JP2006089517A - Fiber-reinforced resin member and method for producing the same - Google Patents

Fiber-reinforced resin member and method for producing the same Download PDF

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JP2006089517A
JP2006089517A JP2004273126A JP2004273126A JP2006089517A JP 2006089517 A JP2006089517 A JP 2006089517A JP 2004273126 A JP2004273126 A JP 2004273126A JP 2004273126 A JP2004273126 A JP 2004273126A JP 2006089517 A JP2006089517 A JP 2006089517A
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fiber
fibers
long
reinforced resin
base resin
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Shintaro Nakatani
慎太郎 中谷
Katsumi Suzuki
克己 鈴木
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Aisin Corp
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Aisin Seiki Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To obtain a fiber-reinforced resin member that keeps sufficient mechanical properties and makes a cost lower and to provide a method for producing the same. <P>SOLUTION: The fiber-reinforced resin member 10 comprises long fibers 12 concentratedly arranged in a surface layer part 16 and, on the other hand, short fibers 14 concentratedly arranged in a middle layer part 18. Since the long fibers 12 are concentratedly arranged in the surface layer part 16, the low-cost fiber-reinforced resin member 10 is actualized while sufficiently keeping a flexural strength. The fiber-reinforced resin member 10 is obtained by mixing long fiber materials 24 composed of the long fibers 12 embedded in a first base resin 20a having a relatively high melt viscosity with short fiber materials 22 composed of the short fibers 14 embedded in a second base resin 20b having a relatively low melt viscosity to give a mixed material 26 and injection-molding the mixed material as a raw material. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、樹脂中に繊維を含有させることにより、樹脂の強度を向上させることができる繊維強化樹脂部材及びその製造方法に関する。   The present invention relates to a fiber-reinforced resin member capable of improving the strength of a resin by containing fibers in the resin and a method for producing the same.

樹脂の中に繊維状のフィラーを含有することで、軽量でかつ機械的強度が優れる繊維強化樹脂部材が知られている。これら繊維強化樹脂部材は、樹脂中に含有させる繊維の長さにより、長繊維強化樹脂部材と短繊維強化樹脂部材とに大別することができる。長繊維強化樹脂部材は、繊維の平均長さが、例えば約０．５〜１０ｍｍとされるいわゆる長繊維を樹脂中に含有させたものであり、短繊維強化樹脂部材は、繊維の平均長さが例えば０．０１〜１ｍｍとされるいわゆる短繊維を樹脂中に含有させたものである。ここで、長繊維強化樹脂部材は、短繊維強化樹脂部材に比べて機械的強度に優れるため、比較的強度が必要とされる部材には好適に採用することができる。一方、短繊維強化樹脂部材は、長繊維強化樹脂部材に比べて低コストであるという特徴がある。また、長繊維が入り込めないような部分にも短繊維であれば入り込めるため、例えば複雑な形状を有する部材の細部においても強度を確保できるというメリットがある。   A fiber-reinforced resin member that is lightweight and excellent in mechanical strength is known by containing a fibrous filler in the resin. These fiber reinforced resin members can be broadly classified into long fiber reinforced resin members and short fiber reinforced resin members, depending on the length of fibers contained in the resin. The long fiber reinforced resin member is a material in which a so-called long fiber having an average fiber length of, for example, about 0.5 to 10 mm is contained in the resin, and the short fiber reinforced resin member has an average fiber length. Is, for example, a so-called short fiber having a thickness of 0.01 to 1 mm. Here, since the long fiber reinforced resin member is superior in mechanical strength as compared with the short fiber reinforced resin member, the long fiber reinforced resin member can be suitably used for a member that requires relatively high strength. On the other hand, the short fiber reinforced resin member has a feature that the cost is lower than that of the long fiber reinforced resin member. Further, since the short fiber can enter the portion where the long fiber cannot enter, there is an advantage that the strength can be ensured even in the detail of the member having a complicated shape, for example.

このような、長繊維強化樹脂部材と短繊維強化樹脂部材との長所を鑑みて、長繊維強化樹脂部材と短繊維強化樹脂部材とを組み合わせた繊維強化樹脂部材が、例えば特開平８−３１１３１１号公報（特許文献１）に開示されている。特許文献１は、樹脂部材全体の強度は長繊維で補強するとともに、ネジ山等の細部においても、短繊維を分布させることにより強度を確保することができるネジを開示するものである。
特開平５−０５２２０６号公報 In view of the advantages of the long fiber reinforced resin member and the short fiber reinforced resin member, a fiber reinforced resin member in which a long fiber reinforced resin member and a short fiber reinforced resin member are combined is disclosed in, for example, Japanese Patent Laid-Open No. 8-311311 It is disclosed in the publication (Patent Document 1). Patent Document 1 discloses a screw in which the strength of the entire resin member is reinforced with long fibers and the strength can be ensured by distributing short fibers even in details such as screw threads.
JP-A-5-052206

