JP6946727B2 - Manufacturing method of composite molded product - Google Patents

Description

The present invention relates to a method for producing a composite molded product, and in particular, a desired portion of a molded product of a resin composition containing a fiber-reinforced thermoplastic resin is made of a continuously reinforced fiber base material prepared in advance using a different thermoplastic resin. The present invention relates to a method for producing a composite molded product that can be easily and efficiently reinforced with high accuracy.

A molded product obtained by molding a resin composition composed of a thermoplastic resin and a filler containing reinforcing fibers (for example, by injection molding) is widely used in various fields. In such a molded product, it is often required to further reinforce the desired portion with continuous reinforcing fibers.

As a reinforcing method, for example, when molding a molded product, a resin composition for molding the main body of the molded product and a resin or resin composition for forming a reinforcing portion containing continuous reinforcing fibers are substantially used in the same mold. There are a method of integrally molding at the same time and a method of joining a resin or a resin composition for forming a reinforcing portion containing continuous reinforcing fibers to a portion to be reinforced after molding the main body of the molded body.

In the former method, since the main body of the molded body and the reinforcing part are integrally molded at the same time, the two parts are firmly integrated and a high reinforcing effect can be obtained. Since the material for forming the main body of the molded body and the material for forming the reinforcing portion must be arranged or injected, it may be difficult to mold into a desired form in the case of a complicated shape having a three-dimensional shape or the like. ..

On the other hand, in the latter method, since the molded body main body is molded first, the molded body main body can be formed into a desired shape with high accuracy relatively easily by, for example, injection molding. In the case of a complicated shape having a three-dimensional shape or the like, it is important how the reinforcing portion can be joined to the desired portion with high accuracy and high strength.

In order to join the reinforcing portion to the main body of the molded product as described above, a method of using an adhesive or a method of welding both portions by utilizing the resin component of the main body of the molded product and the reinforcing portion can be considered. In the method using an adhesive, the process is complicated and the bonding strength of both parts is limited. In order to obtain high bonding strength, it is considered that the method of welding both parts is preferable, and the reinforcing part is partially efficiently bonded to the desired part of the previously molded molded body body with high bonding strength. In order to do so, it is considered that a welding method involving local heating such as ultrasonic welding is suitable.

When the parts to be joined to each other are made of the same type of resin, it is known that they can be directly joined by a joining method such as ultrasonic welding (for example, Patent Documents 1 and 2), but the parts to be joined to each other. When is made of different kinds of resins, it is often necessary to devise a special device between the two resin layers.

For example, Patent Document 3 discloses a laminate in which a bonding interface between a thermosetting resin layer and a thermoplastic resin layer is formed in an uneven shape and integrally bonded, and continuous reinforcing fibers are distributed throughout the inside. There is. However, in the laminate described in Patent Document 3, since the interface between the two resin layers bonded to each other must be formed in an uneven shape, the efficiency is partially applied to the desired portion of the previously molded molded body main body. It cannot be practically adopted when the purpose is to join the reinforcing portion with high joining strength.

Further, for example, Patent Document 4 discloses a molded product obtained by interposing a specific adhesive layer between dissimilar resin layers and integrally molding the whole. However, in the molded product described in Patent Document 4, since the entire molded product is integrally molded by injection molding or press molding, it is partially efficient at a desired portion of the molded product main body portion previously molded. It cannot be practically adopted when the purpose is to join the reinforcing portion with high joining strength. Further, Patent Document 4 does not describe a welding method involving local heating such as ultrasonic welding.

As described above, in particular, when the resin used for the composition of the molded body main body previously molded and the resin used for the composition of the reinforcing portion for reinforcing the molded body main body are made of different kinds of resins. , An effective method for joining the reinforcing portion to the main body of the molded product by ultrasonic welding has not yet been proposed. Regarding the method itself using ultrasonic welding or the like, a method of producing a tape-shaped resin-impregnated unidirectional reinforcing fiber bundle by a pressing body that vibrates ultrasonically on the support surface of the support (Patent Document 5), or a plurality of methods. Ultrasonic welded fiber products (Patent Document 6) in which a part of the fiber member is ultrasonically welded via a welding aid are known, but for producing a tape-shaped resin-impregnated unidirectional reinforcing fiber bundle. Because it is a technology that is limited to technology or belongs to another field for manufacturing ultrasonic welding fiber products, in both cases, the reinforcing part is bonded to the main body of the molded body by ultrasonic welding under the above conditions. It is not a method that can be applied to.

