JP2013132790A - Joined body having joint with both surfaces of molded product adhered thereat with molded products fitted - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a joined body with enhanced impact resistance by preventing peeling of a joint.SOLUTION: In the joined body having the joint C, a molded product B-1 and a molded product B-2 are disposed on both surfaces of a molded product A; (ii) the molded product A has a recess D-1 on a surface contacting with the molded product B-1 and a projection D-2 on a surface contacting with the molded product B-2; (iii) the molded product B-1 has a projection E to be fitted to the recess D-1; (iv) the molded product B-2 has a recess F to be fitted to the projection D-2; (v) the recess D-1 and the projection E, and the projection D-2 and the recess F are mutually fitted and adhered respectively; and (vi) the molded product B-1 and the molded product B-2 include an adhered portion in which they are adhered together to cover an end of the molded product A. (vii) The molded product A is a molded product including an organic fiber X and a thermoplastic resin, and (viii) the molded product B-1 and the molded product B-2 are molded products including a reinforced fiber Y and a thermoplastic resin.

Description

  The present invention relates to a joined body having a joint (C) in which a shaped body (B-1) and a shaped body (B-2) are arranged on both sides of the shaped body (A).

  Plastics, especially thermoplastic resins, can be processed by various molding methods and are indispensable materials for our daily life. However, the flexibility of the thermoplastic resin sometimes leads to low strength and rigidity, and in applications requiring high strength and high rigidity, reinforcement with inorganic fibers such as glass fibers and carbon fibers has been performed. .

  As a joined body using fiber reinforced plastic, for example, Patent Document 1 describes an automobile hood panel including a fiber reinforced plastic outer panel and a fiber reinforced plastic inner panel joined thereto. It is described that, if this automobile hood panel is used, the impact energy at the time of collision with a pedestrian can be effectively absorbed and the pedestrian can be protected from impact while having light weight and basic rigidity. . However, the joint portion between the outer panel made of fiber reinforced plastic and the inner panel made of fiber reinforced plastic is bonded by a general adhesive (Patent Document 1, paragraph 0023). In addition, when subjected to an impact, there is a problem that the joint between the fiber reinforced plastics peels off.

  Patent Document 2 describes the joining of fiber boards formed by mixing natural fibers and resin binders as members for interior and exterior of automobiles. In the invention of Patent Document 2, in order to prevent breakage at the joint portion, a joining margin for joining is provided in a part of the fiber board, and the density of the joining margin is made higher than that of other parts in the fiber board. Forming. However, the bonding of the present invention has been attempted to improve the bonding strength using an adhesive, and has not yet been able to obtain a sufficient bonding strength.

JP 2011-20614 A JP 2007-284808 A

  By using an organic fiber-containing thermoplastic resin molded body and a reinforced fiber-containing thermoplastic resin molded body, a bonded body having a high impact resistance is provided, in which a bonded portion of the bonded body is hardly peeled off.

The present invention for solving such problems has the following configuration.
1, (i) The molded body (B-1) and the molded body (B-2) are arranged on both surfaces of the molded body (A),
(ii) The molded body (A) has at least one recess (D-1) on the surface in contact with the molded body (B-1), and the surface in contact with the molded body (B-2) corresponds to the recess. A convex portion (D-2)
(iii) The molded body (B-1) has a convex portion (E) that can be fitted to the concave portion (D-1),
(iv) The molded body (B-2) has a concave portion (F) that can be fitted to the convex portion (D-2).
(v) The concave portion (D-1) and the convex portion (E), and the convex portion (D-2) and the concave portion (F) are fitted and bonded,
(vi) The molded body (B-1) and the molded body (B-2) have an adhesive portion (G) bonded to cover the end of the molded body (A).
A joined body having a joint (C),
(vii) The molded body (A) is a molded body containing an organic fiber (X) and a thermoplastic resin,
(viii) The above-mentioned joined body, wherein the molded body (B-1) and the molded body (B-2) are molded bodies containing reinforcing fibers (Y) and a thermoplastic resin.
2. The organic fiber (X) is at least one selected from the group consisting of polyethylene terephthalate fiber, polyethylene naphthalate fiber, nylon fiber and polyamide fiber, and the reinforcing fiber (Y) is a carbon fiber. The joined body described.
3. The joined body according to any one of 1 to 2, wherein the molded body (B-1) and the molded body (B-2) are molded bodies using a random mat base material.
4. The joined body according to any one of 1 to 3, wherein the shaped body (B-2) is shaped into a hat-shaped cross-sectional shape and has the joint portion (C) at a hat collar portion.
5. The bonded body according to any one of 1 to 4, wherein the bonding is performed by heat welding.

  The joined body of the present invention is formed by fitting and bonding the concave portion (D-1) and the convex portion (E) and the convex portion (D-2) and the concave portion (F). The molded body (B-2) has a bonded portion (C) that is bonded to the molded body (A) with a portion (G) bonded to cover the end of the molded body (A). Thereby, the bonded body of the present invention has a large bonding area at the bonded portion and has a strong bonding force. Furthermore, the joined body having the joint (C) in the present invention has high bending strength and good impact resistance without peeling off the joint (C) even when subjected to a strong impact.

