JP2017119373A

JP2017119373A - Method for manufacturing composite molding

Info

Publication number: JP2017119373A
Application number: JP2015256180A
Authority: JP
Inventors: 公彦服部; Kimihiko Hattori; 政人菅森; Masato SUGAMORI; 智幸小野寺; Tomoyuki Onodera; 義人黒田; Yoshito Kuroda; 英夫松岡; Hideo Matsuoka; 正三西田; Shozo Nishida
Original assignee: Japan Steel Works Ltd; Toray Industries Inc
Current assignee: Japan Steel Works Ltd; Toray Industries Inc
Priority date: 2015-12-28
Filing date: 2015-12-28
Publication date: 2017-07-06
Anticipated expiration: 2035-12-28
Also published as: JP6666145B2

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a composite molding which can integrate a continuous reinforcing fiber base material formed from a continuous reinforcing fiber and a thermoplastic resin and an injection resin at a desired position of an injection resin molding in the same mold with a high bond strength and high accuracy, in particular, with a three-dimensional shape.SOLUTION: A method for manufacturing a composite molding includes: a primary molding step of inserting a continuous reinforcing fiber base material formed from a continuous reinforcing fiber and a thermoplastic resin A into a first cavity having a three-dimensional shape, which set in a mold having a slide mechanism, and injection-filling the inside of the first cavity with a molten thermoplastic resin composition B to mold a primary molded product; and a secondary molding step of sliding the first cavity to a second cavity together with the primary molded product, arranging the primary molded product in the second cavity, and injection-filling the inside of the second cavity with a molten thermoplastic resin composition C to integrate the resin composition C with the primary molded product.SELECTED DRAWING: Figure 2

Description

本発明は、複合成形品の製造方法に関し、とくに、連続強化繊維と熱可塑性樹脂からなる連続強化繊維基材と射出樹脂とを、３次元形状にて高接合強度と高精度をもって同一金型内で一体化可能な複合成形品の製造方法に関する。 The present invention relates to a method for producing a composite molded article, and in particular, a continuous reinforcing fiber base material made of continuous reinforcing fibers and a thermoplastic resin and an injection resin in a same mold with high bonding strength and high accuracy in a three-dimensional shape. The present invention relates to a method for manufacturing a composite molded product that can be integrated with a single unit.

繊維強化樹脂基材と他の樹脂成形品、特に他の熱可塑性樹脂成形品とを一体化した複合成形品の製造方法は各種知られている。例えば特許文献１には、炭素繊維強化樹脂（ＣＦＲＰ）シート材状基材を型外で仮賦形し、それを型内にインサートして高速昇降温することで賦形し、賦形体を型内にインサートし、樹脂を射出して複合成形品を得る方法が開示されている。しかしこの方法は、少なくとも仮賦形が成形型外で行われるので、同一型内で複合化できるプロセスではなく、成形プロセスが複雑になっている。 Various methods for producing a composite molded product obtained by integrating a fiber reinforced resin base material and another resin molded product, particularly, another thermoplastic resin molded product are known. For example, in Patent Document 1, a carbon fiber reinforced resin (CFRP) sheet material base material is temporarily shaped outside the mold, and then shaped by inserting it into the mold and rapidly raising and lowering the temperature. A method is disclosed in which a composite molded product is obtained by inserting the resin into the inside and injecting resin. However, in this method, at least provisional shaping is performed outside the mold, so that the molding process is complicated rather than a process that can be combined in the same mold.

また、特許文献２には、ＣＦＲＰ基材を射出成形型内に固定し、樹脂を射出して複合化する方法が開示されているが、単純な層状の複合成形品の記載しかなく、とくに３次元形状のＣＦＲＰ基材を賦形する方法については触れられていない。 Further, Patent Document 2 discloses a method of fixing a CFRP base material in an injection mold and injecting a resin to form a composite, but there is only a description of a simple layered composite molded product. There is no mention of a method of shaping a CFRP substrate having a dimensional shape.

また、特許文献３には、ＣＦＲＰを型内でスタンピング成形し、型をバックさせて空間を作り、同一型内に樹脂を射出する複合成形品の製造方法が開示されている。しかし、この方法は、強化繊維がランダムに配されたランダム繊維基材の成形には適しているが、スタンピング成形のための予熱が必要であり、連続繊維基材を成形する場合には、繊維が折れる、配向が乱れるという問題が発生するとともに、基材を複数、あるいは所定の位置に貼りあわようとする場合には、射出時にＣＦＲＰが樹脂とともに流れてしまい、ＣＦＲＰを成形品の望ましい位置に精度よく貼り合わせることが困難であるという問題がある。 Patent Document 3 discloses a method for manufacturing a composite molded product in which CFRP is stamped in a mold, a space is formed by backing the mold, and a resin is injected into the same mold. However, this method is suitable for molding a random fiber base material in which reinforcing fibers are randomly arranged, but preheating for stamping molding is required. When the base material is to be stuck to a plurality of or predetermined positions, CFRP flows with the resin at the time of injection, and the CFRP is placed at a desired position of the molded product. There is a problem that it is difficult to bond together with high accuracy.

さらに、特許文献４には、射出成形品とＣＦＲＰ基材を成形機内で熱溶着するようにした複合成形品の製造方法が開示されている。しかし、この方法では、射出成形品を作製した後、レーザー溶着、プレス成形等でＣＦＲＰ基材を貼り合わせることとなるので、とくに射出成形品の３次元形状部分にＣＦＲＰ基材を貼り合わせることが困難である。 Furthermore, Patent Document 4 discloses a method for manufacturing a composite molded product in which an injection molded product and a CFRP base material are thermally welded in a molding machine. However, in this method, after the injection molded product is manufactured, the CFRP base material is bonded by laser welding, press molding or the like. Therefore, the CFRP base material is particularly bonded to the three-dimensional shape portion of the injection molded product. Have difficulty.

