WO2020196402A1 - 樹脂成形品及び樹脂成形品の製造方法 - Google Patents

樹脂成形品及び樹脂成形品の製造方法 Download PDF

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Publication number
WO2020196402A1
WO2020196402A1 PCT/JP2020/012709 JP2020012709W WO2020196402A1 WO 2020196402 A1 WO2020196402 A1 WO 2020196402A1 JP 2020012709 W JP2020012709 W JP 2020012709W WO 2020196402 A1 WO2020196402 A1 WO 2020196402A1
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WIPO (PCT)
Prior art keywords
resin
molded product
functional layer
resin molded
mold
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/JP2020/012709
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English (en)
French (fr)
Inventor
倫之 吉田
勇 舛澤
津田　義博
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Resonac Corp
Original Assignee
Hitachi Chemical Co Ltd
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 Hitachi Chemical Co Ltd filed Critical Hitachi Chemical Co Ltd
Priority to US17/440,034 priority Critical patent/US12583191B2/en
Priority to CN202080021674.3A priority patent/CN113646152B/zh
Publication of WO2020196402A1 publication Critical patent/WO2020196402A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • 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
    • B29C45/14467—Joining articles or parts of a single article
    • B29C45/14508—Joining juxtaposed sheet-like articles, e.g. for making trim panels
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • 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
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection 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
    • 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
    • B29C45/14311—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 using means for bonding the coating to the articles
    • 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
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed 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
    • 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
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14286—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure means for heating the insert
    • 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
    • B29C45/14311—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 using means for bonding the coating to the articles
    • B29C2045/14327—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 using means for bonding the coating to the articles anchoring by forcing the material to pass through a hole in 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
    • 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
    • B29C45/14467—Joining articles or parts of a single article
    • B29C2045/14532—Joining articles or parts of a single article injecting between two sheets
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous 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
    • B29C70/086—Fibrous 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 and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products

Definitions

  • the present invention relates to a resin molded product and a method for manufacturing a resin molded product.
  • Electric-powered vehicles such as electric vehicles and hybrid vehicles are equipped with multiple batteries on the floor of the vehicle body. These batteries are electrically connected by cables and are mounted on the vehicle body while being housed in a battery case.
  • the battery case in addition to the one made of metal, the one made of resin is being studied in order to reduce the weight of the vehicle, improve the fuel efficiency, and achieve corrosion resistance while shielding the electromagnetic waves generated from the battery (for example).
  • Patent Document 1 in addition to the one made of metal, the one made of resin is being studied in order to reduce the weight of the vehicle, improve the fuel efficiency, and achieve corrosion resistance while shielding the electromagnetic waves generated from the battery (for example).
  • a resin battery case is generally provided with a protrusion for reinforcement in the main body.
  • an electromagnetic wave shielding sheet is provided on the surface to shield the electromagnetic waves generated from the battery.
  • Patent Document 1 describes a configuration in which the electromagnetic wave shielding sheet is arranged along the plate-shaped portion of the battery case main body, and the end portion of the electromagnetic wave shielding sheet is arranged along the side surface of the protruding portion.
  • an object of the present invention is to provide a resin molded product having an excellent degree of freedom in molding and a method for producing the resin molded product.
  • Means for solving the above problems include the following embodiments.
  • the protruding portion is a resin molded product containing a first resin and a second resin.
  • the resin molded product according to ⁇ 1>, wherein the first resin and the second resin are thermoplastic resins.
  • ⁇ 3> The resin molded product according to ⁇ 1> or ⁇ 2>, wherein the melting temperature of the second resin is equal to or lower than the melting temperature of the first resin.
  • a method for producing a resin molded product which comprises a step of: ⁇ 5> The method for producing a resin molded product according to ⁇ 4>, wherein a part of the second resin contained in the functional layer is melted by contact with the first resin supplied to the mold.
  • ⁇ 6> The method for producing a resin molded product according to ⁇ 4> or ⁇ 5>, further comprising a step of pressurizing the first resin after the step of supplying the first resin into the mold.
  • a resin molded product having an excellent degree of freedom in molding and a method for producing the resin molded product are provided.
  • the present invention is not limited to the following embodiments.
  • the components including element steps and the like are not essential unless otherwise specified.
  • the term "process” includes not only a process independent of other processes but also the process if the purpose of the process is achieved even if the process cannot be clearly distinguished from the other process. Is done.