An example of the joined body in which the molded body (B-1) and the molded body (B-2) are arranged on both sides of the molded body (A) (exploded view). Enlarged schematic view (cross-sectional view) of the joint (C) of the joined body Schematic diagram (exploded view) of the molded body (A), the molded body (B-1), and the molded body (B-2) at the joint (C). Schematic diagram in the case of obtaining a joined body using a molded body (B-1) having an energy director and a molded body (B-2). Schematic diagram (exploded view) of a joined body obtained by joining a molded body (A-0) having no projections and recesses and a molded body (B-2) having no recesses outside the present invention. Schematic diagram of a joined portion obtained by joining a molded body (A-0) having no protrusions and recesses and a molded body (B-2) having no recesses, which is outside the present invention Example of shape of molded body (B-1) Example of shape of molded body (B-1) Example of shape of molded body (B-1) Example of shape of molded body (B-1) The schematic diagram which shows the distance between recessed parts (D-2) of a molded object (A)

Embodiments of the present invention will be described below.
[Joint shape]
In the joined body of the present invention, the molded body (B-1) and the molded body (B-2) are arranged on both surfaces of the molded body (A), and are in contact with the molded body (B-1) of the molded body (A). The surface has at least one concave portion (D-1), the surface in contact with the molded body (B-2) has a convex portion (D-2) corresponding to the concave portion, and the molded body (B-1 ) Has a convex portion (E) that can be fitted with the concave portion (D-1), and the molded body (B-2) has a concave portion (F) that can be fitted with the convex portion (D-2). Then, the concave portion (D-1) and the convex portion (E), and the convex portion (D-2) and the concave portion (F) are fitted and bonded. Moreover, a molded object (B-1) and a molded object (B-2) cover the edge part of a molded object (A), and have the part (G) adhere | attached. For example, the end of the molded body (A) can be bonded by using a portion as indicated by G in FIG. In addition to fitting the concave portion (D-1) and the convex portion (E), and the convex portion (D-2) and the concave portion (F), the end portion of the molded body (A) is covered, thereby joining It becomes a joined body with excellent strength. The fitting in the present invention may have a little play, but in order to achieve higher bonding strength, it is preferable that the fitting is completely in close contact.

Compared to the case where the joint (C) has a concave and convex portion, the thickness in the height (Y-axis direction in FIG. 1) direction increases, and the bonding area increases, so that there is no concave portion or convex portion. , Has high impact strength. From the viewpoint of facilitating molding, the convex portion (D-2) is preferably convex in the Y-axis direction in FIG.
Moreover, when the molded body (B-2) has a hat-shaped cross-sectional shape as shown in FIG. 1, the space between the molded body (A) and the molded body (B-2) is preferably an impact buffering space.

[Shape of joint (C)]
The joining portion (C) has at least one concave portion (D-1) on the surface that contacts the molded body (B-1) of the molded body (A), and the surface that contacts the molded body (B-2). It has a convex part (D-2) corresponding to the concave part, the molded body (B-1) has a convex part (E) that can be fitted to the concave part (D-1), and a molded body (B- 2) has a concave portion (F) that can be fitted to the convex portion (D-2), the concave portion (D-1) and the convex portion (E), and the convex portion (D-2) and the concave portion (F). And the molded body (B-1) and the molded body (B-2) have a portion (G) bonded to cover the end of the molded body (A).

Good bonding is maintained by fitting the convex portion (E), the concave portion (F), the concave portion (D-1), and the convex portion (D-2) together.
The convex part (E) matching the concave part (D-1) is not limited to the shape of the molded body (B-1) shown in FIG. For example, two or more discontinuous convex portions as shown in FIG. 7 or a notched convex portion as shown in FIG. 8 may be used. Further, it may have a shape in which a number of conical protrusions are arranged as shown in FIG. 9, and there may be two or more convex portions as shown in FIG.

The shape of the concave portion (D-1) and the shape of the convex portion (D-2) are preferably the same shape from the viewpoint of facilitating molding.
The projected area occupied by the recess (D-1) is preferably 1% or more with respect to the area of the molded body (A) sandwiched between the molded body (B-1) and the molded body (B-2). . By setting it to 1% or more, it becomes easy to maintain good bonding with the molded body (A), the molded body (B-1), and the molded body (B-2).

  Although there is no restriction | limiting in the shape of a recessed part (D-1), A groove shape is preferable from the ease of shaping | molding. In the case of the groove shape, the depth is not particularly limited, but is preferably 10% to 1000% of the thickness of the molded body (A), and when a high bending strength is required for the joint (C), the groove depth It is preferable to increase the thickness. The groove width is not particularly limited, but is preferably 10% to 500% with respect to the groove depth.

[Molding method of molded body (B-1) and molded body (B-2)]
The molded body (B-1) and molded body (B-2) are molded by heating the prepreg (B-1) or prepreg (B-2) with a heating device until the melting point of the thermoplastic resin is reached or higher. The prepared prepreg is set in a molding die, and the mold is clamped and molded. At this time, if the molded body (B-2) and the molded body (B-1) are random mat substrates containing carbon fibers, the shrinkage hardly occurs. Therefore, in this case, the molded body (B-1) and the molded body (B-2) are produced with the same dimensions as the mold.

