INTEGRALLY MOLDED BODY AND METHOD OF PRODUCING SAME

Abstract

An integrally molded body includes a separate structure (C) joined to at least a part of an end section of a sandwich structure constituted of a core layer composed of discontinuous fibers and a thermoplastic resin (A) and a skin layer composed of continuous fibers and a resin (B), wherein: the sandwich structure has a stepped section at least at a part of the end section; the stepped section is constituted of a main body section forming a high surface in the stepped section, an interface section forming an interface connecting the high surface and a low surface of the stepped section, and a thinnest section having a core layer having a porosity lower than a porosity of a core layer in the main body section; and the separate structure (C) does not contact the interface, and is joined to only at least a part of the thinnest section.

Claims

1.-21. (canceled)

22. An integrally molded body in which at least a part of an end section of a sandwich structure constituted of a core layer composed of discontinuous fibers and a thermoplastic resin (A) and a skin layer composed of continuous fibers and a resin (B) is formed as a joining section, and a separate structure (C) is disposed to the joining section, wherein 1) the sandwich structure has a stepped section at least at a part of the end section; the stepped section is constituted of a main body section forming a high surface in the stepped section, an interface section forming an interface connecting the high surface and a low surface of the stepped section, and a thinnest section having a core layer having a porosity lower than a porosity of a core layer in the main body section, and 2) the separate structure (C) does not contact the interface, and is joined to only at least a part of the thinnest section.

23. The integrally molded body according to claim 22, wherein the interface of the interface section has an angle of 1 to 20 with respect to an in-plane direction of the main body section.

24. The integrally molded body according to claim 22, wherein a joining layer is provided at least in a part of a portion between the skin layer and the separate structure (C).

25. The integrally molded body according to claim 22, wherein a joining layer is provided at least in a part of a portion between the core layer and the separate structure (C).

26. The integrally molded body according to claim 22, wherein the porosity of the core layer in a region forming the main body section is 50% or more and 80% or less, and the porosity of the core layer in a region forming the thinnest section is 0% or more and less than 50%.

27. The integrally molded body according to claim 22, wherein the joining section is formed over the entire circumference of the sandwich structure.

28. The integrally molded body according to claim 22, wherein a length Lb of the joining section from an end surface of the sandwich structure is 3 to 30 mm.

29. The integrally molded body according to claim 22, wherein a thickness Db of the main body section is 0.4 to 2 mm and a thickness Tc of the joining section is 0.1 to 1.7 mm.

30. The integrally molded body according to claim 29, wherein Db/Tc is 1.1 to 20.

31. The integrally molded body according to claim 22, wherein a distance L from an edge of the main body section at a side of the interface section to the separate structure (C) joined to only at least a part of the thinnest section is 0.1 to 30 mm.

32. The integrally molded body according to claim 22, wherein the sandwich structure has another stepped section at a portion other than at a part of the end section and another separate structure (C) is arranged, and the other stepped section is constituted of main body sections forming high surfaces on both sides of the other stepped section, other interface sections forming other interfaces connecting the high surfaces on both sides of the other stepped section and a low surface positioned between the high surfaces on both sides, and another thinnest section having a core layer having a porosity lower than porosities of core layers in the main body sections on both sides, and the other separate structure (C) does not contact the other interfaces, and is joined to only at least a part of the other thinnest section.

33. The integrally molded body according to claim 22, wherein a thickness of the main body section and a thickness of a portion composed of only the separate structure (C) joined via the joining section are the same.

34. The integrally molded body according to claim 22, wherein the core layer is formed by expanding a core layer precursor composed of discontinuous fibers and the thermoplastic resin (A) in its thickness direction by spring back due to heating to form pores.

35. The integrally molded body according to claim 22, wherein a content of the discontinuous fibers forming the core layer is 5 to 75% by weight and a content of the thermoplastic resin (A) is 25 to 95% by weight.

36. The integrally molded body according to claim 22, wherein a number average fiber length of the discontinuous fibers forming the core layer is 0.5 to 50 mm.

37. The integrally molded body according to claim 22, wherein the discontinuous fibers forming the core layer are present at a state of fiber bundles each composed of 500 or less single fibers, and the fiber bundles are randomly oriented.

38. The integrally molded body according to claim 37, wherein the discontinuous fibers forming the core layer are dispersed at a monofilament-like state, and an average value of two-dimensional orientation angles formed by discontinuous single fibers (a) and other discontinuous single fibers (b) crossing the discontinuous single fibers (a) is 10 to 80 degrees.

39. A method of producing an integrally molded body in which at least a part of an end section of a sandwich structure constituted of a core layer composed of discontinuous fibers and a thermoplastic resin (A) and a skin layer composed of continuous fibers and a resin (B) is formed as a joining section, and a separate structure (C) is joined to the joining section, the method comprising: (1) a step of preparing a core layer precursor in which a layer of the thermoplastic resin (A) is disposed on at least one surface of a web composed of the discontinuous fibers; (2) a step of forming a molded body precursor by disposing a skin layer precursor impregnated with the resin (B) into the continuous fibers on each of both surfaces of the core layer precursor; (3) a step of heat-press molding the molded body precursor to solidify or cure the skin layer precursor to form a skin layer and integrate the core layer precursor and the skin layer; (4) a step of forming the sandwich structure wherein, when expanding the sandwich structure to a predetermined thickness by exhibiting a restoring force of the discontinuous fibers in the core layer precursor and forming pores in the core layer, by bringing a press mold into contact with the sandwich structure, a stepped section is formed at least at a part of an end section of the sandwich structure, and the stepped section is constituted to have a main body section forming a high surface in the stepped section, an interface section forming an interface connecting the high surface and a low surface of the stepped section, and a thinnest section having a core layer having a porosity lower than a porosity of a core layer in the main body section; and (5) a step of joining and integrating the sandwich structure and the separate structure (C) by disposing the formed sandwich structure in a mold, and injecting a molten resin of the separate structure (C) with respect to the joining section in the mold so that the molten resin does not contact the interface, but only contacts at least a part of the thinnest section, at a state in which the flow of the resin is stopped at a middle portion in the mold.

40. The method according to claim 39, wherein, in step (4) of forming the sandwich structure, after the core layer precursor containing the discontinuous fibers and the thermoplastic resin (A) is heated and pressurized to a temperature higher than a softening point or melting point of the thermoplastic resin (A), the pores are formed by releasing the pressurization and expanding the core layer precursor by spring back.

41. The method according to claim 39, wherein, in step (2) of forming the molded body precursor, a skin layer precursor disposed with a skin layer only to a region corresponding to a main body section in at least one surface of the core layer is formed, the skin layer precursor is solidified or cured by heat pressing to form a skin layer, and the main body section having the core layer having pores is formed by expanding to a predetermined thickness.

42. The method according to claim 39, wherein the sandwich structure and the separate structure (C) are joined and integrated with each other by disposing a thermoplastic resin film or nonwoven fabric or applying an adhesive on the skin layer or core layer forming the joining section and then injection molding the molten resin of the separate structure (C).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a schematic partial sectional view at the time of molding an integrally molded body, showing the problems left in JP-A-2016-049649.

[0015] FIG. 2 is a schematic perspective view of an integrally molded body according to an example.

[0016] FIG. 3 is a schematic sectional view in the thickness direction of the integrally molded body as viewed along line A-A of FIG. 2.

[0017] FIG. 4 is a schematic partial sectional view showing one step of a method of producing an integrally molded body according to an example in contrast with FIG. 1.

[0018] FIG. 5 is a schematic sectional view in the thickness direction of an integrally molded body.

[0019] FIG. 6 is a schematic sectional view in the thickness direction of an integrally molded body according to another example.

[0020] FIG. 7 is a schematic sectional view of when a joining layer is provided to a skin layer of an integrally molded body according to an example.

[0021] FIG. 8 is a schematic sectional view of when a stepped section and a joining layer are provided on each of the upper and lower surfaces of an integrally molded body according to an example.

[0022] FIGS. 9(a) and 9(b) are schematic diagrams showing a dispersion state of discontinuous fibers forming a core layer.