特開２０１２−１５３０６９号公報JP 2012-153069 A 特開２０１３−２５２６４４号公報JP 2013-252644 A 特開平５−１８５４６６号公報JP-A-5-185466 特開２０１１−１４３５５９号公報JP 2011-143559 A

そこで本発明の課題は、上記のような従来技術における問題点に着目し、連続強化繊維と熱可塑性樹脂からなる連続強化繊維基材と射出樹脂を、とくに３次元形状にて、射出樹脂成形品の所望位置に高接合強度と高精度をもって同一金型内で一体化可能な複合成形品の製造方法を提供することにある。 Therefore, the object of the present invention is to pay attention to the problems in the prior art as described above, and to form a continuous reinforcing fiber base material and injection resin composed of continuous reinforcing fiber and thermoplastic resin, particularly in a three-dimensional shape, an injection resin molded product. Another object of the present invention is to provide a method for manufacturing a composite molded product that can be integrated in the same mold with high bonding strength and high accuracy at a desired position.

上記課題を解決するために、本発明に係る複合成形品の製造方法は、連続強化繊維と熱可塑性樹脂Ａからなる連続強化繊維基材を、スライド機構を備えた金型内に設定された、３次元形状を有する第１のキャビティ内に挿入した後、該第１のキャビティ内に溶融した熱可塑性樹脂組成物Ｂを射出充填して１次成形品を成形する１次成形工程と、
前記第１のキャビティを１次成形品とともに第２のキャビティにスライドさせ、前記１次成形品を前記第２のキャビティ内に配置し、該第２のキャビティ内に溶融した熱可塑性樹脂組成物Ｃを射出充填して該溶融熱可塑性樹脂組成物Ｃと前記１次成形品とを一体化する２次成形工程と、
を有することを特徴とする方法からなる。 In order to solve the above-mentioned problem, a method for producing a composite molded article according to the present invention is a continuous reinforcing fiber base composed of continuous reinforcing fibers and a thermoplastic resin A, set in a mold having a slide mechanism, A primary molding step of molding a primary molded article by injection filling the molten thermoplastic resin composition B into the first cavity after being inserted into the first cavity having a three-dimensional shape;
The first cavity is slid into the second cavity together with the primary molded product, the primary molded product is placed in the second cavity, and the thermoplastic resin composition C melted in the second cavity is obtained. A secondary molding step in which the molten thermoplastic resin composition C and the primary molded product are integrated by injection filling,
It consists of the method characterized by having.

このような本発明に係る複合成形品の製造方法においては、先ず、１次成形工程において、連続強化繊維と熱可塑性樹脂Ａからなる連続強化繊維基材が、３次元形状を有する第１のキャビティ内の所定位置に挿入され、連続強化繊維基材が挿入された第１のキャビティ内に溶融した熱可塑性樹脂組成物Ｂが射出充填されて、射出樹脂圧によって連続繊維基材が３次元形状に賦形されると同時に熱可塑性樹脂組成物Ｂが溶着し、連続強化繊維基材と熱可塑性樹脂組成物Ｂが同一金型内で一体化された３次元形状の１次成形品が成形される。そして、２次成形工程において、第１のキャビティが先に成形された１次成形品とともに第２のキャビティに（より具体的には第２のキャビティ形成位置に）スライド機構によりスライドされ、１次成形品が第２のキャビティ内に（つまり、新たに設定された第２のキャビティ内に）配置され、該第２のキャビティ内に溶融した熱可塑性樹脂組成物Ｃが射出充填されて、該溶融熱可塑性樹脂組成物Ｃと１次成形品とが一体化され、目標とする複合成形品が成形される。このように、先に３次元形状を有する第１のキャビティを用いて３次元形状の１次成形品が成形されるので、連続繊維基材と１次成形品の双方は２次成形の前に精度よく目標とする３次元形状に成形される。先に高精度に成形された１次成形品は、第２のキャビティ内にて射出充填された熱可塑性樹脂組成物Ｃと溶着一体化されるが、第１のキャビティが先に成形された１次成形品とともに第２のキャビティに（より具体的には第２のキャビティ形成位置に）スライド機構によりスライドされることで、１次成形品を第２のキャビティの所定の位置に精度良く設置することができ、かつ１次成形品は既に所望の３次元形状に成形済みのものであるから、溶融熱可塑性樹脂組成物Ｃが射出充填される際にも形状が崩れたり、流出したりすることはなく、射出充填された溶融熱可塑性樹脂組成物Ｃにより成形されようとする成形部分に対し、所定の位置に高精度で位置決めされた状態にて高い接合強度をもって一体化される。したがって、最終的に成形される複合成形品においては、２次成形工程で溶融した熱可塑性樹脂組成物Ｃによって成形された成形部分に対し、目標とする３次元形状を有する１次成形品、とくに該１次成形品を構成する連続強化繊維基材が、目標とする所定の位置に高精度で高い接合強度をもって一体化された形態の複合成形品が実現されることになる。また、３次元形状の１次成形品が成形される１次成形工程と、最終的な複合成形品が成形される２次成形工程とは、スライド機構を備えた同一の金型内で実行できるので、成形工程全体の簡素化が可能になり、自動化も可能になる。 In such a method of manufacturing a composite molded article according to the present invention, first, in the primary molding step, the continuous reinforcing fiber base material composed of the continuous reinforcing fiber and the thermoplastic resin A has a first cavity having a three-dimensional shape. The melted thermoplastic resin composition B is injected and filled into the first cavity where the continuous reinforcing fiber base is inserted, and the continuous fiber base is made into a three-dimensional shape by the injection resin pressure. At the same time as shaping, the thermoplastic resin composition B is welded to form a three-dimensional primary molded product in which the continuous reinforcing fiber base material and the thermoplastic resin composition B are integrated in the same mold. . Then, in the secondary molding step, the first cavity is slid into the second cavity (more specifically, at the second cavity forming position) together with the previously molded primary molded product by the slide mechanism. The molded article is placed in the second cavity (that is, in the newly set second cavity), and the molten thermoplastic resin composition C is injected and filled in the second cavity, and the melt The thermoplastic resin composition C and the primary molded product are integrated to form a target composite molded product. As described above, since the primary molded product having the three-dimensional shape is formed using the first cavity having the three-dimensional shape in advance, both the continuous fiber base material and the primary molded product are subjected to the secondary molding. It is accurately formed into a target three-dimensional shape. The primary molded product previously molded with high accuracy is welded and integrated with the thermoplastic resin composition C injected and filled in the second cavity, but the first cavity has been molded first. The primary molded product is accurately placed at a predetermined position of the second cavity by being slid by the slide mechanism (more specifically, at the second cavity forming position) together with the next molded product. Since the primary molded product is already molded into a desired three-dimensional shape, the shape may collapse or flow out when the molten thermoplastic resin composition C is injected and filled. Rather, it is integrated with a high bonding strength in a state of being accurately positioned at a predetermined position with respect to a molded part to be molded by the injection-filled molten thermoplastic resin composition C. Therefore, in the composite molded product finally molded, the primary molded product having a target three-dimensional shape with respect to the molded part molded by the thermoplastic resin composition C melted in the secondary molding process, particularly A composite molded article in which the continuous reinforcing fiber base constituting the primary molded article is integrated with high accuracy and high bonding strength at a predetermined target position is realized. Moreover, the primary molding process in which the three-dimensional primary molded product is molded and the secondary molding process in which the final composite molded product is molded can be executed in the same mold having a slide mechanism. As a result, the entire molding process can be simplified and automated.