[Molding method of molded body (A)]
Although there is no restriction | limiting as a shaping | molding method of a molded object (A), For example, there exist the following two methods. One is when the prepreg (A), which is the precursor of the molded body (A), is set in a molding die, the mold is heated, and the temperature reaches the melting point of the thermoplastic resin of the prepreg (A). Clamp the mold. Thereafter, the mold is cooled with the mold clamped, and the molded body (A) is taken out. At this time, the temperature to be taken out affects the shrinkage rate. However, when it is desired to suppress the shrinkage, it is preferable to remove the mold when the mold temperature is lowered to about room temperature. In this case, the molded body (A) is produced with the same dimensions as the mold.

  Another method is to heat the prepreg (A) with a heating device until it reaches the melting point of the thermoplastic resin or more, set the heated prepreg (A) in a mold, and clamp the mold. Remove body (A). In this method, the molding time can be shortened by shortening the cooling time. However, the shrinkage is larger than that of the former, and it is necessary to mold the mold larger than the shrinkage at the time of manufacturing the mold. It is important to obtain the shrinkage rate in advance by preliminary experiments.

[Material of molded body (A)]
[Organic fiber (X) contained in molded product (A)]
The organic fiber (X) contained in the molded body (A) is not particularly limited, but examples thereof include polyether ether ketone fiber, polyphenylene sulfide fiber, polyether sulfone fiber, aramid fiber, polybenzoxazole fiber, polyarylate fiber, polyketone. Examples thereof include fibers, polyester fibers, polyamide fibers, and polyvinyl alcohol fibers.
Since organic fiber (X) is used as a reinforcing material, it is preferable to use one having a melting point equal to or higher than the molding temperature of the thermoplastic resin of the molded body (A). Among these, at least one selected from the group consisting of polyethylene terephthalate fiber, polyethylene naphthalate fiber, nylon fiber, and polyamide fiber is preferable because the physical properties such as mechanical properties and heat resistance are balanced with the price.

Moreover, it is preferable that organic fiber (X) is a multifilament, and it is preferable that the form is the textile fabric or knitted fabric comprised by a twisted-yarn cord or a twisted-yarn cord. Discontinuous length inorganic fibers may be used in combination with the organic fibers (X).
The composition ratio of the organic fiber (X) and the resin of the molded body (A) is preferably 20 parts to 900 parts, and 25 parts to 400 parts with respect to 100 parts of the organic fiber (X) by volume. More preferred.
When the ratio of the thermoplastic resin to 100 parts of the organic fiber (X) is more than 20 parts, the resin impregnation ratio between the fiber bundles of the organic fiber becomes a preferable range, and the mechanical strength of the molded body (A) is greatly increased. Moreover, when it is less than 900 parts, the reinforcing effect of the organic fiber (X) can be sufficiently exhibited.

The basis weight of organic fiber (X) per 10 mm thickness in the molded body (A) is preferably 1000 to 12000 g / m ² . More preferably, it is 2000-10000 g / m < ² >. When the basis weight of the organic fiber (X) is larger than 1000 g / m ² , higher impact resistance is expressed. On the other hand, if it is less than 12000 g / m ² , the resin impregnation rate between the fiber bundles is in a preferred range, and the mechanical strength of the molded body (A) is increased.
Although the molded object (A) of this invention contains a thermoplastic resin, it is preferable that the thermal deformation temperature of a thermoplastic resin is 80 degreeC or more. The deflection temperature under load is used as an index of thermal deformability. Thereby, in addition to impact resistance, a molded object (A) can have both high strength and high elasticity.

[Thermoplastic resin of molded body (A)]
Examples of the thermoplastic resin contained in the molded article (A) of the present invention include vinyl chloride resin, vinylidene chloride resin, vinyl acetate resin, polyvinyl alcohol resin, polystyrene resin, acrylonitrile-styrene resin (AS resin), acrylonitrile-butadiene- Styrene resin (ABS resin), acrylic resin, methacrylic resin, polyethylene resin, polypropylene resin, polyamide 6 resin, polyamide 11 resin, polyamide 12 resin, polyamide 46 resin, polyamide 66 resin, polyamide 610 resin, polyacetal resin, polycarbonate resin, polyethylene Terephthalate resin, polyethylene naphthalate resin, boribylene terephthalate resin, polyarylate resin, polyphenylene ether resin, polyphenylene sulfide resin, polysulfate Down resins, polyether sulfone resins, polyether ether ketone resins.

  Among these, vinyl chloride resin, polystyrene resin, ABS resin, polyethylene resin, polypropylene resin, polyamide 6 resin, polyamide 66 resin, polyacetal resin, polycarbonate resin, polyethylene terephthalate resin, polyethylene naphthalate resin, boribylene terephthalate resin, polyarylate resin Are more preferable, and polypropylene resin, polyethylene terephthalate resin, polycarbonate resin, polyamide 6 resin, and polyamide 66 resin are particularly preferable.

