Injection molded body and method for producing same

Patent metadata

Field	Value
Publication number	US-9296175-B2
Application number	US-201214001887-A
Country	US
Kind code	B2
Filing date	Feb 24, 2012
Priority date	Feb 28, 2011
Publication date	Mar 29, 2016
Grant date	Mar 29, 2016

Abstract

An injection molded body includes a fiber reinforced thermoplastic resin composition formed by combining fibrous filler with thermoplastic resin so that the weight average fiber length in the injection molded body is 300 μm or more, and the injection molded body has a skin layer, a core layer and a skin layer in this order in the thickness direction. The thickness of the core layer, in which the primary orientation direction of the fibrous filler is 40° or less when the direction perpendicular to the flow direction of the resin composition at the time of injection molding is set at 0°, is 20% or less relatively to the thickness of the injection molded body.

First claim

The invention claimed is:

1. A method of producing an injection molded body by injection molding a fiber reinforced thermoplastic resin composition formed by combining fibrous filler (b) with a thermoplastic resin (a) so that a weight average fiber length in said injection molded body is 300 μm or more, by injection press molding in which a mold is started to be closed after injection is started, wherein injection molding is carried out at a condition where a ratio (t2/t1) of a difference (t2) between a time of finishing injection (tif) and a time of finishing to close said mold (tpf) to a difference (t1) between a time of starting to close said mold (tps) and said time of finishing injection (tif) becomes 1.1 or more.

2. The method according to claim 1 , wherein said injection molded body is an injection molded body having a skin layer, a core layer and a skin layer in this order in a thickness direction, and a thickness of said core layer, in which a primary orientation direction of said fibrous filler (b) is 40° or less when a direction perpendicular to a flow direction of said fiber reinforced thermoplastic resin composition at a time of injection molding is set at 0°, is 20% or less relative to a thickness of said injection molded body.

3. The method according to claim 1 , wherein said thermoplastic resin (a) is at least one selected from the group consisting of a polypropylene, a polyamide, a polyphenylene sulfide, a polyimide, a polyetherketone and a polyetheretherketone.

4. The method according to claim 1 , wherein said fibrous filler (b) is at least one selected from the group consisting of carbon fibers, glass fibers and aramide fibers.

5. The method according to claim 1 , wherein said injection press molding is carried out using long fiber pellets with a same length as a length of said fibrous filler (b) as said fiber reinforced thermo-plastic resin composition.

6. The method according to claim 5 , wherein said injection molded body is an injection molded body having a skin layer, a core layer and a skin layer in this order in a thickness direction, and a thickness of said core layer, in which a primary orientation direction of said fibrous filler (b) is 40° or less when a direction perpendicular to a flow direction of said fiber reinforced thermoplastic resin composition at a time of injection molding is set at 0°, is 20% or less relative to a thickness of said injection molded body.

7. The method according to claim 5 , wherein said thermoplastic resin (a) is at least one selected from the group consisting of a polypropylene, a polyamide, a polyphenylene sulfide, a polyimide, a polyetherketone and a polyetheretherketone.

8. The method according to claim 5 , wherein said fibrous filler (b) is at least one selected from the group consisting of carbon fibers, glass fibers and aramide fibers.

Assignees

• Yamaguchi Koji
• Tateyama Masaru
• Shimizu Nobuhiko
• IMAI Hironori
• Toray Industries

Inventors

• Yamaguchi Koji
• Tateyama Masaru
• Shimizu Nobuhiko
• IMAI Hironori

Classifications

• B29K2105/14

  oriented · CPC title

• Y10T428/249942

  Fibers are aligned substantially parallel · CPC title

• B32B5/145 Primary

  Variation across the thickness of the layer · CPC title

• B29C45/561

  Injection-compression moulding · CPC title

• B29C45/0005 Primary

  using fibre reinforcements · CPC title