WO2023182158A1 - 一体化成形品および一体化成形品の製造方法 - Google Patents

一体化成形品および一体化成形品の製造方法 Download PDF

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Publication number
WO2023182158A1
WO2023182158A1 PCT/JP2023/010371 JP2023010371W WO2023182158A1 WO 2023182158 A1 WO2023182158 A1 WO 2023182158A1 JP 2023010371 W JP2023010371 W JP 2023010371W WO 2023182158 A1 WO2023182158 A1 WO 2023182158A1
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WIPO (PCT)
Prior art keywords
structural member
resin
thermoplastic resin
region
molded product
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2023/010371
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English (en)
French (fr)
Inventor
雅登 本間
美都繁 濱口
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toray Industries Inc
Original Assignee
Toray Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toray Industries Inc filed Critical Toray Industries Inc
Priority to EP23774754.8A priority Critical patent/EP4497579A4/en
Priority to CN202380022343.5A priority patent/CN118715113A/zh
Priority to US18/846,401 priority patent/US20250178290A1/en
Priority to KR1020247029221A priority patent/KR20240165338A/ko
Priority to JP2023517868A priority patent/JPWO2023182158A1/ja
Publication of WO2023182158A1 publication Critical patent/WO2023182158A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/70—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C45/14491—Injecting material between coaxial articles, e.g. between a core and an outside sleeve for making a roll
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1642—Making multilayered or multicoloured articles having a "sandwich" structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1671—Making multilayered or multicoloured articles with an insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5221—Joining tubular articles for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5344—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2012/00—Frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts

Definitions

  • the present invention relates to an integrated molded product formed by joining a fiber-reinforced thermosetting resin structural member having a cylindrical portion or a columnar portion to another resin structural member.
  • Fiber-reinforced composite materials are materials with excellent mechanical properties and light weight, and are widely used in components such as aircraft, automobiles, and industrial equipment.
  • a frame structure whose main skeleton is a fiber-reinforced composite material may be employed.
  • Patent Document 1 discloses a method of bolting a joint portion of a fiber-reinforced resin pipe and mechanically joining it to a joining member.
  • Patent Document 2 discloses a structure in which a pipe made of carbon fiber reinforced resin and a joint are joined with an adhesive.
  • An object of the present invention is to produce a lightweight and highly rigid integrated molded product with good productivity and in a strong bonded state.
  • the present invention that solves the above problems is as follows.
  • An integrally molded product formed by joining a structural member (a) having a cylindrical or columnar part essentially made of fiber-reinforced thermosetting resin and a resin structural member (b), wherein the resin structure
  • the member (b) has an overlapping region that overlaps the outer circumferential surface and/or inner circumferential surface of the cylindrical portion or columnar portion of the structural member (a), and the structure is formed in at least a portion of the overlapping region.
  • FIG. 2 is a schematic diagram showing an example of an integrally molded product in which the joint shown in FIG. 1 is joined to a structural member (a). It is a schematic diagram which shows the example of the pedestal as a resin structural member (b).
  • FIG. 4 is a schematic diagram showing an example of an integrally molded product in which the pedestal shown in FIG. 3 is joined to a structural member (a). It is a schematic diagram which shows the example of the rib as a resin structural member (b).
  • FIG. 6 is a schematic diagram showing an example of an integrally molded product in which the rib shown in FIG. 5 is joined to a structural member (a).
  • FIG. 8 is a schematic diagram showing an example of an integrally molded product in which the second cylindrical body shown in FIG. 7 is joined to a structural member (a).
  • FIG. 3 is a cross-sectional view showing an example of a joint between a structural member (a) and a resin structural member (b).
  • FIG. 2 is a schematic diagram showing an example of an integrated molded product in which a thermoplastic resin is insert-molded between a structural member (a) and a resin structural member (b).
  • FIG. 2 is a perspective view showing an example of a cross section of a joint of an integrated molded product in which a thermoplastic resin is insert-molded between a structural member (a) and a resin structural member (b).
  • the integrated molded article according to the present invention consists essentially of a fiber-reinforced thermosetting resin and includes a structural member (a) having at least a cylindrical or columnar part, and another resin structural member (b). It is an integrated molded product made by joining together.
  • "consisting essentially of a certain material” means that it contains the material as a main component and is typically composed only of the material, but other materials may be included as long as the effect of the invention is not lost. This means that it may contain ingredients.
  • the fibers contained in the fiber-reinforced thermosetting resin of the structural member (a) in the present invention can be those commonly used as reinforcing fibers.
