Production method of producing fiber-reinforced resin molding

Patent metadata

Field	Value
Publication number	US-9849614-B2
Application number	US-201514861165-A
Country	US
Kind code	B2
Filing date	Sep 22, 2015
Priority date	Sep 25, 2014
Publication date	Dec 26, 2017
Grant date	Dec 26, 2017

Abstract

A production method of producing a fiber-reinforced resin molding includes: kneading, in a kneader, molten thermoplastic resin with opened reinforcing fibers obtained by opening a bundle of reinforcing fibers, to produce a kneaded mixture; and placing or charging the kneaded mixture into a molding device to produce a fiber-reinforced resin molding.

First claim

What is claimed is:

1. A production method of producing a fiber-reinforced resin molding, the production method comprising:
opening a bundle of reinforcing fibers to obtain opened reinforcing fibers;
cutting the opened reinforcing fibers, using a cutter, into cut reinforcing fibers having a predetermined length;
feeding pellets of thermoplastic resin into a kneader via a resin feed port of the kneader;
kneading and heating, in the kneader using a screw in the kneader, the pellets of thermoplastic resin into a molten thermoplastic resin;
feeding the cut reinforcing fibers into the kneader via a fiber feed port that is located downstream of the resin feed port, wherein the fiber feed port is disposed below the cutter so that the cut reinforcing fibers fall toward the fiber feed port and a suction unit that is provided at the fiber feed port suctions the cut reinforcing fibers to introduce the cut reinforcing fibers into the kneader;
kneading, in the kneader, the molten thermoplastic resin with the cut reinforcing fibers, to produce a kneaded mixture;
conveying the kneaded mixture extruded from an extrusion port of the kneader to a mold by a robotic hand, and placing or charging the kneaded mixture into the mold; and
pressing the kneaded mixture in the mold by a molding device to produce a fiber-reinforced resin molding.

2. The production method according to claim 1 , wherein:
the kneader has, at least at a position between the resin feed port and the fiber feed port, a vent through which volatile gas generated from the molten thermoplastic resin is discharged from the kneader.

3. The production method according to claim 1 , wherein the predetermined length of at least 95% of the cut reinforcing fibers is 5 to 10 mm.

Assignees

• Toyota Motor Co Ltd

Inventors

• Oda Tetsuya

Classifications

• B29C48/40

  using two or more parallel screws {or at least two parallel non-intermeshing screws}, e.g. twin screw extruders · CPC title

• B29B7/845

  Venting, degassing or removing evaporated components in devices with rotary stirrers · CPC title

• B29B7/905

  with means for pretreatment of the charges or fibres · CPC title

• B29B7/90

  Fillers or reinforcements {, e.g. fibres} · CPC title

• B29B7/603

  in measured doses, e.g. proportioning of several materials · CPC title