[0023] FIGS. 10(a) to 10(f) are schematic diagrams showing an example of a method of producing an integrally molded body according to an example.

[0024] FIG. 11 is a schematic sectional view in the thickness direction of an integrally molded body showing an example of when another stepped section and another separate structure (C) are provided at a portion other than an end section of a sandwich structure.

[0025] FIG. 12 is a schematic sectional view in the thickness direction of an integrally molded body showing another example of when another stepped section and another separate structure (C) are provided at a portion other than an end section of a sandwich structure.

EXPLANATION OF SYMBOLS

[0026] 1,41: sandwich structure [0027] 2: skin layer [0028] 3: core layer [0029] 3a: core layer with high porosity [0030] 3b: core layer with low porosity [0031] 4: fibers in core layer [0032] 5: pores [0033] 6: joining section [0034] 7: separate structure (C) [0035] 8: main body section [0036] 8a: high surface of stepped section [0037] 9, 42: interface section [0038] 9a: interface [0039] 10, 43: thinnest section [0040] 10a: low surface of stepped section (upper surface of thinnest section) [0041] 10b: side surface of thinnest section [0042] 11: stepped section [0043] 12: mold [0044] 13: damming structure section [0045] 14, 15, 16, 17, 18, 19: discontinuous single fibers [0046] 20: two-dimensional contact angle, two-dimensional orientation angle [0047] 21: joining layer [0048] 31: web composed of discontinuous fibers [0049] 32: thermoplastic resin (A) [0050] 33: core layer precursor [0051] 34: skin layer precursor [0052] 35: upper mold of press mold [0053] 36: lower mold of press mold [0054] 37: region with different gap in press mold [0055] 45, 51: another stepped section [0056] 46, 53: separate structure (C) [0057] 47: main body section [0058] 47a: high surface of another stepped section [0059] 48, 52: another interface section [0060] 48a, 52a: another interface [0061] 49: another thinnest section [0062] 49a: low surface of another stepped section (upper surface of another thinnest section) [0063] 50a: core layer with high porosity [0064] 50b: core layer with low porosity [0065] 100, 200, 201: integrally molded body

DETAILED DESCRIPTION

[0066] Hereinafter, examples will be explained in detail with reference to the drawings. This disclosure is not however limited by the drawings at all.

[0067] An integrally molded body is an integrally molded body in which at least a part of an end section of a sandwich structure constituted of a core layer composed of discontinuous fibers and a thermoplastic resin (A) and a skin layer composed of continuous fibers and a resin (B) is formed as a joining section, and a separate structure (C) is disposed to the joining section, wherein: the sandwich structure has a stepped section at least at a part of the end section; the stepped section is constituted of a main body section forming a high surface in the stepped section, an interface section forming an interface connecting the high surface and a low surface of the stepped section, and a thinnest section having a core layer having a porosity lower than a porosity of a core layer in the main body section; and the separate structure (C) does not contact with the interface, and is joined to only at least a part of the thinnest section.

[0068] FIG. 2 shows an integrally molded body according to an example, and FIG. 3 shows a schematic section in the thickness direction of the integrally molded body as viewed along the line A-A of FIG. 2. In a sandwich structure 1 composed of a core layer 3 and skin layers 2 in FIG. 2, the core layer 3 is composed of discontinuous fibers 4 and a thermoplastic resin (A) of a matrix resin, and pores 5 with a certain size are formed in the core layer 3. A joining section 6 is provided in at least a part of the end section of the sandwich structure 1, and to the joining section 6, a resin (C) forming a separate structure (C) 7 (for convenience, the matrix resin forming the core layer is also referred to as thermoplastic resin (A), the matrix resin forming the skin layer is also referred to as resin (B), and the matrix resin forming the separate structure (C) is also referred to as resin (C)) is injection molded and joined, whereby an integrally molded body 100 is formed. A stepped section 11 is provided on at least a part of the end section of the sandwich structure 1, and the stepped section 11 is constituted of a main body section 8 forming a high surface 8a in the stepped section 11, an interface section 9 forming an interface 9a connecting the high surface 8a and a low surface 10a of the stepped section 11 and a thinnest section 10 having a core layer 3b with a porosity lower than the porosity of the core layer 3a in the main body section 8. The separate structure (C) 7 does not contact the interface 9a, but is joined to at least a part of the thinnest section 10. In this integrally molded body 100, first, as compared to when a separate structure (C) is joined to the flat portion on the side surface of the sandwich structure, the joining area can be widened and an effect of enhancing the joining strength can be obtained.

[0069] In the integrally molded body 100 according to this example, as also shown in FIG. 3, the separate structure (C) 7 is joined to only at least a part of the thinnest section 10 having the core layer 3b having a lower porosity (including an example with no pores) than that of the core layer 3a in the main body section 8, and the lower surface side of FIG. 3 is formed as a design surface. The above-described joining section 6 may be provided over the entire circumference of the sandwich structure 1 or may be provided only in a necessary part in the circumferential direction of the sandwich structure 1. It may be decided according to the use of the integrally molded body 100.

[0070] Although the details of the production method will be described later, the structure in the integrally molded body 100 in which the separate structure (C) 7 does not contact the interface 9a and is joined to only at least a part of the thinnest section 10 is formed, for example, as shown in FIG. 4 which is shown in comparison with FIG. 1. The shaped sandwich structure 1 formed as shown in FIG. 3 is placed in a mold 12, and the resin (C) forming the separate structure (C) 7 is injected into the mold 12, whereas a damming structure section 13 that dams the resin R being injected to be joined with the side surface 10b and only a part of the upper surface 10a (a part on the end section side) of the thinnest section 10 and to not contact the interface 9a, is disposed in the inner surface side of the mold 12 at a state integrally with or separately from the mold 12. Thus, by such a manner that the resin R is injected to be joined to only a part of the thinnest section 10, such a problem as shown in FIG. 1, in which the heat of the injected resin R is transferred to the core layer in the interface section 9 or the main body section 8, the amount of shrinkage of the core layer at cooling becomes great in the region where relatively many pores are present in the core layer 3, and whereby on the design surface side of the integrally molded body to be molded, a defect originating from the deformation due to sink marks caused by the shrinkage of the core layer may occur, can be solved, and a desired design surface can be reliably obtained. Namely, while the separate structure (C) 7 is joined with a high joining strength, an integrally molded body 100 that can be thin and lightweight, and does not cause defects on the design surface side, can be obtained. In the thinnest section 10, the porosity of the core layer is lowered to increase the strength and the thinnest section 10 is thinned so that it is also possible to make the thickness of the separate structure (C) 7 equal to the thickness of the main body section 8, that is, a structure can be achieved wherein the thickness of main body section 8 and the thickness of the portion composed of only the separate structure (C) 7 joined via the joining section 6 are set to have the same thickness, and it becomes possible to make the thickness of the integrally molded body 100 uniform over the whole thereof. Alternatively, it also becomes possible to have a thickness and shape within a predetermined range for the entire integrally molded body 100 including the separate structure (C) 7. As a result, the entire integrally molded body 100 can be made thin and light.

[0071] It is preferred that the porosity of the core layer 3 in the region forming the main body section 8 in the integrally molded body 100 as described above is 50% or more and 80% or less, and the porosity of the core layer 3 in the region forming the thinnest section 10 is 0% or more and less than 50%. By providing a certain amount of pores in the core layer and changing the porosity, it is possible to form a desired thickness. The porosity of the core layer 3 in the region forming the main body section 8 is preferably 52 to 78%, more preferably 58 to 75%, further preferably 60 to 70%. If the porosity is less than 50%, a certain height in the main body section 8 cannot be secured, and the effect of enhancing the joining strength between the sandwich structure 1 and the separate structure (C) 7 may be weakened. If the porosity is larger than 80%, the strength of the sandwich structure 1 may be insufficient. Further, the porosity of the core layer 3 in the region forming the thinnest section 10 is preferably 0 to 45%, more preferably 0 to 40%, further preferably 0 to 35%. If the porosity is 50% or more, it is impossible to secure a certain difference in height compared to the main body section 8, and the effect of enhancing the joining strength between the sandwich structure 1 and the separate structure (C) may be weakened.