[Resin impregnation rate of molded product (A)]
Moreover, in order to improve the impact resistance of the molded body (A), it is preferable to lower the resin impregnation rate of the molded body (A) to give the fibers freedom. In order to improve the degree of freedom of organic fibers, multifilaments are used for organic fibers, and if a thermoplastic resin with higher viscosity than thermosetting resin is used, the fiber bundle of organic fibers is adjusted not to be impregnated with resin This is preferable because it is possible.
By forming the organic fiber of the molded body (A) as a multifilament and obtaining a molded body (A) having a high resin impregnation ratio between the organic fiber bundles of the molded body (A) and a low resin impregnation ratio inside the fiber bundle, Good physical properties can be obtained.
Specifically, the resin impregnation rate between the organic fiber bundles is preferably 90% or more. If the organic fiber bundles are sufficiently filled with the resin, no gaps remain between the long fiber bundles. The strength of the body (A) increases.

Considering the impact resistance of the inside of the organic fiber bundle, it is preferable to have a low resin impregnation rate inside the organic fiber bundle because it is more effective in absorbing energy of impact if the fiber has some freedom in the material. . The resin impregnation rate inside the organic fiber bundle is preferably 50% or less, and it is more preferable that the resin is substantially unimpregnated.
By making the resin impregnation rate within the above range, the single yarn constituting the organic fiber in the molded body (A) has a degree of freedom of deformation and movement, thereby absorbing the impact received by the molded body (A). Therefore, the material is excellent in impact resistance.
The degree of resin penetration into the organic fiber bundle is determined by the selection of the type of thermoplastic resin in addition to the above-described twisted yarn, woven fabric, and knitted fabric, and the molding pressure and thermoplasticity in the resin impregnation step between the fiber bundles as described later It can be controlled by the temperature of the resin.

The resin impregnation rate can be confirmed by microscopic observation such as an electron microscope or an optical microscope, and can be obtained from the area of the voids in the cross section of the molded article. Moreover, the resin impregnation rate between fiber bundles can be calculated by how much single yarn constituting the multifilament can be taken out from the organic fiber taken out from the molded body (A).
When the impact resistance of the molded body subjected to the impact is high, the joined portion of the joined body is peeled before the molded body is peeled off when the impact is received. That is, the impact strength of the joined body depends on the strength of the joined portion. On the other hand, in the case of the joined body using the molded body (A) composed of the organic fiber and the resin in the present invention, since the joined portion is strengthened, the peel strength of the joined portion increases, and the impact strength of the joined body as a whole. improves.

[Materials of molded body (B-1) and molded body (B-2)]
[Thermoplastic resin of molded body (B-1) and molded body (B-2)]
The thermoplastic resin contained in the molded body (B-1) and the molded body (B-2) is not particularly limited, but from the viewpoint of facilitating welding described later, the thermoplastic resin of the molded body (A), A resin that is compatible with heat welding is preferable. For example, polyamide resin, polycarbonate resin, polyacetal resin, polyphenylene sulfide resin, polyphenylene ether resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polyethylene naphthalate resin, polyethylene resin, polypropylene resin, polystyrene resin, polymethyl methacrylate resin, AS resin and The thermoplastic resin selected from at least one selected from the group consisting of ABS resins may be the same or different. From the viewpoint of heat welding, it is preferable to select the same resin as the thermoplastic resin contained in the molded body (B-1) and the molded body (B-2). Moreover, even if it is not the same resin, it is not limited to the combination quoted here, For example, the combination of ABS resin and polycarbonate, ABS resin and acrylic resin can also be welded.
The thermoplastic resin content of the molded body (B-1) and the molded body (B-2) may be 30 to 99% by weight based on the total weight of the molded body, and 30 to 80% by weight. It is preferable that it is present, and more preferably 30 to 60% by weight.

[Reinforcing fiber (Y) contained in molded body (B-1) and molded body (B-2)]
There is no restriction | limiting in particular in the reinforced fiber (Y) contained in a molded object (B-1), Carbon fiber, glass fiber, stainless steel fiber, an alumina fiber, inorganic fibers, such as a mineral fiber, polyetheretherketone fiber, polyphenylene sulfide fiber, Examples thereof include organic fibers such as polyethersulfone fiber, aramid fiber, polybenzoxazole fiber, polyarylate fiber, polyketone fiber, polyester fiber, polyamide fiber, and polyvinyl alcohol fiber. Among these, in applications where the molded body is required to have strength and rigidity, it is preferably at least one selected from the group consisting of carbon fibers, aramid fibers, and glass fibers. For applications that require electrical conductivity, carbon fibers are preferred, and carbon fibers coated with a metal such as nickel are more preferred. In applications that require electromagnetic wave transparency, glass fibers and organic fibers are preferred, and aramid fibers and glass fibers are more preferred from the balance of electromagnetic wave permeability and strength. In applications where impact resistance is required, organic fibers are preferable, and polyamide fibers and polyester fibers are more preferable in consideration of cost. Among these, carbon fiber is preferable in that it can provide a molded body that is lightweight and excellent in strength.

