Production method of producing fiber-reinforced resin molding

Abstract

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

Claims

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

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

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

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:

(2) FIG. 1 is a schematic view illustrating a process of opening bundles of reinforcing fibers to obtain opened reinforcing fibers;

(3) FIG. 2A and FIG. 2B are schematic views illustrating a production method of producing a fiber-reinforced resin molding according to a first embodiment of the invention, in which the opened reinforcing fibers are used;

(4) FIG. 3A and FIG. 3B are schematic views illustrating a production method of producing a fiber-reinforced resin molding according to a second embodiment of the invention, in which cut reinforcing fibers are used;

(5) FIG. 3C is a view illustrating a modified example of the second embodiment of the invention;

(6) FIG. 4 is a photographic chart illustrating reinforcing fibers sampled from a fiber-reinforced resin molding produced by a conventional production method;

(7) FIG. 5 is a photographic chart illustrating reinforcing fibers sampled from a fiber-reinforced resin molding produced by the production method according to the invention;

(8) FIG. 6A is a photographic chart illustrating locations of a fiber-reinforced resin molding, from which bending test pieces are cut out;

(9) FIG. 6B is a graph illustrating the bending strength of each test piece detected in a bending test and a standard deviation in bending strength of the test pieces in each of an example according to the invention and a comparative example; and

(10) FIG. 6C is a graph illustrating the bending elastic modulus of each test piece detected in the bending test and a standard deviation in bending elastic modulus of the test pieces in each of the example and the comparative example.

DETAILED DESCRIPTION OF EMBODIMENTS

(11) Hereinafter, production methods of producing fiber-reinforced resin moldings according to first and second embodiments of the invention will be described with reference to the accompanying drawings. A press molding device is used as a molding device in the production method illustrated in the drawings. However, molding methods other than press molding, for example, injection molding and injection compression molding may also be employed to mold a kneaded mixture. When the molding methods other than press molding are employed, molding devices (molding devices) suitable for these molding methods are used. In the production method illustrated in the drawings, a kneaded mixture extruded from a kneader is conveyed to the molding device by a robotic hand. However, it goes without saying that a kneaded mixture may be conveyed to the molding device, for example, by a roller conveyer that extends from the kneader to the molding device, or may be conveyed manually to the molding device.

(12) Hereafter, the production method of producing a fiber-reinforced resin molding according to the first embodiment of the invention will be described. FIG. 1 is a schematic view illustrating a process of opening bundles of reinforcing fibers to obtain opened reinforcing fibers. FIG. 2A and FIG. 2B are schematic views illustrating the production method of producing a fiber-reinforced resin molding according to the first embodiment of the invention, in which the opened reinforcing fibers are used.

(13) First, as illustrated in FIG. 1, reinforcing fiber bundles FB are opened by an opening device (not illustrated) to obtain opened reinforcing fibers F1 having a prescribed opening width and a prescribed opening thickness.

(14) Examples of the reinforcing fibers used in this case include single-material fibers composed of any one of the following kinds of fibers and mixed-material fibers composed of two or more of the following kinds of fibers: ceramic fibers made of boron, alumina, silicon carbide, silicon nitride, or zirconia; glass fibers; carbon fibers (both polyacrylonitrile (PAN)-based carbon fibers and pitch-based carbon fibers may be applicable); metal fibers made of copper, steel, aluminum, or stainless steel; and organic fibers made of polyamide or polyester.

(15) Next, a kneaded mixture M of a thermoplastic resin and reinforcing fibers is produced by a kneader 10 illustrated in FIG. 2A. The kneader 10 illustrated in FIG. 2A includes a screw 12 incorporated in a main body 11 of the kneader 10. Further, the kneader 10 is provided with a resin feed port (hopper) 13 located on the most upstream side, and an extrusion port 14 located on the most downstream side.

(16) Two vents 16, 17 are provided at positions downstream of the resin feed port 13. The volatile gas generated from the molten thermoplastic resin is discharged from the main body 11 through the vents 16, 17 along gas discharging directions Y1, Y2, respectively. Further, a fiber feed port 15 is provided at a position between the vents 16, 17. Resin pellets J made of a thermoplastic resin are fed into the resin feed port 13 along a direction X1.

(17) In this case, either crystalline plastics or amorphous plastics may be used as the thermoplastic resin. Examples of crystalline plastics include polyethylene (PE), polypropylene (PP), nylon (PA: nylon 6, nylon 66, etc.), polyacetal (POM), and polyethylene terephthalate (PET). Examples of amorphous plastics include polystyrene (PS), polycarbonate (PC), polymethylmethacrylate (PMMA), ABS resin, and thermoplastic epoxy.

(18) The resin pellets J fed from the resin feed port 13 are heated and melted in the main body 11, and delivered downstream along a direction Z while being kneaded by the screw 12.