上記特許文献１に開示されている繊維強化樹脂部材（ネジ）においては、長繊維及び短繊維との両者の長所により、部材全体としての機械的特性を良好に維持するとともに、細部においても十分な機械的特性を維持することができる。しかしながら、このような繊維強化樹脂部材においては、細部ではなくその部材自体の機械的特性を向上させるには、長繊維のフィラーを樹脂部材に多量に含有させなければならないので、樹脂部材のコストが高くなるという問題がある。なお、引用文献１に開示されている技術においては、長繊維を樹脂部材のメインの部分に分布させ、短繊維を細部に分布させるようにしているとはいっても、長繊維と短繊維を含む樹脂を単に射出成形することで得られるものであり、長繊維と短繊維とをこれらの特性に応じて積極的に配列させるという意図は感じられない。   In the fiber reinforced resin member (screw) disclosed in Patent Document 1, the mechanical properties of the entire member are satisfactorily maintained due to the advantages of both the long fiber and the short fiber, and the details are sufficient. Mechanical properties can be maintained. However, in such a fiber reinforced resin member, in order to improve the mechanical characteristics of the member itself, not the details, it is necessary to contain a long fiber filler in the resin member in large quantities. There is a problem of becoming higher. In the technique disclosed in the cited document 1, long fibers and short fibers are included even though the long fibers are distributed in the main part of the resin member and the short fibers are distributed in detail. It is obtained by simply injection molding the resin, and the intention of actively arranging long fibers and short fibers according to these characteristics is not felt.

本発明は、以上のような現状を鑑みてなされたものであり、十分な機械的特性を維持することができるとともに、よりコストを低下させることができる繊維強化樹脂部材を提供することを課題とする。また、そのような繊維強化樹脂部材を製造する方法を提供することを課題とする。   The present invention has been made in view of the current situation as described above, and it is an object to provide a fiber-reinforced resin member that can maintain sufficient mechanical characteristics and can further reduce costs. To do. Another object of the present invention is to provide a method for producing such a fiber reinforced resin member.

上記課題を解決するために、本発明の繊維強化樹脂部材の第１の様相は、ベース樹脂に短繊維と長繊維とが含有されている繊維強化樹脂部材において、表層部における前記長繊維の含有量が中層部における前記長繊維の含有量よりも多く、前記中層部における前記短繊維の含有量が前記表層部における前記短繊維の含有量よりも多くされていることを特徴とする。   In order to solve the above problems, the first aspect of the fiber-reinforced resin member of the present invention is a fiber-reinforced resin member in which short fibers and long fibers are contained in the base resin, and the inclusion of the long fibers in the surface layer portion. The amount is larger than the content of the long fibers in the middle layer portion, and the content of the short fibers in the middle layer portion is larger than the content of the short fibers in the surface layer portion.

また、上記課題を解決するために、本発明の繊維強化樹脂部材の第２の様相は、第１ベース樹脂に長繊維が含有されてなる長繊維材料と、第２ベース樹脂に短繊維が含有されてなり、該長繊維材料よりも溶融粘度が低い短繊維材料とを混合して得られた混合材料を射出成形することにより成形されたことを特徴とする。   Moreover, in order to solve the said subject, the 2nd aspect of the fiber reinforced resin member of this invention is the long fiber material by which a 1st base resin contains a long fiber, and the 2nd base resin contains a short fiber. It is characterized by being formed by injection molding a mixed material obtained by mixing a short fiber material having a melt viscosity lower than that of the long fiber material.

なお、溶融粘度とは、長繊維あるいは短繊維が含有されるベース樹脂が溶融したときの材料の粘度をいう。   The melt viscosity means the viscosity of the material when the base resin containing long fibers or short fibers is melted.

さらに、上記課題を解決するために、本発明の繊維強化樹脂部材の製造方法は、第１ベース樹脂に長繊維が含有されてなる長繊維材料と、第２ベース樹脂に短繊維が含有されてなり、前記長繊維材料よりも溶融粘度が低い短繊維材料とを混合する工程と、前記長繊維材料と前記短繊維材料とが混合された混合材料を溶融状態で成形型に形成されるキャビティに射出する射出成形工程と、を有することを特徴とする。   Furthermore, in order to solve the said subject, the manufacturing method of the fiber reinforced resin member of this invention has the long fiber material by which the 1st base resin contains the long fiber, and the 2nd base resin contains the short fiber. A step of mixing a short fiber material having a melt viscosity lower than that of the long fiber material, and a mixed material obtained by mixing the long fiber material and the short fiber material into a cavity formed in a mold in a molten state. An injection molding step of injecting.