上記本発明に係る複合成形品の製造方法において、好ましい形態として、上記連続強化繊維基材が、連続強化繊維を一方向に配列させた一方向基材からなる形態を挙げることができる。このような一方向基材は、連続強化繊維が配列された特定の方向に対して特に高い機械特性を発現できるので、複合成形体に用いるのに最も適している。その一方で、３次元形状への賦形性に劣る課題があったが、本発明の製造方法を用いることにより、３次元形状への賦形性が大幅に向上するとともに、連続強化繊維基材が目標とする所定の位置にて高精度で貼り合わせ一体化されることで、複合成形品全体として所望の特定の方向に対して効率よく高い機械特性を発現できるようになる。この一方向基材としては、布帛状の広く面方向に広がる基材とすることも可能であるが、一方向基材がテープ状基材からなる場合、最終的に成形される複合成形品に対し、補強が要求される部位に的を絞って効率良く所定の補強を行うことが可能になる。 In the method for producing a composite molded article according to the present invention, as a preferred embodiment, the continuous reinforcing fiber substrate may be a unidirectional substrate in which continuous reinforcing fibers are arranged in one direction. Such a unidirectional substrate is most suitable for use in a composite molded article because it can exhibit particularly high mechanical properties in a specific direction in which continuous reinforcing fibers are arranged. On the other hand, there was a problem inferior in formability to a three-dimensional shape, but by using the manufacturing method of the present invention, the shapeability into a three-dimensional shape was greatly improved, and a continuous reinforcing fiber base material Is bonded and integrated with high precision at a predetermined target position, so that the entire composite molded product can efficiently exhibit high mechanical properties in a desired specific direction. As this unidirectional base material, it is possible to use a fabric-like base material that spreads widely in the surface direction, but when the unidirectional base material is a tape-like base material, On the other hand, it is possible to efficiently perform a predetermined reinforcement by focusing on a portion where reinforcement is required.

また、本発明に係る複合成形品の製造方法においては、上記熱可塑性樹脂組成物Ｂとしては、樹脂単独であってもよく、必要に応じて機械強度その他の特性を付与するために、さらに充填材を配合することが可能である。充填材は特に限定されるものでないが、繊維状、非繊維状（板状、鱗片状、粒状、不定形状、破砕品など）などのいずれの充填剤も使用することができる。 In the method for producing a composite molded article according to the present invention, the thermoplastic resin composition B may be a resin alone, and further filled to give mechanical strength and other characteristics as necessary. It is possible to mix materials. Although a filler is not specifically limited, Any fillers, such as fibrous form and non-fibrous form (a plate shape, scale shape, a granular form, an indefinite shape, a crushed product, etc.), can be used.

本発明に係る複合成形品の製造方法においては、上記熱可塑性樹脂組成物Ｂに用いる熱可塑性樹脂としては、特に制限はないが、機械特性に優れることから、ポリアミド系樹脂、ポリアリーレンサルファイド系樹脂、ポリオレフィン系樹脂から選ばれる少なくとも１種の樹脂であることが好ましい。また、上記熱可塑性樹脂組成物Ｃに用いる熱可塑性樹脂としては、上記熱可塑性樹脂組成物Ｂと同様のものを用いることができる。 In the method for producing a composite molded article according to the present invention, the thermoplastic resin used in the thermoplastic resin composition B is not particularly limited, but is excellent in mechanical properties, so that a polyamide-based resin and a polyarylene sulfide-based resin are used. It is preferably at least one resin selected from polyolefin resins. Moreover, as a thermoplastic resin used for the said thermoplastic resin composition C, the thing similar to the said thermoplastic resin composition B can be used.