(19) As described above, volatile gas is generated from the molten thermoplastic resin. However, the volatile gas is discharged through the vents 16, 17 along the direction Y1 and the direction Y2. This prevents a problem that a supply of the opened reinforcing fibers F1 into the fiber feed port 15 is hindered by an upward flow of the volatile gas.

(20) The opened reinforcing fibers F1 fed through the fiber feed port 15 along a direction X2 are cut by the screw 12, kneaded with the molten thermoplastic resin, and extruded to the extrusion port 14. Then, the kneaded mixture M is obtained through the extrusion port 14.

(21) Next, as illustrated in FIG. 2B, the kneaded mixture M extruded through the extrusion port 14 is held by a robotic hand 20 disposed next to the extrusion port 14 of the kneader 10. Then, the kneaded mixture M is conveyed along a direction W1 to a molding device 30 disposed next to the robotic hand 20.

(22) The molding device 30 is a press molding device. In the molding device 30, the kneaded mixture M is placed on a lower mold 32, which is a component of the molding device 30, and a punch 31 is moved downward along a direction W2 onto the kneaded mixture M to press the kneaded mixture M. In this way, a fiber-reinforced resin molding having a desired shape is produced.

(23) According to the production method in the first embodiment illustrated in FIG. 2A and FIG. 2B, the kneaded mixture M is produced by feeding the opened reinforcing fibers F1 into the kneader 10, and a fiber-reinforced resin molding is produced by placing the kneaded mixture M in the molding device 30. Thus, the external force (cutting force) applied from the kneader 10 to the opened reinforcing fibers F1 fed into the kneader 10 becomes as uniform as possible over the entire region of opened reinforcing fibers F1, so that the fiber lengths of the reinforcing fibers after cutting become as uniform as possible. As a result, the kneaded mixture M containing the reinforcing fibers having a narrower fiber length distribution is obtained. Therefore, it is possible to produce a high-quality fiber-reinforced resin molding with a narrower range of physical property variations.

(24) Hereafter, the production method of producing a fiber-reinforced resin molding according to the second embodiment of the invention will be described. FIG. 3A and FIG. 3B are schematic views illustrating the production method of producing a fiber-reinforced resin molding according to the second embodiment of the invention, in which cut opened reinforcing fibers are used.

(25) In the production method according to the second embodiment, an airflow generator 50 is disposed above the fiber feed port 15 of the kneader 10. The airflow generator 50 is a fan, and serves as a feed assist mechanism that assists the introduction of the reinforcing fibers into the fiber feed port 15. Further, a cutter 40 is disposed above the airflow generator 50. The cutter 40 cuts the opened reinforcing fibers F1.

(26) As the opened reinforcing fibers F1 pass along a direction X4 through the cutter 40 that is rotating along a direction X3, cut reinforcing fibers F2 having fiber lengths as uniform as possible are obtained. Then, the cut reinforcing fibers F2 thus obtained fall toward the fiber feed port 15.

(27) The airflow generator 50, which is a fan, is disposed below the cutter 40, as the feed assist mechanism that assists the introduction of the cut reinforcing fibers F2 into the fiber feed port 15. Thus, the rotation of the airflow generator 50 along a direction X5 generates an airflow heading toward the fiber feed port 15, and the airflow effectively introduces the cut reinforcing fibers F2 into the fiber feed port 15 along a direction X6. Instead of being introduced into the fiber feed port 15 by an airflow generated by the airflow generator 50, the cut reinforcing fibers F2 may be introduced into the fiber feed port 15 in the following manner. As illustrated in FIG. 3C, a suction unit 60 is provided near the fiber feed port 15, and the cut reinforcing fibers F2 are suctioned by the suction unit 60 to be introduced into the kneader 10.

(28) As described above, the cut reinforcing fibers F2 are obtained by cutting the opened reinforcing fibers F1, and the cut reinforcing fibers F2 are fed into the kneader 10. Thus, it is possible to make the fiber length distribution narrower, thereby producing the kneaded mixture M containing the reinforcing fibers having a narrower fiber length distribution.

(29) As in the production method according to the first embodiment, the kneaded mixture M thus produced is conveyed by the robotic hand 20 to the molding device 30. In the molding device 30, press molding is performed to produce a fiber-reinforced resin molding.

(30) According to the production method in the second embodiment illustrated in FIG. 3A and FIG. 3B, the kneaded mixture M is produced by cutting the opened reinforcing fibers F1 into the cut reinforcing fibers F2 having a uniform fiber length and feeding the cut reinforcing fibers F2 into the kneader 10, and a fiber-reinforced resin molding is produced from the kneaded mixture M. Thus, it is possible to produce a higher-quality fiber-reinforced resin molding having a narrower range of physical property variations as compared to a fiber-reinforced resin molding produced by the production method according to the first embodiment.