Japanese Unexamined Patent Publication No. 2013-043321 Japanese Unexamined Patent Publication No. 2012-158141 WO2004 / 060658 WO2014 / 112501A Japanese Patent No. 5870392 Japanese Unexamined Patent Publication No. 2006-346862

Therefore, in view of the above circumstances, the subject of the present invention is particularly used for the composition of the resin used for the composition of the molded body main body previously molded and the configuration of the reinforcing portion for reinforcing the molded body main body. Even if the resin is made of a different type of resin, the desired part of the molded product is easily and efficiently made with a continuously reinforcing fiber base material prepared in advance using the different type of resin with high accuracy and high bonding strength. An object of the present invention is to provide a method for producing a composite molded product that can be reinforced.

In order to solve the above problems, the method for producing a composite molded body according to the present invention is a thermoplastic sheet material (B) having a functional group on a molded body (A) formed by molding a thermoplastic resin composition. After laminating the fiber-reinforced resin molded body (C) made of a different type of thermoplastic resin from the thermoplastic resin of the reinforcing fiber bundle and the molded body (A) on the thermoplastic sheet material (B). The method comprises joining the thermoplastic sheet material (B) and the fiber-reinforced resin molded body (C) to the molded body (A) by ultrasonic welding.

In such a method for producing a composite molded product according to the present invention, first, a thermoplastic sheet material (B) having a functional group is laminated on the previously molded molded product (A), and the thermoplastic sheet material (B) having a functional group is laminated on the thermoplastic sheet material (B) having a functional group. , The thermoplastic sheet material (B) in which the fiber-reinforced resin molded body (C) prepared in advance made of different types of thermoplastic resin from the thermoplastic resin of the reinforcing fiber bundle and the molded body (A) is laminated and laminated. The fiber-reinforced resin molded body (C) is integrally bonded to the molded body (A) by ultrasonic welding to form a composite molded body. In this ultrasonic welding, in particular, the thermoplastic sheet material (B) and the fiber-reinforced resin molded body (C) are heated to form the thermoplastic sheet material (B) and the fiber-reinforced resin molded body (C). The plastic resin is bonded to the molded body (A) while maintaining the state in which the thermoplastic resin forming the fiber-reinforced resin molded body (C) is impregnated in the reinforced fiber bundle. Since the thermoplastic resin of the fiber-reinforced resin molded body (C) and the thermoplastic resin of the molded body (A) are different types of thermoplastic resins, the fiber-reinforced resin molded body (C) is directly used as the molded body (A). ), The affinity between different types of thermoplastic resins is low, and in many cases a good and strong bonded state cannot be obtained. However, in the present invention, the thermoplastic sheet material (B) having a functional group in between. The thermoplastic sheet material (B) having this functional group has a high affinity with both the thermoplastic resin of the fiber-reinforced resin molded body (C) and the thermoplastic resin of the molded body (A). The fiber-reinforced resin molded body (C) is satisfactorily and firmly bonded to the thermoplastic sheet material (B) by the intervention of the thermoplastic sheet material (B) having a functional group, and the thermoplastic sheet material (B) is bonded to the thermoplastic sheet material (B). It is satisfactorily and firmly bonded to the molded body (A), and eventually, the reinforcing material made of the fiber-reinforced resin molded body (C) is satisfactorily and firmly bonded to the molded body (A). The thermoplastic sheet material (B) and the fiber-reinforced resin molded body (C) are particularly the fiber-reinforced resin molded body (C) in the form of a continuously reinforced fiber base material, which is a predetermined portion targeted by the molded body (A). Since it is only necessary to join the molded body (A), the predetermined portion of the molded product (A) is easily and efficiently reinforced with high accuracy, and high bonding strength can be obtained at the reinforced portion as described above. Further, when the reinforcing fibers of the fiber-reinforced resin molded body (C) used for reinforcement are in the form of a reinforcing fiber bundle, the fiber-reinforced resin molded body (C) containing the reinforcing fiber bundle is applied to the molded body (A). , It becomes possible to easily arrange and join the reinforcing fiber bundles so that the reinforcing fiber bundles are arranged in a desired direction for reinforcing the molded product (A) so as to locally conform to an arbitrary shape. Even if the molded body (A) has a complicated three-dimensional shape, the fiber-reinforced resin molded body (C) and, by extension, the reinforced fiber bundle can be easily arranged along the shape. .. Therefore, regardless of substantially any shape of the molded body (A), the fiber reinforced resin molding is carried out by adopting the ultrasonic welding method with the thermoplastic sheet material (B) interposed therebetween. The continuous reinforcing fiber base material made of the body (C) makes it possible to easily and efficiently reinforce the molded body (A) with high accuracy and high bonding strength.

