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JP5738610B2 - Composite and production method thereof - Google Patents

Composite and production method thereof Download PDF

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JP5738610B2
JP5738610B2 JP2011015637A JP2011015637A JP5738610B2 JP 5738610 B2 JP5738610 B2 JP 5738610B2 JP 2011015637 A JP2011015637 A JP 2011015637A JP 2011015637 A JP2011015637 A JP 2011015637A JP 5738610 B2 JP5738610 B2 JP 5738610B2
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sheet material
mold
composite
thermoplastic resin
molding
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JP2012153069A (en
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佐藤 義久
義久 佐藤
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Ono Sangyo Co Ltd
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Description

本発明は、強化繊維を含有する熱可塑性樹脂からなるシートと熱可塑性樹脂成形体が一体に融着された複合体及びその製造方法に関するものである。 The present invention relates to a composite sheet and the thermoplastic resin molded article comprising a thermoplastic resin containing reinforcing fibers are fused together and manufacturing how.

プラスチック射出成形品は、自動車の内装部材や外装部材などとして用いられる。具体的には、強化繊維を含むシート材に樹脂を含浸させ、該シート材に樹脂を射出成形して一体化した複合材などが、前記内装部材や外装部材として使用される。前記樹脂を熱硬化性樹脂とすると、熱を加える必要がありコストが大きくなり、また、形状の自由度が低く大量生産には不向きである。一方、前記樹脂として熱可塑性樹脂を用いるときは、最終的には冷却して金型から取り出すため、量産には適している。このような熱可塑性樹脂を用いた複合材を製造する技術としては、例えば、下記特許文献1に示す技術がある。   Plastic injection-molded products are used as automobile interior members and exterior members. Specifically, a composite material obtained by impregnating a resin into a sheet material containing reinforcing fibers and injection-molding the resin into the sheet material is used as the interior member or the exterior member. When the resin is a thermosetting resin, it is necessary to apply heat, resulting in an increase in cost and a low degree of freedom in shape, which is not suitable for mass production. On the other hand, when a thermoplastic resin is used as the resin, it is finally cooled and taken out from the mold, which is suitable for mass production. As a technique for producing a composite material using such a thermoplastic resin, for example, there is a technique shown in Patent Document 1 below.

当該特許文献1には、溶融樹脂を注入するゲートと、成形体を成形する複数の成形空間と、前記ゲートと各成形空間とを繋ぐ樹脂流通路を備える金型に、繊維に熱可塑性樹脂を含浸させた基材を配置する型配置工程と、前記ゲートから前記溶融樹脂を射出して、前記溶融樹脂が前記樹脂流通路を通り、前記各成形空間に前記溶融樹脂を充填する射出工程と、前記溶融樹脂を冷却し固化させることにより前記成形体を成形する二次成形工程と、を含み、前記射出成形工程において、1つの前記ゲートから分岐して前記各成形空間に前記溶融樹脂が送り込まれることを特徴とする繊維基材の製造方法が開示されている。そして、前記型配置工程と射出工程との間に、前記基材を加熱成形する一次成形工程を設けることで、プレボードの外周不要部分を金型によりせん断し、基材を所定形状に形成している。   In Patent Document 1, a thermoplastic resin is applied to a fiber in a mold including a gate for injecting a molten resin, a plurality of molding spaces for molding a molded body, and a resin flow passage that connects the gate and each molding space. A mold placement step of placing the impregnated base material, an injection step of injecting the molten resin from the gate, the molten resin passing through the resin flow path, and filling the molten resin into the molding spaces; A secondary molding step of molding the molded body by cooling and solidifying the molten resin, and in the injection molding step, the molten resin is branched from one of the gates and fed into the molding spaces. The manufacturing method of the fiber base material characterized by this is disclosed. Then, by providing a primary molding step for thermoforming the base material between the mold placement step and the injection step, the unnecessary portion of the outer periphery of the preboard is sheared by a mold, and the base material is formed into a predetermined shape. Yes.

特開2010−274636号公報JP 2010-274636 A

しかしながら、上述した特許文献1に記載の背景技術では、射出工程において溶融樹脂が成形空間内へ運ばれる途中で固化することがないように、前記一次成形工程において金型を加熱して流動性を確保しているが、熱プレス成形で基材の形状を作るため、形状制約があり角等の形状追従性に乏しいという不都合がある。また、基材の繊維が表面に露出するため、複合体の形成後に表面処理(平滑化処理や塗装の下処理など)が必要になるという不都合もある。   However, in the background art described in Patent Document 1 described above, the mold is heated in the primary molding step so that the molten resin does not solidify in the course of being transported into the molding space in the injection step. However, since the shape of the substrate is made by hot press molding, there is a disadvantage that there is a shape restriction and the shape following ability such as corners is poor. In addition, since the fibers of the base material are exposed on the surface, there is a disadvantage that a surface treatment (smoothing treatment, coating pretreatment, etc.) is required after formation of the composite.