  • the numerical values before and after "-" are included as the minimum value and the maximum value, respectively.
  • the upper limit value or the lower limit value described in one numerical range may be replaced with the upper limit value or the lower limit value of another numerical range described stepwise. Good. Further, in the numerical range described in the present specification, the upper limit value or the lower limit value of the numerical range may be replaced with the value shown in the examples.
  • the resin molded article of the present disclosure is arranged on a main body containing the first resin and at least a part of the surface of the main body, and is arranged on the functional layer containing the fiber and the second resin and the functional layer.
  • a resin molded product comprising a projecting portion, wherein the projecting portion contains a first resin and a second resin.
  • the resin molded product of the present disclosure has an excellent degree of freedom in molding. The reason will be explained with reference to the drawings.
  • the resin molded product of the present disclosure is not limited to the configuration shown in the drawings.
  • FIG. 1 and 2 are cross-sectional views schematically showing an example of a manufacturing process of a resin molded product.
  • the mold 10 shown in FIG. 1 has a space for supplying the first resin 1 in a molten state corresponding to the main body of the resin molded product, and a recess having a shape corresponding to the protruding portion of the resin molded product. ing.
  • a functional layer 2 containing fibers and a second resin is arranged inside the mold 10.
  • the base region 3 of the functional layer 2 corresponding to the base of the protruding portion is not in contact with the surface of the mold 10. Therefore, the second resin contained in the base region 3 of the functional layer 2 is difficult to be cooled by the mold 10, and is brought into contact with the first resin 1 to be melted. As a result, the first resin 1 can pass between the fibers contained in the base region 3 of the functional layer 2.
  • the mold 10 is operated to compress the space to which the first resin 1 is supplied. As a result, a part of the pressurized first resin 1 passes between the fibers in the base region 3 and flows toward the recess of the mold 10. Further, the second resin contained in the base region 3 of the functional layer 2 also flows toward the recess of the mold 10. As a result, the recesses of the mold 10 are filled with the first resin and the second resin to form the protruding portion 4.
  • the resin molded product of the present disclosure is manufactured.
  • the resin molded product of the present disclosure a part of the melt of the first resin forming the main body passes between the fibers contained in the functional layer to form a protruding portion. Therefore, it is not necessary to perform processing such as drilling at a position corresponding to the protruding portion of the functional layer, and the degree of freedom in molding is excellent. Further, in the resin molded product of the present disclosure, the main body and the protruding portion are integrally formed via the functional layer. Therefore, the strength of the protruding portion is superior to that of a method of attaching the protruding portion manufactured in another step to the main body.
  • the main body of the resin molded product contains the first resin.
  • the type of the first resin is not particularly limited. Examples thereof include polyolefins such as polyethylene and polypropylene, polyesters such as polycarbonate, polyamides, polyvinyl chlorides, polyurethanes, and thermoplastic resins such as acrylic resins, which can be selected according to the use of the resin molded product.
  • the first resin may consist of only one type of resin or may be a combination of two or more types of resins.
  • the melting temperature of the first resin is not particularly limited and can be selected according to the method for producing the resin molded product and the like. For example, it may be selected from the range of 100 ° C. to 300 ° C.
  • the main body may contain components other than the first resin.
  • components other than the first resin include inorganic fillers, mold release agents, flame retardants, colorants and the like.
  • the main body contains an inorganic filler.
  • the inorganic filler include silica, alumina, talc, clay, mica, boron nitride, and aluminum nitride.
  • the shape of the inorganic filler is not particularly limited, and may be fibrous, powdery, beaded or the like.
  • the amount is not particularly limited. From the viewpoint of the effect of adding the inorganic filler and the fluidity in the mold, the amount may be 1 part by mass to 50 parts by mass with respect to 100 parts by mass of the first resin.
  • the shape of the main body is not particularly limited and can be selected according to the application. For example, it may be plate-shaped or may have another desired three-dimensional shape.
  • the thickness of the thinnest portion of the main body may be 1 mm or more, 3 mm or more, or 5 mm or more.
  • the functional layer contains fibers and a second resin.
  • the type of the second resin is not particularly limited. For example, it may be selected from the resins exemplified as the first resin.
  • the first resin and the second resin may be the same or different.
  • the second resin is different from the first resin, it is preferable to select from resins having compatibility with the first resin.