In the method for producing a composite molded product according to the present invention, the thermoplastic resin of the molded product (A) and the thermoplastic resin of the fiber-reinforced resin molded product (C) may be different types of thermoplastic resins. The combination of thermoplastic resins can be appropriately selected. However, in order to prepare the fiber-reinforced resin molded body (C) in advance, it is desirable to easily and satisfactorily impregnate the reinforcing fiber bundle with the thermoplastic resin to form a continuous reinforcing fiber base material having a desired form. However, for that purpose, it is preferable that the thermoplastic resin of the fiber-reinforced resin molded body (C) is made of a polyamide-based resin. In that case, the thermoplastic resin of the molded product (A) is made of a thermoplastic resin other than the polyamide resin. Examples of the thermoplastic resin other than the polyamide resin include polyester resin, polyolefin resin, polyarylene sulfide resin, styrene resin and the like.

Further, in the method for producing a composite molded body according to the present invention, the thermoplastic sheet material (B) itself is the thermoplastic resin of the molded body (A) and the thermoplastic resin of the fiber-reinforced resin molded body (C). It secures the ease of joining and the joining strength between different types of thermoplastic resins, and does not directly support the partial reinforcement of the molded body (A), but on the thermoplastic sheet material (B) layer. A fiber-reinforced resin molded body (C) responsible for reinforcing the molded body (A) is laminated on the surface, and the laminated fiber-reinforced resin molded body (C) is supported on the fiber-reinforced resin molded body (C). In order to exert the excellent reinforcing function of the molded body (A), it is preferable that the thermoplastic sheet material (B) is in good contact with the surface of the molded body (A). Based on JIS B0601, it is preferable that the center line average surface roughness Ra of the laminated surface of the thermoplastic sheet material (B) of the molded product (A) is in the range of 1 ≦ Ra ≦ 10 (μm) from this surface. ..

Further, in the method for producing a composite molded product according to the present invention, the fiber-reinforced resin molded product (C) is made of a different type of thermoplastic resin from the reinforced fiber bundle and the thermoplastic resin of the molded product (A). In order to efficiently reinforce a desired portion of the body (A) with high accuracy, it is preferable to easily and highly accurately supply and laminate the desired portion, and for that purpose, particularly fiber-reinforced resin molding. It is preferable that the body (C) is made of a tape-like base material.

Further, in the method for producing a composite molded body according to the present invention, it is preferable that the molded body (A) is molded by injection molding. In the case of injection molding, the thermoplastic resin composition constituting the molded body (A) can be easily molded along the mold with high precision. By the method according to the present invention, the target reinforcement can be performed on the site with high accuracy.