The form of the reinforcing fiber (Y) to be used is not particularly limited, and may be a continuous fiber, a discontinuous fiber, or a random mat substrate described later. In the case of continuous fibers, for example, a form such as a unidirectional substrate or a nonwoven fabric in which carbon fibers are aligned in a uniaxial direction can be mentioned, but this is not restrictive. Moreover, in the case of a discontinuous fiber, it does not specifically limit regarding fiber length.
Moreover, a molded object (B-1) and a molded object (B-2) may contain an additive separately in the range which does not impair the objective of this invention. Examples of additives include flame retardants, heat stabilizers, ultraviolet absorbers, nucleating agents, plasticizers and the like.

[Random mat substrate]
It is more preferable that the molded body (B-1) and the molded body (B-2) of the present invention have a layer molded using a random mat substrate described later and are substantially isotropic.
Furthermore, a molded object (B-1) and a molded object (B-2) contain the reinforcing fiber (Y) and thermoplastic resin of 5-100 mm of average fiber length, and a reinforcing fiber (Y) is 25-3000 g / m < ² >. The ratio of the reinforcing fiber bundle composed of the number of critical single yarns defined in (1) below to the total amount of reinforcing fibers is 20 Vol% or more and 99 Vol% or less. More preferable.
Critical number of single yarns = 600 / D (1)
(Here, D is the average fiber diameter (μm) of the reinforcing fibers)

Random mat means that the reinforcing fibers that make up the random mat base material and prepreg (in which the thermoplastic resin is impregnated in the reinforcing fiber bundle and the reinforcing fiber bundle in the random mat base material) are in a specific direction. It means not oriented (in-plane isotropic). When the molded body is obtained from the random mat base material, the isotropy of the reinforcing fibers in the random mat is maintained in the molded body. By obtaining a molded body from a random mat base material and obtaining a ratio of tensile modulus in two directions orthogonal to each other, the isotropic property of the random mat base material and the molded body therefrom can be quantitatively evaluated. The ratio (Eδ) obtained by dividing the measured value of the tensile modulus of elasticity by the smaller one for an arbitrary direction of the molded body and a direction orthogonal thereto is 2 or less, more preferably 1.3 or less. I will do it.
There is no restriction | limiting in particular in the thickness of a random mat base material, The thing of 1-150 mm thickness can be used. It is preferable to set it as 2-100 mm thickness at the point which exhibits the effect from which a molded object thinner than a random mat base material is obtained.

[Jointing procedure]
Although the preferable manufacturing method of the conjugate | zygote of this invention is demonstrated below, referring FIGS. 2-4, this invention is not limited to these.
As shown in FIG. 3, the molded body (B-1) and the molded body (B-2) are prepared on both sides of the molded body (A) and thermally welded, and the joint portion referred to in FIG. create.
Examples of the heat welding method include, but are not limited to, hot plate welding, vibration welding, and ultrasonic welding. In the present invention, ultrasonic welding is preferable from the viewpoint of easy adhesion.

  When ultrasonic welding is used, it is preferable to provide a projection called an energy director for efficient welding (FIG. 4). The energy director 2 has a structure for facilitating melting and uniform welding of the resin molded body by receiving concentrated vibration, and bonding the molded body (B-1) and the molded body (B-2). It is preferable to provide it on the surface. Further, (B-1) and (B-2) are also applied to the adhesive surface between the molded body (A) and the molded body (B-1) and the adhesive surface between the molded body (A) and the molded body (B-2). ) Side is preferably provided with an energy director. Although there is no restriction | limiting in the shape of an energy director, For example, as shown in FIG. 4, there exists a triangular thing which makes the vertex of an energy director contact the other party to adhere | attach.

[Fitting of molded body (A) and molded body (B-1) and molded body (A) and molded body (B-2)]
Convex part (D-2) of molded body (A) and concave part (F) of molded body (B-2) and concave part (D-1) of molded body (A) and convex part of molded body (B-1) Since the part is assembled, the groove pitch of the concave part and the convex part (length of a in FIG. 11) needs to match. In the molding of the molded body (A) and the molded body (B-1) and the molded body (B-2), the distance between the irregularities of the molded body varies depending on the material and molding conditions. It is preferable to manufacture and mold a mold.

When the molded body (A), the molded body (B-1), and the molded body (B-2) are made of different materials, the concave portion (D-1), the convex portion (E), and the convex portion ( D-2) and the recess (F) need to be adjusted to a shape that can completely match. For example, when a random mat base material in which the reinforcing fibers included in the molded bodies (B-1) and (B-2) are carbon fibers is used, the precursor of the molded body (B-1) and the molded body (B-2). Since the difference between the heat shrinkage rate of the prepreg (B-1) and the prepreg (B-2), which is the body, and the heat shrinkage rate of the precursor prepreg (A) of the molded body (A) is large, the molded body can be fitted. Adjust the size of.
Moreover, when a molded object (B-2) is shape | molded by the hat-shaped cross-sectional shape, it is preferable to set it as a somewhat flexible shape in the X-axis direction. Thereby, a molded object (A), a molded object (B-2), and a molded object (A) and a molded object (B-2) are easy to fit.

  EXAMPLES Hereinafter, although this invention is demonstrated concretely based on an Example, this invention is not limited to these.