上記の本発明の繊維強化樹脂部材の第１の様相によれば、長繊維が部材の外周面側にある表層部に集中的に分布し、短繊維が部材の内部にある中層部に集中的に分布する形態を実現することができる。短繊維が中層部に集中的に分布し、長繊維が表層部に集中的に分布するような形態を実現することで、繊維強化樹脂部材全体に含まれる長繊維の割合を低減させることができ、繊維強化樹脂部材のコストを低下させることができる。さらに、長繊維が繊維強化樹脂部材の表層部に集中的に分布しているため、繊維強化樹脂部材の機械的特性を十分に維持することができる。特に、繊維強化樹脂部材の曲げ強度を、長繊維及び短繊維の部材全体における配合量及び配合割合が同一で、かつ長繊維と短繊維が部材全体に略均一に分布している他の樹脂部材よりも格段に向上させることができる。これは、曲げ中心となる中層部よりも、該中層部から距離の遠い表層部における強度が強いためである。このように、本発明の繊維強化樹脂部材の第１においては、部材中における長繊維の含有量を全体として比較的少なくしても、長繊維が樹脂部材の表層部に集中的に分布するような構成とすることで、十分な機械的特性を維持することができる。したがって、機械的特性に優れる繊維強化樹脂部材をより低コストで実現することができる。   According to the above first aspect of the fiber reinforced resin member of the present invention, long fibers are concentrated in the surface layer portion on the outer peripheral surface side of the member, and short fibers are concentrated in the middle layer portion in the member. Can be realized. By realizing a form in which short fibers are intensively distributed in the middle layer part and long fibers are intensively distributed in the surface layer part, the proportion of long fibers contained in the entire fiber reinforced resin member can be reduced. The cost of the fiber reinforced resin member can be reduced. Furthermore, since the long fibers are concentrated in the surface layer portion of the fiber reinforced resin member, the mechanical properties of the fiber reinforced resin member can be sufficiently maintained. In particular, other resin members in which the bending strength of the fiber reinforced resin member is the same in the blending amount and blending ratio of the long fiber and short fiber members as a whole, and the long fibers and short fibers are distributed substantially uniformly throughout the member. It can be significantly improved. This is because the strength of the surface layer portion far from the middle layer portion is stronger than that of the middle layer portion serving as the bending center. Thus, in the first fiber-reinforced resin member of the present invention, even if the content of long fibers in the member is relatively small as a whole, the long fibers are intensively distributed on the surface layer portion of the resin member. By adopting a simple configuration, sufficient mechanical characteristics can be maintained. Therefore, a fiber reinforced resin member having excellent mechanical properties can be realized at a lower cost.

さらに、上記のような本発明の繊維強化樹脂部材を製造するためには、第１ベース樹脂に長繊維が含有され、比較的溶融粘度が高い長繊維材料と、第２ベース樹脂に短繊維が含有され、比較的溶融粘度が低い短繊維材料とを混合した混合材料を用いて射出成形すればよい。射出成形においては、射出成形に使用する金型の金型面側に溶融粘度の高い部分が流れ、一方、該金型の金型面から離れた内部には溶融粘度の低い部分が流れる。したがって、本発明のように、溶融粘度の比較的高い長繊維材料は、金型の金型面側に優先的に流れる。そのため、長繊維材料に含有される長繊維が金型の金型面側に優先的に分布することになる。一方、比較的溶融粘度の低い短繊維材料は、金型の金型面から離れた金型内部に優先的に流れる。そのため、短繊維材料に含有される短繊維が金型の内部に優先的に分布することになる。そのため、機械的特性が十分に維持されるとともに低コストな本発明に係る繊維強化樹脂部材を製造することができる。なお、長繊維材料及び短繊維材料の溶融粘度を規定する指標はいくつか考えられるが、例えば、メルトフローレートやスパイラルフロー長等を、粘度の指標として採用することができる。   Furthermore, in order to manufacture the fiber reinforced resin member of the present invention as described above, the first base resin contains long fibers, the relatively high melt viscosity of the long fiber material, and the second base resin contains short fibers. What is necessary is just to carry out injection molding using the mixed material which mixed the short fiber material contained and comparatively low melt viscosity. In injection molding, a portion having a high melt viscosity flows on the mold surface side of a mold used for injection molding, while a portion having a low melt viscosity flows inside the mold away from the mold surface. Therefore, as in the present invention, the long fiber material having a relatively high melt viscosity flows preferentially to the mold surface side of the mold. Therefore, the long fibers contained in the long fiber material are preferentially distributed on the mold surface side of the mold. On the other hand, the short fiber material having a relatively low melt viscosity flows preferentially inside the mold away from the mold surface of the mold. Therefore, the short fibers contained in the short fiber material are preferentially distributed inside the mold. Therefore, it is possible to manufacture the fiber-reinforced resin member according to the present invention with sufficient mechanical characteristics and low cost. There are several indexes that define the melt viscosity of the long fiber material and the short fiber material. For example, a melt flow rate, a spiral flow length, or the like can be used as the viscosity index.

上記のような、本発明の繊維強化樹脂部材の製造方法から、前述した本発明の繊維強化樹脂部材の第２の様相も想定できる。つまり、上記のような本発明に係る繊維強化樹脂部材の製造方法によれば、長繊維が繊維強化樹脂部材の表層部に集中的に分布するため、表層部における長繊維の含有量が中層部に比べて多くなる。そのため、本発明の繊維強化樹脂部材の第１の様相で説明した繊維強化樹脂部材と同様の繊維強化樹脂部材を得ることができる。   From the manufacturing method of the fiber reinforced resin member of the present invention as described above, the second aspect of the fiber reinforced resin member of the present invention described above can also be assumed. That is, according to the method for producing a fiber reinforced resin member according to the present invention as described above, since the long fibers are concentrated in the surface layer portion of the fiber reinforced resin member, the content of the long fibers in the surface layer portion is the middle layer portion. More than Therefore, a fiber reinforced resin member similar to the fiber reinforced resin member described in the first aspect of the fiber reinforced resin member of the present invention can be obtained.

