Production method for fiber-reinforced component

Patent metadata

Field	Value
Publication number	US-10160166-B2
Application number	US-201414916791-A
Country	US
Kind code	B2
Filing date	Sep 3, 2014
Priority date	Sep 6, 2013
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

A production method for a fiber-reinforced component according to the present invention includes: a step 1, in which a melt of a thermoplastic resin is formed in a lower die, a mat-shaped material formed from a reinforcing fiber B is placed on the melt, an upper die for pressing is closed on the lower die and is pressed, and an impregnation treatment is performed, and then, the mat-shaped material impregnated with the resin is cooled and solidified, whereby a main body part formed from a fiber-reinforced resin is molded; and a step 2, in which the upper die for pressing is opened, an upper die for injection molding is closed on the lower die to form an injection molding die, and then, injection molding is performed to form an additional part, whereby a fiber-reinforced component having the additional part combined with the main body part is molded.

First claim

The invention claimed is:

1. A production method for a fiber-reinforced component, comprising:
a step 1, in which a melt of a thermoplastic resin is formed in a lower die, a mat-shaped material formed from a reinforcing fiber B is placed on the melt, an upper die for pressing is closed on the lower die and is pressed, and an impregnation treatment is performed, and then the mat-shaped material impregnated with the thermoplastic resin is cooled and solidified, whereby a main body part obtained from a fiber-reinforced resin is molded; and
a step 2, in which the upper die for pressing is opened, an upper die for injection molding is closed on the lower die to form an injection molding die, and then injection molding is performed to form an additional part, whereby a fiber-reinforced component having the additional part combined with the main body part is molded.

2. The production method for a fiber-reinforced component according to claim 1 , wherein the melt is formed only from a thermoplastic resin or formed from a thermoplastic resin containing a reinforcing fiber A.

3. The production method for a fiber-reinforced component according to claim 2 , wherein the reinforcing fiber A has an average fiber length of 0.1 to 25 mm.

4. The production method for a fiber-reinforced component according to claim 1 , wherein the reinforcing fiber B has an average fiber length of 1 to 100 mm.

5. The production method for a fiber-reinforced component according to claim 1 , wherein the volume content of the reinforcing fiber in the main body part of the fiber-reinforced component is from 10 to 70%.

6. The production method for a fiber-reinforced component according to claim 1 , wherein the additional part contains a reinforcing fiber M having an average fiber length of 0.1 to 25 mm at a volume content of 0 to 50%.

7. The production method for a fiber-reinforced component according to claim 1 , wherein the additional part is a convex part, a boss, a rib, a hinge, a flange, a tab, or a side wall part formed in the main body part.

8. The production method for a fiber-reinforced component according to claim 1 , wherein the melt is formed by applying the thermoplastic resin containing the reinforcing fiber A supplied from a plasticizing discharge machine.

9. The production method for a fiber-reinforced component according to claim 1 , wherein in the step 1, the melt of the thermoplastic resin including the mat-shaped material by the impregnation treatment is solidified by cooling the lower die and the upper die for pressing, whereby the main body part obtained from the fiber-reinforced resin is molded.

10. The production method for a fiber-reinforced component according to claim 1 , wherein the fiber-reinforced component is molded by cutting a sprue after performing the injection molding in the step 2.

11. The production method for a fiber-reinforced component according to claim 1 , wherein a thermoplastic resin for injection molding is supplied to the main body part through the upper die for injection molding in the step 2.

12. The production method for a fiber-reinforced component according to claim 11 , wherein the thermoplastic resin for injection molding contains a reinforcing fiber M.

13. The production method for a fiber-reinforced component according to claim 1 , wherein the thermoplastic resin is polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, polyamide, polycarbonate, or polymethyl methacrylate.

Assignees

• Japan Steel Works Ltd

Inventors

• Ono Akio
• NIYAMA Takuya
• Ito Hiroshi
• Nishida Shoso

Classifications

• B29C45/14

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• B29L2031/3481

  Housings or casings incorporating or embedding electric or electronic elements · CPC title

• B29K2101/12

  Thermoplastic materials · CPC title

• B29K2105/0854

  in the form of a non-woven mat · CPC title

• B29C69/02

  of moulding techniques only · CPC title