  • the second resin may consist of only one kind of resin or may be a combination of two or more kinds of resins.
  • the functional layer may contain components other than the fiber and the second resin.
  • components other than the fiber and the second resin include inorganic fillers, mold release agents, flame retardants, colorants and the like.
  • the melting temperature of the second resin is not particularly limited and can be selected according to the method for producing the resin molded product and the like. For example, it may be selected from the same range as the first resin. However, since the second resin needs to be melted by contact with the first resin, the melting temperature of the second resin is selected to be equal to or lower than the melting temperature of the first resin.
  • the fibers contained in the functional layer may be inorganic fibers or organic fibers, and can be selected according to the application.
  • the inorganic fiber include fibers such as carbon, glass, and ceramics.
  • the organic fiber include fibers such as aramid and cellulose.
  • the fibers contained in the functional layer may be only one type or a combination of two or more types. Further, the fibers contained in the functional layer may be in the state of single fibers (filaments) and in the state of fiber bundles (strands).
  • the proportion of fibers contained in the functional layer is not particularly limited.
  • the proportion of fibers in the entire functional layer may be 50% by mass to 85% by mass.
  • the state of arrangement of the fibers contained in the functional layer is not particularly limited as long as the melt of the first resin can pass through.
  • Examples of the state of fiber arrangement include a state of being oriented in one direction, a state of being oriented in two orthogonal directions (cross), and a state of being randomly arranged without being oriented in a specific direction.
  • the functional layer can be made in a state where the melt of the first resin can pass through.
  • the thickness of the functional layer is not particularly limited as long as the melt of the first resin can pass through. For example, it may be 2000 ⁇ m or less, 1000 ⁇ m or less, or 500 ⁇ m or less. From the viewpoint of sufficiently obtaining the effect of arranging the functional layer, the thickness of the functional layer may be 10 ⁇ m or more.
  • the thickness of the functional layer may or may not be constant. When the thickness of the functional layer is not constant, the thickness at least in the region corresponding to the protrusion is selected from the thickness through which the melt of the first resin can pass.
  • the function that the functional layer gives to the resin molded product is not particularly limited.
  • it may have functions such as reinforcement, electromagnetic wave shielding, heat insulation, antistatic, and decoration.
  • the protruding portion includes a first resin and a second resin. That is, as described with reference to FIG. 1, among the first resins supplied to the mold in the process of manufacturing the resin molded product, those that fill the recesses corresponding to the protruding portions and the first resin contained in the functional layer. Of the two resins, those that are melted by contact with the first resin and fill the recesses corresponding to the protrusions are included.
  • the protruding portion attached on the functional layer after being produced in a separate step using the first resin and the same resin as the second resin does not correspond to the protruding portion in the present disclosure.
  • the protruding portion contains the first resin and the second resin can be confirmed by a known method. For example, as a result of analyzing the components contained in the main body, the functional layer and the protruding portion of the resin molded product, the protruding portion contains components common to the main body (first resin) and the functional layer (second resin), respectively. If so, it can be determined that the protruding portion contains the first resin and the second resin.
  • the protrusion may contain components other than the first resin and the second resin.
  • the components other than the first resin and the second resin include inorganic fillers, mold release agents, flame retardants, colorants and the like.
  • the height of the protruding portion is not particularly limited and can be selected according to a desired function or the like.
  • the height from the functional layer may be 0.5 mm or more, or 100 mm or less.
  • the thickness of the protruding portion is not particularly limited and can be selected according to a desired function or the like.
  • the thickness of the functional layer may be 0.5 mm or more, or 100 mm or less.
  • the shape of the protruding portion is not particularly limited and can be selected according to a desired function or the like. For example, it may have a plate shape, a cylinder shape, a cylinder shape, or any other desired three-dimensional shape.
  • the protruding portion may be a so-called rib, boss, clip or the like provided on the resin molded product.
  • the shape of the protruding portion may be a shape that satisfies the condition that the ratio of thickness to height (thickness / height) is 1.0 or less.
  • the method for producing a resin molded product of the present disclosure includes a step of arranging a functional layer containing a fiber and a second resin in a mold provided with a recess corresponding to a protruding portion of the resin molded product, and melting in the mold.