[0072] It is preferred that a parameter related to each shape in the integrally molded body 100 as described above is set as follows. Each shape parameter is shown in FIG. 5 and, first, it is preferred that the interface 9a of the interface section 9 has an angle of 1 to 20 with respect to the in-plane direction of the main body section 8. When the angle is 90, the interface 9a of the interface section 9 stands up vertically from the thinnest section 10. The angle () is more preferably 2 to 10, and further preferably 3 to 8.

[0073] Further, it is preferred that the length Lb of the joining section 6 from the end surface of the sandwich structure 1 is 3 to 30 mm. By making the length Lb within a specified range, it becomes possible to increase the strength and thinning of the sandwich structure 1 and enhance the joining strength with the separate structure (C) 7. If Lb is less than 3 mm, the joining strength with the separate structure (C) 7 may be weakened. If it exceeds 30 mm, the region occupied by the main body section 8 of the sandwich structure 1 may be reduced too much, and the rigidity of the sandwich structure 1 itself may decrease.

[0074] Further, it is preferred that the thickness Db of the main body section 8 of the sandwich structure 1 is 0.4 to 2 mm and the thickness Tc of the joining section 6 is 0.1 to 1.7 mm. Furthermore, in the relationship between Db and Tc, it is preferred that Db/Tc is 1.1 to 20. If Db is less than 0.4 mm or Db/Tc is less than 1.1, the joining strength between the sandwich structure 1 and the separate structure (C) 7 may be weakened. When Db exceeds 2 mm or Db/Tc exceeds 20, thinning of the sandwich structure 1 may be obstructed.

[0075] Furthermore, it is preferred that the distance L from the edge of interface section 9 side of the main body section 8 to the separate structure (C) 7 joined to only at least a part of the thinnest section 10 is 0.1 to 30 mm. If the distance L is less than 0.1 mm, it is difficult to secure a non-contact state with the interface section 9 of the separate structure (C) 7, and if the distance L exceeds 30 mm, the space portion to be formed between the separate structure (C) 7 and the main body section 8 becomes too long, and there is a possibility that an inconvenience may occur on the application of the integrally molded body 100.

[0076] In the integrally molded body, for example, as shown in FIG. 6, the angle of the interface 9a of the interface section 9 with respect to the in-plane direction of the main body section 8 can also be set at 900, and in such an example, although a region forming the interface section 9 does not substantially appear, the non-contact state with respect to the interface section 9 of the separate structure (C) 7 is secured as shown. Parameters relating to each shape other than the angle in this example are shown in FIG. 6 using the same symbols as those used in FIG. 5.

[0077] Further, for example, as shown in FIG. 7, a joining layer 21 can be provided at least at a part of a portion between the skin layer 2 and the separate structure (C) 7 or/and between the core layer 3 and the separate structure (C) 7. FIG. 7 shows an example where the joining layer is provided on the skin layer 2, and exemplifies when the above-described angle of the interface 9a of the interface section 9 with respect to the in-plane direction of the main body section 8 is set at 90. It is a configuration wherein the joining layer 21 is provided in advance on the skin layer 2 forming the joining section 6 and, thereafter, the separate structure (C) 7 is formed. Further, as shown in FIG. 8, stepped sections and joining layers 21 can also be provided on skin layers 2 on the upper and lower surfaces. By these configurations, the joining strength between the skin layer 2 and the separate structure (C) 7 can be enhanced.

[0078] As the joining layer 21, an adhesive such as an acrylic type, an epoxy type, a styrene type, a nylon type, an ester type, a thermoplastic resin film, a nonwoven fabric or the like can be used. To further improve adhesiveness, it is preferred to provide a thermoplastic resin layer as a joining layer to the outermost layer of the skin layer 2 or the core layer 3. If the joining layer 21 provided to the outermost layer of the skin layer 2 or the core layer 3 is made of the same material as that of the separate structure (C) 7, it is also possible to enhance the joining strength. The resin provided to the outermost layer of the skin layer 2 or the core layer 3 is not limited to the same resin as the adhesive used in the joining layer, and is not particularly limited as long as it has a good compatibility, and it is preferred to select a better one depending upon the type of the resin forming the separate structure (C) 7.

[0079] The continuous fibers used for the skin layer 2 means continuous reinforcing fibers extending over at least 150 mm in length, preferably 200 mm or more in at least one direction. Namely, the discontinuous fibers means fibers having a length of less than 150 mm.

[0080] The discontinuous fibers used for the core layer 3 are not particularly limited and, for example, exemplified are metal fibers such as aluminum, brass and stainless steel, carbon fibers of polyacrylonitrile (PAN) type, rayon type, lignin type and pitch type, graphite fibers, insulating fibers such as glass fibers, organic fibers such as aramid resin, polyphenylene sulfide resin, polyester resin, acrylic resin, nylon resin and polyethylene resin, and inorganic fibers such as silicon carbide and silicon nitride. Further, these fibers may be subjected to a surface treatment. As the surface treatment, in addition to adhesion treatment of a metal as a conductor, treatment with a coupling agent, treatment with a sizing agent, treatment with a binding agent, adhesion treatment of additives and the like are available. In addition, one type of reinforcing fibers may be used alone, or two or more types may be used in combination. Among them, from the viewpoint of weight reduction effect, carbon fibers of PAN type, pitch type, rayon type and the like excellent in specific strength and specific rigidity are preferably used. Further, from the viewpoint of enhancing the economic efficiency of an obtained molded article, glass fibers are preferably used and, in particular, it is preferred to use carbon fibers and glass fibers in combination from the viewpoint of balance between mechanical properties and economic efficiency. Further, from the viewpoint of enhancing the impact absorption and forming property of an obtained molded article, aramid fibers are preferably used and, in particular, it is preferred to use carbon fibers and aramid fibers in combination from the viewpoint of the balance between mechanical properties and impact absorption properties. Further, from the viewpoint of enhancing the conductivity of an obtained molded article, it is also possible to use reinforcing fibers coated with a metal such as nickel, copper, ytterbium or the like. Among these, PAN-based carbon fibers excellent in mechanical properties such as strength and elastic modulus can be used more preferably.

[0081] Further, the type of thermoplastic resin (A) used for the core layer 3 is not particularly limited, and any resin of thermoplastic resins exemplified below can be used. For example, exemplified are polyester resins such as polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, polyethylene naphthalate (PEN) resin and liquid crystal polyester resin, polyolefin resins such as polyethylene (PE) resin, polypropylene (PP) resin and polybutylene resin, polyoxymethylene (POM) resins, polyamide (PA) resins, polyarylene sulfide resins such as polyphenylene sulfide (PPS) resin, polyketone (PK) resins, polyether ketone (PEK) resins, polyether ether ketone (PEEK) resins, polyetherketoneketone (PEKK) resins, polyether nitrile (PEN) resins, fluorine-based resins such as polytetrafluoroethylene resins, crystalline resins such as liquid crystal polymers (LCP), styrene-based resins, in addition, polycarbonate (PC) resins, polymethyl methacrylate (PMMA) resins, polyvinyl chloride (PVC) resins, polyphenylene ether (PPE) resins, polyimide (PI) resins, polyamideimide (PAI) resins, polyetherimide (PEI) resins, polysulfone (PSU) resins, polyethersulfone resins, amorphous resins such as polyarylate (PAR) resins, and in addition, phenolic-based resins, phenoxy-based resins, and further, thermoplastic elastomers of polystyrene-based resins, polyolefin-based resins, polyurethane-based resins, polyester-based resins, polyamide-based resin, polybutadiene-based resins, polyisoprene-based resins, fluorine-based resins, acrylonitrile-based resin and the like, and thermoplastic resins selected from copolymers and modified products thereof. Among them, a polyolefin resin is preferable from the viewpoint of light weight of an obtained molded article, and from the viewpoint of strength, a polyamide resin is preferable, and from the viewpoint of surface appearance, a polycarbonate resin, a styrene-based resin, and an amorphous resin such as a modified polyphenylene ether-based resin, and from the viewpoint of heat resistance, a polyarylene sulfide resin is preferable, and from the viewpoint of continuously used temperature, a polyether ether ketone resin is preferably used.