Further, in the method for producing a composite molded product according to the present invention, the filler used for the molded product (A) is not particularly limited, and a fibrous or non-fibrous filler (plate-shaped, scaly, granular, etc.) Any filler (indefinite shape, crushed product, etc.) can be used, and from the viewpoint of producing a high-strength composite molded product, the filler is preferably a reinforcing fiber. That is, when the molded product (A) is originally a fiber-reinforced composite molded product, the target predetermined portion of the molded product (A) is placed on the fiber-reinforced resin molded product (C) via the thermoplastic sheet material (B). Is further reinforced by ultrasonic welding. As the reinforcing fiber used as the filler of the molded product (A), either continuous fiber or discontinuous fiber can be used, but the molded product (A) to which the application of the present invention is considered to be particularly suitable is complicated. When the molded product (A) has a three-dimensional shape, it is considered preferable to injection-mold the molded product (A) as described above. In that case, the reinforcing fiber used as the filler of the molded product (A) is used. It is preferably a discontinuous fiber.

The type of reinforcing fiber used as a filler in the molded body (A) is not particularly limited, and for example, any one of carbon fiber, glass fiber, and aramid fiber, or a combination of any of these can be used. Above all, it is preferable to use glass fiber and carbon fiber. Non-fibrous fillers include mica, talc, kaolin, silica, calcium carbonate, glass beads, glass flakes, glass microballoons, clay, molybdenum disulfide, wallastenite, calcium polyphosphate, graphite, metal powder, metal flakes, etc. Examples thereof include metal ribbons, metal oxides (alumina, zinc oxide, titanium oxide, etc.), carbon powder, graphite, carbon hooks, scaly carbon, carbon nanotubes, and the like. Specific examples of metal powders, metal flakes, and metal types of metal ribbons include silver, nickel, copper, zinc, aluminum, stainless steel, iron, brass, chromium, and tin.

Further, the type of the reinforcing fiber constituting the reinforcing fiber bundle in the fiber-reinforced resin molded body (C) is not particularly limited, and is, for example, carbon fiber, glass fiber, aramid fiber, or any one of these. Combinations and the like can be used, but considering that the reinforcing fiber bundle in the fiber-reinforced resin molded body (C) is used for the purpose of efficiently reinforcing a predetermined portion of the molded body (A), the carbon fiber Preferable to use.

In the form of the reinforcing fiber bundle in the fiber reinforced resin molded body (C), the reinforcing fibers are arranged in one direction regardless of whether the woven fabric is a continuous reinforcing fiber or the reinforcing fibers are arranged in one direction. The layers may be laminated in multiple layers in different directions. Orientation in one direction is preferable because the composite molded body can exhibit high mechanical strength in a specific direction in which the continuous reinforcing fibers are oriented.

Further, in the method for producing a composite molded body according to the present invention, the thermoplastic sheet material (B) interposed as described above is selected from at least an epoxy group, a glycidyl group, a carboxyl group and a carbonyl group as functional groups. It is preferable to include one. By having such a functional group in the thermoplastic sheet material (B), in the thermoplastic resin and fiber reinforced resin molded body (C) of the molded body (A) located on both sides of the thermoplastic sheet material (B). Any of the thermoplastic resins can be easily bonded with high bonding strength.

More specifically, the thermoplastic sheet material (B) is made from, for example, a polyolefin resin having an epoxy group and / or a glycidyl group as a functional group, an acid-modified olefin-based copolymer, or a modified vinyl-based copolymer. It is mentioned as a preferable form that it is formed by at least one selected.

For example, a preferable combination of the thermoplastic resin of the molded product (A) and the material of the thermoplastic sheet material (B) can be exemplified as a polyolefin resin and an acid-modified olefin copolymer, and a styrene resin and a modified vinyl. Examples thereof include a combination of a polymer, a polyester resin and a modified vinyl copolymer or a polyolefin resin having an epoxy group and / or a glycidyl group.

Further, in the method for producing a composite molded product according to the present invention, it is preferable that the volume content of the reinforcing fiber bundle in the fiber reinforced resin molded product (C) is in the range of 5 to 70%. Considering that the fiber-reinforced resin molded product (C) plays a role of partially and efficiently reinforcing the desired portion of the molded product (A) via the thermoplastic sheet material (B), the volume content range is within the above range. Among them, a high volume content is more preferable.