  • the melting temperature of the second resin contained in the functional layer is equal to or lower than the melting temperature of the first resin. Therefore, a part of the second resin contained in the functional layer (the second resin contained in the base region shown in FIG. 1) comes into contact with the melt of the first resin and melts. As a result, the melt of the first resin can pass between the fibers of the functional layer, and the melt of the first resin flows toward the recess corresponding to the protrusion of the mold. The melt of the second resin also flows together with the melt of the first resin toward the recess corresponding to the protrusion.
  • the above method is the first method in the mold.
  • the step of pressurizing the first resin may be further provided.
  • the method of pressurizing the first resin is not particularly limited. For example, it may be carried out by a method (injection compression molding method) in which the space in the mold is compressed by operating the mold after supplying the first resin.
  • the resin molded product produced by the above method may satisfy the conditions of the above-mentioned resin molded product.
  • the above-mentioned details and preferred embodiments of the resin molded product and material can be referred to.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

第１の樹脂を含む本体と、前記本体の表面の少なくとも一部に配置され、繊維及び第２の樹脂を含む機能層と、前記機能層の上に配置される突出部と、を備え、前記突出部は第１の樹脂と第２の樹脂とを含む、樹脂成形品。

Description

樹脂成形品及び樹脂成形品の製造方法
　本発明は、樹脂成形品及び樹脂成形品の製造方法に関する。
　電気自動車、ハイブリッド自動車等の電気を動力とする車両には、車体の床面に複数のバッテリーが搭載されている。これらのバッテリーはケーブルで電気的に接続され、バッテリーケース内に収容された状態で車体に取り付けられている。バッテリーケースとしては、金属製のもののほか、バッテリーから発生する電磁波を遮蔽しながら車両の軽量化、燃費効率の向上、耐腐食性等を達成するために樹脂製のものが検討されている（例えば、特許文献１参照）。
　樹脂製のバッテリーケースは一般に、補強のための突出部が本体に設けられている。また、バッテリーから発生する電磁波を遮蔽するために電磁波遮蔽シートが表面に設けられている。特許文献１には、電磁波遮蔽シートをバッテリーケース本体の板状部に沿うように配設し、電磁波遮蔽シートの端部を突出部の側面に沿うようにした構成が記載されている。
特開２０１４－２１３６０２号公報
　特許文献１に開示された構成では、電磁波遮蔽シートを突出部に沿うように確実に配設する為には突出部の内部に保持部材を埋め込んだり、突出部の形状に合わせた電磁波遮蔽シートの賦形、トリミング等を行う必要があり、成形自由度の点で制約が大きい。
