１２の長手方向が繊維状無機充填剤の長手方向とは異なる斜格子状に形成することが好ましい。また、溝１２を格子状に形成する場合、溝１２の形状はひし形状であっても良い。
　溝１２の長さは特に限定されるものでなく、溝１２が短い場合、開口部の形状は四角形であってもよいし、丸形や楕円形であってもよい。アンカー効果を得るためには、溝１２は長い方が好ましい。
　また、溝１２の深さＤについても特に限定されるものではないが、より高いアンカー効果を得られる点で、溝１２の深さは深い方が好ましく、溝に露出する繊維状無機充填剤の一部を除去することで、溝に照射されるレーザの遮蔽が少なくなり、より深い溝を容易に作成することが出来る。本発明によれば、溝の深さは、２００μｍ以上であっても形成することが出来る。深さＤが浅いと、溝１２で他の成形品２０と接合して複合成形品１を形成する際に、溝１２に露出する繊維状無機充填剤１１と他の成形品２０との間に十分なアンカー効果を生じないことから、溝付き樹脂成形品１０と他の成形品２０とを強固に密接できないことがある。
＜溝付き樹脂成形品１０の製造方法＞
　溝付き樹脂成形品１０は、繊維状無機充填剤１１を含有する樹脂成形品にレーザの照射を行なうことで、樹脂を部分的に除去し、少なくとも表面側において繊維状無機充填剤１１の端部が側面より突出して露出された溝１２が形成されることによって得られる。
　レーザの照射は、照射対象材料の種類やレーザ装置の出力等をもとに設定される。
　また、レーザの照射条件は、樹脂を部分的に除去する態様であれば特に限定されるものでないが、成形品の表面に対して垂直以外の方向から行うことにより、樹脂を部分的に除去するとともに繊維状無機充填剤の一部を除去することが好ましい。樹脂の一部及び繊維状無機充填剤の一部の両方を除去することで、繊維状無機充填剤１１の端部が溝の表面側において溝の両側面より対向する側面方向に突出して露出させること、より具体的には、溝の両側面より同軸線上に対向して突出して露出させることができる。
＜複合成形品１＞
　図２は本発明の複合成形品１の概略拡大断面の模式図である。複合成形品１において、溝付き樹脂成形品１０の溝１２を有する面上に他の成形品２０が隣接されている。溝１２の内部における他の成形品２０の態様は特に限定されるものでないが、高いアンカー効果を得るため、他の成形品２０は、溝１２の内部において、繊維状無機充填剤１１を囲むように配置されることが好ましい。
［他の成形品２０］
　他の成形品２０は、未硬化状態の場合に、繊維状無機充填剤１１が露出された溝１２に入ることが可能なものであれば特に限定されるものでなく、熱可塑性樹脂、硬化性樹脂（熱硬化性樹脂、光硬化性樹脂、放射線硬化性樹脂等）、ゴム、接着剤、金属等のいずれであってもよい。
＜複合成形品１の製造方法＞
　複合成形品１は、多重成形に限らず、超音波溶着、レーザ溶着、高周波誘導加熱溶着等、樹脂成形品の加熱溶融によっても得られる。
　従来、樹脂成形品どうしを加熱溶着する際、１次成形品の第一溶着予定面と、２次成形品の第二溶着予定面との両方を加熱溶融したとしても、溶着する組合せは極めて限定的である。しかしながら、本明細書に記載の発明では、第二溶着予定面を加熱溶融すれば足り、溶着する材料の組合せである必要もない。本明細書に記載の発明によると、予め溝１２を形成した第一溶着予定面に対して他の樹脂成形品２０を加熱圧接すれば足りるので、樹脂成形品の材料の組合せを選ばず、寸法精度と接合強度との両方に優れた複合成形品１を得ることができる。
［多重成形］
　図３は、多重成形によって複合成形品１を得るときの概略説明図である。まず、図３の（１）に示すように、１次樹脂を１次成形し、溝付き樹脂成形品予備体１０’を作製する。続いて、図３の（２）に示すように、予備体１０’の表面の少なくとも一部に対し、樹脂の部分的除去を行い、溝１２を形成する。これによって、溝付き樹脂成形品１０が作製される。