[Evaluation method]
(Bending test)
The (A) side of the joined body was placed downward, and the bending strength by three-point bending was evaluated. Using a universal testing machine 5587 300 kN capacity floor type testing machine manufactured by Instron, a bending test was performed at a test speed of 5 mm / min. The number of samples was 5 per test.

(Falling weight test)
The molded body (A) side of the joined body was placed upward and an impact resistance was evaluated by dropping an iron ball of known weight from above so as to fall to the center of the molded body (A). An 8 kg iron ball was used for the test, and the height to be dropped was gradually increased to evaluate the peeling of the joint (C).
Also, the number of samples was 10 per test, and the energy with respect to the height at which half of them were destroyed was calculated.

(Resin impregnation rate between fiber bundles)
The molded body (A) is cut with a microtome, the cross section is observed with a microscope, and the void ratio is calculated by binarizing between the fiber bundles. The value obtained by subtracting the void ratio from 100% is calculated between the fiber bundles. The resin impregnation rate was calculated.

(Resin impregnation rate inside the organic fiber bundle)
It was measured how much single yarn constituting the multifilament could be taken out from the organic fiber taken out from the molded body (A). When the number of single yarns of the multifilament is X and the number of free single yarns taken out is Y, the resin impregnation rate inside the fiber bundle is 1-Y / X (%).

[Making polyethylene terephthalate twisted cord]
A polyethylene terephthalate fiber P900M 1100T250f manufactured by Teijin Fibers Ltd. was used as a raw yarn, and a twist of 275 T / m was applied in the Z direction using a ring twisting machine manufactured by Kajitec Co., Ltd. (twist count 3.0). Next, two lower twisted yarns were combined, and an upper twist of 200 T / m was applied in the S direction (twist count 3.0) to obtain an experimental twisted yarn cord. The diameter of one twisted cord was 0.5 mm.

[Creation of molded body (A-0) and molded body (A-1)]
After affixing to a flat aluminum plate with a polyamide 6 film (Unitika emblem ON film, standard grade, thickness 25 μm) on one side, the above polyethylene terephthalate twisted cord has a uniform thickness of 200 g / m ^2. I wrapped it like this. This aluminum plate was hot pressed to obtain a unidirectional material of polyethylene terephthalate twisted cord partially impregnated with polyamide 6 resin. For the aluminum plate, a part of the wound fiber was cut out and taken out. Based on the fiber direction of the unidirectional material, it is overlapped with the 0 degree direction, 90 degree direction, and 0 degree direction, cut into an appropriate size, and then heated and pressed again to form 150 mm width x 300 mm depth x 3.0 mm thickness A body was obtained (width: X-axis direction in FIG. 1, depth: Z-axis direction in FIG. 1, thickness: Y-axis direction in FIG. 1). This was designated as a molded product (A-0). The resin impregnation ratio between the fiber bundles of the molded body (A-0) was 95%, the resin impregnation ratio inside the fiber bundle was 30%, and the fiber volume fraction was 40%.

When a ball drop test was performed on the molded body (A-0), the molded body (A-0) was not broken even at a dropping height of the iron ball of 2.5 m.
The molded body (A-0) was pressed at 240 ° C. in the mold at 3 MPa, and then cooled to 30 ° C. while the mold was pressed, so that the concave portion (D-1) and the convex portion (D-2) were formed. A molded body (A-1) was obtained. The concave portion (D-1) of the obtained molded body (A-1) has a groove shape, and the concave side has a groove width of 2 mm (X-axis direction in FIG. 1) × groove depth of 5.2 mm (Y-axis direction in FIG. 1). The convex side (D-2 side) corresponding to this was 7.3 mm in width (X-axis direction in FIG. 1) × 5 mm in height (Y-axis direction in FIG. 1). The resin impregnation rate between the fiber bundles of the formed body (A-1) was 95%, the resin impregnation rate inside the fiber bundle was 30%, and the fiber volume fraction was 40%.
At this time, the distance between the recesses (D-1) provided on both sides of the molded body (A-1) (the length in FIG. 11a) is 68.8 mm for the mold size of about 69.3 mm. The body was obtained. That is, the shrinkage of about 0.5% occurred with respect to the molded body size of the mold used.

[Creation of molded body (A-2)]
After affixing to a flat aluminum plate with a polyamide 6 film (Unitika emblem ON film, standard grade, thickness 25 μm) on one side, the above polyethylene terephthalate twisted cord has a uniform thickness of 200 g / m ^2. I wrapped it like this. This aluminum plate was hot pressed to obtain a unidirectional material of polyethylene terephthalate twisted cord partially impregnated with polyamide 6 resin.
Based on the fiber direction of the unidirectional material, it is overlapped with the 0 degree direction, 90 degree direction, and 0 degree direction, cut into an appropriate size, and then heated and pressed again to form 150 mm width x 300 mm depth x 3.0 mm thickness A body was obtained (width: X-axis direction in FIG. 1, depth: Z-axis direction in FIG. 1, thickness: Y-axis direction in FIG. 1). Further, after the fibers were fixed, some of the fibers were cut out and the aluminum plate was taken out.