[0082] The exemplified thermoplastic resin may contain an impact resistance improver such as an elastomer or a rubber component, other fillers and additives as long as the desired result is not impaired. As examples of these, exemplified are inorganic fillers, flame retardants, conductivity imparting agents, crystal nucleating agents, ultraviolet absorbers, antioxidants, vibration damping agents, antibacterial agents, insect repellents, deodorants, coloring inhibitors, thermal stabilizers, release agents, antistatic agents, plasticizers, lubricants, colorants, pigments, dyes, foaming agents, foam inhibitors, or coupling agents.

[0083] As the continuous fibers used for the skin layer 2, for example, reinforcing fibers of the same type as the aforementioned discontinuous fibers used in the core layer 3 can be used.

[0084] Further, from the viewpoint of the rigidity of the sandwich structure, the continuous fibers preferably having a tensile modulus of 360 to 1000 GPa, more preferably 500 to 800 GPa can be used. When the tensile modulus of the reinforcing fibers is less than 360 GPa, the rigidity of the sandwich structure may be poor, and when it is more than 1000 GPa, it is necessary to increase the crystallinity of reinforcing fibers and it becomes difficult to produce reinforcing fibers. When the tensile modulus of the reinforcing fibers is within the above-described range, it is preferable from the viewpoint of further improving the rigidity of the sandwich structure and improving the productivity of the reinforcing fibers. The tensile modulus of the reinforcing fibers can be determined by the strand tensile test described in JIS R 7601-1986.

[0085] The resin (B) used for the skin layer 2 is not particularly restricted, and a thermoplastic resin or a thermosetting resin can be used. In thermoplastic resin, for example, a same kind of resin as the aforementioned thermoplastic resin (A) used in the core layer 3 can be used. Further, as examples of thermosetting resin, thermosetting resins such as unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol (resol type) resin, urea-melamine resin, polyimide resin, maleimide resin, benzoxazine resin and the like can be preferably used. A resin prepared by blending two or more of these may be applied. Among them, an epoxy resin is particularly preferable from the viewpoint of the mechanical properties and heat resistance of a molded body. To exhibit its excellent mechanical properties, the epoxy resin is preferably contained as a main component of the resin to be used, specifically, it is preferably contained in an amount of 60% by weight or more per resin composition.

[0086] The resin used for the separate structure (C) is not particularly restricted, and the aforementioned thermoplastic resins or thermosetting resins can be used. In particular, from the viewpoints of heat resistance and chemical resistance, a PPS resin is more preferably used, from the viewpoints of molded article appearance and dimensional stability, a polycarbonate resin or a styrene-based resin is more preferably used, and from the viewpoint of strength and impact resistance of a molded article, polyamide resin is more preferably used.

[0087] Further, it is also preferred to contain reinforcing fibers as the resin (C) used for the separate structure (C) to make the integrally molded body high-strength and high-rigidity. As the reinforcing fibers, for example, can be used metal fibers such as aluminum fibers, brass fibers and stainless steel fibers, inorganic fibers such as carbon fibers such as polyacrylonitrile type, rayon type, lignin type, pitch type and the like, graphite fibers, glass fibers, silicon carbide fibers, silicon nitride fibers, and organic fibers such as aramid fibers, polyparaphenylene benzobisoxazole (PBO) fibers, polyphenylene sulfide fibers, polyester fibers, acrylic fibers, nylon fibers and polyethylene fibers. These reinforcing fibers may be used solely or in combination of two or more kinds. Among these, from the viewpoint of balancing the specific strength, the specific rigidity and the light weight, carbon fibers are preferable, and from the viewpoint of excellent specific strength and specific elastic modulus, it is preferred to include at least polyacrylonitrile-based carbon fibers.

[0088] Furthermore, the resin (C) forming the separate structure (C) may contain other fillers and additives within ranges not damaging the desired result depending upon required properties. For example, exemplified are inorganic fillers, flame retardants other than phosphorus type, conductivity imparting agents, crystal nucleating agents, ultraviolet absorbers, antioxidants, vibration damping agents, antibacterial agents, insect repellents, deodorants, coloring inhibitors, thermal stabilizers, release agents, antistatic agents, plasticizers, lubricants, colorants, pigments, dyes, foaming agents, foam inhibitors, coupling agents and the like.

[0089] Further, it is preferred that the sandwich structure 1 has a rectangular parallelepiped shape having a side surface area smaller than a bottom area. For example, in a so-called thin-walled rectangular parallelepiped shape having a side surface area smaller than a bottom area as in a casing of a personal computer, the area of the side surface portion is narrow and a strong joining strength is required to join a separate structure to that portion. Even in such a form, by employing the joining structure or the joining method described later, it is possible to join the separate structure with a high strength even with a joining section having a small area.

[0090] Further, it is preferred that the core layer 3 is formed by expanding a core layer precursor composed of discontinuous fibers and the thermoplastic resin (A) in its thickness direction by spring back due to heating to form pores. After heating and pressurizing the molded body containing the discontinuous fibers and the thermoplastic resin (A) forming the core layer 3 to a temperature higher than the softening point or melting point of the resin, the pressure is released, and by expanding by the restoring force to be returned to the original form when the residual stress of the discontinuous fibers is released, so-called spring back, desired pores can be formed in the core layer 3. In the restoration stage, if the restoring action is suppressed by a certain pressurizing means or the like at a part of the region, the porosity can be suppressed.

[0091] Further, it is preferred that the content of the discontinuous fibers forming the core layer 3 is 5 to 75% by mass and the content of the thermoplastic resin (A) is 25 to 95% by mass.

[0092] In the formation of the core layer 3, the compounding ratio of the discontinuous fibers and the thermoplastic resin (A) is one factor specifying porosity. Although there are no particular restrictions on how to determine the compounding ratio of the discontinuous fibers and the thermoplastic resin (A), for example, it is possible to determine it by removing the resin component contained in the core layer 3 and measuring the weight of only discontinuous fibers remaining. As a method of removing the resin component contained in the core layer 3, a dissolving method, a burning-off method or the like can be exemplified. For weight measurement, it can be measured using an electronic weighing device or an electronic balance. It is possible to set the size of the molding material to be measured at 100 mm100 mm square and the measurement times at n=3, and to use the average value thereof. The compounding ratio of the core layer 3 is preferably 7 to 70% by mass of discontinuous fibers and 30 to 93% by mass of thermoplastic resin (A), more preferably 20 to 50% by mass of discontinuous fibers and 50 to 80% by mass of thermoplastic resin (A), and further preferably 25 to 40% by mass of discontinuous fibers and 60 to 75% by mass of thermoplastic resin (A). If the discontinuous fibers are less than 5% by mass and the thermoplastic resin (A) is more than 95% by mass, because spring back is unlikely to occur, the porosity cannot be increased, and it may become difficult to provide regions having different porosities in the core layer 3 and, as a result, the joining strength with the separate structure (C) 7 also decreases. On the other hand, if the discontinuous fibers are more than 75% by mass and the thermoplastic resin (A) is less than 25% by mass, the specific rigidity of the sandwich structure 1 decreases.

[0093] Further, it is preferred that the number average fiber length of the discontinuous fibers forming the core layer is 0.5 to 50 mm.

[0094] By setting the number average fiber length of the discontinuous fibers at a specific length, generation of pores by the spring back of the core layer can be ensured. The number average fiber length is preferably 0.8 to 40 mm, more preferably 1.5 to 20 mm, further preferably 3 to 10 mm. If the number average fiber length is shorter than 0.5 mm, it may be difficult to form pores having a certain size or more. On the other hand, if the number average fiber length is longer than 50 mm, because it becomes difficult that the fiber bundles are randomly dispersed and the core layer 3 can produce a sufficient spring back, the size of the pores becomes limited and the joining strength with the separate structure (C) 7 decreases.