  • glass fiber, polyacrylonitrile-based, rayon-based, lignin-based, pitch-based carbon fiber (including graphite fiber), titanate potassium whisker, zinc oxide whisker, calcium carbonate whisker, wollastenite whisker, aluminum borate whisker, aramid fiber examples include alumina fiber, silicon carbide fiber, ceramic fiber, asbestos fiber, gypsum fiber, and metal fiber.
  • glass fiber, polyacrylonitrile-based carbon fiber, and pitch-based carbon fiber are preferable.
  • Acrylonitrile-based and pitch-based carbon fibers are more preferred, and polyacrylonitrile-based carbon fibers are particularly preferred.
  • the fibers contained in the structural member (a) are surface-treated with a sizing agent.
  • Sizing agents include polyfunctional epoxy resins, acrylic acid polymers, polyhydric alcohols, polyethyleneimine, etc., and specifically, glycerol triglycidyl ether, diglycerol polyglycidyl ether, polyglycerol polyglycidyl ether, and sorbitol polyglycidyl ether.
  • polyglycidyl ethers of aliphatic polyhydric alcohols such as arabitol polyglycidyl ether, trimethylolpropane triglycidyl ether, pentaerythritol polyglycidyl ether, polyacrylic acid, copolymers of acrylic acid and methacrylic acid, acrylic acid and maleic acid Copolymers with acids or mixtures of two or more of these, polyvinyl alcohol, glycerol, diglycerol, polyglycerol, sorbitol, arabitol, trimethylolpropane, pentaerythritol, polyethyleneimine containing more amino groups in one molecule, etc.
  • glycerol triglycidyl ether diglycerol polyglycidyl ether, and polyglycerol contain many highly reactive epoxy groups in one molecule, are highly water-soluble, and can be easily applied to fibers.
  • Glycerol polyglycidyl ether is preferably used in the present invention.
  • the sizing agent is preferably contained in an amount of 0.01 to 5 parts by mass, more preferably 0.1 to 2 parts by mass, per 100 parts by mass of fibers.
  • the fibers contained in the structural member (a) are preferably continuous fibers.
  • the continuous fiber in this specification means a fiber having a length of 10 mm or more, and as long as it has this length, it does not necessarily have to be a continuous fiber throughout the entire member, but may be broken in the middle. Good too.
  • Examples of the form of the continuous fibers include a cross fabric in which fiber bundles are woven, and forms in which filaments, braids, filament bundles, spun yarns, etc. are aligned in one direction.
  • the structural member (a) can also be formed by using two or more types of reinforcing fibers in combination.
  • the structural member (a) is preferably a molded body having a laminated structure formed by laminating and molding prepreg sheets made of fiber-reinforced thermosetting resin.
  • the prepreg sheet has reinforcing fibers aligned in one direction, it is possible to have a laminated structure in which the angle of the reinforcing fibers is approximately 0°, approximately ⁇ 45°, approximately 90°, etc.
  • a layer configuration having an angle other than the above may be included.
  • the mass content of fibers present in 100% by mass of structural member (a) is preferably 20 to 70% by mass, more preferably 25 to 70% by mass, particularly preferably 30 to 65% by mass. .
  • thermosetting resin constituting the fiber-reinforced thermosetting resin of structural member (a) is not particularly limited, and examples thereof include unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol (resol type) resin, urea melamine, etc. Examples include resins, polyimide resins, copolymers and modified products thereof, and resins obtained by blending at least two of these. Among these, thermosetting resins containing epoxy resin as a main component are more preferable from the viewpoint of mechanical properties of molded articles, since they have excellent rigidity and strength. Note that the main component in the thermosetting resin means that the component ratio in the thermosetting resin is 60% by mass or more.
  • the fiber-reinforced thermosetting resin may contain other fillers and additives depending on the intended use.
  • elastomer or rubber components inorganic fillers, flame retardants, conductivity imparting agents, antibacterial agents, insect repellents, deodorants, color inhibitors, mold release agents, antistatic agents, plasticizers, colorants, pigments, dyes, Examples include foaming agents, antifoaming agents, and coupling agents.
  • the structural member (a) is a member that has a cylindrical portion or a columnar portion at least in part.
  • columnar means a solid shape with no hollow space in the cylindrical part.
  • the structural member (a) can have a columnar or cylindrical shape as a whole.
  • the structural member (a) may have a cylindrical portion or a columnar portion and other shaped portions.
  • the thickness of the cylindrical portion may vary.
  • the cylindrical portion or columnar portion of the structural member (a) may be curved.
  • a cross section parallel to the opening surface of the cylindrical form (hereinafter simply referred to as a "cross section" of the structural member (a)) is a cross section in the cylindrical part of the structural member (a).