Further, in the method for producing a composite molded body according to the present invention, the thermoplastic sheet material (B) itself has the thermoplasticity of the thermoplastic resin of the molded body (A) and the fiber-reinforced resin molded body (C). Since it ensures the ease and strength of bonding between different types of thermoplastic resins and does not directly support the partial reinforcement of the molded body (A), it can be used for joining between different types of thermoplastic resins. It suffices to have the required thickness, and it is not necessary to have such a large thickness. From this point of view, the thickness of the thermoplastic sheet material (B) is preferably in the range of 10 to 300 μm, more preferably in the range of 10 to 200 μm. It is more preferably in the range of 20-100 μm.

As described above, in the present invention, even when the molded body (A) has a complicated three-dimensional shape, the molded body (A) can be easily and efficiently reinforced with high accuracy and high bonding strength. The present invention is also problematic when at least a part of the joint surface of the molded body (A) with the thermoplastic sheet material (B) and the joint surface with the molded body (A) is formed on a curved surface (including a three-dimensional curved surface). Applicable without.

As described above, according to the method for producing a composite molded body according to the present invention, even when the molded body (A) has a complicated shape, the thermoplastic sheet material (B) adopts the ultrasonic welding method. ) With a continuously reinforced fiber base material made of the fiber-reinforced resin molded body (C), the molded body (A) can be easily and efficiently reinforced with high accuracy and high bonding strength.

It is the schematic of the molded article of 3D shape produced in an Example (unit of each dimension: mm).

Hereinafter, the present invention will be described in more detail together with embodiments.
In the method for producing a composite molded body according to the present invention, a thermoplastic sheet material (B) having a functional group is laminated on a molded body (A) formed by molding a thermoplastic resin composition, and the thermoplastic sheet is laminated. A fiber-reinforced resin molded body (C) made of a thermoplastic resin different from the thermoplastic resin of the reinforcing fiber bundle and the molded body (A) is laminated on the material (B), and then the thermoplastic sheet material is ultrasonically welded. The method comprises joining the (B) and the fiber-reinforced resin molded body (C) to the molded body (A).

As the different types of thermoplastic resins in the molded body (A) and the fiber-reinforced resin molded body (C), as described above, for example, the thermoplastic resin of the fiber-reinforced resin molded body (C) is applied to the reinforcing fiber bundle. From the viewpoint of impregnation property, it is a polyamide resin, and the molded product (A) thermoplastic resin is a thermoplastic resin other than the polyamide resin, for example, a polyester resin, a polyolefin resin, a polyarylene sulfide resin, a styrene resin, or the like. Is preferable.

Preferred examples of the above-mentioned polyamide resin are polycaproamide (nylon 6), polytetramethylene adipamide (nylon 46), polyhexamethylene adipamide (nylon 66), and polycaproamide / polyhexamethylene adipamide. Copolymer (Nylon 6/66), Polyundecamide (Nylon 11), Polycaproamide / Polyundecamide Copolymer (Nylon 6/11), Polydodecamide (Nylon 12), Polycaproamide / Polydodecamide Copolymer (Nylon 6/12) , Polyhexamethylene sebacamide (nylon 610), polyhexamethylene dodecamide (nylon 612), polyundecamethylene adipamide (nylon 116) and mixtures or copolymers thereof. Of these, nylon 6 is particularly preferable. In addition, the polyamide resin may be used alone or in combination of two or more.

Preferred examples of the polyester resin include polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polypropylene terephthalate, polycyclohexanedimethylene terephthalate, polypropylene naphthalate, polybutylene naphthalate, polyethylene isophthalate / terephthalate, and polypropylene isophthalate / terephthalate. , Polybutylene isophthalate / terephthalate, polyethylene terephthalate / naphthalate, polypropylene terephthalate / naphthalate, polybutylene terephthalate / naphthalate, polylactic acid, polyglycolic acid, and mixtures or copolymers thereof. Of these, polybutylene terephthalate and polyethylene terephthalate are preferable. In addition, the polyester resin may be used alone or in combination of two or more.