また、本発明に係る複合成形品の製造方法において、上記熱可塑性樹脂Ａとしては、連続強化繊維基材を構成できるものであれば特に限定されないが、機械特性、軽量性に優れることから、ポリアミド系樹脂、ポリアリーレンサルファイド系樹脂、ポリオレフィン系樹脂から選ばれる少なくとも１種の樹脂であることが好ましい。ポリアミド系樹脂としては、例えば、ポリカプロアミド（ナイロン６）、ポリテトラメチレンアジパミド（ナイロン４６）、ポリヘキサメチレンアジパミド（ナイロン６６）、ポリカプロアミド／ポリヘキサメチレンアジパミドコポリマー（ナイロン６／６６）、ポリウンデカミド（ナイロン１１）、ポリカプロアミド／ポリウンデカミドコポリマー（ナイロン６／１１）、ポリドデカミド（ナイロン１２）、ポリカプロアミド/ポリドデカミドコポリマー（ナイロン６/１２）、ポリヘキサメチレンセバカミド（ナイロン６１０）、ポリヘキサメチレンドデカミド（ナイロン６１２）、ポリウンデカメチレンアジパミド（ナイロン１１６）およびこれらの混合物ないし共重合体等が挙げることができる。中でもナイロン６が特に好ましい。ポリアリーレンサルファイド系樹脂の代表例としては、ポリフェニレンサルファイド（以下、ＰＰＳと略す場合もある）、ポリフェニレンサルファイドスルホン、ポリフェニレンサルファイドケトン、これらのランダム共重合体、ブロック共重合体およびそれらの混合物などが挙げられ、中でもポリフェニレンサルファイドが特に好ましく使用される。また、ポリオレフィン系樹脂の代表例としては、ポリプロピレン系樹脂が挙げられ、ポリプロピレン系樹脂としては、プロピレン単独重合体、またはプロピレンとエチレンもしくは炭素数が４〜２０のα−オレフィンとの共重合体である。また、ポリオレフィン系樹脂として、炭素数が４〜２０のα−オレフィン系樹脂が挙げられ、炭素数が４〜２０のα−オレフィンとしては、１ −ブテン、１−ペンテン、１−ヘキセン、４−メチル−１−ペンテン、１−オクテン、１−デセン、１−ドデセン、１−テトラデセン、１−ヘキサデセン、１−オクタデセン、１−エイコセンなどが挙げられる。これらの中ではエチレンまたは炭素数が４〜１０のα−オレフィンが好ましい。これらのα−オレフィンは、プロピレンとランダム共重合体を形成してもよく、またブロック共重合体を形成してもよい。 Further, in the method for producing a composite molded article according to the present invention, the thermoplastic resin A is not particularly limited as long as it can constitute a continuous reinforcing fiber base material. Preferably, the resin is at least one resin selected from a resin based on polysulfene, a polyarylene sulfide based resin, and a polyolefin based resin. Examples of polyamide resins include polycaproamide (nylon 6), polytetramethylene adipamide (nylon 46), polyhexamethylene adipamide (nylon 66), polycaproamide / polyhexamethylene adipamide copolymer ( Nylon 6/66), polyundecamide (nylon 11), polycaproamide / polyundecamide copolymer (nylon 6/11), polydodecamide (nylon 12), polycaproamide / polydodecamide copolymer (nylon 6/12), poly Examples thereof include hexamethylene sebamide (nylon 610), polyhexamethylene dodecamide (nylon 612), polyundecamethylene adipamide (nylon 116), and mixtures or copolymers thereof. Of these, nylon 6 is particularly preferable. Typical examples of polyarylene sulfide resins include polyphenylene sulfide (hereinafter sometimes abbreviated as PPS), polyphenylene sulfide sulfone, polyphenylene sulfide ketone, random copolymers thereof, block copolymers, and mixtures thereof. Among them, polyphenylene sulfide is particularly preferably used. A typical example of a polyolefin resin is a polypropylene resin, and the polypropylene resin is a propylene homopolymer or a copolymer of propylene and ethylene or an α-olefin having 4 to 20 carbon atoms. is there. Further, examples of the polyolefin resin include α-olefin resins having 4 to 20 carbon atoms. Examples of the α-olefin having 4 to 20 carbon atoms include 1-butene, 1-pentene, 1-hexene, 4- Examples thereof include methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicocene and the like. Among these, ethylene or an α-olefin having 4 to 10 carbon atoms is preferable. These α-olefins may form a random copolymer with propylene, or may form a block copolymer.

また、本発明に係る複合成形品の製造方法において、連続強化繊維基材に用いられる強化繊維の種類としては、炭素繊維やガラス繊維、アラミド繊維、あるいは他の強化繊維、さらにはこれら強化繊維の組み合わせのいずれも採用可能であるが、最終的に成形される複合成形品の特定の部位の機械特性を連続強化繊維基材によって効率よく向上させるためには、連続強化繊維として炭素繊維を含むことが好ましい。 In the method for producing a composite molded article according to the present invention, the types of reinforcing fibers used for the continuous reinforcing fiber substrate include carbon fibers, glass fibers, aramid fibers, or other reinforcing fibers, and further these reinforcing fibers. Any combination can be adopted, but in order to efficiently improve the mechanical properties of a specific part of the composite molded article to be finally formed by the continuous reinforcing fiber base material, carbon fibers should be included as continuous reinforcing fibers. Is preferred.

さらに、本発明に係る複合成形品の製造方法においては、上記１次成形工程において、第１のキャビティ内に挿入した連続強化繊維基材を、必要に応じて、該第１のキャビティ内でピン等の固定具により固定することが好ましい。１次成形品を高精度で効率よく所望の３次元形状に成形するためには、連続強化繊維基材が第１のキャビティ内で第１のキャビティの内面に沿って所定の３次元形状に保たれていることが好ましいので、連続強化繊維基材を第１のキャビティ内に挿入した後、その位置や姿勢をピン等の固定具により固定しておくのである。このように固定しておくと、溶融熱可塑性樹脂Ｂの射出充填の際にも、連続強化繊維基材の第１のキャビティ内での位置ずれを防ぐことができる。 Furthermore, in the method for producing a composite molded article according to the present invention, the continuous reinforcing fiber base material inserted into the first cavity in the primary molding step is inserted into the first cavity as necessary. It is preferable to fix with fixing tools, such as. In order to form the primary molded product into a desired three-dimensional shape with high accuracy and efficiency, the continuous reinforcing fiber substrate is maintained in a predetermined three-dimensional shape along the inner surface of the first cavity in the first cavity. Since it is preferable, after inserting a continuous reinforcement fiber base material in a 1st cavity, the position and attitude | position are fixed with fixing tools, such as a pin. When fixed in this manner, it is possible to prevent the positional displacement of the continuous reinforcing fiber base material in the first cavity even during the injection filling of the molten thermoplastic resin B.