　続いて、図３の（３）に示すように、溝付き樹脂成形品１０を金型（図示せず）に入れ、この金型の内部に、溝１２を有する面を接触面として、２次樹脂（他の成形品２０を構成する材料の未硬化物）を封入し、この材料を硬化する。上記工程を経ることで、多重成形による硬化性樹脂との複合成形品１が得られる。また、同様に、２次樹脂を加熱溶融した熱可塑性樹脂とすることにより、多重成形による熱可塑性樹脂との複合成形品１が得られる。金型の種類は特に限定されるものでないが、溝付き樹脂成形品１０について、レーザの照射によって形成された溝を有する面を接触面として射出成形用金型にインサートし、他の成形品２０に係る材料を射出成形にて一体化し、複合成形品を得ることが好ましい。射出成形は、溝付き樹脂成形品１０を入れた金型内に未硬化状態の他の成形品２０を高い圧力をかけて注入することで、繊維状無機充填剤１１が露出された溝１２に効果的に入り込ませ、一体化した複合成形品を容易に得ることができる。
　下記の実施例では、溝付き成形品１０が溝１１を有し、他の成形品２０が溝を有しないものとして説明されているが、これに限るものでなく、例えば、他の成形品２０も溝を有し、型の一側面に溝付き成形品１０を入れ、他の側面に他の成形品２０を入れた後、溝付き成形品１０と他の成形品２０との間に接着剤組成物を入れ、この接着剤組成物が溝付き成形品１０の溝１１と他の成形品２０の溝とに入り込むようにしてもよい。このようにすることで、接着剤組成物の種類にかかわらず、接着剤組成物が溝付き成形品１０と他の成形品２０との間の層間接着に好適とはいえない場合であっても、溝付き成形品１０と他の成形品２０とを強固に接合できる。
　以下、本発明を予備試験例及び実施例によりさらに詳細に説明するが、本発明はこれらによって限定されるものではない。
（ジュラファイドにおける射出成形の条件）
　予備乾燥：１４０℃、３時間
　シリンダ温度：３２０℃
　金型温度：１４０℃
　射出速度：２０ｍｍ／ｓｅｃ
　保圧：５０ＭＰａ（５００ｋｇ／ｃｍ２）
 
（ジュラコンにおける射出成形の条件）
　予備乾燥：８０℃、３時間
　シリンダ温度：１９０℃
　金型温度：８０℃
　射出速度：１６ｍｍ／ｓｅｃ
　保圧：８０ＭＰａ（８００ｋｇ／ｃｍ２）
＜実施例１＞　ガラス繊維の一部除去（照射角度の比較）
　溝の表面において繊維状無機充填剤を一部除去する溝の形成は、次の方法により行うことができる。
Figure JPOXMLDOC01-appb-T000001
［溝付き樹脂成形品の製造］
　ガラス繊維入りＰＰＳ（製品名：ジュラファイドＰＰＳ　１１４０Ａ１，ポリプラスチックス社製）を上記（射出成形の条件）で示した条件で射出成形した射出成形品に、スポット径５０μｍのレーザを１０回づつ２５μｍずらして３回繰り返し、照射巾が１００μｍとなるように計３０回照射した。レーザを照射する際、一方は、図４の（１）に示すように、射出成形品の表面に対して垂直に照射し、他方は、図４の（２）に示すように、射出成形品を水平方向から３０度傾け、射出成形品の表面に対して６０度の方向に照射した。レーザの発振波長は１．０６４μｍ、最大定格出力は１３Ｗ（平均）とし、出力は９０％、周波数は４０ｋＨｚ、走査速度は１０００ｍｍ／ｓとした。これにより、実施例ならびに参考例に係る溝付き樹脂成形品を得た。
［評価］
　溝を有する面を電子顕微鏡（ＳＥＭ）で拡大観察した。倍率は１００倍、３００倍の２種類とした。結果を図５及び表２に示す。
Figure JPOXMLDOC01-appb-T000002
　実施例１に係る溝付き樹脂成形品は、レーザの照射により樹脂を一部除去する際、繊維状無機充填剤の一部を除去したものである。その結果、少なくとも表面側において繊維状無機充填剤の端部が溝の側面より突出して露出されていることが確認された。また、予備試験に比べて溝の深さをより深くすることができ、その結果、高いアンカー効果を得られることが確認された。
　特に、レーザの照射を、成形品の表面に対して垂直以外の方向から行うことで、繊維状無機充填剤の一部除去が容易に行え、結果として、より深い溝を得ることが容易となることが確認された（実施例１、図５）。
＜実施例２＞　ガラス繊維の一部除去（樹脂材料の比較）
　続いて、好適な樹脂材料を検証した。
Figure JPOXMLDOC01-appb-T000003