ここで、繊維強化樹脂部材を構成するベース樹脂としては、基本的に射出成形可能な熱可塑性樹脂を採用することができる。さらに具体的には、ポリオレフィン系樹脂、ポリアミド系樹脂、ポリフェニレンサルファイド系樹脂、ポリエステル系樹脂、ポリカーボネート系樹脂、ポリスチレン系樹脂、アクリロニトリル／スチレン（ＡＳ）系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）系樹脂等の熱可塑性プラスチックが挙げられる。   Here, as the base resin constituting the fiber reinforced resin member, a thermoplastic resin that can be basically injection-molded can be employed. More specifically, polyolefin resins, polyamide resins, polyphenylene sulfide resins, polyester resins, polycarbonate resins, polystyrene resins, acrylonitrile / styrene (AS) resins, acrylonitrile / butadiene / styrene (ABS) resins. And other thermoplastics.

また、長繊維材料の溶融粘度を比較的高くし、短繊維材料の溶融粘度を比較的低くする場合、例えば長繊維材料を構成する第１ベース樹脂の溶融粘度を比較的高くして、短繊維材料を構成する第２ベース樹脂の溶融粘度を比較的低くすることで実現することができる。具体的には、長繊維材料の第１ベース樹脂は、短繊維材料の第２ベース樹脂よりも溶融粘度が高いものを採用することができる。なお、第１ベース樹脂の溶融粘度と第２ベース樹脂の溶融粘度とが略同等の場合、あるいは第１ベース樹脂の溶融粘度より第２ベース樹脂の溶融粘度のほうが高い場合でも、長繊維あるいは短繊維が含有されることにより、長繊維材料のほうが短繊維材料より溶融粘度が高くなるような場合があってもよい。   Further, when the melt viscosity of the long fiber material is made relatively high and the melt viscosity of the short fiber material is made relatively low, for example, the melt viscosity of the first base resin constituting the long fiber material is made relatively high so that the short fiber This can be realized by relatively lowering the melt viscosity of the second base resin constituting the material. Specifically, the first base resin of the long fiber material may be one having a higher melt viscosity than the second base resin of the short fiber material. Even when the melt viscosity of the first base resin is substantially equal to the melt viscosity of the second base resin, or even when the melt viscosity of the second base resin is higher than the melt viscosity of the first base resin, the long fibers or the short fibers There may be a case where the melt viscosity of the long fiber material is higher than that of the short fiber material due to the inclusion of the fibers.

また、ベース樹脂の粘度は、当該樹脂の平均分子量に依存するため、第１ベース樹脂及び第２ベース樹脂の分子量を調整することにより、それぞれのベース樹脂の溶融粘度を適宜好適な程度に設定することができる。具体的には、一般的に平均分子量が多い樹脂は溶融粘度が高く、平均分子量が少ない樹脂は溶融粘度が低いと言える。そのため、比較的溶融粘度の高い第１ベース樹脂として、比較的平均分子量の大きな樹脂を採用することができる。一方、比較的溶融粘度が低い第２ベース樹脂として、比較的平均分子量の小さな樹脂を採用することができる。樹脂の種類としては、上述したような数種類の樹脂から、第1ベース樹脂あるいは第２ベース樹脂として好適な平均分子量を有するものを選択して採用することができる。   Further, since the viscosity of the base resin depends on the average molecular weight of the resin, the melt viscosity of each base resin is appropriately set to an appropriate level by adjusting the molecular weight of the first base resin and the second base resin. be able to. Specifically, it can be said that a resin having a high average molecular weight generally has a high melt viscosity, and a resin having a low average molecular weight has a low melt viscosity. Therefore, a resin having a relatively large average molecular weight can be employed as the first base resin having a relatively high melt viscosity. On the other hand, as the second base resin having a relatively low melt viscosity, a resin having a relatively small average molecular weight can be employed. As the type of resin, a resin having an average molecular weight suitable as the first base resin or the second base resin can be selected and used from several types of resins as described above.

なお、第１ベース樹脂と第２ベース樹脂とは、同一種類の樹脂において、平均分子量が異なるものを採用することができる。すなわち、第１ベース樹脂と第２ベース樹脂とを同一の樹脂で構成し、第１ベース樹脂の平均分子量を第２ベース樹脂の平均分子量よりも高くすることができる。第１ベース樹脂と第２ベース樹脂とが同一の樹脂で構成されているため、それぞれの樹脂の相溶性を十分に維持することができる。   In addition, the 1st base resin and 2nd base resin can employ | adopt what differs in average molecular weight in the same kind of resin. That is, the first base resin and the second base resin can be made of the same resin, and the average molecular weight of the first base resin can be made higher than the average molecular weight of the second base resin. Since the first base resin and the second base resin are made of the same resin, the compatibility of each resin can be sufficiently maintained.