Preferred examples of the polyolefin-based resin include polypropylene, polyethylene, polybutene, poly-4-methylpentene, and mixtures or copolymers thereof. Of these, polypropylene and polyethylene are preferable. Further, the polyolefin-based resin may be used alone or in combination of two or more.

Preferred examples of the polyarylene sulfide-based resin include polyphenylene sulfide, polyphenylene sulfide sulfone, polyphenylene sulfide ketone, and mixtures or copolymers thereof. Of these, polyphenylene sulfide is particularly preferable. Further, the polyarylene sulfide resin may be used alone or in combination of two or more.

Preferred examples of the styrene resin include acrylonitrile / butadiene / styrene copolymer (ABS resin), polystyrene (PS), impact resistant polystyrene (HIPS), acrylonitrile / styrene copolymer (AS resin), and acrylonitrile / acrylic. At least one resin selected from rubber / styrene copolymer (AAS resin), acrylonitrile / ethylenepropylene-based rubber / styrene copolymer (AES resin), methyl methacrylate / butadiene / styrene copolymer (MBS resin), etc. Can be mentioned. Of these, ABS resin is particularly preferable. In addition, the styrene resin may be used alone or in combination of two or more.

When the reinforcing fiber is used as the filler of the molded body (A), the reinforcing fiber and the reinforcing fiber constituting the reinforcing fiber bundle in the fiber-reinforced resin molded body (C) may be of the same type. It may be different. Examples of the reinforcing fiber include inorganic fiber such as carbon fiber and glass fiber, synthetic resin fiber such as polyamide fiber, polyester fiber and aramid fiber, and metal fiber such as titanium fiber, boron fiber and stainless fiber, but these are not necessarily used. It is not limited to. The reinforcing fibers are preferably carbon fibers and glass fibers. By using carbon fiber and glass fiber, a composite molded product having excellent mechanical strength can be obtained.

When reinforcing fibers are used as the filler of the molded product (A), the form of the reinforcing fibers is preferably discontinuous fibers as described above. If the material contains discontinuous reinforcing fibers, injection molding becomes possible, and the molded body (A) is easily formed into a complicated shape. Therefore, the molded body (A) to which the method according to the present invention is preferably applied is suitable. It becomes the form of. However, the method according to the present invention can also be applied to a molded product (A) in which the filler is other than the reinforcing fiber and a molded product (A) in which the continuous reinforcing fiber is used as the filler.

When the molded body (A) is injection-molded, the molded body (A) itself can be easily formed into a desired shape with high accuracy and good productivity by a usual molding method, and is molded first. By applying the method according to the present invention to the molded product (A), a continuously reinforcing fiber group composed of the fiber-reinforced resin molded product (C) via the thermoplastic sheet material (B) only for a desired portion. The molded body (A) can be easily and efficiently reinforced with a material with high accuracy and high bonding strength.

The thickness of the fiber-reinforced resin molded body (C) is preferably relatively thin because it can be laminated well along the shape of the molded body (A), and is preferably the thickness of the fiber-reinforced resin molded body (C). Is in the range of about 0.1 to 1 mm. Further, the fiber-reinforced resin molded product (C) preferably has a certain degree of flexibility in order to conform well to the surface shape of the molded product (A).

Further, as described above, the volume content of the reinforcing fiber bundle in the fiber-reinforced resin molded product (C) is preferably in the range of 5 to 70%, and more preferably the volume content is 20 to 65%. The range, more preferably the volume content, is in the range of 30-60%. The volume content of the reinforcing fiber bundle can be obtained by measuring according to JIS K 7052 or K 7075.

Due to the thickness of the fiber-reinforced resin molded product (C) in the above range and the volume content of the reinforcing fiber bundle, the thermoplasticity of a relatively thin layer even in the molded product (A) having a complicated three-dimensional curved surface. A predetermined portion of the molded body (A) can be partially and efficiently reinforced via the sheet material (B).

Examples and comparative examples will be described below. First, the method for measuring the physical properties used in Examples and Comparative Examples will be described.