  • the tubular shape has a longer length in the direction perpendicular to the opening surface than the diameter of the cross section parallel to the opening surface of the shape.
  • the length of the tubular part in the longitudinal direction is not particularly limited, but it is preferably 0.05 m or more, more preferably 0.1 m or more, particularly preferably 0.15 m or more.
  • the length is preferably 3 m or less, more preferably 2 m or less, particularly preferably 1 m or less.
  • the structural member (a) is a cylindrical body having a cylindrical shape as a whole, and a particularly preferred embodiment of the present invention is a member having a tubular shape as a whole, that is, a pipe-shaped member. It is a mode.
  • the cross-sectional shape of the cylindrical portion or columnar portion of the structural member (a) is not particularly limited, but is preferably circular or rectangular. Further, the cross-sectional area of the cylindrical portion or columnar portion of the structural member (a) is preferably 20 mm 2 or more, more preferably 50 mm 2 or more. Moreover, it is preferably 300 mm 2 or less, more preferably 200 mm 2 or less. When the structural member (a) has a cross-sectional area within the above range, a highly rigid integral molded product can be obtained with good productivity.
  • the structural member (a) is made essentially of a thermosetting resin, and at least a portion of the outer circumferential surface and/or inner circumferential surface, typically the portion joined to the resin structural member (b), When the thermoplastic resin region is exposed on the surface, the structural member (a) and the resin structural member (b) are joined via the thermoplastic resin by thermal welding with the resin structural member (b). In particular, it is possible to easily form a state in which the thermoplastic resin is present on the surface of the structural member (a) located on the structural member (a) side from the bonding interface, as will be described later.
  • Such a thermoplastic resin region is typically thinly provided on the surface of the structural member (a), and its thickness is usually 1 to 300 ⁇ m, more preferably 50 to 150 ⁇ m.
  • the distance La from the central axis of the cylindrical part or columnar part to the outermost layer is It is preferable that the distance Lb from the central axis of the cylindrical portion or the columnar portion to the interface between the thermosetting resin and the thermoplastic resin region satisfies the following equation (1).
  • 0.9 ⁇ Lb/La ⁇ 0.9999 (1) The form of such a thermoplastic resin region is not particularly limited as long as it forms a region where the thermoplastic resin is exposed on the inner peripheral surface or outer peripheral surface of the cylindrical portion or columnar portion of the structural member (a). Examples include layered, spot-like, mesh-like, and lattice-like shapes.
  • thermoplastic resins constituting such a thermoplastic resin region include polyolefin resins, polyester resins, polyamide resins, polycarbonate resins, polyphenylene sulfide resins, polyimide resins, polyamideimide resins, polyetherimide resins, and polyetherketone resins. , polyetheretherketone resin, polyetherketoneketone resin, polyarylate resin, etc. are preferable.
  • the linear expansion coefficient of the thermoplastic resin constituting the thermoplastic resin region is preferably 60 ppm/°C or more, and 70 ppm/°C or more from the viewpoint of obtaining high bonding strength in the measurement temperature range of 60°C to 150°C. More preferably, it is 200 ppm/°C or less, and more preferably 150 ppm or less.
  • the interface between the thermosetting resin and the thermoplastic resin region of the structural member (a) forms an uneven shape from the viewpoint of obtaining high bonding strength.
  • an uneven interface means that the interface between the thermosetting resin and the thermoplastic resin region is not flat, but is recessed toward the thermosetting resin side, and when the interface is recessed toward the thermoplastic resin region. This shows that a boundary surface is formed with a mixture of different forms.
  • the depth of the depression is preferably 1 to 200 ⁇ m, more preferably 10 to 100 ⁇ m.
  • the method for manufacturing the structural member (a) is not particularly limited.
  • the manufacturing method is to use a filament winding method, a sheet winding method, etc. to prepare a prepreg made of reinforcing fibers impregnated with a thermosetting resin under a predetermined tension. Examples include a method in which the material is applied while being wrapped around a mandrel to shape it and then hardened, internal pressure molding using a shaping mold, or a method in which it is shaped by press molding and then hardened.
  • thermoplastic resin region on at least a part of the outer peripheral surface or inner peripheral surface of the structural member (a)
  • at least one layer of a film made of a thermoplastic resin is wound at the beginning or end
  • a method of curing by integrating with a thermosetting resin can be mentioned.
  • the resin structural member (b) in the present invention can be a member essentially made of thermoplastic resin.
  • the thermoplastic resin is not particularly limited, and examples thereof include polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate (PEN), polybutylene naphthalate (PBN), and liquid crystal polyester.