また、上記のようなベース樹脂に含有される強化繊維としては、ガラス繊維、炭素繊維等の無機繊維、シリコン繊維、チタン繊維、炭素繊維、ボロン繊維等の金属繊維、アラミド繊維、ポリエステル繊維、ポリアミド繊維、ビニロン等の有機合成繊維、絹、綿、麻等の天然繊維等を例示することができる。これらは単独で用いてもよく、２種以上組合わせて用いてもよいが、機械的物性の向上及び入手の容易性の点からガラス繊維を採用するのがより好ましい。ガラス繊維の具体例としては、Ｅガラス（Electrical glass ）、Ｃガラス（Chemical glass ）、Ａガラス（Alkali glass ）、Ｓガラス（High strength glass ）、及び耐アルカリガラス等のガラスを溶融紡糸して得られるフィラメント状の繊維を例示することができる。   The reinforcing fibers contained in the base resin as described above include inorganic fibers such as glass fibers and carbon fibers, metal fibers such as silicon fibers, titanium fibers, carbon fibers, and boron fibers, aramid fibers, polyester fibers, and polyamides. Examples thereof include organic synthetic fibers such as fibers and vinylon, and natural fibers such as silk, cotton and hemp. These may be used singly or in combination of two or more, but it is more preferable to employ glass fibers from the viewpoint of improvement in mechanical properties and availability. Specific examples of glass fibers are obtained by melt spinning glass such as E glass (Electrical glass), C glass (Chemical glass), A glass (Alkali glass), S glass (High strength glass), and alkali-resistant glass. Examples of the filament-like fibers that can be obtained.

長繊維と短繊維とをあわせた強化繊維全体の含有量は、前記ベース樹脂に対して１０〜５０重量％が好ましく、２５〜４５重量％がより好ましい。強化繊維の含有量が１０重量％未満の場合には、繊維強化樹脂部材の機械的特性を十分に維持することができない。一方、同強化繊維の含有量が５０重量％を超えると、成形性が低下するとともにコストアップの原因となり好ましくない。   The total content of the reinforcing fibers including the long fibers and the short fibers is preferably 10 to 50% by weight, and more preferably 25 to 45% by weight with respect to the base resin. When the content of the reinforcing fiber is less than 10% by weight, the mechanical properties of the fiber reinforced resin member cannot be sufficiently maintained. On the other hand, if the content of the reinforcing fiber exceeds 50% by weight, the moldability is lowered and the cost is increased, which is not preferable.

さらに、長繊維については、その平均繊維長を例えば０．５ｍｍ〜１０ｍｍとすることができる。平均繊維長が０．５ｍｍ未満であると、強化繊維としての機能が短繊維と区別できず、長繊維としての長所を効果的に得ることができない。一方、短繊維については、その平均繊維長を０．０１ｍｍ〜０．５ｍｍとすることができる。平均繊維長が０．０１ｍｍ未満であると、強化繊維としての機能を十分に発揮することができない。   Furthermore, about a long fiber, the average fiber length can be 0.5 mm-10 mm, for example. When the average fiber length is less than 0.5 mm, the function as the reinforcing fiber cannot be distinguished from the short fiber, and the advantage as the long fiber cannot be obtained effectively. On the other hand, about a short fiber, the average fiber length can be 0.01 mm-0.5 mm. When the average fiber length is less than 0.01 mm, the function as the reinforcing fiber cannot be sufficiently exhibited.

以下、添付の図面を用いて、本発明に係る繊維強化樹脂部材及びその製造方法の実施形態について説明する。ここでは、特に自動車用部品であるアウトサイドハンドルフレームに好適に使用される繊維強化樹脂部材について説明する。図１は、本実施形態の繊維強化樹脂部材を示す断面模式図である。図１に示すように、本実施形態の繊維強化樹脂部材１０は、ベース樹脂２０中に長繊維１２と短繊維１４とが含有されているものである。ここで、本実施形態の繊維強化樹脂部材１０においては、その外周面側に位置する表層部１６は、ベース樹脂２０は第１ベース樹脂２０ａにより構成されている。一方、繊維強化樹脂部材１０の内部である中層部１８は、ベース樹脂２０は第２ベース樹脂２０ｂにより構成されている。ここで、第１ベース樹脂２０ａと第２ベース樹脂２０ｂとは前述したような熱可塑性樹脂により構成することができる。特に、前述した自動車部品に採用する場合には、第１ベース樹脂としてポリプロピレンを採用することができる。軽量であるためである。一方、第２ベース樹脂として第１ベース樹脂と同種のポリプロピレンを採用することができる。本実施形態においては、第１ベース樹脂と第２ベース樹脂とは同種の樹脂であるが、平均分子量を第２ベース樹脂よりも第１ベース樹脂において高くしており、第１ベース樹脂の溶融粘度のほうが、第２ベース樹脂の溶融粘度よりも高く設定されている。また、本実施形態においては、長繊維１２及び短繊維１４は前述したガラス繊維により構成されている。   Hereinafter, embodiments of a fiber-reinforced resin member and a method for manufacturing the same according to the present invention will be described with reference to the accompanying drawings. Here, a fiber reinforced resin member that is preferably used for an outside handle frame that is an automotive part will be described. FIG. 1 is a schematic cross-sectional view showing the fiber-reinforced resin member of this embodiment. As shown in FIG. 1, the fiber reinforced resin member 10 of the present embodiment is one in which long fibers 12 and short fibers 14 are contained in a base resin 20. Here, in the fiber reinforced resin member 10 of the present embodiment, the base resin 20 of the surface layer portion 16 located on the outer peripheral surface side is constituted by the first base resin 20a. On the other hand, in the middle layer portion 18 which is the inside of the fiber reinforced resin member 10, the base resin 20 is constituted by the second base resin 20b. Here, the first base resin 20a and the second base resin 20b can be made of a thermoplastic resin as described above. In particular, when employed in the above-described automobile parts, polypropylene can be employed as the first base resin. This is because it is lightweight. On the other hand, the same type of polypropylene as the first base resin can be used as the second base resin. In the present embodiment, the first base resin and the second base resin are the same type of resin, but the average molecular weight is higher in the first base resin than in the second base resin, and the melt viscosity of the first base resin. This is set higher than the melt viscosity of the second base resin. Moreover, in this embodiment, the long fiber 12 and the short fiber 14 are comprised by the glass fiber mentioned above.