このように、本発明に係る複合成形品の製造方法によれば、連続繊維基材を３次元形状に賦形すると同時に熱可塑性樹脂組成物Ｂと高い接合強度をもって一体化することができるとともに、１次成形品の形状精度を高めることができる。さらに、高精度で目標とする３次元形状に賦形される１次成形品を成形する１次成形工程と、射出成形を伴う２次成形工程とを同一型内で行うことができるので、最終的に成形される複合成形品においては、３次元形状の連続強化繊維基材を目標とする特定の部位に高精度をもって一体化することができる。連続強化繊維基材の高精度配置により、複合成形品の機械特性を効率よく向上させることが可能になる。また、連続強化繊維基材が３次元形状を有する場合にあっても、複合成形品における連続強化繊維基材位置の設計自由度も高い。なお、射出成形品を一旦作製した後、レーザー溶着、プレス成形等で強化繊維基材を溶着する場合、３次元形状部分に強化繊維基材を溶着することは困難である。 Thus, according to the method for producing a composite molded article according to the present invention, the continuous fiber substrate can be shaped into a three-dimensional shape and simultaneously integrated with the thermoplastic resin composition B with high bonding strength, The shape accuracy of the primary molded product can be increased. Furthermore, since the primary molding process for molding the primary molded product shaped into the target three-dimensional shape with high accuracy and the secondary molding process with injection molding can be performed in the same mold, the final In a composite molded product that is molded in an automated manner, a three-dimensional continuous reinforcing fiber substrate can be integrated with high accuracy into a specific portion targeted. The high-precision arrangement of the continuous reinforcing fiber base makes it possible to efficiently improve the mechanical properties of the composite molded product. Further, even when the continuous reinforcing fiber base has a three-dimensional shape, the degree of freedom in designing the position of the continuous reinforcing fiber base in the composite molded product is high. In addition, when a reinforcing fiber base material is welded by laser welding, press molding or the like after once producing an injection molded product, it is difficult to weld the reinforcing fiber base material to a three-dimensional shape portion.

また、本発明に係る複合成形品の製造方法では、２次成形工程の前に行われる１次成形工程において、溶融した熱可塑性樹脂組成物Ｂの射出により、予め高精度の３次元形状を有する１次成形品が成形されるので、予めプリフォームした強化繊維基材を金型内にインサートして射出成形する場合と比べて、プリフォームのための専用設備を用いる必要がなくなるだけでなく、１次成形品と２次成形工程における射出樹脂、ひいては、連続強化繊維基材と溶融熱可塑性樹脂組成物Ｂ、さらには溶融熱可塑性樹脂組成物Ｃで形成される樹脂部とが良好に溶着できるようになり、高い溶着強度を達成できることもできる。 Moreover, in the manufacturing method of the composite molded product which concerns on this invention, it has a highly accurate three-dimensional shape beforehand by injection | pouring of the molten thermoplastic resin composition B in the primary molding process performed before a secondary molding process. Since the primary molded product is molded, it is not only necessary to use a dedicated equipment for preforming, as compared with the case where a preformed reinforcing fiber base is inserted into a mold and injection molded, The primary molded product and the injection resin in the secondary molding process, and hence the continuous reinforcing fiber base, the molten thermoplastic resin composition B, and the resin portion formed of the molten thermoplastic resin composition C can be welded well. As a result, high welding strength can be achieved.

本発明の一実施態様に係る複合成形品の製造方法における１次成形工程を示す概略縦断面図である。It is a schematic longitudinal cross-sectional view which shows the primary shaping | molding process in the manufacturing method of the composite molded product which concerns on one embodiment of this invention. 図１に示した１次成形工程に続いて行われる２次成形工程を示す概略縦断面図（図２（Ａ））および縦断面図とは直角方向の概略横断面図（図２（Ｂ）〜（Ｄ））である。FIG. 2 is a schematic longitudinal sectional view (FIG. 2A) showing a secondary molding process performed subsequent to the primary molding process shown in FIG. 1 and a schematic transverse sectional view perpendicular to the longitudinal sectional view (FIG. 2B). To (D)). １次成形品の一例を示す斜視図である。It is a perspective view which shows an example of a primary molded product. ２次成形品としての複合成形品の一例を示す斜視図である。It is a perspective view which shows an example of the composite molded product as a secondary molded product.

以下に、本発明の実施の形態について、図面を参照しながら説明する。
本発明に係る複合成形品の製造方法は、１次成形工程と２次成形工程を有する。１次成形工程では、連続強化繊維と熱可塑性樹脂Ａからなる連続強化繊維基材が、スライド機構を備えた金型内に設定された、３次元形状を有する第１のキャビティ内に挿入された後、該第１のキャビティ内に溶融熱可塑性樹脂組成物Ｂが射出充填されて１次成形品が成形され、２次成形工程では、第１のキャビティが１次成形品とともに第２のキャビティにスライドされ、１次成形品が第２のキャビティ内に配置され、該第２のキャビティ内に溶融熱可塑性樹脂組成物Ｃが射出充填されて該溶融熱可塑性樹脂組成物Ｃと１次成形品とが一体化される。 Embodiments of the present invention will be described below with reference to the drawings.
The method for producing a composite molded product according to the present invention includes a primary molding step and a secondary molding step. In the primary molding step, a continuous reinforcing fiber base material composed of continuous reinforcing fibers and thermoplastic resin A was inserted into a first cavity having a three-dimensional shape set in a mold provided with a slide mechanism. Thereafter, the molten thermoplastic resin composition B is injected and filled into the first cavity to form a primary molded product, and in the secondary molding process, the first cavity and the primary molded product become the second cavity. Slided, the primary molded product is placed in the second cavity, and the molten thermoplastic resin composition C is injected and filled in the second cavity, so that the molten thermoplastic resin composition C, the primary molded product, Are integrated.