The obtained molded body was heated to 240 ° C. with a heater and placed in a mold. This was clamped to obtain a molded body (A-2). The metal mold | die used at this time used the metal mold | die 10% larger in each direction compared with the metal mold | die for a molded object (A-1). The mold temperature was constant at 120 ° C. from molding to release.
The concave portion (D-1) of the obtained molded body (A-2) has a groove shape, and the concave side has a groove width of 2 mm (X-axis direction in FIG. 1) × groove depth of 5.2 mm (Y-axis direction in FIG. 1). The convex side (D-2 side) corresponding to this was 7.3 mm in width (X-axis direction in FIG. 1) × 5 mm in height (Y-axis direction in FIG. 1). The formed article (A-2) had a resin impregnation ratio of 95% between the fiber bundles, a resin impregnation ratio inside the fiber bundle of 30%, and a fiber volume fraction of 40%.
At this time, the distance between the recesses (D-1) provided on both sides of the molded body (A-1) (the length in FIG. 11a) was 69.69 mm compared to the mold size of about 76.2 mm. A 0 mm shaped body was obtained. That is, the shrinkage of about 10.4% occurred with respect to the molded body size of the mold used. Further, the shrinkage in the thickness direction was about 0.5%.

[Creation of molded body (A-3)]
After affixing to a flat aluminum plate with a polyamide 6 film (Unitika emblem ON film, standard grade, thickness 25 μm) on one side, the above polyethylene terephthalate twisted cord has a uniform thickness of 200 g / m ^2. I wrapped it like this. This aluminum plate was hot pressed to obtain a unidirectional material of polyethylene terephthalate twisted cord partially impregnated with polyamide 6 resin.
Based on the fiber direction of the unidirectional material, it is overlapped with the 0 degree direction, 90 degree direction, and 0 degree direction, cut into an appropriate size, and then heated and pressed again to form 150 mm width x 300 mm depth x 3.0 mm thickness A body was obtained (width: X-axis direction in FIG. 1, depth: Z-axis direction in FIG. 1, thickness: Y-axis direction in FIG. 1). Further, after the fibers were fixed, the aluminum plate was taken out.

The obtained molded body was heated to 240 ° C. with a heater, and placed in the mold used for forming the molded body (A-1). This was clamped at a pressure of 10 MPa to obtain a molded body (A-3). At this time, the mold temperature was constant at 120 ° C. from molding to mold release.
The concave portion (D-1) of the obtained molded body (A-3) has a groove shape, and the concave side has a groove width of 2 mm (X-axis direction in FIG. 1) × groove depth of 5.2 mm (Y-axis direction in FIG. 1). The convex side (D-2 side) corresponding to this was 7.3 mm in width (X-axis direction in FIG. 1) × 5 mm in height (Y-axis direction in FIG. 1). The molded article (A-3) thus prepared had a resin impregnation rate between fiber bundles of 95%, a resin impregnation ratio inside the fiber bundle of 30%, and a fiber volume fraction of 40%.
At this time, a molded body with a molded body of 63.1 mm was obtained for a groove pitch of a mold size of about 69.3 mm. That is, shrinkage of about 9.0% occurred with respect to the size of the mold used. Further, the shrinkage in the thickness direction was about 0.5%.

[Creation of molded body (B-1) and molded body (B-2)]
The molded body (B-1) and the molded body (B-2) used carbon fibers as reinforcing fibers. Carbon fiber (Toho Tenax, STS40, average fiber diameter 7 μm) is cut to an average of 20 mm, the supply amount of carbon fiber is introduced into the taper tube at 301 g / min, and air is blown into the carbon fiber in the taper tube to bundle the fiber bundle. While partially opening, it was spread on a table installed at the lower part of the taper tube outlet. Also, as a matrix resin, PA6 (Unitika nylon 6 manufactured by Unitika) cut into 2 mm is supplied into the tapered tube at 278 g / min and dispersed simultaneously with the carbon fibers, so that carbon fibers with an average fiber length of 20 mm and PA6 are mixed. A random mat base material having a carbon fiber basis weight of 540 g / m ² was obtained. When the form of the reinforcing fiber in the random mat base material was observed, the fiber axis of the reinforcing fiber was almost parallel to the surface and was randomly dispersed in the surface. The weight ratio of the carbon fiber was 52 parts by weight with respect to the whole. When the average fiber length and the ratio of the reinforcing fiber bundle of the obtained random mat base material were examined, the average fiber length was 20 mm and the critical single yarn number was 86. The ratio of the reinforcing fiber bundle to the total amount of fibers of the random mat base material Was 60 Vol%. This random mat base material was cold-press molded to obtain molded bodies (B-1) and molded bodies (B-2).

The base material thickness of the molded body (B-1) and the molded body (B-2) at the joint (C) was 1.5 mm (thickness: Y-axis direction in FIG. 1). The convex part (E) had a shape along the concave side of the molded body (A), and had a protrusion width of 2 mm and a height of 5 mm. The convex portion (F) had a shape along the convex side of the molded body (A), and the concave side had a groove width of 7.5 mm and a groove depth of 5 mm.
The molded body (B-1) was 300 mm wide × 22 mm long × 1.5 mm thick, and the convex portion (E) was 5 mm high × 2 mm wide at the tip. In order to cover the end of the molded body (A), the end of the molded body (B-1) has a height of 4.5 mm. (Height: Y-axis direction in Fig. 1)
The molded body (B-2) had a hat-shaped cross section, a width of 300 mm, a length of 150 mm, a thickness of 1.5 mm, and a height of 30 mm.
Moreover, what was a hat shape of the same shape as a molded object (B-2), and does not have a recessed part (F) was made into the molded object (B-3).