ここで、本実施形態の繊維強化樹脂部材１０において、表層部１６は、繊維強化樹脂部材の外周面側に位置し、長繊維１２が集中的に分布している領域である。一方、中層部１８は、表層部１６よりも内部の領域であり、短繊維１４が集中的に分布している領域である。長繊維１２あるいは短繊維１４が集中的に分布しているとは、表層部１６における長繊維１２の含有量は、中層部１８における長繊維１２の含有量よりも多くされており、中層部１８における短繊維１４の含有量は、表層部１６における短繊維１４の含有量よりも多くされていることである。ここで、表層部１６に短繊維１４が含まれていてもよいし、中層部１８に長繊維１２が含まれていてもよい。   Here, in the fiber reinforced resin member 10 of the present embodiment, the surface layer portion 16 is located on the outer peripheral surface side of the fiber reinforced resin member, and is an area where the long fibers 12 are intensively distributed. On the other hand, the middle layer portion 18 is a region inside the surface layer portion 16 and is a region in which the short fibers 14 are intensively distributed. The fact that the long fibers 12 or the short fibers 14 are intensively distributed means that the content of the long fibers 12 in the surface layer portion 16 is larger than the content of the long fibers 12 in the middle layer portion 18, and the middle layer portion 18. The content of the short fibers 14 in is that the content of the short fibers 14 in the surface layer portion 16 is larger. Here, the short fiber 14 may be included in the surface layer portion 16, and the long fiber 12 may be included in the middle layer portion 18.

このように、本実施形態の繊維強化樹脂部材１０によれば、該繊維強化樹脂部材１０の外周面側である表層部１６に長繊維１２が集中的に分布しており、内部の中層部１８に短繊維１４が集中的に分布しているため、長繊維及び短繊維が同量・同割合でベース樹脂に配合されている繊維強化樹脂部材に比べて曲げ強度が高い。これは、中心部から距離が離れた領域の強度が強いほど、部材の曲げ強度が高くなることによる。   As described above, according to the fiber reinforced resin member 10 of the present embodiment, the long fibers 12 are intensively distributed on the surface layer portion 16 on the outer peripheral surface side of the fiber reinforced resin member 10, and the inner middle layer portion 18. Since the short fibers 14 are intensively distributed, the bending strength is higher than that of the fiber reinforced resin member in which the long fibers and the short fibers are mixed in the base resin in the same amount and in the same ratio. This is because the bending strength of the member increases as the strength of the region far from the center increases.

次に、上記のような本実施形態の繊維強化樹脂部材を得るための本実施形態にかかる製造方法について、図２を参照しつつ説明する。まず、第１ベース樹脂２０ａに強化繊維として長繊維１２が含有されている長繊維材料２４と、第２ベース樹脂に強化繊維として短繊維１４が含有されている短繊維材料２２とを用意する。ここで、長繊維材料２４は、例えば細長い円筒状形状を有するものであり、その軸方向に沿って長繊維１２が含有されているものである。さらに、長繊維１２の繊維長は、長繊維材料２４の軸方向の長さＬと略同じとされており、本実施形態の場合、Ｌは０．５〜１０ｍｍとされている。なお、第１ベース樹脂２０ａとしてはポリプロピレンが使用され、長繊維１２はガラス繊維である。一方、短繊維材料２２は、円盤状あるいは不特定形状の樹脂の塊であり、ベース樹脂２０ｂの内部に平均繊維長が０．０１〜０．５ｍｍの短繊維１４が含有されているものである。なお、第２ベース樹脂２０ｂとしてはポリプロピレンが使用され、短繊維１４としてはガラス繊維である。ここで、長繊維材料２４を構成する第１ベース樹脂２０ａにおいては、短繊維材料２２を構成する第２ベース樹脂２０ｂよりも平均分子量が高くされており、第２ベース樹脂２０ｂよりも溶融粘度が高く設定されている。溶融粘度は、メルトフローレートあるいはスパイラルフロー長さ等の指標により比較することができる。   Next, the manufacturing method concerning this embodiment for obtaining the fiber reinforced resin member of this embodiment as mentioned above is demonstrated, referring FIG. First, a long fiber material 24 in which long fibers 12 are contained as reinforcing fibers in the first base resin 20a and a short fiber material 22 in which short fibers 14 are contained as reinforcing fibers in the second base resin are prepared. Here, the long fiber material 24 has, for example, an elongated cylindrical shape, and contains the long fibers 12 along the axial direction thereof. Furthermore, the fiber length of the long fiber 12 is substantially the same as the length L in the axial direction of the long fiber material 24. In the present embodiment, L is 0.5 to 10 mm. Note that polypropylene is used as the first base resin 20a, and the long fibers 12 are glass fibers. On the other hand, the short fiber material 22 is a lump of resin having a disk shape or an unspecified shape, and the short fibers 14 having an average fiber length of 0.01 to 0.5 mm are contained inside the base resin 20b. . Note that polypropylene is used as the second base resin 20b, and the short fibers 14 are glass fibers. Here, in the first base resin 20a constituting the long fiber material 24, the average molecular weight is higher than that of the second base resin 20b constituting the short fiber material 22, and the melt viscosity is higher than that of the second base resin 20b. It is set high. The melt viscosity can be compared by an index such as a melt flow rate or a spiral flow length.