(1) Bending evaluation A strip-shaped test piece of 10 mm × 150 mm × 3.3 mm was cut out, and the strip was pressed and bent at a distance between spans of 64 mm and a bending speed of 2 mm / min. Measurement was performed at n = 3, and bending strength and flexural modulus were measured.

(2) Heat-resistant aging test A strip test piece for bending evaluation is put into a hot air oven (manufactured by Tabai) in an atmosphere of 80 ° C, taken out after 500 hours, held at 23 ° C and 50% RH for 24 hours, and bent. The strength and flexural modulus were measured.

(3) Evaluation of warm water resistance A strip test piece for bending evaluation is immersed in warm water at 50 ° C., taken out after 500 hours, and after removing water, held at 23 ° C. and 50% RH for 24 hours to obtain bending strength and bending. The elastic modulus was measured.

(4) Adhesion confirmation evaluation The adhesion of the ultrasonic welding test piece of the three-dimensional shape molded product was visually evaluated.

<Manufacturing method of each molded product>
(A) A method for producing a molded product (A) obtained by molding a thermoplastic resin composition:
The thermoplastic resin composition shown in Table 1 was molded to obtain a molded product having a size of 100 × 150 × 3 mmt.
Further, the thermoplastic resin composition shown in Table 1 was molded using a three-dimensional mold to obtain a three-dimensional molded product 1 shown in FIG.

(B) Method for producing a thermoplastic sheet material having a functional group:
The desired sheet material was obtained using the materials shown in Table 1.
(B-1) As the modified PP film (9710B, thickness 50 μm), the film was used as it was.
(B-2) Using "Dylark" (registered trademark) D332 (pellet-like material), pressurize and melt at a press temperature of 160 ° C. and a press pressure of 2.0 MPa for 3 minutes, and then cool to obtain a sheet having a thickness of 150 μm. Obtained.
(B-3) Using "Modiper" (registered trademark) A4300 (pellet-like material), pressurize and melt at a press temperature of 140 ° C. and a press pressure of 2.0 MPa for 3 minutes, and then cool to obtain a sheet having a thickness of 150 μm. Obtained.
(B-4) Using "Modiper" (registered trademark) A4400 (pellet-like material), pressurize and melt at a press temperature of 140 ° C. and a press pressure of 2.0 MPa for 3 minutes, and then cool to obtain a sheet having a thickness of 150 μm. Obtained.
(B-5) Using "Bond First" (registered trademark) 7M (pellet-like material), pressurize and melt at a press temperature of 120 ° C. and a press pressure of 2.0 MPa for 3 minutes, then cool and a sheet with a thickness of 150 μm. Got
(B-6) Using J106G (pellet-like material), pressure melting was performed at a press temperature of 200 ° C. and a press pressure of 2.0 MPa for 3 minutes, and then cooling was performed to obtain a sheet having a thickness of 150 μm.
(B-7) Using H1052 (pellet-like material), the sheet was pressurized and melted at a press temperature of 160 ° C. and a press pressure of 2.0 MPa for 3 minutes, and then cooled to obtain a sheet having a thickness of 150 μm.

(C) Manufacturing method of fiber reinforced resin molded product (C-1):
Toray Industries, Inc. carbon fiber "Treca" (registered trademark) T700S (12K) is aligned, put into an impregnated die filled with nylon 6 resin, and then drawn to form a continuous fiber with a width of 50 mm and a thickness of 0.28 mm. A fiber-reinforced resin molded product (C-1) having a content of 60% by weight was obtained.

<Manufacturing method of composite molded product>
(C) The fiber-reinforced resin molded product was cut to a length of 150 mm, and (B) a thermoplastic sheet having a functional group was also cut to the same size as 50 mm in width and 150 mm in length according to the size.
A molded product obtained by molding (A) a thermoplastic resin composition using an ultrasonic welding device (manufactured by Adwells), (B) a thermoplastic resin sheet having a functional group, and (C) a fiber-reinforced resin molded product. They were stacked in order and set on the stage. After adjusting the position of the ultrasonic horn, a composite molded body was obtained by ultrasonic welding.