　表３において、樹脂成形品における樹脂の材質は次のとおりである。
　ガラス繊維入りＰＰＳ　１１４０　Ａ１　ＣＢ０．２％：ジュラファイドＰＰＳ　１１４０Ａ１，カーボンブラック０．２％，ポリプラスチックス社製）
　ガラス繊維入りＰＰＳ　１１４０　Ａ１　ＣＢ０．０１％：ジュラファイドＰＰＳ　１１４０Ａ１カーボンブラック０．０１％，ポリプラスチックス社製）
　ＰＯＭ：ジュラコンＰＯＭ　Ｍ４５０－４４，ポリプラスチックス社製
［溝付き樹脂成形品の製造］
　表３に示した樹脂材料を上記（射出成形の条件）で示した条件で射出成形した射出成形品に、実施例１と同じ照射回数が１０回になるように、射出成形品の表面に対して垂直方向から斜格子状に照射した。レーザの発振波長は１．０６４μｍ、最大定格出力は１３Ｗ（平均）とし、出力は９０％、周波数は４０ｋＨｚ、走査速度は１０００ｍｍ／ｓとした。これにより、溝幅が１００μｍで格子状の、実施例及び参考例に係る溝付き樹脂成形品を得た。
［複合成形品の製造］
　実施例、参考例及び比較例に係る溝付き樹脂成形品のそれぞれについて、レーザの照射によって形成された溝を有する面を接触面として射出成形用金型にインサートし、表１に示す他の成形品に係る材料を上記の条件で射出成形し、複合成形品を得た。
［評価］
〔溝付き樹脂成形品の拡大観察〕
　溝付き樹脂成形品について、溝を有する面を電子顕微鏡（ＳＥＭ）で拡大観察した。倍率は１００倍、３００倍の３種類とした。
〔溝の深さ〕
　溝付き樹脂成形品について、断面観察にて溝の深さを測定した。
〔強度〕
　接合強度を確かめるため、複合成形品について破壊荷重を測定した。破壊荷重の測定は次のようにして行った。測定機器としてテンシロンＵＴＡ－５０ｋＮ（オリエンテック社製）を使用し、クロスヘッド速度が１ｍｍ／分の条件で複合成形体（１２０ｍｍ長さ、１２ｍｍ幅、６ｍｍ厚み）を引張り剥がすことで行った。結果を図６及び表４に示す。比較例については、弱い力で破壊し、強度を測定できなかった。
Figure JPOXMLDOC01-appb-T000004
　実施例２及び３に係る溝付き樹脂成形品は、レーザの照射により樹脂を一部除去する際、繊維状無機充填剤の一部を除去したものである。その結果、少なくとも表面側において繊維状無機充填剤の端部が溝の側面より突出して露出されていることが確認された。また、繊維状無機充填剤を一部除去しなかった場合比べて溝の深さを容易に深くすることができ、その結果、高いアンカー効果を得られることが確認された。
　接合強度を測定する際、複合成形品１は、単なる剥離ではなく、溝に他の成形品の一部が残った状態で他の成形品が破損する母材破壊によって破壊された。これは、繊維状無機充填剤の端部が溝の表面側において溝の両側面より対向する側面方向に突出して露出されているためと考えられる。そして、このことから、溝付き樹脂成形品と他の成形品とが一体化された複合成形品において、溝付き樹脂成形品と他の成形品とを引きはがす力が加わる際、繊維状無機充填剤が他の成形品と効果的に係合し、溝から他の成形品２０が引き出されることを防止できるものと予想される。
　特に、溝付き樹脂成形品を構成する樹脂を、レーザ吸収をカーボンブラックの量を調整した樹脂にすることで、繊維状無機充填剤が効果的に一部除去できることが確認された（実施例２－２、図６）。その結果、溝の深さを容易に深くすることができ、また、溝の内部に容易に深く他の樹脂が満たされ、その結果、よりいっそう高いアンカー効果を得られることが確認された。
　１　　　複合成形品
　１０　　溝付き樹脂成形品
　１１　　繊維状無機充填剤
　１２　　溝
　１２ａ　溝の側面
　１３　　山
　２０　　他の成形品

Claims (15)

  1. 　繊維状無機充填剤の端部が溝内部の少なくとも表面側において溝の側面より対向する側面方向に突出して露出された溝を有する溝付き樹脂成形品の前記溝を有する面上に他の材料が一体化された複合成形品。
  2. 　前記繊維状無機充填剤の端部の露出及び前記溝の形成は、レーザの照射によってなされる、請求項１に記載の複合成形品。