　本発明は上記事情に鑑み、成形自由度に優れる樹脂成形品及び樹脂成形品の製造方法を提供することを目的とする。
　上記課題を解決するための手段には、以下の実施態様が含まれる。
＜１＞第１の樹脂を含む本体と、前記本体の表面の少なくとも一部に配置され、繊維及び第２の樹脂を含む機能層と、前記機能層の上に配置される突出部と、を備え、前記突出部は第１の樹脂と第２の樹脂とを含む、樹脂成形品。
＜２＞第１の樹脂及び第２の樹脂が熱可塑性樹脂である、＜１＞に記載の樹脂成形品。
＜３＞第２の樹脂の溶融温度が第１の樹脂の溶融温度以下である、＜１＞又は＜２＞に記載の樹脂成形品。
＜４＞樹脂成形品の突出部に対応する凹部を備える金型内に繊維及び第２の樹脂を含む機能層を配置する工程と、前記金型内に溶融した状態の第１の樹脂を供給する工程と、を備え、第２の樹脂の溶融温度は第１の樹脂の溶融温度以下である、樹脂成形品の製造方法。
＜５＞前記機能層に含まれる第２の樹脂の一部が前記金型に供給された第１の樹脂との接触により溶融する、＜４＞に記載の樹脂成形品の製造方法。
＜６＞前記金型内に第１の樹脂を供給する工程の後に、第１の樹脂を加圧する工程をさらに備える、＜４＞又は＜５＞に記載の樹脂成形品の製造方法。
　本発明の一態様によれば、成形自由度に優れる樹脂成形品及び樹脂成形品の製造方法が提供される。
樹脂成形品の製造工程の一例を概略的に示す図である。 樹脂成形品の製造工程の一例を概略的に示す図である。
　以下、本発明を実施するための形態について詳細に説明する。但し、本発明は以下の実施形態に限定されるものではない。以下の実施形態において、その構成要素（要素ステップ等も含む）は、特に明示した場合を除き、必須ではない。数値及びその範囲についても同様であり、本発明を制限するものではない。
　本明細書において「工程」との語には、他の工程から独立した工程に加え、他の工程と明確に区別できない場合であってもその工程の目的が達成されれば、当該工程も含まれる。
　本明細書において「～」を用いて示された数値範囲には、「～」の前後に記載される数値がそれぞれ最小値及び最大値として含まれる。
　本明細書中に段階的に記載されている数値範囲において、一つの数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本明細書中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
＜樹脂成形品＞
　本開示の樹脂成形品は、第１の樹脂を含む本体と、前記本体の表面の少なくとも一部に配置され、繊維及び第２の樹脂を含む機能層と、前記機能層の上に配置される突出部と、を備え、前記突出部は第１の樹脂と第２の樹脂とを含む、樹脂成形品である。
　本開示の樹脂成形品は、成形自由度に優れている。その理由について、図面を参照しながら説明する。本開示の樹脂成形品は、図面に示す構成に限定されるものではない。
　図１及び図２は、樹脂成形品の製造工程の一例を概略的に示す断面図である。図１に示す金型１０は、樹脂成形品の本体に対応し、溶融した状態の第１の樹脂１が供給される空間と、樹脂成形品の突出部に対応する形状の凹部とを有している。金型１０の内部には、繊維及び第２の樹脂を含む機能層２が配置されている。
　図１に示すように、機能層２のうち突出部の基部に対応する基部領域３は、金型１０の表面と接していない。このため、機能層２の基部領域３に含まれる第２の樹脂は金型１０により冷却されにくく、第１の樹脂１と接触して溶融する。その結果、機能層２の基部領域３に含まれる繊維間を第１の樹脂１が通過可能な状態になる。
　次に、図２に示すように、金型１０を操作して第１の樹脂１が供給された空間を圧縮する。これにより、加圧された第１の樹脂１の一部が基部領域３の繊維間を通過して金型１０の凹部に向けて流動する。また、機能層２の基部領域３に含まれていた第２の樹脂も金型１０の凹部に向けて流動する。その結果、金型１０の凹部が第１の樹脂及び第２の樹脂で充填されて突出部４が形成される。以上の工程を経て、本開示の樹脂成形品が製造される。
　本開示の樹脂成形品は、本体を形成する第１の樹脂の溶融物の一部が機能層に含まれる繊維の間を通過して突出部を形成する。このため、機能層の突出部に対応する位置に穴あけ等の加工を施す必要がなく、成形自由度に優れている。また、本開示の樹脂成形品は、本体と突出部とが機能層を介して一体的に形成されている。このため、別工程で作製した突出部を本体に取り付ける方法等に比べ、突出部の強度に優れている。
（本体）