<Examples 1 to 6>
The material combinations shown in Table 1 were laminated, and composite molded bodies 1 to 6 of Examples 1 to 6 were obtained by ultrasonic welding. As a result of the bending test, it was confirmed that both the bending strength and the elastic modulus were improved as compared with the simple substance of the molded product obtained by molding the (A) thermoplastic resin composition shown in Table 1. Even after the bending test, no peeling was observed between the laminates, confirming that the welded state was good. In addition, no significant decrease in bending strength or elastic modulus was observed in the bending evaluation after the evaluation of heat aging resistance and thermal water resistance.
Further, the three-dimensional molded products shown in FIG. 1 were laminated in the combinations shown in Table 1, and a composite molded product was produced by ultrasonic welding, and it was confirmed by visual confirmation that all of them had good adhesion.

<Comparative Examples 1 to 5>
The material combinations shown in Table 1 were laminated and ultrasonically welded, but (A) the molded body obtained by molding the thermoplastic resin composition and (C) the fiber-reinforced resin molded body were not welded, and a bending test was performed. Was not feasible, and heat aging resistance and thermal water resistance tests were also not feasible.
Further, ultrasonic welding was carried out using the three-dimensional molded product shown in FIG. 1 in the combination shown in Table 1, but the adhesion was not visually confirmed because the welding was not performed in the same manner as described above.

The method according to the present invention is particularly suitable when it is desired to easily and effectively reinforce a desired portion of an injection-molded molded product, and can be applied to reinforcing a molded product in all fields.

1 Three-dimensional molded product produced in the example

Claims (10)

At least selected from an epoxy group, a glycidyl group, and a carboxyl group on a molded body (A) formed by molding a thermoplastic resin composition consisting of at least one selected from a polyester resin, a polyolefin resin, and a styrene resin. A thermoplastic sheet material (B) having one functional group is laminated, and a fiber-reinforced resin molded body (C) made of a reinforcing fiber bundle and a polyamide resin is laminated on the thermoplastic sheet material (B), and then super A method for producing a composite molded body, which comprises joining the thermoplastic sheet material (B) and the fiber-reinforced resin molded body (C) to the molded body (A) by sonic welding. The method for producing a composite molded product according to claim 1, wherein the molded product (A) contains discontinuous reinforcing fibers as a filler. The composite molding according to claim 1 or 2 , wherein the center line average surface roughness Ra of the laminated surface of the thermoplastic sheet material (B) of the molded body (A) is in the range of 1 ≦ Ra ≦ 10 (μm). How to make a body. The method for producing a composite molded product according to any one of claims 1 to 3 , wherein the fiber-reinforced resin molded product (C) is made of a tape-shaped base material. The method for producing a composite molded body according to any one of claims 1 to 4 , wherein the molded body (A) is molded by injection molding. The method for producing a composite molded product according to any one of claims 1 to 5 , wherein the reinforcing fiber bundle in the fiber-reinforced resin molded product (C) is formed by arranging reinforcing fibers in one direction. The thermoplastic sheet material (B) is formed of at least one selected from a polyolefin resin having an epoxy group and / or a glycidyl group as a functional group, an acid-modified olefin-based copolymer, and a modified vinyl-based copolymer. The method for producing a composite molded product according to any one of claims 1 to 6. As a combination of the thermoplastic resin of the molded product (A) and the material of the thermoplastic sheet material (B), a polyolefin resin and an acid-modified olefin-based copolymer, a styrene-based resin and a modified vinyl-based copolymer, and a polyester-based material are used. The method for producing a composite molded product according to any one of claims 1 to 7 , wherein the resin is a modified vinyl-based copolymer or a polyolefin-based resin having an epoxy group and / or a glycidyl group. The method for producing a composite molded product according to any one of claims 1 to 8 , wherein the thickness of the thermoplastic sheet material (B) is in the range of 10 to 300 μm. Wherein at least a portion of the junction surface between the thermoplastic sheet material (B) and the fiber-reinforced resin molded article of the molded article (A) (C) is formed in a curved surface, to any one of claims 1-9 The method for producing a composite molded product according to the description.

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