（１）１次成形工程（１次成形品の成形）
本発明に係る複合成形品の製造方法に用いられる金型は、例えば図１（Ａ）に示すように構成されている。図１（Ａ）に型開きされた状態の金型１を示すように、金型１は、複数の構成部材で構成されているが、これら構成部材を大きく分けて、金型１は上型２と下型３から構成されている。また、金型１は、後述するようなスライド機構を備えている。本実施態様では、上型２内に、３次元形状を有する第１のキャビティ４を形成する空間を有しており、下型３内には、溶融熱可塑性樹脂組成物Ｂの射出用樹脂注入路５を有している。第１のキャビティ４は、本実施態様では、横断面が狭幅板状の空間で、それが環状に、あるいは環状形状の一部分として延び、該延設部位の一部において図に示す縦断面における姿勢、とくに傾きが変わるように形成されている。 (1) Primary molding process (molding of primary molded products)
The metal mold | die used for the manufacturing method of the composite molded product which concerns on this invention is comprised as shown, for example to FIG. 1 (A). As shown in FIG. 1A, the mold 1 is in a state where the mold is opened. The mold 1 is composed of a plurality of constituent members. 2 and lower mold 3. Further, the mold 1 is provided with a slide mechanism as will be described later. In this embodiment, the upper mold 2 has a space for forming the first cavity 4 having a three-dimensional shape, and the lower mold 3 is injected with an injection resin for injecting the molten thermoplastic resin composition B. It has a path 5. In the present embodiment, the first cavity 4 is a space having a narrow plate-like cross section, which extends in a ring shape or as a part of the ring shape, and in a vertical cross section shown in the drawing at a part of the extended portion. The posture, especially the tilt, is changed.

上記金型１が開かれた状態にて、図１（Ｂ）に示すように、金型１内に設定された第１のキャビティ４内に、連続強化繊維と熱可塑性樹脂Ａからなる連続強化繊維基材６が挿入される。このとき、第１のキャビティ４内に挿入された連続強化繊維基材６を、例えば次の型閉じまで、第１のキャビティ４内でピン等の固定具（図示略）により固定しておくこともできる。連続強化繊維基材６は、本実施態様では、テープ状に延び、そのテープ状長手方向に連続強化繊維（例えば、連続炭素繊維）が一方向に配列された一方向基材に構成されている。 In the state where the mold 1 is opened, as shown in FIG. 1 (B), the continuous reinforced fiber and the thermoplastic resin A are continuously strengthened in the first cavity 4 set in the mold 1. A fiber substrate 6 is inserted. At this time, the continuous reinforcing fiber base 6 inserted into the first cavity 4 is fixed by a fixing tool (not shown) such as a pin in the first cavity 4 until the next mold closing, for example. You can also. In the present embodiment, the continuous reinforcing fiber base 6 is configured as a unidirectional base material extending in a tape shape and having continuous reinforcing fibers (for example, continuous carbon fibers) arranged in one direction in the longitudinal direction of the tape. .

連続強化繊維基材６が第１のキャビティ４内に挿入された後、図１（Ｃ）に示すように、金型１が閉じられ、連続強化繊維基材６は第１のキャビティ４内に保持される。金型１が所定温度に加熱されるとともに、閉じられた金型１の第１のキャビティ４内に、図１（Ｄ）に示すように、下型３に設けられた射出用樹脂注入路５を通して溶融熱可塑性樹脂組成物Ｂ（７）が射出されて充填され、１次成形品８が成形される。 After the continuous reinforcing fiber base 6 is inserted into the first cavity 4, as shown in FIG. 1C, the mold 1 is closed, and the continuous reinforcing fiber base 6 is placed in the first cavity 4. Retained. While the mold 1 is heated to a predetermined temperature, an injection resin injection path 5 provided in the lower mold 3 is provided in the first cavity 4 of the closed mold 1 as shown in FIG. The molten thermoplastic resin composition B (7) is injected and filled through, and the primary molded product 8 is molded.

例えば、連続強化繊維基材６の熱可塑性樹脂Ａ（マトリクス樹脂）がポリアミド６からなり、熱可塑性樹脂組成物Ｂ（７）がガラス繊維４０％強化ポリアミド６からなる場合、射出成形機のシリンダー温度は２７０℃、金型１の温度は１５０℃程度に設定され、充填された溶融熱可塑性樹脂Ｂ（７）の熱と樹脂圧および金型１の熱により、１次成形品８が賦形されて成形される。 For example, when the thermoplastic resin A (matrix resin) of the continuous reinforcing fiber base 6 is made of polyamide 6 and the thermoplastic resin composition B (7) is made of glass fiber 40% reinforced polyamide 6, the cylinder temperature of the injection molding machine Is set to about 270 ° C. and the temperature of the mold 1 is set to about 150 ° C., and the primary molded product 8 is shaped by the heat and pressure of the molten thermoplastic resin B (7) and the heat of the mold 1. To be molded.

この１次成形工程においては、３次元形状を有する第１のキャビティ４内の所定位置に挿入された連続強化繊維基材６が、第１のキャビティ４内に射出充填される溶融熱可塑性樹脂組成物Ｂ（７）の射出樹脂圧によって第１のキャビティ４内面に押し付けられて所定の３次元形状に精度よく賦形される同時に熱可塑性樹脂組成物Ｂが溶着され、連続強化繊維基材６と熱可塑性樹脂組成物Ｂが一体化された３次元形状の１次成形品８が高精度で成形される。 In this primary molding step, a molten thermoplastic resin composition in which a continuous reinforcing fiber base material 6 inserted into a predetermined position in the first cavity 4 having a three-dimensional shape is injected and filled into the first cavity 4. The thermoplastic resin composition B is pressed to the inner surface of the first cavity 4 by the injection resin pressure of the object B (7) and accurately shaped into a predetermined three-dimensional shape. At the same time, the continuous reinforcing fiber base 6 and A three-dimensional primary molded product 8 in which the thermoplastic resin composition B is integrated is molded with high accuracy.