[0095] As a method of measuring the fiber length of discontinuous fibers, for example, there is a method of directly extracting discontinuous fibers from a group of discontinuous fibers and measuring them by microscopic observation. When a resin is adhered to the group of discontinuous fibers, there is a method of dissolving the resin from the group of discontinuous fibers using a solvent that dissolves only the resin contained therein, filtering out remaining discontinuous fibers and measuring them by microscopic observation (dissolution method), and when there is no solvent dissolving the resin, there is a method of burning off only the resin in a temperature range where discontinuous fibers are not oxidized and reduced, classifying discontinuous fibers and measuring them by microscopic observation (burning-off method), or the like. It is possible to randomly select 400 discontinuous fibers from the group of discontinuous fibers, measure the lengths thereof up to a level of 1 Lm unit with an optical microscope and determine the fiber length and its ratio. When comparing the method of directly extracting discontinuous fibers from the group of discontinuous fibers with the method of extracting discontinuous fibers by the burning-off method or the dissolution method, by selecting the conditions appropriately, a special difference does not occur in the obtained result therebetween. Among these measurement methods, it is preferred to employ the dissolution method from the viewpoint that the weight change of discontinuous fibers is small.

[0096] Further, it is preferred that the discontinuous fibers forming the core layer are present at a state of fiber bundles each composed of 500 or less single fibers, and the fiber bundles are randomly oriented.

[0097] Further, it is preferred that the discontinuous fibers forming the core layer are dispersed at a monofilament-like state, and an average value of two-dimensional orientation angles formed by discontinuous single fibers (a) and other discontinuous single fibers (b) crossing the discontinuous single fibers (a) is 10 to 80 degrees.

[0098] By the condition where the discontinuous fibers are present in the form of fiber bundles of 500 single fibers or less and the fiber bundles are randomly oriented, because the discontinuous fibers forming the core layer can exist in an intersecting manner, a large spring back can be obtained, and pores of a certain size or more can be formed. Being dispersed at a monofilament-like state means that with respect to discontinuous fibers arbitrarily selected in the core layer of the sandwich structure, the proportion of single fibers having a two-dimensional contact angle of 1 degree or more (hereinafter, also referred to as fiber dispersion rate) is 80% or more and, in other words, it means that in the constituent elements, bundles each in which two or more single fibers are contact with each other and parallel are less than 20%. Therefore, here, only those whose weight fraction of fiber bundles with 100 filaments or less in the core layer composed of at least discontinuous fibers corresponds to 100% are targeted.

[0099] The two-dimensional contact angle is an angle formed by discontinuous single fibers and other discontinuous single fibers contacting the discontinuous single fibers, and among angles formed by the discontinuous single fibers contacting each other, it is defined as an angle of acute angle side of 0 degrees or more and 90 degrees or less. The two-dimensional contact angle will be further explained using the drawings. FIGS. 9(a) and 9(b) show an example with schematic views when discontinuous fibers in the core layer of a sandwich structure are observed from the plane direction (a) and the thickness direction (b). When a discontinuous single fiber 14 is referred to as a reference, the discontinuous single fiber 14 is observed intersecting discontinuous single fibers 15 to 19 in FIG. 9(a), whereas the discontinuous single fiber 14 does not contact with discontinuous single fibers 18 and 19 in FIG. 9(b). In this example, with respect to the discontinuous single fiber 14 as a reference, the evaluation targets of the two-dimensional contact angle are discontinuous single fibers 15 to 17, and the two-dimensional contact angle is an angle 20 of an acute angle side of 0 or more and 90 or less among two angles formed by two discontinuous single fibers contacted with each other.

[0100] Although there is no particular restriction on the method of measuring the two-dimensional contact angle, for example, a method of observing the orientation of discontinuous fibers from the surface of the core layer 3 of the sandwich structure 1 can be exemplified. In this example, polishing the surface of the sandwich structure 1 to expose the discontinuous fibers of the core layer 3 makes it easier to observe the discontinuous fibers. Further, a method of photographing an orientation image of the discontinuous fibers through X-ray CT transmission observation can also be exemplified. In discontinuous fibers with high X-ray transmissibility, it is preferable to mix fibers for tracer fibers with discontinuous fibers, or to apply a chemical for tracer to discontinuous fibers, because it becomes easy to observe the discontinuous fibers. Further, when it is difficult to measure by the above-described methods, a method can be exemplified wherein, after separating the core layer 3 from the sandwich structure 1, the core layer 3 is placed under a high temperature by a heating furnace or the like to burn out the thermoplastic resin component and, then, from a mat composed of discontinuous fibers taken out, the orientation of discontinuous fibers is observed using an optical microscope or an electron microscope. Based on the above-described observation method, the fiber dispersion rate is measured by the following procedure. With respect to a randomly selected discontinuous single fiber (discontinuous single fiber 14 in FIGS. 9(a) and 9(b)), the two-dimensional contact angles thereof formed by all discontinuous single fibers (discontinuous single fibers 15 to 17 in FIGS. 9(a) and 9(b)) in contact therewith are measured. This is carried out for 100 discontinuous single fibers, and the rate is calculated from the ratio of the total number of all discontinuous single fibers for which the two-dimensional contact angles have been measured, and the number of discontinuous single fibers having a two-dimensional contact angle of 1 degree or more.

[0101] Further, it is particularly preferred that the discontinuous fibers forming the core layer 3 are randomly dispersed. That discontinuous fibers are randomly dispersed means that the average value of the two-dimensional orientation angles of arbitrarily selected reinforcing fibers in the sandwich structure 1 is 30 to 60 degrees. Such a two-dimensional orientation angle is an angle formed by a discontinuous single fiber and another discontinuous single fiber intersecting the discontinuous single fiber, and is defined as an angle on the acute angle side of 0 degree or more and 90 degrees or less among the angles formed the discontinuous single fibers intersected with each other. This two-dimensional orientation angle will be further explained using the drawings. In FIGS. 9(a) and 9(b), when the discontinuous single fiber 14 is referred to as a reference, the discontinuous single fiber 14 intersects with other discontinuous single fibers 15 to 19. The intersection means a state in which discontinuous single fiber as a reference is observed crossing other discontinuous single fibers in a two-dimensional plane to be observed, and the discontinuous single fiber 14 is not necessarily required to be contacted with the discontinuous single fibers 15 to 19, and a state observed to be intersected at a projected condition also is not an exception. Namely, when observing the reference discontinuous single fiber 14 which is a reference, all of the discontinuous single fibers 15 to 19 are objects to be evaluated for the two-dimensional orientation angle, and in FIG. 9(a), the two-dimensional orientation angle is the angle 20 which is an angle of acute angle side of 0 degrees or more and 90 degrees or less, among the two angles formed by two discontinuous single fibers intersecting with each other.

[0102] Although there is no particular restriction on the method of measuring the two-dimensional orientation angle, for example, a method of observing the orientation of discontinuous fibers from the surface of the constituent element can be exemplified, and the same means as the above-described method of measuring the two-dimensional contact angle can be employed. The average value of the two-dimensional orientation angles is determined by the following procedure. The average value of the two-dimensional orientation angles of all discontinuous single fibers intersecting with a discontinuous single fiber (discontinuous single fibers 15 to 19 in FIGS. 9(a) and 9(b)) with the randomly selected discontinuous single fiber (discontinuous single fiber 14 in FIGS. 9(a) and 9(b)) is determined. For example, when there are many other discontinuous single fibers intersecting with a certain discontinuous single fiber, it may be employed to randomly select 20 of the other intersecting discontinuous single fibers and to substitute an average value of the measured values thereof. The measurement is repeated five times in total with the other discontinuous single fibers, and the average value thereof is calculated as the average value of the two-dimensional orientation angles.

[0103] By a condition where the discontinuous fibers are dispersed at a monofilament-like state and randomly, pores can be more uniformly present in the core layer 3 than the above-described condition where the discontinuous fibers are dispersed in a form of fiber bundles each formed with 500 or less single fibers. For example, even if pores are formed with a certain size, if the pores are present unevenly, there is a possibility that the sandwich structure 1 locally becomes weak in a region where there are many pores. Therefore, making pores exist uniformly and continuously in the core layer 3 is preferable from the viewpoint of making the sandwich structure 1 high strength.