本発明は、以上の点に着目したもので、軽量で強度や耐久性に優れ、かつ、外観や手触り感が良好な複合材及びその製造方法を提供することを、その目的とする。 The present invention has focused on the above points, lightweight and excellent in strength and durability, and that appearance and touch feeling to provide a satisfactory composite material and its manufacturing how, and an object.

本発明の複合体の製造方法は、固定型と可動型から構成される金型のパーティング面にキャビティが形成されるとともに、前記可動型に設けられた加熱冷却機構と、前記固定型側に設けられており熱可塑性樹脂を前記キャビティへ射出する射出機構とを備えた複合体製造装置を用いて、強化繊維を含有し、熱可塑性樹脂からなるシート材を熱成形して仮賦形する工程1と、該工程1によって仮賦形されたシート材を、金型へインサートし、前記可動型側のキャビティ面に貼り付ける工程2と、前記金型を型締めするとともに、前記金型へインサートされたシート材を、前記可動型側に設けた加熱冷却機構によって加熱冷却成形して、該シート材を金型形状に追従させる工程3と、前記シート材の全部又は一部に熱可塑性樹脂を射出成形し、前記シート材と熱可塑性樹脂成形体が一体に融着された複合体を形成する工程4と、を含むことを特徴とする。 In the method for producing a composite according to the present invention , a cavity is formed on a parting surface of a mold composed of a fixed mold and a movable mold, a heating / cooling mechanism provided in the movable mold, and a fixed mold side. A step of thermoforming a sheet material containing a reinforcing fiber and made of a thermoplastic resin by using a composite manufacturing apparatus provided with an injection mechanism for injecting a thermoplastic resin into the cavity. 1, the sheet material is temporarily shaped by the step 1, was inserted into a mold, and step 2 that stuck to the cavity surface of the movable mold side, thereby clamping the mold, to the mold The inserted sheet material is heated and cooled by a heating and cooling mechanism provided on the movable mold side , and the sheet material is made to follow the shape of the mold, and a thermoplastic resin is added to all or part of the sheet material. The injection molding before The sheet material and the thermoplastic resin molded article characterized in that it comprises a step 4 to form a complex that is fused together.

主要な形態の一つは、前記工程3と同時に、前記工程4を行うことを特徴とする。他の形態は、前記工程の仮賦形を、真空成形又は圧空成形により行うことを特徴とする。 One of the main forms is characterized in that the step 4 is performed simultaneously with the step 3. Another aspect is characterized in that the temporary shaping in the step 1 is performed by vacuum forming or pressure forming.

本発明の複合体は、前記いずれかに記載の製造方法で形成されたことを特徴とする。本発明の前記及び他の目的,特徴,利点は、以下の詳細な説明及び添付図面から明瞭になろう。

The composite of the present invention is formed by any one of the production methods described above . The above and other objects, features and advantages of the present invention will become apparent from the following detailed description and the accompanying drawings.

本発明によれば、強化繊維を含有する熱可塑性樹脂からなるシート材を、熱成形によって仮賦形してから金型表面に貼り付け、該シート材を加熱冷却して金型形状に追従させ、前記加熱冷却後に、あるいは、前記加熱冷却と同時に、前記シート材の主面全体あるいは一部に、熱可塑性樹脂を射出成形することとした。このため、軽量で強度や耐久性能に優れ、しかも、外観や手触り感も良好なシート材と樹脂成形体の複合体が得られるという効果がある。   According to the present invention, a sheet material made of a thermoplastic resin containing reinforcing fibers is temporarily formed by thermoforming and then attached to the surface of the mold, and the sheet material is heated and cooled to follow the mold shape. Then, after the heating and cooling, or simultaneously with the heating and cooling, a thermoplastic resin is injection-molded on the whole or a part of the main surface of the sheet material. For this reason, there is an effect that a composite of a sheet material and a resin molded body that is lightweight, excellent in strength and durability, and excellent in appearance and feel can be obtained.