（２）２次成形工程（２次成形品としての複合成形品の成形）
上記のような１次成形工程に続き、同一の金型１を使用して、例えば図２に示すように２次成形工程が実施される。図２（Ａ）に示すように、１次成形後に金型１が開かれ、図２（Ｂ）（図２（Ａ）に対し直角方向（９０度異なる方向）からみた横断面図）に示すように、金型１のスライド機構（あるいはスライド兼回動機構）により、金型部位１１が金型部位１２に対し矢印のように回動されるとともに紙面における手前側にスライド移動され、これら金型部位１１、１２に対し金型部位１３が開かれる。 (2) Secondary molding process (molding of composite molded products as secondary molded products)
Subsequent to the primary molding step as described above, using the same mold 1, for example, a secondary molding step is performed as shown in FIG. 2. As shown in FIG. 2 (A), the mold 1 is opened after the primary molding, and shown in FIG. 2 (B) (a cross-sectional view seen from a direction perpendicular to the direction (90 degrees different from FIG. 2A)). In this way, the mold part 11 is rotated as indicated by an arrow with respect to the mold part 12 by the slide mechanism (or slide / rotation mechanism) of the mold 1 and is slid to the front side in the drawing. The mold part 13 is opened with respect to the mold parts 11 and 12.

次いで、図２（Ｃ）に示すように、金型１が閉じられて、該金型１内に上記１次成形品８とともに第１のキャビティ４がスライドされて形成される２次成形用の第２のキャビティ１４が設定され、該第２のキャビティ１４内の所定位置に、１次成形品８が配置され、第２のキャビティ１４内に射出用樹脂注入路１５を介して溶融熱可塑性樹脂組成物Ｃ（１６）が射出されて充填され、該溶融熱可塑性樹脂組成物Ｃ（１６）と１次成形品８が一体化され、２次成形品としての複合成形品１７が成形される。 Next, as shown in FIG. 2 (C), the mold 1 is closed, and the first cavity 4 is formed in the mold 1 by sliding the first cavity 4 together with the primary molded product 8. The second cavity 14 is set, the primary molded product 8 is disposed at a predetermined position in the second cavity 14, and the molten thermoplastic resin is injected into the second cavity 14 via the injection resin injection path 15. The composition C (16) is injected and filled, and the molten thermoplastic resin composition C (16) and the primary molded product 8 are integrated to form a composite molded product 17 as a secondary molded product.

成形された複合成形品１７は、図２（Ｄ）に示すように、金型１が開かれて、外部に取り出される。このとき、より容易に取り出すことができるように、金型１に取り出し用の押し出しピン１８等を設けておいてもよい。なお、図２（Ｄ）における取り出された複合成形品１７に一点鎖線を付してあるのは、この一点鎖線に対し反対側にも対称に複合成形品１７の部位が存在していることを示しており、複合成形品１７の一形状例を示すためである。 As shown in FIG. 2D, the molded composite article 17 is taken out by opening the mold 1. At this time, an extrusion push pin 18 or the like may be provided in the mold 1 so that the die 1 can be taken out more easily. In addition, what is attached | subjected with the dashed-dotted line to the taken out composite molded product 17 in FIG.2 (D) is that the site | part of the composite molded product 17 exists symmetrically also on the opposite side with respect to this dashed-dotted line. It is for showing a shape example of the composite molded product 17.

このような２次成形工程においては、先に１次成形工程で高精度に３次元形状を有する１次成形品８が成形されており、先に高精度に成形された１次成形品８は、第２のキャビティ１４内にて射出充填された溶融熱可塑性樹脂組成物Ｃ（１６）と一体化される際に、形状が崩れたり、流出したりすることはなく、射出充填された溶融熱可塑性樹脂組成物Ｃ（１６）と所定の位置にて、つまり、高精度で位置決めされた状態にて、高い接合強度をもって一体化される。したがって、最終的に成形される２次成形品としての複合成形品１７においては、３次元形状を有する１次成形品８、とくに該１次成形品８を構成する連続強化繊維基材６が、目標とする所定の位置に高精度で高い接合強度をもって一体化された形態の複合成形品１７が実現される。 In such a secondary molding step, the primary molded product 8 having a three-dimensional shape with high accuracy is formed in the primary molding step first, and the primary molded product 8 molded with high accuracy first is When the molten thermoplastic resin composition C (16) injected and filled in the second cavity 14 is integrated with the molten thermoplastic resin composition C (16), the shape does not collapse or flow out. It is integrated with the plastic resin composition C (16) with a high bonding strength at a predetermined position, that is, in a state of being positioned with high accuracy. Therefore, in the composite molded product 17 as the secondary molded product finally molded, the primary molded product 8 having a three-dimensional shape, in particular, the continuous reinforcing fiber base 6 constituting the primary molded product 8 is A composite molded product 17 is realized that is integrated at a predetermined target position with high accuracy and high bonding strength.

上記のような成形工程により成形される成形品の例を図３、図４に示す。図３は、１次成形工程により成形された１次成形品２１の一例を示しており、図４は、２次成形工程により成形された最終的な複合成形品２２の一例を示している。図３、図４に例示されるように、本発明では複雑な３次元形状を有し、その３次元形状の所望の部位、とくに３次元形状を有する所望の部位に高精度で高い接合強度をもって連続強化繊維基材を一体化した複合成形品を得ることができる。 Examples of molded products molded by the molding process as described above are shown in FIGS. FIG. 3 shows an example of the primary molded product 21 molded by the primary molding process, and FIG. 4 shows an example of the final composite molded product 22 molded by the secondary molding process. As illustrated in FIGS. 3 and 4, the present invention has a complicated three-dimensional shape, and has a high accuracy and high bonding strength to a desired portion of the three-dimensional shape, particularly a desired portion having a three-dimensional shape. A composite molded product in which the continuous reinforcing fiber base is integrated can be obtained.