[0104] From such a viewpoint, the fiber dispersion rate of the core layer 3 composed of discontinuous fibers is preferably 90% or more, more preferably closer to 100%. Further, the average value of the two-dimensional orientation angles of discontinuous fibers is preferably 40 to 50 degrees, and it is preferable that it approaches closer to 45 degrees which is an ideal angle.

[0105] A mat of discontinuous fibers suitably used for the core layer 3 having pores or a molded body in which a thermoplastic resin (A) is impregnated into discontinuous fibers can be produced, for example, by in advance dispersing discontinuous fibers in the form of fiber bundles each formed by not more than 500 single fibers and/or at a monofilament-like state. As a method of producing a discontinuous fiber mat, concretely, can be used a dry process such as an air laid method of forming discontinuous fibers into a dispersion sheet by air flow or a carding method of mechanically combing discontinuous fibers to form a sheet, and a wet process due to RadRite Corporation method in which discontinuous fibers are stirred in water to make a paper. As a means of bringing discontinuous fibers closer to a monofilament-like state, with respect to the dry process, can be exemplified a method of providing an opening bar, a method of further oscillating the opening bar, a method of making the eyes of the card fine (ultrafine state), a method of adjusting the viscosity of the card, or the like, and with respect to the wet process, can be exemplified a method of adjusting stirring conditions of discontinuous fibers, a method of diluting the reinforcing fiber concentration of the dispersion, a method of adjusting the viscosity of the dispersion, a method of suppressing eddy currents at the time of transfer of the dispersion, or the like. In particular, the discontinuous fiber mat is preferably produced by the wet method, and by increasing the concentration of the input fibers, or adjusting the flow velocity (flow rate) of the dispersion and the speed of a mesh conveyor, the rate of the reinforcing fibers in the discontinuous fiber mat can be easily adjusted. For example, by slowing the speed of the mesh conveyor as compared to the flow velocity of the dispersion, it is difficult for the orientation of the fibers in the obtained mat composed of discontinuous fibers to be oriented in the take-off direction, and it is possible to produce a mat composed of bulky discontinuous fibers. The mat composed of discontinuous fibers may be constituted of discontinuous fibers alone, and the discontinuous fibers may be mixed with matrix resin components in powder form or fiber form, the discontinuous fibers may be mixed with organic compounds or inorganic compounds, or the discontinuous reinforcing fibers may be bound to each other with an interspersed resin component.

[0106] Next, a method of producing an integrally molded body will be explained with reference to the drawings.

[0107] We provide a method of producing an integrally molded body in which at least a part of an end section of a sandwich structure constituted of a core layer composed of discontinuous fibers and a thermoplastic resin (A) and a skin layer composed of continuous fibers and a resin (B) is formed as a joining section, and a separate structure (C) is joined to the joining section, the method comprising at least the following steps [1] to [5]:

[1] a step of preparing a core layer precursor in which a layer of the thermoplastic resin (A) is disposed on at least one surface of a web composed of the discontinuous fibers;
[2] a step of forming a molded body precursor by disposing a skin layer precursor impregnated with the resin (B) into the continuous fibers on each of both surfaces of the core layer precursor;
[3] a step of heat-press molding the molded body precursor to solidify or cure the skin layer precursor to form a skin layer and to integrate the core layer precursor and the skin layer;
[4] a step of forming the sandwich structure wherein, when expanding the sandwich structure to a predetermined thickness by exhibiting a restoring force of the discontinuous fibers in the core layer precursor and forming pores in the core layer, by bringing a press mold into contact with the sandwich structure, a stepped section is formed at least at a part of an end section of the sandwich structure, and the stepped section is constituted to have a main body section forming a high surface in the stepped section, an interface section forming an interface connecting the high surface and a low surface of the stepped section, and a thinnest section having a core layer which has a porosity lower than a porosity of a core layer in the main body section; and
[5] a step of joining and integrating the sandwich structure and the separate structure (C) by disposing the formed sandwich structure in a mold, and by injecting a molten resin of the separate structure (C) with respect to the joining section in the mold so that the molten resin does not contact with the interface but contacts with only at least a part of the thinnest section, at a state in which the flow of the resin is stopped at a middle portion in the mold.

[0108] An example of one step of the production method will be explained using FIGS. 10(a) to 10(f).

[0109] FIG. 10(a) shows the step 1 of preparing a core layer precursor 33 in which a thermoplastic resin (A) layer 32 is disposed on each of both surfaces of a web 31 composed of discontinuous fibers. The thermoplastic resin (A) layer 32 is preferably a film or a nonwoven fabric from the viewpoint of workability of laminating with another base material.

[0110] FIG. 10(b) shows the step 2 of forming a molded body precursor by disposing a skin layer precursor 34 impregnated with resin (B) on each of both surfaces of the core layer precursor 33. The skin layer precursor 34 is preferably, for example, a prepreg prepared by impregnating a resin (B) comprising a thermosetting resin or a thermoplastic resin into continuous fibers.

[0111] FIG. 10(c) shows the step 3 of integrating the core layer precursor 33 and the skin layer precursor 34 by heat press molding using the upper mold 35 and the lower mold 36 to mold a sandwich structure. In this step 3, when the resin (B) used for the skin layer precursor 34 is a thermosetting resin, it is cured or solidified by heating, but in a thermoplastic resin, after it is softened by heating, cooling is required until the thermoplastic resin is solidified.

[0112] The pressure when impregnating the thermoplastic resin (A) layer 32 having the form of a film or a nonwoven fabric into the web 31 composed of discontinuous fibers is preferably 0.5 to 30 MPa, more preferably 1 to 5 MPa. If the pressure is lower than 0.5 MPa, the thermoplastic resin (A) layer 32 may not be impregnated into the discontinuous fiber web 31 and, if higher than 30 MPa, the discontinuous fibers of the core layer precursor 33 may flow by the thermoplastic resin (A) layer 32 and the discontinuous fiber web 31 may break. In a thermoplastic resin, the temperature at the time of impregnating the film or the nonwoven fabric of the thermoplastic resin (A) layer 32 is preferably a temperature equal to or higher than the melting point or the softening point of the thermoplastic resin, more preferably equal to or higher than the melting point or the softening point+10 C., and further preferably equal to or higher than the melting point or the softening point+20 C. If the temperature at the time of impregnating the film or the nonwoven fabric of the thermoplastic resin (A) layer 32 is too high compared to the melting point or the softening point of the thermoplastic resin, because decomposition or degradation of the thermoplastic resin may occur, it is preferably equal to or lower than the melting point or the softening point of the thermoplastic resin+150 C.

[0113] Next, the process of preparing the skin layer 34 will be explained. For example, when the resin (B) is a thermosetting resin, a prepreg impregnated with the rein into continuous fibers is prepared as skin layer precursor. By forming a laminate in which the skin layer precursor 34 is disposed on at least one surface of the core layer precursor 33 obtained in the step 1, and heating this laminate by heating press molding and applying a pressure of 0.5 to 30 MPa, the resin (B) of the skin layer precursor is cured and a skin layer can be manufactured. Further, when the resin (B) is a thermoplastic resin, a prepreg impregnated with the rein into continuous fibers can be prepared as the skin layer precursor 34, and by heating by heating press molding and applying a pressure of 0.5 to 30 MPa, the thermoplastic resin is softened, thereafter, by conveying it to a press molding machine for cooling and pressing it up to a temperature at which the thermoplastic resin is solidified, a skin layer can be made. At this time, by simultaneously heat press molding the core layer precursor and the skin layer precursor, the discontinuous fiber web of the core layer precursor enters into the skin layer, and by anchoring effect due to the discontinuous fiber web, an integrally molded body of the core layer precursor and the skin layer precursor can be obtained. The core layer or the core layer precursor and the skin layer are firmly adhered to each other, and such a state is preferable from the viewpoint of exhibiting the flexural properties of the sandwich structure as much as possible.