図1(A)〜(F)は、本発明の実施例1の製造工程の一例を示す図,図1(G)は本実施例の複合体を示す側面図である。1 (A) to 1 (F) are views showing an example of the production process of Example 1 of the present invention, and FIG. 1 (G) is a side view showing the composite of this example. 前記実施例1による複合体製品を示す図であり、(A)は製品の一部を示す画像,(B)は前記(A)の製品のエッジ部を拡大して示す画像,(C)は前記(A)の表面の一部を175倍に拡大した画像である。It is a figure which shows the composite product by the said Example 1, (A) is an image which shows a part of product, (B) is an image which expands and shows the edge part of the product of said (A), (C) is It is the image which expanded a part of surface of said (A) by 175 times. 比較例による複合体製品を示す図であり、(A)は製品の一部を示す画像,(B)は前記(A)の製品のエッジ部を拡大して示す画像、(C)は前記(A)の表面の一部を175倍に拡大した画像である。It is a diagram showing a composite product according to a comparative example, (A) is an image showing a part of the product, (B) is an image showing an enlarged edge portion of the product of (A), (C) is the ( It is the image which expanded a part of surface of A) by 175 times. 前記実施例1による複合体製品と比較例による複合体製品の角部の断面画像である。It is a cross-sectional image of the corner | angular part of the composite product by the said Example 1, and the composite product by a comparative example. 本発明の他の実施例を示す図である。It is a figure which shows the other Example of this invention.

以下、本発明を実施するための形態を、実施例に基づいて詳細に説明する。   Hereinafter, the form for implementing this invention is demonstrated in detail based on an Example.

最初に、図1〜図4を参照しながら本発明の実施例1を説明する。本発明は、自動車の内装部材や外装部材,あるいは、携帯電話の筐体,液晶テレビの筐体などに用いられる複合体であって、強化繊維を含有する熱可塑性樹脂シート材と、熱可塑性樹脂の射出成形体を一体に融着した複合体に関するものである。図1(A)〜(F)には、本実施例による複合体の製造工程の一例が示され、図1(G)には前記製造工程によって製造された複合体の側面図が示されている。図1(G)に示すように、本実施例の複合体10は、シート材20の主面20B側に、熱可塑性樹脂の射出成形部50を一体に融着した構成となっており、該射出成形部50は、前記シート材主面20Bと融着する平面部52と、他の部品等に取り付けるための突状の取付用脚部54A,54Bを備えている。前記シート材20としては、強化繊維を含有する熱可塑性樹脂シートが用いられる。前記強化繊維としては、例えば、炭素繊維、ガラス繊維、アラミド繊維、アルミナ繊維、金属繊維、植物繊維等から選択された1種又は2種以上の繊維が用いられ、シート材20及び射出成形部50を構成する熱可塑性樹脂としては、例えば、ABS、PC、PP、PA、PBT等の熱可塑性樹脂,又は、これらのアロイ材が用いられる。寸法安定性の観点から、射出成形部50を構成する熱可塑性樹脂も前記シート材20と同様の強化繊維を含有することが好ましい。   First, Embodiment 1 of the present invention will be described with reference to FIGS. The present invention relates to a composite used for an interior member or exterior member of an automobile, a casing of a mobile phone, a casing of a liquid crystal television, or the like, and a thermoplastic resin sheet material containing a reinforcing fiber, and a thermoplastic resin The present invention relates to a composite body obtained by integrally fusing the injection molded body. 1 (A) to (F) show an example of the manufacturing process of the composite according to the present embodiment, and FIG. 1 (G) shows a side view of the composite manufactured by the manufacturing process. Yes. As shown in FIG. 1 (G), the composite 10 of this example has a configuration in which an injection molded portion 50 of a thermoplastic resin is integrally fused to the main surface 20B side of the sheet material 20, The injection molding portion 50 includes a flat portion 52 that is fused to the sheet material main surface 20B, and protruding mounting legs 54A and 54B that are attached to other components. As the sheet material 20, a thermoplastic resin sheet containing reinforcing fibers is used. As the reinforcing fiber, for example, one type or two or more types of fibers selected from carbon fiber, glass fiber, aramid fiber, alumina fiber, metal fiber, plant fiber, and the like are used, and the sheet material 20 and the injection molding unit 50 are used. As the thermoplastic resin that constitutes, for example, thermoplastic resins such as ABS, PC, PP, PA, PBT, or alloy materials thereof are used. From the viewpoint of dimensional stability, it is preferable that the thermoplastic resin constituting the injection-molded part 50 also contains the same reinforcing fibers as the sheet material 20.

