Thermoplastic resin molded article having hollow portion and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-9855700-B2
Application number	US-201214364385-A
Country	US
Kind code	B2
Filing date	Dec 25, 2012
Priority date	Dec 28, 2011
Publication date	Jan 2, 2018
Grant date	Jan 2, 2018

Abstract

A method of manufacturing a thermoplastic resin molded article having a hollow portion includes setting a molded article (A) premolded from a thermoplastic resin in a first die, forming a melted thermoplastic resin plate (B) in a shape along an inner surface of a second die facing the first die by being attached to the inner surface of the second die by vacuum pressure, welding the thermoplastic resin plate (B) and the molded article (A) only in a predetermined region by mold-clamping the first die and the second die, and forming at least part of an unwelded region as a hollow portion.

First claim

The invention claimed is:

1. A method of manufacturing a thermoplastic resin molded article having a hollow portion comprising:
premolding thermoplastic resin into a molded article (A) having a predetermined shape that is a same shape as that of an entire die surface of a first die in a subsequent step;
setting the molded article (A) in the first die;
forming a melted thermoplastic resin plate (B) in a shape along an inner surface of a second die facing said first die by being attached to said inner surface of said second die by vacuum pressure;
welding said thermoplastic resin plate (B) and said molded article (A) only in a predetermined region by mold-clamping said first die and said second die; and
forming at least part of an unwelded region as a hollow portion.

2. The method according to claim 1 , wherein at least said thermoplastic resin plate (B) among said molded article (A) and said thermoplastic resin plate (B) comprises a fiber reinforced thermoplastic resin.

3. The method according to claim 2 , wherein reinforcing fibers of said fiber reinforced thermoplastic resin are at least one kind of fibers selected from the group consisting of carbon fibers, glass fibers and aramide fibers.

4. The method according to claim 2 , wherein reinforcing fibers of said fiber reinforced thermoplastic resin comprise discontinuous fibers.

5. The method according to claim 4 , wherein a weight average fiber length of said discontinuous fibers is 10 mm or more.

6. The method according to claim 4 , wherein a content of said discontinuous fibers in said fiber reinforced thermoplastic resin is 5 to 50 wt. %.

7. The method according to claim 2 , wherein reinforcing fibers of said fiber reinforced thermoplastic resin comprise continuous fibers.

8. The method according to claim 7 , wherein said reinforcing fibers comprise continuous fibers arranged in one direction.

9. The method according to claim 7 , wherein a content of said continuous fibers in said fiber reinforced thermoplastic resin is 1 to 80 wt. %.

10. The method according to claim 7 , wherein said reinforcing fibers of said fiber reinforced thermoplastic resin are formed as a woven fabric.

11. The method according to claim 7 , wherein said thermoplastic resin plate (B) comprises a tape-like fiber reinforced thermoplastic resin pre-integrated with reinforcing fibers arranged in one direction and a thermoplastic resin by heat press.

12. The method according to claim 11 , wherein a tape width of said tape-like fiber reinforced thermoplastic resin is 6 to 50 mm.

13. The method according to claim 1 , wherein a die having holes that suck air from an interior of a cavity is used as said second die.

14. The method according to claim 1 , wherein a die having suction holes that retain said molded article (A) is used as said first die.

15. The method according to claim 1 , wherein a thermoplastic resin forming said molded article (A) and said thermoplastic resin plate (B) comprises at least one selected from the group consisting of a polyphenylene sulfide resin, a polyamide resin, a polyolefin resin, a polyester resin, an ABS resin, a polycarbonate resin and a polyacetal resin.

16. The method according to claim 1 , wherein said thermoplastic resin plate (B) is formed while an outer circumferential part of said thermoplastic resin plate (B) is held down.

17. The method according to claim 1 , wherein a heater is provided at a portion corresponding to at least part of said welded region at least in said second die, and said welding is performed utilizing heat from said heater.

Assignees

• Toray Industries

Inventors

• Tateyama Masaru
• Koshi Masayuki

Classifications

• B29C51/002 Primary

  characterised by the choice of material · CPC title

• B29K2067/00

  Use of polyesters {or derivatives thereof}, as moulding material · CPC title

• B29K2069/00

  Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material · CPC title

• B29K2023/00

  Use of polyalkenes {or derivatives thereof} as moulding material · CPC title

• B29K2081/04

  Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof · CPC title