(31) Hereafter, description will be provided on experiments regarding a fiber length distribution of the reinforcing fibers contained in prototyped fiber-reinforced resin moldings and experiments regarding a bending strength in the prototypes, and results of the experiments. The present inventor et al. produced a fiber-reinforced resin molding by a conventional production method (comparative example) and also produced a fiber-reinforced resin molding by the production method according to the invention (example). Then, the present inventor et al. extracted reinforcing fibers from each of the fiber-reinforced resin moldings produced by these production methods, measured the mass % of the reinforcing fibers in each fiber length range to verify the difference in fiber length distribution between the fiber-reinforced resin molding in the example and the fiber-reinforced resin molding in the comparative example. Further, the present inventor et al. cut a plurality of test pieces out from the fiber-reinforced resin moldings in the example and the comparative example, carried out bending tests to measure the bending strength and the bending elastic modulus of each test piece and obtain the standard deviations, thereby verifying the difference in strength variations between the fiber-reinforced resin molding in the example and the fiber-reinforced resin molding in the comparative example.

(32) In this case, “conventional production method” means a method in which a kneaded mixture is produced by feeding bundles of reinforcing fibers into a kneader without opening the fibers and kneading the reinforcing fibers with molten thermoplastic resin, and then a fiber-reinforced resin molding is produced by subjecting the kneaded mixture thus produced to press molding. Further, “production method according to the invention” means a method in which opened reinforcing fibers are obtained by opening bundles of reinforcing fibers, a kneaded mixture is produced by feeding the opened reinforcing fibers into a kneader and kneading the opened reinforcing fibers with molten thermoplastic resin, and then a fiber-reinforced resin molding is produced by subjecting the produced kneaded mixture to press molding.

(33) FIG. 4 is a photographic chart illustrating the reinforcing fibers sampled from the fiber-reinforced resin molding produced by the conventional production method. FIG. 5 is a photographic chart illustrating the reinforcing fibers sampled from the fiber-reinforced resin molding produced by the production method according to the invention.

(34) As can be seen from FIG. 4, the reinforcing fibers in the fiber-reinforced resin molding produced by the conventional production method have a wide fiber length distribution. Specifically, the fiber-reinforced resin molding produced by the conventional production method contains various lengths of reinforcing fibers such as reinforcing fibers shorter than 5 mm and reinforcing fibers longer than 25 mm.

(35) In contrast to this, as can be seen from FIG. 5, the reinforcing fibers in the fiber-reinforced resin molding produced by the production method according to the invention have a considerably narrow fiber length distribution. Specifically, the fiber-reinforced resin molding produced by the production method according to the invention contains neither reinforcing fibers shorter than 5 mm nor reinforcing fibers longer than 25 mm, and the reinforcing fibers having a fiber length of 5 to 10 mm account for 95 mass % or more of the entirety of the reinforcing fibers.

(36) FIG. 6A is a photographic chart illustrating locations of a fiber-reinforced resin molding, from which bending test pieces are cut out. FIG. 6B is a graph illustrating the bending strength of each test piece detected in a bending test and a standard deviation in bending strength of the test pieces in each of the example and the comparative example. FIG. 6C is a graph illustrating the bending elastic modulus of each test piece detected in the bending test and a standard deviation in bending elastic modulus of the test pieces in each of the example and the comparative example.

(37) In the prototyped fiber-reinforced resin moldings, PA6 was used as the thermoplastic resin and reinforcing fibers made of carbon fibers were used. In the test pieces in the comparative example, bundles of unopened reinforcing fibers (in a size of 50K (50000 fibers per bundle)) were used. In each of the comparative example and the example, seven test pieces, 80 mm long by 15 mm wide, were cut out from the fiber-reinforced resin moldings in the form of a flat plate (400 mm×400 mm×4 mm thick), and the bending strengths were evaluated.

(38) As can be seen from FIG. 6B and FIG. 6C, the bending strength and bending elastic modulus of the test pieces in the example are both higher than those of the test pieces in the comparative example. Moreover, the standard deviations in bending strength and bending elastic modulus of the test pieces in the example are significantly smaller than those of the test pieces in the comparative example (the standard deviations in bending strength and bending elastic modulus of the test pieces in the example are about 60% and about 40%, respectively, of those of the test pieces in the comparative example). This means that the strength variations in the example are significantly smaller than those in the comparative example.

(39) It is deemed that the increase in strength and the decrease in strength variations are attributed to the production method in which the fiber-reinforced resin molding was produced by kneading the thermoplastic resin with the opened reinforcing fibers obtained by opening the bundles of reinforcing fibers.

(40) While the embodiments of the invention have been described in detail with reference to the accompanying drawings, the specific configurations of the invention are not limited to those in the foregoing embodiments, and configurations with design changes within the scope of the invention are included in the invention.