[0114] In the above-described step 3, as a facility for producing the core layer precursor and the skin layer, a press molding machine or a double belt press can be suitably used. In a batch system, it is preferable to apply the former, and when a thermoplastic resin is used, productivity can be improved by employing an intermittent press system in which two or more machines for heating and for cooling are arranged in parallel. In a continuous system, it is preferable to apply the latter, and because continuous processing can be easily performed, continuous productivity is excellent.

[0115] FIG. 10(d) shows a state where in exhibiting the restoring force of the discontinuous fibers in the core layer precursor to expand it up to a predetermined thickness, a press die provided with a shape, of at least a part of the joining section of the board end section and the main body other than the joining section of the sandwich structure, is brought into contact. Concretely, it is a step of changing the upper die 35 to a die having a cavity (region) 37 corresponding to the main body section of the sandwich structure and press molding again to form a core layer. When the core layer precursor 33 is heated by press molding, the binding force of the thermoplastic resin (A) with the discontinuous fibers is weakened by heating due to the press molding and, thereafter, the residual stress of the reinforcing fibers is released by releasing the pressurization, the discontinuous fiber mat present inside springs back, and a core layer with pores whose thickness has been adjusted at a predetermined expansion magnification is formed. At this time, in the board end section of the sandwich structure, by giving a height difference between the region 37 corresponding to the main body section and the region corresponding to the joining section, as shown in FIG. 10(e), a sandwich structure 1 having regions of the main body section and the joining section different in porosity of core layer can be formed.

[0116] Thereafter, as shown in FIG. 10(f), by injection molding the molten resin (C) into the joining section 6 formed in at least a part of the end section of the sandwich structure 1, an integrated integrally molded body 100 joined and integrated with the separate structure (C) 7 is obtained. When injection molding the resin (C), as shown in FIG. 10(f), the molten resin for the separate structure (C) 7 is injected at a state where the flow of the resin is stopped at a middle in the mold to not contact the interface 9a and to contact only at least a part of the thinnest section 10. There is no particular restriction on the method of integrating the separate structure (C) and the sandwich structure. For example, there are (1) a method of separately molding a sandwich structure and a separate structure (C) in advance and joining both structures, and (2) a method of molding a sandwich structure in advance and joining both structures simultaneously at the time of molding a separate structure (C). As a concrete example of the above-described (1), a sandwich structure is press molded and a separate structure (C) is manufactured by injection molding. There is a method of joining the manufactured respective members by known welding means such as hot plate welding, vibration welding, ultrasonic welding, laser welding, resistance welding, and induction heating welding. On the other hand, as a concrete example of the above-described (2), there is a method of press molding a sandwich structure, then inserting it into an injection molding die, and injection molding a material forming a separate structure (C) into the mold, thereby integrating them. From the viewpoint of mass productivity of an integrated molded article, the method (2) is preferably used, and insert injection molding and outsert injection molding are preferably used.

[0117] Further, in the forming step of the sandwich structure shown in FIG. 10(e), it is preferred that the pores formed in the core layer are formed by heating the core layer precursor containing the discontinuous fibers and the thermoplastic resin (A) to a temperature higher than the softening point or the melting point of the thermoplastic resin (A) and pressurizing it, then releasing the pressurization, and expanding it by spring back. By thus heating and pressurizing the entire core layer precursor at a time and releasing the pressurization, even in a sandwich structure having a large area or a joining section having a complicated stepped section, it is possible to mold the entire sandwich structure at a time accurately.

[0118] The porosity can be controlled by adjusting the thickness of the core layer. The larger the thickness of the core layer at the time of releasing pressurization is controlled, the more the amount of expansion due to spring back is increased and the porosity formed in the core layer can be increased. Concretely, in addition to making the cavity height of the upper mold to become a predetermined core layer height, when the product types increase, a method of controlling a distance between the upper mold and the lower mold at the time of releasing the pressurization can also be used.

[0119] The method of manufacturing the joining section will be further explained. As shown in FIG. 10(e), although the skin layer can be deformed to conform to the shape of the region 37 of the upper mold by the spring back of the core layer precursor, it is also possible to form the joining section by other methods.

[0120] Further, as a facility for heating the skin layer precursor and the core layer precursor, a hot air oven and an IR (infrared) heater can be suitably used.

[0121] Furthermore, it is preferred that by providing a joining layer in the skin layer or the core layer of the sandwich structure and thereafter injection molding the molten resin (C) of the separate structure, and by solidifying or curing the injection molding resin (C) onto a portion different in thickness formed in the circumferential end section of the sandwich structure, the separate structure (C) is joined and integrated. As the method of providing a joining layer in the skin layer or the core layer of the sandwich structure, there are a method of applying an adhesive of the same material as that of the separate structure (C) to a portion different in thickness formed on the side surface of the circumferential end section of the sandwich structure, and a method of laminating a film or a nonwoven fabric of the same material as that of the separate structure (C) on the outermost layer of the layer or the core layer and integrating the joining layer with the sandwich structure by heat press molding. From the viewpoint of excellent productivity, the method of laminating a film or a nonwoven fabric of the same material as that of the separate structure (C) on the outermost layer of the layer or the core layer and integrating the joining layer with the sandwich structure by heat press molding is preferred.

[0122] As described above, in the integrally molded body, it is essential to form a stepped section in the end section of the sandwich structure and to have the separate structure (C) joined to only at least a part of the thinnest section, but it is possible to provide a similar structural part in a part other than the end section of the sandwich structure. For example, as shown in a schematic sectional view in the thickness direction of an integrally molded body 200 showing an example in which another stepped section and another separate structure (C) are provided to a portion other than the end section of the sandwich structure in FIG. 11, stepped sections 42 similar to that shown in FIGS. 2 and 3 are formed in at least a part of the end sections of a sandwich structure 41, and separate structures (C) 44 are joined to only at least a part of thinnest sections 43 thereof, and in this example, another stepped section 45 is formed also in an arbitrary part other than a part of the end sections of the sandwich structure 41, and another separate structure (C) 46 different from the separate structure (C) 44 is arranged. This another stepped section 45 comprises main body sections 47 forming high surfaces 47a on both sides of the stepped section 45, interface sections 48 which form other interfaces 48a each connecting the high surface 47 on each side of the stepped section 45 and a low surface 49a located between the high surfaces 47a on both sides, and another thinnest section 49 having a core layer 50b which has a porosity lower than porosities of core layers 50a in the main body sections 47 on both sides, and the separate structure (C) 46 does not contact with any of other interfaces 48a, and is joined to only at least a part of another thinnest section 49. In the illustrated example, each of the other interfaces 48a located on both sides of the stepped section 45 has an inclination angle similar to that shown in FIGS. 2 and 3, and the separate structure (C) 46 is joined to a part of the upper surface of the upper-side skin layer of another thinnest section 49.

[0123] Thus, joining the separate structure (C) to only at least a part of the thinnest section without contacting it with the interface of the interface section can also be applied similarly to parts other than the end section of the sandwich structure. Therefore, it becomes possible to substantially prevent heat transfer from the resin forming the separate structure (C) to the interface section also at a portion other than the end section of the sandwich structure, to remove the possibility of occurrence of defects on the design surface side originating from sink marks caused by the heat transfer, and to obtain a desired integrally molded body more reliably and easily.

[0124] Further, when the method is applied to a portion other than the end section of the sandwich structure, for example, as shown in the example of another integrally molded body 201 in FIG. 12, another interface 52a of another interface section 52 (one of the other interface sections in the illustrated example) of another stepped section 51 formed in an arbitrary portion other than a part of the end section of the sandwich structure 41 is formed as a surface standing up vertically from the upper surface of another thinnest section 49 (the low surface in another stepped section 51), and the separate structure (C) 53 does not contact with another interface 48a and another interface 52a, but is joined to only at least a part of another thinnest section 49. In the illustrated example, the separate structure (C) 53 is disposed at a position shifted to the one side from the center of the upper surface of another thinnest section 49 (low surface in another stepped section 51). Thus, the separate structure (C) 53 can be disposed at an arbitrary position as long as it adopts a structure not to be contacted with another interface 48a and another interface 52a, another stepped sections 45, 51 can also be formed substantially in an arbitrary shape, and further, the separate structures (C) 46, 53 to be joined can also be formed to have substantially arbitrary shape and size.