次に、図1(A)〜(F)を参照して、本実施例の製造工程の一例を説明する。まず、図1(A)に示すように、強化繊維を含有する熱可塑性樹脂シート材20を用意し、図1(B)に示すように、該シート材20を熱成形により仮賦形する。該熱成形は、例えば、真空成形や圧空成形により行われる。次に、仮賦形したシート材20を、図1(C)に示すように、金型30のキャビティ36にインサートし、キャビティ面に貼り付ける。前記金型30は、図1(C)〜(E)に示すように、固定型32と可動型34から構成されており、そのパーティング面に前記キャビティ36が形成されている。図示の例では、該キャビティ36には、前記シート材20を収納するスペースのほかに、前記射出成形部50の平面部52に相当する成形スペース38Aと、前記射出成形部50の取付用脚部54A,54Bに相当する成形スペース38B,38Cが設けられている。   Next, an example of the manufacturing process of the present embodiment will be described with reference to FIGS. First, as shown in FIG. 1 (A), a thermoplastic resin sheet material 20 containing reinforcing fibers is prepared, and as shown in FIG. 1 (B), the sheet material 20 is temporarily shaped by thermoforming. The thermoforming is performed by, for example, vacuum forming or pressure forming. Next, as shown in FIG. 1C, the temporarily shaped sheet material 20 is inserted into the cavity 36 of the mold 30 and attached to the cavity surface. As shown in FIGS. 1C to 1E, the mold 30 includes a fixed mold 32 and a movable mold 34, and the cavity 36 is formed on a parting surface thereof. In the illustrated example, in addition to the space for storing the sheet material 20, the cavity 36 includes a molding space 38 </ b> A corresponding to the flat surface portion 52 of the injection molding portion 50, and mounting leg portions for the injection molding portion 50. Molding spaces 38B and 38C corresponding to 54A and 54B are provided.

更に、前記キャビティ36には、射出装置からノズル(いずれも図示せず)を介して供給される溶融樹脂の流入通路であるゲート40が接続されている。図示の例では、該ゲート40は、固定型32を貫通して直接キャビティ36に接続するダイレクトゲート構造となっている。また、前記可動型34には、前記キャビティ36の周囲に、複数の加熱冷却手段42が設けられている。該加熱冷却手段42は、前記キャビティ36にインサートされた前記シート材20の主面20Aを加熱冷却するためのものであって、例えば、熱媒体の流路と、該流路を流れる加熱媒体及び冷却媒体などにより構成されるが、他の公知の加熱冷却機構を利用してもよい。   Further, the cavity 36 is connected to a gate 40 that is an inflow passage of a molten resin supplied from an injection device through a nozzle (none of which is shown). In the illustrated example, the gate 40 has a direct gate structure that penetrates the fixed mold 32 and is directly connected to the cavity 36. The movable mold 34 is provided with a plurality of heating / cooling means 42 around the cavity 36. The heating / cooling means 42 is for heating and cooling the main surface 20A of the sheet material 20 inserted into the cavity 36, and includes, for example, a heat medium flow path, a heating medium flowing through the flow path, and Although it is constituted by a cooling medium or the like, other known heating and cooling mechanisms may be used.

以上のような構成の金型30のキャビティ36に、仮賦形したシート材20をインサートした後、単に射出成形を行うのみでは、シート材20とキャビティ36の角部36A,36Bや縁部36C,36Dとの間に生じる隙間44(図1(C)参照)をなくすことができず、仕上がった製品の見栄えが低下してしまう。また、上述した背景技術で示すようにシート材20と金型30を加熱して熱プレス成形と射出成形を行う方法では、熱プレス成形はシート材20が局所的に延びるためシワや破れ等の問題により形状制約があり、角等の形状追従性も乏しい。更に、射出成形後、シート材20を金型30より離型する際に、変形などの離型不良が発生し易いため、複雑な形状への対応が難しく、シート材20と射出成形部50の融着部に離型応力による歪が残り、融着強度の低下が発生する。そこで、本実施例では、仮賦形したシート材20をキャビティ面に貼り付けた状態で溶融樹脂を射出成形するにあたり、前記シート材20を前記加熱冷却手段42により加熱冷却成形することで、図1(D)及び(E)に示すように、シート材20を金型形状に追従させる。   By simply performing injection molding after inserting the temporarily shaped sheet material 20 into the cavity 36 of the mold 30 having the above configuration, the corner portions 36A and 36B and the edge portion 36C of the sheet material 20 and the cavity 36 are used. , 36D cannot be eliminated, and the appearance of the finished product is deteriorated. Further, as shown in the background art described above, in the method in which the sheet material 20 and the mold 30 are heated to perform hot press molding and injection molding, since the sheet material 20 extends locally, the hot press molding causes wrinkles and tears. There are shape restrictions due to problems, and shape followability such as corners is poor. Further, when the sheet material 20 is released from the mold 30 after the injection molding, it is easy to cause a mold release failure such as deformation, so that it is difficult to cope with a complicated shape. Distortion due to mold release stress remains in the fused portion, resulting in a decrease in fusion strength. Therefore, in this embodiment, when the molten resin is injection-molded in a state where the temporarily shaped sheet material 20 is attached to the cavity surface, the sheet material 20 is heated and cooled by the heating / cooling means 42 to obtain a figure. 1 (D) and (E), the sheet material 20 is made to follow the mold shape.