次に、このような長繊維材料２４と短繊維材料２２とを混合し混合材料２６とする。具体的には、長繊維材料２４と短繊維材料２２とはドライブレンドにより混合することができる。   Next, the long fiber material 24 and the short fiber material 22 are mixed to obtain a mixed material 26. Specifically, the long fiber material 24 and the short fiber material 22 can be mixed by dry blending.

続いて、上記のようにして混合された長繊維材料２４と短繊維材料２２との混合材料２６を原料として、図２に示す射出成形機３０を用いて、射出成形を行う。具体的には、ホッパー３１に混合材料２６を充填する。充填された混合材料２６はまず可塑化装置３３に導入される。この可塑化装置３３は加熱シリンダ３２と該加熱シリンダ３２に内蔵されたスクリュ３４とを備える装置である。これら加熱シリンダ３２及びスクリュ３４によって、混合材料２６を回転攪拌しつつ、可塑化装置３３の前方部３３ａに混合材料２６を可塑化移送する。続いて、スクリュ３４を可塑化装置３３の前方に向かって押し出すことにより、可塑化された混合材料２６を、ノズル３５を通じて該ノズル３５に接続される成形用金型３６のキャビティ３７内に充填する。そして、該成形用金型３６内で所要時間加熱及び加圧を行う。その後、成形用金型３６を離型することにより所定形状の繊維強化樹脂部材が得られる。   Subsequently, injection molding is performed using an injection molding machine 30 shown in FIG. 2 using the mixed material 26 of the long fiber material 24 and the short fiber material 22 mixed as described above as raw materials. Specifically, the hopper 31 is filled with the mixed material 26. The filled mixed material 26 is first introduced into the plasticizing device 33. The plasticizing device 33 includes a heating cylinder 32 and a screw 34 built in the heating cylinder 32. By the heating cylinder 32 and the screw 34, the mixed material 26 is plasticized and transferred to the front portion 33a of the plasticizing device 33 while the mixed material 26 is rotationally stirred. Subsequently, the screw 34 is extruded toward the front of the plasticizing device 33, whereby the plasticized mixed material 26 is filled into the cavity 37 of the molding die 36 connected to the nozzle 35 through the nozzle 35. . Then, heating and pressurization are performed in the molding die 36 for a required time. Thereafter, the molding die 36 is released to obtain a fiber-reinforced resin member having a predetermined shape.

このとき、本実施形態によれば、第１ベース樹脂の平均分子量を第２ベース樹脂の平均分子量よりも高くしており、第１ベース樹脂の溶融粘度が第２ベース樹脂の溶融粘度よりも高く設定されている。そのため、図３に示すように、ノズル３５から金型３６のキャビティ３７に可塑化された混合材料３６が射出されると、溶融粘度が比較的低く流れやすい第２ベース樹脂がキャビティ３７の中央部に流れこむ。一方、溶融粘度が比較的高く流れにくい第１ベース樹脂がキャビティ２７の金型面側に流れこむ。すなわち、第１ベース樹脂に含まれる長繊維１２が成形金型３６内で流速の遅い金型面側に集中的に配列することになり、一方、第２ベース樹脂に含まれる短繊維１４が成形金型３６内の流速の速い金型の中央部に集中的に配列することになる。したがって、図１に示すように、部材の外周面側である表層部１６に集中的に長繊維１２が分布するとともに、部材の内部である中層部１８に集中的に短繊維１４が分布する繊維強化樹脂部材１０を得ることができる。   At this time, according to this embodiment, the average molecular weight of the first base resin is higher than the average molecular weight of the second base resin, and the melt viscosity of the first base resin is higher than the melt viscosity of the second base resin. Is set. Therefore, as shown in FIG. 3, when the plasticized mixed material 36 is injected from the nozzle 35 into the cavity 37 of the mold 36, the second base resin having a relatively low melt viscosity flows easily in the center of the cavity 37. Flow into. On the other hand, the first base resin having a relatively high melt viscosity and difficult to flow flows into the mold surface side of the cavity 27. That is, the long fibers 12 included in the first base resin are concentratedly arranged in the molding die 36 on the side of the mold surface having a low flow velocity, while the short fibers 14 included in the second base resin are molded. In this way, the mold 36 is intensively arranged at the center of the mold having a high flow velocity. Therefore, as shown in FIG. 1, the long fibers 12 are intensively distributed in the surface layer portion 16 on the outer peripheral surface side of the member, and the short fibers 14 are intensively distributed in the middle layer portion 18 inside the member. The reinforced resin member 10 can be obtained.

