Integrally molded body and method for producing the same

Patent metadata

Field	Value
Publication number	US-11141893-B2
Application number	US-201816641436-A
Country	US
Kind code	B2
Filing date	Aug 24, 2018
Priority date	Aug 31, 2017
Publication date	Oct 12, 2021
Grant date	Oct 12, 2021

Abstract

In order to solve reduction in strength and rigidity at a weldline which is a problem of an injection molding body, and enable free design such as thin wall molding or complex shape molding of the injection molding body, there is provided an integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated, in which the substrate for reinforcement (a) has a difference in an orientation angle of the discontinuous fiber (a1) in each of regions obtained by dividing a major axis direction of the substrate for reinforcement (a) into 10 equal parts of within 10°, and the substrate for reinforcement (a) covers a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b).

First claim

The invention claimed is:

1. An integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated,
the substrate for reinforcement (a) having a difference in an orientation angle of the discontinuous fiber (a1) in each of regions obtained by dividing a major axis direction of the substrate for reinforcement (a) into 10 equal parts of within 10° ,
the substrate for reinforcement (a) covering a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b),
wherein the substrate for reinforcement (a) has a thickness of 0.03 mm or more and 0.25 mm or less, and
wherein the substrate for reinforcement (a) is 5% or more and 30% or less with respect to projected area of the integrally molded body.

2. The integrally molded body according to claim 1 , wherein a bonding strength between the substrate for reinforcement (a) and the injection molding body (b) is 7 MPa or more, and
a thickness variation of the substrate for reinforcement (a) in the integrally molded body is within 10%.

3. An integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated,
a bonding strength between the substrate for reinforcement (a) and the injection molding body (b) being 7 MPa or more,
a thickness variation of the substrate for reinforcement (a) in the integrally molded body being within 10%,
the substrate for reinforcement (a) covering a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b),
wherein the substrate for reinforcement (a) has a thickness of 0.03 mm or more and 0.25 mm or less, and
wherein the substrate for reinforcement (a) is 5% or more and 30% or less with respect to projected area of the integrally molded body.

4. The integrally molded body according to claim 1 , wherein the substrate for reinforcement (a) is substantially isotropic.

5. The integrally molded body according to claim 1 , wherein the substrate for reinforcement (a) has a linear expansion coefficient of 7×10 −6 /K or less.

6. The integrally molded body according to claim 1 , wherein the substrate for reinforcement (a) has a flexural modulus of 10 GPa or more.

7. The integrally molded body according to claim 1 , wherein the substrate for reinforcement (a) is in the form of a tape.

8. A method for producing an integrally molded body comprising arranging a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) in a mold and integrating the substrate for reinforcement (a) with a weldline of an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2),
the substrate for reinforcement (a) having a difference in an orientation angle of the discontinuous fiber (a1) in each of regions obtained by dividing a length direction of the substrate for reinforcement (a) when arranged in the mold into 10 equal parts of within 10 ° ,
wherein the substrate for reinforcement (a) has a thickness of 0.03 mm or more and 0.25 mm or less, and
wherein the substrate for reinforcement (a) is 5% or more and 30% or less with respect to projected area of the integrally molded body.

9. The method for producing an integrally molded body according to claim 8 , wherein, when arranging the substrate for reinforcement (a) in the mold, a ratio of the area of the substrate for reinforcement not in contact with the mold is 5% or less.

10. The method for producing an integrally molded body according to claim 8 , comprising pre-shaping the substrate for reinforcement (a) and then inserting it into the mold for molding.

11. A method for producing an integrally molded body comprising integrating a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) with a weldline of an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2),
the substrate for reinforcement (a) having a difference in an orientation angle of the discontinuous fiber (a1) in each of regions obtained by dividing a length direction of the substrate for reinforcement (a) when laying up the substrate for reinforcement (a) on the injection molding body (b) into 10 equal parts of within 10 ° ,
wherein the substrate for reinforcement (a) has a thickness of 0.03 mm or more and 0.25 mm or less, and
wherein the substrate for reinforcement (a) is 5% or more and 30% or less with respect to projected area of the integrally molded body.

12. The method for producing an integrally molded body according to claim 11 , wherein, when the substrate for reinforcement (a) is laid up on the injection molding body (b), a ratio of the area of the substrate for reinforcement not in contact with the injection molding body (b) is 5% or less.

13. The method for producing an integrally molded body according to claim 8 , wherein the substrate for reinforcement (a) is substantially isotropic.

14. The method for producing an integrally molded body according to claim 8 , wherein the substrate for reinforcement (a) has a linear expansion coefficient of 7×10 −6 /K or less.

15. The method for producing an integrally molded body according to claim 8 , wherein the substrate for reinforcement (a) has a flexural modulus of 10 GPa or more.

16. The method for producing an integrally molded body according to claim 8 , wherein the substrate for reinforcement (a) is in the form of a tape.

Assignees

• Toray Industries

Inventors

• Suzuki Takafumi
• Sento Yuichiro
• Imai Naokichi
• Hamaguchi Mitsushige
• Honma Masato

Classifications

• B29C45/14 Primary

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

• B32B2262/101

  Glass fibres · CPC title

• B29C70/10 Primary

  characterised by the structure of fibrous reinforcements {, e.g. hollow fibres} · CPC title

• C08J5/04

  Reinforcing macromolecular compounds with loose or coherent fibrous material · CPC title

• B32B27/08

  of synthetic resin · CPC title