[0125] Also, in a portion other than the end section of the sandwich structure as described above, the aforementioned structure applicable in the end section of the sandwich structure, for example, the structure wherein the interface of the interface section has an angle of 1 to 200 with respect to the in-plane direction of the main body section, the structure wherein the joining layer is provided at least in a part of a portion between the skin layer and the separate structure (C), the structure wherein the porosity of the core layer in the region forming the main body section is 50% or more and 80% or less, and the porosity of the core layer in the region forming the thinnest section is 0% or more and less than 50%, the structure wherein the thickness Db of the main body section is 0.4 to 2 mm, and the thickness Tc in the joining section of the separate structure (C) is 0.1 to 1.7 mm, the structure wherein Db/Tc is 1.1 to 20, and the structure wherein the distance L from the edge of the interface section side of the main body section to the separate structure (C) joined to only at least a part of the thinnest section is 0.1 to 30 mm can be similarly applied.

EXAMPLES

[0126] Hereinafter, the desired effects will be concretely explained based on examples, but the following examples do not limit this disclosure at all. Measurement methods used in the examples are described below.

(1) Length and Angle of Sandwich Structure and Separate Structure (C):

[0127] A small piece including a joining section was cut out from an integrally molded body, and after being embedded in an epoxy resin, a cross section in the thickness direction of the integrally molded body was polished to prepare a sample. After photographing this sample using a laser microscope (VK-9510, supplied by Keyence Corporation), using an image measurement tool, as shown in FIG. 5, a length of a joining section (Lb) of a separate structure (C) joined to a sandwich structure, a distance (L) from the edge of an interface section to the separate structure (C), and an angle () of the interface section of the sandwich structure were measured.

(2) Joining Strength:

[0128] A test piece was cut out to have a size of 50 mm in length and 25 mm in width in a plane perpendicular to the thickness direction of the integrally molded body so that the joining section was located at the center in the longitudinal direction of the integrally molded body, the flexural strength was determined in accordance with ASTM D 790 at a condition where the distance between fulcrums was 32 times the thickness of the test piece, and this was taken as the joining strength. Furthermore, the obtained joining strength was evaluated according to the following criteria. A and B were acceptable and C and D were failed.

A: 100 MPa or more
B: 60 MPa or more and less than 100 MPa
C: 40 MPa or more and less than 60 MPa
D: less than 40 MPa or impossible to measure

(3) Depression and Appearance on Design Surface Side of Integrally Molded Body:

[0129] Depression of the design surface side near the joining section with the separate structure (C) joined to the sandwich structure as shown in FIG. 1 was measured by the undulation measurement of a surface roughness meter (Surfcom 480A, supplied by Tokyo Seimitsu Co., Ltd.), and the appearance was visually confirmed. Furthermore, the obtained depression amount and appearance were evaluated according to the following criteria. was accepted, and and x were rejected.

: depression is less than 5 m and visual depression is not seen
: depression is not less than 5 m and less than 20 m
x: depression is 20 m or more

Example 1

[0130] When manufacturing a sandwich structure in which the porosities of the core layers of the main body section and the thinnest section are different as shown in FIG. 10(e), by using the upper mold 35 giving an angle of 4 degrees to the interface section, a sandwich structure with an angle () of 4 degrees for its interface section was obtained.

[0131] The sandwich structure obtained above was set in an injection molding mold, the mold was closed, and then a molten resin (C) was injection molded to produce an integrally molded body shown in the schematic diagram of FIG. 5. The integrally molded body has a high joining strength and a good appearance with no design surface side depression near the joining section with the separate structure (C) joined to the sandwich structure was obtained. The properties of the integrally molded body are summarized in Table 1.

Example 2

[0132] When manufacturing a sandwich structure in which the porosities of the core layers of the main body section and the thinnest section are different as shown in FIG. 10(e), by using the upper mold 35 giving an angle of 90 degrees to the interface section, a sandwich structure with an angle () of 90 degrees for its interface section was obtained.

[0133] The sandwich structure obtained above was set in an injection molding mold, the mold was closed, and then a molten resin (C) was injection molded to produce an integrally molded body shown in the schematic diagram of FIG. 5. The integrally molded body has a high joining strength and a good appearance with no design surface side depression near the joining section with the separate structure (C) joined to the sandwich structure was obtained. The properties of the integrally molded body are summarized in Table 1.

Example 3

[0134] When manufacturing a sandwich structure in which the porosities of the core layers of the main body section and the thinnest section are different as shown in FIG. 10(e), by using the upper mold 35 giving an angle of 2 degrees to the interface section, a sandwich structure with an angle () of 2 degrees for its interface section was obtained.

[0135] The sandwich structure obtained above was set in an injection molding mold, the mold was closed, and then a molten resin (C) was injection molded to produce an integrally molded body shown in the schematic diagram of FIG. 5. The integrally molded body has a high joining strength and a good appearance with no design surface side depression near the joining section with the separate structure (C) joined to the sandwich structure was obtained. The properties of the integrally molded body are summarized in Table 1.

Example 4

[0136] When manufacturing a sandwich structure in which the porosities of the core layers of the main body section and the thinnest section are different as shown in FIG. 10(e), by using the upper mold 35 giving an angle of 18 degrees to the interface section, a sandwich structure with an angle () of 18 degrees for its interface section was obtained.

[0137] The sandwich structure obtained above was set in an injection molding mold, the mold was closed, and then a molten resin (C) was injection molded to produce an integrally molded body shown in the schematic diagram of FIG. 5. The integrally molded body has a high joining strength and a good appearance with no design surface side depression near the joining section with the separate structure (C) joined to the sandwich structure was obtained. The properties of the integrally molded body are summarized in Table 1.

Reference Example 5

[0138] The sandwich structure was manufactured in the same manner as in Example 1. After setting the obtained sandwich structure in the injection molding mold, and closing the mold, when injection molding the molten resin (C), an integrally molded body shown in the schematic diagram of FIG. 5, in which the length (Lb) of the joining section was short to be 2 mm, was produced. Although a good appearance with no design surface side depression near the joining section with the separate structure (C) joined to the sandwich structure was obtained, the joining strength of the integrally molded body was low and it did not reach the acceptance level. As a result, it was found from the comparison with Example 3 that it is preferable to set the length (Lb) of the joining section to 3 mm to bring also the joining strength to the acceptance level. The properties of the integrally molded body are summarized in Table 1.

Comparative Example 1

[0139] The sandwich structure was manufactured in the same manner as in Example 1. After setting the obtained sandwich structure in the injection molding mold, and closing the mold, when injection molding the molten resin (C), an integrally molded body, in which the separate structure (C) was joined up to the interface section as shown in FIG. 1, was produced. Although the integrally molded body has a high joining strength, the design surface side depression near the joining section with the separate structure (C) joined to the sandwich structure was large. The properties of the integrally molded body are summarized in Table 1.

Comparative Example 2

[0140] The sandwich structure was manufactured in the same manner as in Example 4. After setting the obtained sandwich structure in the injection molding mold, and closing the mold, when injection molding the molten resin (C), an integrally molded body, in which the length (Lb) of the joining section was short to be 2 mm and the separate structure (C) was joined up to the interface section as shown in FIG. 1, was produced. The integrally molded body was low in joining strength and did not reach the acceptable level. Further, the design surface side depression near the joining section with the separate structure (C) joined to the sandwich structure was also large. The properties of the integrally molded body are summarized in Table 1.

TABLE-US-00001 TABLE 1 Reference Comparative Comparative Example 1 Example 2 Example 3 Example 4 Example 5 Example 1 Example 2 Length of joining section mm 5 5 3 30 2 15 2 (Lb) Distance (L) from edge on mm 10 0.1 30 30 13 0 0 side of interface section to separate structure (C) Angle of interface section Degree 4 90 2 18 4 4 18 or joining section () Joining strength A A B A C A C Depression mm x x

INDUSTRIAL APPLICABILITY

[0141] The integrally molded body and the method of producing the same can be applied to any application requiring to be lightweight, high strength, high rigidity and requiring thinning.