加熱冷却成形は、例えば、シート材20の荷重たわみ温度以上かつ熱分解温度以下に金型30の加熱を行い、型締めし(図1(D))、前記シート材20の主面20B側に、前記ゲート40を介して、図示しない射出装置から溶融状態の熱可塑性樹脂60を射出した後(図1(E))に、加重たわみ温度未満であって冷却固化の促進が可能な温度へ冷却する。そして、図1(F)に示すように、強化繊維を含有した熱可塑性樹脂からなるシート材20と、熱可塑性樹脂製の射出成形部50が一体に融着した複合体10を離型し、ゲート40に相当する部分を切除する。このような加熱冷却成形を行うことにより、単に仮賦形したシート材20をインサート成形する場合や、シート材20と金型30を加熱して熱プレス成形及び射出成形する場合と比べて、仮賦形したシート材20をインサートし金型を加熱することで局所的な延びを防ぎ形状追従性が向上し、前記隙間44がなくなり、キャビティ36の凹凸形状に追従したシート材20が成形され、シート材20の表面が改質される。また、金型30から離型する際に強制的に冷却することで、外観や手触り感などが良好なシート材20と射出成形部50の複合体10が得られるとともに、成形サイクル時間を短縮することができる。更に、前記複合体10は、シート材20の主面20A側に別途表面処理(平滑化処理や塗装の下処理など)を施すことなく、そのまま仕上がり面として利用することができる。また、本実施例では、前記シート材20の他方の主面20B側に射出成形部50を設けており、該射出成形部50の部分を、他の部品等に取り付けるための構造体として用いる。   In the heat-cooling molding, for example, the mold 30 is heated to a temperature not lower than the deflection temperature of the sheet material 20 and not higher than the thermal decomposition temperature, and the mold is clamped (FIG. 1 (D)). After the molten thermoplastic resin 60 is injected from an injection device (not shown) through the gate 40 (FIG. 1 (E)), it is cooled to a temperature that is lower than the weighted deflection temperature and can promote cooling and solidification. To do. And as shown in FIG.1 (F), the sheet | seat material 20 which consists of a thermoplastic resin containing a reinforced fiber, and the composite_body | complex 10 which the injection molding part 50 made from a thermoplastic resin fuse | melted integrally are demolded, A portion corresponding to the gate 40 is cut out. By performing such heat-cooling molding, the provisionally shaped sheet material 20 is insert-molded, or compared with the case where the sheet material 20 and the mold 30 are heated to perform hot press molding and injection molding. By inserting the shaped sheet material 20 and heating the mold, local extension is prevented and the shape followability is improved. The surface of the sheet material 20 is modified. In addition, by forcibly cooling when releasing from the mold 30, the composite 10 of the sheet material 20 and the injection molded part 50 with good appearance and touch feeling can be obtained, and the molding cycle time can be shortened. be able to. Furthermore, the composite 10 can be used as a finished surface as it is without subjecting the main surface 20 </ b> A side of the sheet material 20 to a separate surface treatment (smoothing treatment or coating pretreatment). Further, in this embodiment, the injection molding part 50 is provided on the other main surface 20B side of the sheet material 20, and the part of the injection molding part 50 is used as a structure for attaching to other parts or the like.