[Example 1]
When the molded body (A-1), the molded body (B-1), and the molded body (B-2) are overlapped as shown in FIG. 1, the molded body (A-1) and the molded body are overlapped. (B-1) and a molded object (A-1) and the molded object (B-2) were able to closely_contact | adhere. Adhesion of the fitting portions was performed by ultrasonic welding. The conditions were an amplitude of 40 μm, a welding time of 10 seconds, and a pressure of 0.3 MPa. Table 1 shows the results of the bending test and falling weight test of this joined body. In the bending test, the breaking load was 3.6 kN. Moreover, the falling weight test result was 2.5 m.

[Example 2]
When the molded body (A-2), the molded body (B-1), and the molded body (B-2) are overlapped as shown in FIG. The body (B-1) and the molded body (A-2) and the molded body (B-2) were able to be brought into close contact with each other. These adhesions were performed by ultrasonic welding. The conditions were an amplitude of 40 μm, a welding time of 10 seconds, and a pressing force of 0.3 MPa.
At this time, the molded body (A-2), the molded body (B-1), and the molded body (A-2) and the molded body (B-2) were closely fitted, and there was no play. . Table 1 shows the results of the bending test and falling weight test of the manufactured joined body. In the bending test, the breaking load was 3.5 kN. The falling weight test result was 2.4 m.

[Comparative Example 1]
The molded body (A-0) provided with no recesses and convex portions and the molded body (B-3) were welded as shown in FIG. Welding was ultrasonic welding, and the conditions were an amplitude of 40 μm, a welding time of 10 seconds, and a pressure of 0.3 MPa.
Table 1 shows the results of the bending test and falling weight test of this joined body. In the bending test, the breaking load was 2.7 kN. The falling weight test result was 1.7 m. At this time, it peeled off at the joint surface.

[Reference Example 1]
The molded body (A-3) provided with the groove, the molded body (B-1), and the molded body (B-2) were overlapped as shown in FIG. At this time, the molded body (B-1) and the molded body (A-2) could be fitted. However, since the convex part (F) of the molded body (A-3) and the molded body (B-2) did not match and could not be fitted, the study was stopped.

A Organic fiber-containing resin molded body B-1 Reinforced fiber-containing thermoplastic resin molded body B-2 Reinforced fiber-containing thermoplastic resin molded body D-1 On the surface in contact with the molded body (B-1), the molded body (A) is Convex part D-2 Convex part E corresponding to concave part (D-1) Convex part F that can be fitted to concave part (D-1) Concave part G that can be fitted to convex part (D-2) Molded article (B-1) And the molded body (B-2) are joined to cover the end of the molded body (A) X width direction Y thickness direction, height direction Z depth direction 1 impact load 2 energy director 3 recess (D -1) and molded body (A) having no projection (D-2)
4 Molded body (B-3) having no concave portion (F) corresponding to the convex portion (D-2)
5 Joint part 6 of molded body (A) having no recess (D-1) and convex part (D-2) of molded body (B-3) having no concave part (F) corresponding to the convex part (D-2) Junction

Claims (5)

(i) The molded body (B-1) and the molded body (B-2) are arranged on both surfaces of the molded body (A),
(ii) The molded body (A) has at least one recess (D-1) on the surface in contact with the molded body (B-1), and the surface in contact with the molded body (B-2) corresponds to the recess. A convex portion (D-2)
(iii) The molded body (B-1) has a convex portion (E) that can be fitted to the concave portion (D-1),
(iv) The molded body (B-2) has a concave portion (F) that can be fitted to the convex portion (D-2).
(v) The concave portion (D-1) and the convex portion (E), and the convex portion (D-2) and the concave portion (F) are fitted and bonded,
(vi) The molded body (B-1) and the molded body (B-2) have an adhesive portion (G) bonded to cover the end of the molded body (A).
A joined body having a joint (C),
(vii) The molded body (A) is a molded body containing an organic fiber (X) and a thermoplastic resin,
(viii) The above-mentioned joined body, wherein the molded body (B-1) and the molded body (B-2) are molded bodies containing reinforcing fibers (Y) and a thermoplastic resin.   2. The organic fiber (X) is at least one selected from the group consisting of polyethylene terephthalate fiber, polyethylene naphthalate fiber, nylon fiber and polyamide fiber, and the reinforcing fiber (Y) is a carbon fiber. The joined body.   The joined body according to claim 1, wherein the shaped body (B-1) and the shaped body (B-2) are formed bodies using a random mat base material.   The joined body according to any one of claims 1 to 3, wherein the shaped body (B-2) is shaped into a hat-shaped cross-sectional shape and has the joint portion (C) at a hat collar portion.   The bonded body according to any one of claims 1 to 4, wherein the bonding is performed by heat welding.