  3. 　前記溝の深さが２００μｍ以上である、請求項１又は２のいずれかに記載の複合成形品。
  4. 　前記繊維状無機充填剤の端部は、前記溝内部の少なくとも表面側において溝の両側面より突出して露出されている、請求項１から３のいずれかに記載の複合成形品。
  5. 　前記繊維状無機充填剤の端部は、前記溝の両側面より同軸線上に対向して突出して露出されている、請求項４に記載の複合成形品。
  6. 　前記他の材料からなる成形品は、前記溝の内部において、前記繊維状無機充填剤を囲んで配されている、請求項１から５のいずれかに記載の複合成形品。
  7. 　射出成形により一体化されている、請求項１から６のいずれかに記載の複合成形品。
  8. 　繊維状無機充填剤を含有する樹脂成形品に樹脂の一部除去を行い、少なくとも溝内部の表面側において繊維状無機充填剤の端部が溝の側面より対向する側面方向に突出して露出された溝を形成する溝形成工程と、
    　前記溝を有する面を接触面として他の材料と一体化して複合成形品を製造する複合成形工程とを含む、複合成形品の製造方法。
  9. 　前記樹脂の一部除去は、レーザの照射により行われる、請求項８に記載の複合成形品の製造方法。
  10. 　前記レーザの照射を、成形品の表面に対して垂直以外の方向から行う、請求項９に記載の複合成形品の製造方法。
  11. 　前記樹脂の一部除去は、前記溝の深さが２００μｍ以上になるまで行われる、請求項８から１０のいずれかに記載の複合成形品の製造方法。
  12. 　前記溝形成工程は、前記樹脂成形品に樹脂の一部除去を行い、少なくとも溝内部の表面側において繊維状無機充填剤の端部が溝の両側面より対向する側面方向に突出して露出された溝を形成する工程である、請求項８から１１のいずれかに記載の複合成形品の製造方法。
  13. 　前記溝形成工程は、前記繊維状無機充填剤の一部除去を併せて行う工程である、請求項８から１２のいずれかに記載の複合成形品の製造方法。
  14. 　前記溝形成工程は、前記繊維状無機充填剤の一部除去により、前記繊維状無機充填剤の端部を溝の両側面より対向して突出して露出させる工程である、請求項８から１３のいずれかに記載の複合成形品の製造方法。
  15. 　前記複合成形工程は、前記溝を有する面を接触面として他の材料と射出成形により一体化して複合射出成形品を製造する工程である、請求項８から１４のいずれかに記載の複合成形品の製造方法。
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KR102343382B1 (ko) 2019-01-25 2021-12-24 포리프라스틱 가부시키가이샤 복합 성형품
DE112020000517B4 (de) 2019-01-25 2022-11-24 Polyplastics Co., Ltd. Verbundformkörper
JP2021120194A (ja) * 2020-01-30 2021-08-19 オムロン株式会社 複合成形体
JP7404899B2 (ja) 2020-01-30 2023-12-26 オムロン株式会社 複合成形体

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CN106062052A (zh) 2016-10-26
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TWI626148B (zh) 2018-06-11
TW201607736A (zh) 2016-03-01
JPWO2015146767A1 (ja) 2017-04-13
CN106062052B (zh) 2017-06-06
KR20160103155A (ko) 2016-08-31
JP5918451B2 (ja) 2016-05-18
US20170015047A1 (en) 2017-01-19
US10232547B2 (en) 2019-03-19

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