次に、図2及び図3を参照して、本実施例により製造された複合体と、上述した背景技術により製造された複合体について比較を行う。図2は、本実施例による複合体製品を示す図であり、(A)は鏡面部70と艶消し面部72を含む製品表面の一部を示す画像,(B)は前記(A)の製品の開口部74のエッジ部76を拡大して示す画像,(C)は前記(A)の表面の一部(前記(A)中の鏡面部70を点線で囲った領域P)を175倍に拡大した画像である。なお、前記鏡面とは、金型表面の鏡面から転写して得られた表面のことを意味しており、ここでは、比較例との表面状態の差を分かりやすくするために鏡面部の拡大画像を示したが、シボの転写も可能であることはいうまでもない。一方、図3は、背景技術による比較例の複合体製品を示す図であり、(A)は製品の表面部80の一部を示す画像,(B)は前記(A)の製品の開口部82のエッジ部84を拡大して示す画像,(C)は前記(A)の表面の一部(前記(B)中の点線で囲った領域Q)を175倍に拡大した画像である。これら図2(A)〜(C)と図3(A)〜(C)の比較から明らかなように、本実施例によれば、製品のエッジ部の形状が整っており、表面の平滑度も高いことが分かる。また、図4には、本実施例と比較例による製品の角部の金型形状への追従性を比較するための画像が示されている。図4(A)が本実施例の製品の断面画像,図4(B)が比較例の製品の断面画像である。図4(A)に示すように、本実施例により製造した複合体製品は、シート材20の角部22の曲率半径が0.14mmであるのに対し、図4(B)に示す比較例では、角部22の曲率半径は0.50mmとなっており、本実施例の方法で製造することにより、シート材20の金型形状への追従性が向上することが確認できる。   Next, with reference to FIG. 2 and FIG. 3, the composite manufactured by the present Example and the composite manufactured by the background art mentioned above are compared. FIG. 2 is a diagram showing a composite product according to the present example, in which (A) is an image showing a part of the product surface including the mirror surface part 70 and the matte surface part 72, and (B) is the product of (A). (C) is a magnified view of a part of the surface of (A) (region P surrounded by the dotted line of the mirror surface portion 70 in (A)). This is an enlarged image. The mirror surface means a surface obtained by transferring from the mirror surface of the mold surface, and here, in order to make the difference in surface state from the comparative example easier to understand, an enlarged image of the mirror surface portion However, it goes without saying that embossing is also possible. On the other hand, FIG. 3 is a view showing a composite product of a comparative example according to the background art, in which (A) is an image showing a part of the surface portion 80 of the product, and (B) is an opening of the product of (A). 82 is an enlarged view of the edge portion 84, and (C) is an image obtained by enlarging a part of the surface of (A) (region Q surrounded by the dotted line in (B)) by 175 times. As is clear from the comparison between FIGS. 2 (A) to 2 (C) and FIGS. 3 (A) to 3 (C), according to the present embodiment, the shape of the edge portion of the product is arranged and the smoothness of the surface is obtained. It can be seen that it is expensive. Further, FIG. 4 shows images for comparing the followability of the corner portions of the products according to the present example and the comparative example to the mold shape. 4A is a cross-sectional image of the product of this example, and FIG. 4B is a cross-sectional image of the product of the comparative example. As shown in FIG. 4 (A), the composite product manufactured in this example has a radius of curvature of the corner 22 of the sheet material 20 of 0.14 mm, whereas the comparative example shown in FIG. 4 (B). Then, the radius of curvature of the corner portion 22 is 0.50 mm, and it can be confirmed that the followability of the sheet material 20 to the mold shape is improved by manufacturing according to the method of this embodiment.

このように、実施例1によれば、強化繊維を含有し、熱可塑性樹脂からなるシート材20を、熱成形によって仮賦形してから金型30のキャビティ36にインサートし、該シート材20の主面20Bに熱可塑性樹脂60を射出する際に、加熱冷却して金型形状に追従させることで、軽量で強度や耐久性能に優れ、しかも、成形後に別途表面処理を施すことなく、外観や手触り感も良好な複合体が得られるという効果がある。また、シート材20と射出成形部50の融着強度を向上させることができる。   As described above, according to Example 1, the sheet material 20 containing the reinforcing fiber and made of the thermoplastic resin is temporarily formed by thermoforming, and then inserted into the cavity 36 of the mold 30. When injecting the thermoplastic resin 60 onto the main surface 20B, it is lightweight and excellent in strength and durability performance by heating and cooling to follow the shape of the mold. In addition, there is an effect that a composite with good touch feeling can be obtained. Further, the fusion strength between the sheet material 20 and the injection molded part 50 can be improved.

なお、本発明は、上述した実施例に限定されるものではなく、本発明の要旨を逸脱しない範囲内において種々変更を加え得ることができる。例えば、以下のものも含まれる。
(1)前記実施例で示したキャビティ36やゲート40の形状・構造は一例であり、必要に応じて適宜変更してよい。
(2)前記実施例で示した加熱冷却手段42も一例であり、同様の効果を奏するものであれば、他の公知の各種の加熱冷却手段を用いてよい。
(3)前記実施例では、シート材20をキャビティ36にインサートして、該シート材20の主面20Bに熱可塑性樹脂60を射出すると同時に、加熱冷却して複合体10を得ることとしたが、これも一例であり、シート材20をキャビティ36にインサートしてから、まず、シート材20のみを加熱冷却成形し、その後に、主面20Bに熱可塑性樹脂60を射出成形するようにしても、上述した実施例1と同様の効果を得ることができる。
(4)本発明の複合体の製造を、2色成形機を利用して行ってもよい。例えば、前記実施例1の図1(C)に示す工程の後、図5(A)に示すように、1次射出用の固定型32Aにシート材20をプレスするための型を取り付け、プレスと同時にシート材20の加熱冷却成形を行う。そして、金型30を開いて可動型34側を180度回転させて、図1(D)に示す工程に戻り、射出成形を行う。以降の工程は、上述した実施例1と同様である。このように、既存の2色成形機を利用することにより、本発明を容易に実施することができる。
In addition, this invention is not limited to the Example mentioned above, A various change can be added in the range which does not deviate from the summary of this invention. For example, the following are also included.
(1) The shapes and structures of the cavity 36 and the gate 40 shown in the above embodiment are merely examples, and may be changed as appropriate.
(2) The heating / cooling means 42 shown in the above embodiment is also an example, and other known various heating / cooling means may be used as long as the same effects can be obtained.
(3) In the above-described embodiment, the sheet material 20 is inserted into the cavity 36 and the thermoplastic resin 60 is injected into the main surface 20B of the sheet material 20, and at the same time, the composite 10 is obtained by heating and cooling. This is also an example. After the sheet material 20 is inserted into the cavity 36, only the sheet material 20 is first heated and cooled, and then the thermoplastic resin 60 is injection-molded on the main surface 20B. The same effects as those of the first embodiment can be obtained.
(4) The composite of the present invention may be produced using a two-color molding machine. For example, after the step shown in FIG. 1C of the first embodiment, as shown in FIG. 5A, a die for pressing the sheet material 20 is attached to the fixed die 32A for primary injection, and the press At the same time, the sheet material 20 is heated and cooled. Then, the mold 30 is opened, the movable mold 34 side is rotated 180 degrees, and the process returns to the step shown in FIG. 1D, and injection molding is performed. Subsequent steps are the same as those in the first embodiment. Thus, the present invention can be easily implemented by using an existing two-color molding machine.