　樹脂成形品の本体は、第１の樹脂を含む。第１の樹脂の種類は特に制限されない。例えば、ポリエチレン、ポリプロピレン等のポリオレフィン、ポリカーボネート等のポリエステル、ポリアミド、ポリ塩化ビニル、ポリウレタン、アクリル樹脂などの熱可塑性樹脂が挙げられ、樹脂成形品の用途に応じて選択できる。第１の樹脂は１種の樹脂のみからなっても、２種以上の樹脂の組み合わせであってもよい。
　第１の樹脂の溶融温度は特に制限されず、樹脂成形品の作製方法等に応じて選択できる。例えば、１００℃～３００℃の範囲から選択してもよい。
　必要に応じ、本体は第１の樹脂以外の成分を含んでもよい。第１の樹脂以外の成分としては、無機フィラー、離型剤、難燃剤、着色剤等が挙げられる。
　樹脂成形体の強度向上、熱膨張率の調整等の観点からは、本体は無機フィラーを含むことが好ましい。無機フィラーとして具体的には、シリカ、アルミナ、タルク、クレー、マイカ、窒化ホウ素、窒化アルミニウム等が挙げられる。無機フィラーの形状は特に制限されず、繊維状、粉末状、ビーズ状等であってもよい。
　本体が無機フィラーを含む場合、その量は特に制限されない。無機フィラーの添加による効果と金型内での流動性の観点からは、第１の樹脂１００質量部に対して１質量部～５０質量部であってもよい。
　本体の形状は特に制限されず、用途等に応じて選択できる。例えば、板状であってもその他の所望の立体形状であってもよい。
　本体は、最も厚みの小さい部分の厚みが１ｍｍ以上であってもよく、３ｍｍ以上であってもよく、５ｍｍ以上であってもよい。
（機能層）
　機能層は、繊維及び第２の樹脂を含む。第２の樹脂の種類は特に制限されない。例えば、第１の樹脂として例示した樹脂から選択してもよい。第１の樹脂と第２の樹脂とは同じであっても異なっていてもよい。第２の樹脂が第１の樹脂と異なる場合、第１の樹脂と相溶性を持つ樹脂から選択することが好ましい。また、第２の樹脂は１種の樹脂のみからなっても、２種以上の樹脂の組み合わせであってもよい。
　必要に応じ、機能層は、繊維及び第２の樹脂以外の成分を含んでもよい。繊維及び第２の樹脂以外の成分としては、無機フィラー、離型剤、難燃剤、着色剤等が挙げられる。
　第２の樹脂の溶融温度は特に制限されず、樹脂成形品の作製方法等に応じて選択できる。例えば、第１の樹脂と同じ範囲から選択してもよい。ただし、第２の樹脂は第１の樹脂との接触により溶融する必要があるため、第２の樹脂の溶融温度は第１の樹脂の溶融温度以下となるように選択される。
　機能層に含まれる繊維は無機繊維であっても有機繊維であってもよく、用途に応じて選択できる。無機繊維としてはカーボン、ガラス、セラミックス等の繊維が挙げられる。有機繊維としてはアラミド、セルロース等の繊維が挙げられる。機能層に含まれる繊維は、１種のみでも２種以上の組み合わせであってもよい。また、機能層に含まれる繊維は、単繊維（フィラメント）の状態であって繊維束（ストランド）の状態であってもよい。
　機能層に含まれる繊維の割合は、特に制限されない。例えば、機能層全体に占める繊維の割合が５０質量％～８５質量％であってもよい。
　機能層に含まれる繊維の配置の状態は、第１の樹脂の溶融物が通過可能な状態であれば特に制限されない。繊維の配置の状態としては、１方向に配向した状態、直交する２方向に配向した状態（クロス）、特定の方向に配向せずランダムに配置された状態等が挙げられる。例えば、機能層に含まれる繊維間の領域（樹脂で含浸されている領域）の大きさを調節することで、機能層を第１の樹脂の溶融物が通過可能な状態にすることができる。
　機能層の厚さは、第１の樹脂の溶融物が通過可能な厚さであれば特に制限されない。例えば、２０００μｍ以下であってもよく、１０００μｍ以下であってもよく、５００μｍ以下であってもよい。機能層を配置することによる効果を充分に得る観点からは、機能層の厚さは１０μｍ以上であってもよい。機能層の厚さは一定であっても一定でなくてもよい。機能層の厚さが一定でない場合、少なくとも突出部に対応する領域における厚さを第１の樹脂の溶融物が通過可能な厚さから選択する。
　機能層が樹脂成形品に付与する機能は、特に制限されない。例えば、補強、電磁波遮蔽、断熱、帯電防止、装飾等の機能であってもよい。
（突出部）
　突出部は、第１の樹脂と第２の樹脂とを含む。すなわち、図１を参照して説明したように、樹脂成形品の作製工程において金型に供給される第１の樹脂のうち突出部に対応する凹部を充填するものと、機能層に含まれる第２の樹脂のうち第１の樹脂との接触により溶融し、突出部に対応する凹部を充填するものと、を含む。
　なお、第１の樹脂及び第２の樹脂と同じ樹脂を用いて別工程で作製した後に機能層の上に取り付けられる突出部は、本開示における突出部には該当しないものとする。