本実施形態の繊維強化樹脂部材を示す断面模式図。The cross-sectional schematic diagram which shows the fiber reinforced resin member of this embodiment. 本実施形態の繊維強化樹脂部材を製造する方法示す模式図。The schematic diagram which shows the method of manufacturing the fiber reinforced resin member of this embodiment. 本実施形態に係る繊維強化樹脂部材の製造方法の作用を説明するための模式図。The schematic diagram for demonstrating the effect | action of the manufacturing method of the fiber reinforced resin member which concerns on this embodiment.

符号の説明Explanation of symbols

１０ 繊維強化樹脂部材
１２ 長繊維
１４ 短繊維
１６ 表層部
１８ 中層部
２０ ベース樹脂
２０ａ 第１ベース樹脂
２０ｂ 第２ベース樹脂
２２ 短繊維材料
２４ 長繊維材料
３６ 成形金型（成形型）
３７ キャビティ DESCRIPTION OF SYMBOLS 10 Fiber reinforced resin member 12 Long fiber 14 Short fiber 16 Surface layer part 18 Middle layer part 20 Base resin 20a 1st base resin 20b 2nd base resin 22 Short fiber material 24 Long fiber material 36 Mold (mold)
37 cavities

Claims (3)

ベース樹脂に短繊維と長繊維とが含有されている繊維強化樹脂部材において、
表層部における前記長繊維の含有量が中層部における前記長繊維の含有量よりも多く、前記中層部における前記短繊維の含有量が前記表層部における前記短繊維の含有量よりも多くされていることを特徴とする繊維強化樹脂部材。 In a fiber reinforced resin member in which short fibers and long fibers are contained in the base resin,
The content of the long fibers in the surface layer part is larger than the content of the long fibers in the middle layer part, and the content of the short fibers in the middle layer part is larger than the content of the short fibers in the surface layer part. A fiber-reinforced resin member. 第１ベース樹脂に長繊維が含有されてなる長繊維材料と、第２ベース樹脂に短繊維が含有されてなり、該長繊維材料よりも溶融粘度が低い短繊維材料とを混合して得られた混合材料を射出成形することにより成形されたことを特徴とする繊維強化樹脂部材。   It is obtained by mixing a long fiber material in which long fibers are contained in the first base resin and a short fiber material in which short fibers are contained in the second base resin and having a melt viscosity lower than that of the long fiber material. A fiber-reinforced resin member formed by injection-molding the mixed material. 第１ベース樹脂に長繊維が含有されてなる長繊維材料と、第２ベース樹脂に短繊維が含有されてなり、前記長繊維材料よりも溶融粘度が低い短繊維材料とを混合する工程と、
前記長繊維材料と前記短繊維材料とが混合された混合材料を溶融状態で成形型に形成されるキャビティに射出する射出成形工程と、を有することを特徴とする繊維強化樹脂部材の製造方法。 Mixing a long fiber material containing long fibers in the first base resin and a short fiber material containing short fibers in the second base resin and having a melt viscosity lower than that of the long fiber material;
An injection molding step of injecting a mixed material obtained by mixing the long fiber material and the short fiber material into a cavity formed in a molding die in a molten state.
JP2004273126A 2004-09-21 2004-09-21 Fiber-reinforced resin member and method for producing the same Withdrawn JP2006089517A (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012215094A1 (en) * 2012-08-24 2014-02-27 Siemens Aktiengesellschaft Fiber-reinforced plastic material comprises fibers with reinforcing short fibers and/or reinforcing particles, which are embedded in a polymer matrix
KR101425977B1 (en) * 2013-12-30 2014-08-06 연세대학교 산학협력단 Mobile Phone Case Comprising Composite Material and Manufacturing Method Thereof
JP2018149726A (en) * 2017-03-13 2018-09-27 パナソニック株式会社 Molded article and molding method of the same

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012215094A1 (en) * 2012-08-24 2014-02-27 Siemens Aktiengesellschaft Fiber-reinforced plastic material comprises fibers with reinforcing short fibers and/or reinforcing particles, which are embedded in a polymer matrix
KR101425977B1 (en) * 2013-12-30 2014-08-06 연세대학교 산학협력단 Mobile Phone Case Comprising Composite Material and Manufacturing Method Thereof
JP2018149726A (en) * 2017-03-13 2018-09-27 パナソニック株式会社 Molded article and molding method of the same
US10596737B2 (en) 2017-03-13 2020-03-24 Panasonic Corporation Molded article and molding method thereof

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