(5)前記実施例では、シート材主面20Bの一部に射出成形部50を設けることとしたが、該射出成形部50の形成範囲や形状も一例であり、必要に応じて適宜変更してよい。
(6)前記シート材20として、多層構造のものを用いてもよい。例えば、図5(B)に示す例では、2枚のシート90A,90Bを、繊維の向きが略直交するように重ねたものをシート材20として利用した例である。繊維(例えば、カーボンファイバ)入りのシートは、シート製造(例えば押出し成形)時に繊維が一方向となるため、繊維の配列方向により強度差が生じるが、図5(B)に示すように繊維の向きが直交するように積層することにより、縦横方向のシート材の割れやすさを改善することができる。また、図5(C)に示す例のように、前記シート90A,90Bの間(あるいはその表裏のいずれか)に、更に、これらシート90A,90Bとは繊維の向きが45度ずれたシート90C,90Dを、これらシート90Cとシート90Dの向きが直交し、かつ、前記シート90A,90Bの繊維の向きに対して45度ずれるように重ねたものを、シート材20として利用してもよい。このようにすると、前記図5(B)に示す例と比べて、更に強度が強くなり、全方向における割れやすさを大きく改善することができる。
(7)本発明により製造した複合体は、塗装などの後処理を行うことなく、良好な外観や手触りを得ることができるが、必要に応じて製品表面(シート材20の表面)に、塗装などの表面処理を施すことを妨げるものではない。
(8)前記実施例では、本実施例の複合体10の適用例として、自動車の内装部品,外装部品,携帯電話の筐体,液晶テレビの筐体などを例に挙げたが、本発明は、これらに限定されるものではなく、強化繊維を含有する熱可塑性シートと、熱可塑性樹脂の射出成形品を一体構成とした複合体の用途全般に適用可能である。
(5) In the above embodiment, the injection molding part 50 is provided on a part of the sheet material main surface 20B. However, the formation range and shape of the injection molding part 50 are also examples, and may be changed as necessary. It's okay.
(6) The sheet material 20 may have a multilayer structure. For example, in the example shown in FIG. 5 (B), two sheets 90A and 90B are used as the sheet material 20 in which the fibers are stacked so that the directions of the fibers are substantially orthogonal. In a sheet containing fibers (for example, carbon fibers), since the fibers are unidirectional during sheet production (for example, extrusion molding), a difference in strength occurs depending on the arrangement direction of the fibers. However, as shown in FIG. By laminating so that the directions are orthogonal, the ease of cracking of the sheet material in the vertical and horizontal directions can be improved. Further, as in the example shown in FIG. 5C, between the sheets 90A and 90B (or either of the front and back sides), a sheet 90C in which the direction of the fibers is deviated by 45 degrees from the sheets 90A and 90B. , 90D may be used as the sheet material 20 in which the directions of the sheet 90C and the sheet 90D are orthogonal to each other and deviated by 45 degrees with respect to the direction of the fibers of the sheets 90A, 90B. In this way, compared with the example shown in FIG. 5B, the strength is further increased, and the ease of cracking in all directions can be greatly improved.
(7) The composite produced according to the present invention can obtain a good appearance and feel without performing post-treatment such as painting, but can be painted on the product surface (the surface of the sheet material 20) as necessary. It does not prevent the surface treatment such as.
(8) In the above embodiment, examples of application of the composite 10 of this embodiment include automobile interior parts, exterior parts, mobile phone casings, liquid crystal television casings, and the like. However, the present invention is not limited to these, and the present invention can be applied to all uses of composites in which a thermoplastic sheet containing reinforcing fibers and an injection molded product of a thermoplastic resin are integrated.