　突出部が第１の樹脂と第２の樹脂とを含むか否かは、公知の手法により確認することができる。例えば、樹脂成形品の本体、機能層及び突出部に含まれる成分を分析した結果、突出部に本体（第１の樹脂）及び機能層（第２の樹脂）と共通する成分がそれぞれ含まれている場合、突出部が第１の樹脂と第２の樹脂とを含むと判断することができる。
　必要に応じ、突出部は第１の樹脂及び第２の樹脂以外の成分を含んでもよい。第１の樹脂及び第２の樹脂以外の成分としては、無機フィラー、離型剤、難燃剤、着色剤等が挙げられる。
　突出部の高さ（機能層からの立ち上がり部分の高さ）は特に制限されず、所望の機能等に応じて選択できる。例えば、機能層からの高さは０．５ｍｍ以上であってもよく、１００ｍｍ以下であってもよい。
　突出部の厚み（機能層からの立ち上がり部分の厚み）は特に制限されず、所望の機能等に応じて選択できる。例えば、機能層の厚みは０．５ｍｍ以上であってもよく、１００ｍｍ以下であってもよい。
　突出部の形状は特に制限されず、所望の機能等に応じて選択できる。例えば、板状、円筒状、円柱状その他の所望の立体形状であってもよい。突出部は、樹脂成形品に設けられるいわゆるリブ、ボス、クリップ等であってもよい。
　突出部の形状は、厚みと高さの比（厚み／高さ）が１．０以下となる条件を満たす形状であってもよい。
＜樹脂成形品の製造方法＞
　本開示の樹脂成形品の製造方法は、樹脂成形品の突出部に対応する凹部を備える金型内に繊維及び第２の樹脂を含む機能層を配置する工程と、前記金型内に溶融した状態の第１の樹脂を供給する工程と、を備え、第２の樹脂の溶融温度は第１の樹脂の溶融温度以下である、樹脂成形品の製造方法である。
　上記方法では、機能層に含まれる第２の樹脂の溶融温度が第１の樹脂の溶融温度以下である。このため、機能層に含まれる第２の樹脂の一部（図１に示す基部領域に含まれる第２の樹脂）が第１の樹脂の溶融物と接触して溶融する。これにより、第１の樹脂の溶融物が機能層の繊維の間を通過可能な状態になり、第１の樹脂の溶融物が金型の突出部に対応する凹部に向けて流動する。第２の樹脂の溶融物もまた、第１の樹脂の溶融物とともに突出部に対応する凹部に向けて流動する。
　第１の樹脂（及び第１の樹脂に接触して溶融した第２の樹脂）を金型の突出部に対応する凹部に効率よく流動させる観点からは、上記方法は、金型内に第１の樹脂を供給した後に、第１の樹脂を加圧する工程をさらに備えてもよい。第１の樹脂を加圧する方法は特に制限されない。例えば、第１の樹脂を供給した後に金型を操作して金型内の空間を圧縮する方法（射出圧縮成形法）により行ってもよい。
　上記方法で製造される樹脂成形品は、上述した樹脂成形品の条件を満たすものであってもよい。上記方法で製造される樹脂成形品及び材料の詳細及び好ましい態様については、上述した樹脂成形品及び材料の詳細及び好ましい態様を参照することができる。
　日本国特許出願第２０１９－０６００７９号の開示は、その全体が参照により本明細書に取り込まれる。本明細書に記載された全ての文献、特許出願、および技術規格は、個々の文献、特許出願、および技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書中に参照により取り込まれる。

Claims (6)

  1. 　第１の樹脂を含む本体と、前記本体の表面の少なくとも一部に配置され、繊維及び第２の樹脂を含む機能層と、前記機能層の上に配置される突出部と、を備え、前記突出部は第１の樹脂と第２の樹脂とを含む、樹脂成形品。
  2. 　第１の樹脂及び第２の樹脂が熱可塑性樹脂である、請求項１に記載の樹脂成形品。
  3. 　第２の樹脂の溶融温度が第１の樹脂の溶融温度以下である、請求項１又は請求項２に記載の樹脂成形品。
  4. 　樹脂成形品の突出部に対応する凹部を備える金型内に繊維及び第２の樹脂を含む機能層を配置する工程と、前記金型内に溶融した状態の第１の樹脂を供給する工程と、を備え、第２の樹脂の溶融温度は第１の樹脂の溶融温度以下である、樹脂成形品の製造方法。
  5. 　前記機能層に含まれる第２の樹脂の一部が前記金型に供給された第１の樹脂との接触により溶融する、請求項４に記載の樹脂成形品の製造方法。
  6. 　前記金型内に第１の樹脂を供給する工程の後に、第１の樹脂を加圧する工程をさらに備える、請求項４又は請求項５に記載の樹脂成形品の製造方法。
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JP7120113B2 (ja) 2022-08-17
US20220184897A1 (en) 2022-06-16

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