本発明に係る複合成形品の製造方法は、連続強化繊維基材を３次元形状にて高接合強度と高精度をもって射出樹脂成形品と一体化することが望まれるあらゆる複合成形品の製造に適用可能である。 The method for producing a composite molded product according to the present invention is applied to the production of any composite molded product in which a continuous reinforcing fiber base material is desired to be integrated with an injection resin molded product in a three-dimensional shape with high bonding strength and high accuracy. Is possible.

１金型
２上型
３下型
４第１のキャビティ
５射出用樹脂注入路
６連続強化繊維基材
７溶融熱可塑性樹脂組成物Ｂ
８１次成形品
１１、１２、１３金型部位
１４第２のキャビティ
１５射出用樹脂注入路
１６溶融熱可塑性樹脂組成物Ｃ
１７複合成形品
１８押し出しピン
２１１次成形品
２２複合成形品 DESCRIPTION OF SYMBOLS 1 Mold 2 Upper mold | type 3 Lower mold | type 4 1st cavity 5 Injection resin injection path 6 Continuous reinforcement fiber base material 7 Melt thermoplastic resin composition B
8 Primary molded article 11, 12, 13 Mold part 14 Second cavity 15 Injection resin injection path 16 Molten thermoplastic resin composition C
17 Composite molded product 18 Extruded pin 21 Primary molded product 22 Composite molded product

Claims

連続強化繊維と熱可塑性樹脂Ａからなる連続強化繊維基材を、スライド機構を備えた金型内に設定された、３次元形状を有する第１のキャビティ内に挿入した後、該第１のキャビティ内に溶融した熱可塑性樹脂組成物Ｂを射出充填して１次成形品を成形する１次成形工程と、
前記第１のキャビティを１次成形品とともに第２のキャビティにスライドさせ、前記１次成形品を前記第２のキャビティ内に配置し、該第２のキャビティ内に溶融した熱可塑性樹脂組成物Ｃを射出充填して該溶融熱可塑性樹脂組成物Ｃと前記１次成形品とを一体化する２次成形工程と、
を有することを特徴とする複合成形品の製造方法。 After inserting a continuous reinforcing fiber base composed of continuous reinforcing fiber and thermoplastic resin A into a first cavity having a three-dimensional shape set in a mold having a slide mechanism, the first cavity A primary molding step of injecting and filling the molten thermoplastic resin composition B into a primary molded product;
The first cavity is slid into the second cavity together with the primary molded product, the primary molded product is placed in the second cavity, and the thermoplastic resin composition C melted in the second cavity is obtained. A secondary molding step in which the molten thermoplastic resin composition C and the primary molded product are integrated by injection filling,
A method for producing a composite molded product comprising:

前記連続強化繊維基材が、連続強化繊維を一方向に配列させた一方向基材からなる、請求項１に記載の複合成形品の製造方法。 The method for producing a composite molded article according to claim 1, wherein the continuous reinforcing fiber base is a unidirectional base material in which continuous reinforcing fibers are arranged in one direction.

前記一方向基材が、テープ状基材からなる、請求項２に記載の複合成形品の製造方法。 The method for producing a composite molded article according to claim 2, wherein the unidirectional base material comprises a tape-shaped base material.

前記熱可塑性樹脂組成物Ｂが、不連続強化繊維を含んでいる、請求項１〜３のいずれかに記載の複合成形品の製造方法。 The manufacturing method of the composite molded product in any one of Claims 1-3 in which the said thermoplastic resin composition B contains the discontinuous reinforcement fiber.

前記熱可塑性樹脂Ａが、ポリアミド系樹脂、ポリアリーレンサルファイド系樹脂、ポリオレフィン系樹脂から選ばれる少なくとも１種の樹脂からなる、請求項１〜４のいずれかに記載の複合成形品の製造方法。 The manufacturing method of the composite molded product in any one of Claims 1-4 in which the said thermoplastic resin A consists of at least 1 sort (s) of resin chosen from polyamide-type resin, polyarylene sulfide-type resin, and polyolefin-type resin.

前記熱可塑性樹脂組成物Ｂに用いる熱可塑性樹脂が、ポリアミド系樹脂、ポリアリーレンサルファイド系樹脂、ポリオレフィン系樹脂から選ばれる少なくとも１種の樹脂からなる、請求項１〜５のいずれかに記載の複合成形品の製造方法。 The composite according to any one of claims 1 to 5, wherein the thermoplastic resin used in the thermoplastic resin composition B is composed of at least one resin selected from polyamide resins, polyarylene sulfide resins, and polyolefin resins. Manufacturing method of molded products.

前記熱可塑性樹脂組成物Ｃに用いる熱可塑性樹脂が、ポリアミド系樹脂、ポリアリーレンサルファイド系樹脂、ポリオレフィン系樹脂から選ばれる少なくとも１種の樹脂からなる、請求項１〜６のいずれかに記載の複合成形品の製造方法。 The composite according to any one of claims 1 to 6, wherein the thermoplastic resin used in the thermoplastic resin composition C is composed of at least one resin selected from a polyamide-based resin, a polyarylene sulfide-based resin, and a polyolefin-based resin. Manufacturing method of molded products.

前記連続強化繊維が炭素繊維を含む、請求項１〜７のいずれかに記載の複合成形品の製造方法。 The manufacturing method of the composite molded product in any one of Claims 1-7 in which the said continuous reinforcement fiber contains carbon fiber.

前記１次成形工程において、前記第１のキャビティ内に挿入した連続強化繊維基材を該第１のキャビティ内でピン等の固定具により固定する、請求項１〜８のいずれかに記載の複合成形品の製造方法。 The composite according to any one of claims 1 to 8, wherein, in the primary molding step, the continuous reinforcing fiber base inserted into the first cavity is fixed by a fixing tool such as a pin in the first cavity. Manufacturing method of molded products.