本発明によれば、強化繊維を含有し、熱可塑性樹脂からなるシート材を、熱成形によって仮賦形してから金型表面に貼り付け、該シート材を加熱冷却して金型形状に追従させ、前記加熱冷却後に、あるいは、前記加熱冷却と同時に、前記シート材の主面全体あるいは一部に、熱可塑性樹脂を射出成形することとした。このため、軽量で強度や耐久性能に優れ、しかも、外観や手触り感も良好な複合体が得られることから、各種物品の内装材,外装材,筐体などに用いられる複合体に適用できる。   According to the present invention, a sheet material containing a reinforcing fiber and made of a thermoplastic resin is temporarily formed by thermoforming and then attached to the surface of the mold, and the sheet material is heated and cooled to follow the mold shape. Then, after the heating and cooling, or simultaneously with the heating and cooling, a thermoplastic resin is injection-molded on the whole or a part of the main surface of the sheet material. For this reason, since it is lightweight, excellent in strength and durability, and having a good appearance and feel, it can be applied to composites used for interior materials, exterior materials, housings and the like of various articles.

10:複合体
20:シート材
20A,20B:主面
22:角部
30:金型
32,32A:固定型
34:可動型
36:キャビティ
36A,36B:角部
36C,36D:縁部
38A〜38C:成形スペース
40:ゲート
42:加熱冷却手段
44:隙間
50:射出成形部
52:平面部
54A,54B:取付用脚部
60,60A:熱可塑性樹脂
70:鏡面部
72:艶消し面部
74:開口部
76:エッジ部
80:表面部
82:開口部
84:エッジ部
90A〜90D:シート
10: Composite 20: Sheet material 20A, 20B: Main surface 22: Corner 30: Mold 32, 32A: Fixed mold 34: Movable mold 36: Cavity 36A, 36B: Corner 36C, 36D: Edges 38A-38C : Molding space 40: Gate 42: Heating / cooling means 44: Clearance 50: Injection molding part 52: Plane part 54A, 54B: Mounting leg part 60, 60A: Thermoplastic resin 70: Mirror surface part 72: Matte surface part 74: Opening Portion 76: Edge portion 80: Surface portion 82: Opening portion 84: Edge portions 90A to 90D: Sheet

Claims (4)

固定型と可動型から構成される金型のパーティング面にキャビティが形成されるとともに、前記可動型に設けられた加熱冷却機構と、前記固定型側に設けられており熱可塑性樹脂を前記キャビティへ射出する射出機構とを備えた複合体製造装置を用いて、
強化繊維を含有し、熱可塑性樹脂からなるシート材を熱成形して仮賦形する工程1と、
該工程1によって仮賦形されたシート材を、金型へインサートし、前記可動型側のキャビティ面に貼り付ける工程2と、
前記金型を型締めするとともに、前記金型へインサートされたシート材を、前記可動型側に設けた加熱冷却機構によって加熱冷却成形して、該シート材を金型形状に追従させる工程3と、
前記シート材の全部又は一部に熱可塑性樹脂を射出成形し、前記シート材と熱可塑性樹脂成形体が一体に融着された複合体を形成する工程4と、
を含むことを特徴とする複合体の製造方法。
A cavity is formed on a parting surface of a mold composed of a fixed mold and a movable mold, and a heating / cooling mechanism provided on the movable mold, and a thermoplastic resin provided on the fixed mold side is disposed on the cavity. Using a complex manufacturing apparatus equipped with an injection mechanism for injecting
Step 1 for thermoforming a sheet material containing a reinforcing fiber and made of a thermoplastic resin,
The sheet material is temporarily shaped by the step 1, was inserted into a mold, and step 2 that stuck to the cavity surface of the movable mold side,
While clamping the mold, the sheet material which is inserted into the mold, and molding heating and cooling by the heating and cooling mechanism provided on the movable mold side, step 3 to follow the sheet material into the mold shape ,
Step 4 of injection molding a thermoplastic resin to all or a part of the sheet material to form a composite in which the sheet material and the thermoplastic resin molded body are integrally fused;
The manufacturing method of the composite_body | complex characterized by including.
前記工程3と同時に、前記工程4を行うことを特徴とする請求項1記載の複合体の製造方法。   The method for producing a composite according to claim 1, wherein the step 4 is performed simultaneously with the step 3. 前記工程の仮賦形を、真空成形又は圧空成形により行うことを特徴とする請求項1又は2記載の複合体の製造方法。 The method for producing a composite according to claim 1 or 2, wherein the temporary shaping in step 1 is performed by vacuum forming or pressure forming. 請求項1〜3のいずれか一項に記載の製造方法で形成されたことを特徴とする複合体。   A composite formed by the production method according to claim 1.
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