  • polycaproamide (nylon 6), polyhexamethylene adipamide (nylon 66), polypentamethylene adipamide (nylon 56), polyhexamethylene sebamide (nylon 610), polyhexamethylene dodecamide (nylon 612) ), polyundecaneamide (nylon 11), polydodecanamide (nylon 12), polycaproamide/polyhexamethylene adipamide copolymer (nylon 6/66), polycaproamide/polyhexamethylene terephthalamide copolymer (nylon 6/ 6T), polyhexamethylene adipamide/polyhexamethylene terephthalamide copolymer (nylon 66/6T), polyhexamethylene adipamide/polyhexamethylene isophthalamide copolymer (nylon 66/6I), polyhexamethylene adipamide/ Polyhexamethylene isophthalamide copolymer (nylon 66/6I), polyhexamethylene isophthalamide/caproamide
  • thermoplastic resin region the thermoplastic resin constituting the thermoplastic resin region and the resin structure
  • thermoplastic resins present on the surface of the resin structural member (b) in the region where the member (b) is joined to the structural member (a), that is, the overlap region described below, are of the same type.
  • the resin structural member (b) is essentially composed of a thermoplastic resin
  • the resin structural member (b) is preferably a joint, a pedestal, or a rib.
  • a joint connects two cylindrical sections or columnar sections, changes the direction, connects cylindrical sections or columnar sections of different thicknesses, or connects three or more cylindrical sections or columnar sections.
  • the pedestal is a member for receiving and fixing the cylindrical part or the columnar part.
  • the rib is a member for improving the strength and rigidity of the cylindrical portion or the columnar portion by forming a plate-like protrusion.
  • At least one of these cylindrical parts is the above-mentioned structural member (a) having the cylindrical part, and in a preferred embodiment, all of them are the above-mentioned cylindrical parts.
  • Figures 1A to D show typical joints
  • Figures 2A to D show an integrated molded product in which the structural member (a) (cylindrical body) and the joint are integrated
  • Figures 3A to B show typical pedestals.
  • 4A to 4B show an integrated molded product in which the structural member (a) (cylindrical body) and the pedestal are integrated
  • FIG. 5 shows a typical rib
  • FIGS. ) and ribs are shown, but the structure of each is not limited to this.
  • the resin structural member (b) may be a member essentially made of a thermosetting resin.
  • the thermosetting resin is not particularly limited, and like the structural member (a), examples include unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol (resol type) resin, urea/melamine resin, and polyimide resin. etc., copolymers and modified products thereof, and resins obtained by blending at least two of these.
  • thermosetting resins containing epoxy resin as a main component are more preferable from the viewpoint of mechanical properties of molded articles, since they have excellent rigidity and strength.
  • other fillers and additives may be contained depending on the intended use.
  • elastomer or rubber components inorganic fillers, flame retardants, conductivity imparting agents, antibacterial agents, insect repellents, deodorants, color inhibitors, mold release agents, antistatic agents, plasticizers, colorants, pigments, dyes, Examples include foaming agents, antifoaming agents, and coupling agents.
  • the resin structural member (b) when the resin structural member (b) is essentially composed of a thermosetting resin, the resin structural member (b) is a thermoplastic resin region in which the thermoplastic resin is exposed on at least a part of its surface. It may have. This allows the structural member (a) and the resin structural member (b) to be joined by thermal welding via the thermoplastic resin region. In a more preferred embodiment, both the structural member (a) and the resin structural member (b) have such a thermoplastic resin region, and the thermoplastic resin region of the structural member (a) and the resin structural member (b) The thermoplastic resin area is joined by thermal welding.
  • both the structural member (a) and the resin structural member (b) have a thermoplastic resin region, from the viewpoint of bonding strength between the two, both the structural member (a) and the resin structural member (b) have a thermoplastic resin region. It is preferable that the types of thermoplastic resins constituting are the same.
  • thermoplastic resin region is typically thinly provided on the surface of the resin structural member (b), and its thickness is usually 1 to 300 ⁇ m, more preferably 50 to 150 ⁇ m.
  • the form of the thermoplastic resin region is not particularly limited as long as the thermoplastic resin forms an exposed area on the surface of the resin structural member (b), but examples include layered, spot-like, mesh-like, and lattice-like shapes. For example,
  • the resin structural member (b) is essentially composed of a thermosetting resin
  • the resin structural member (b) is preferably a cylindrical body.
  • the cylindrical body is a cylindrical body that is different in length, diameter, thickness, etc. from the cylindrical part or columnar part of the structural member (a).
  • Fig. 7 shows a typical cylindrical body
  • Fig. 8 shows a structure in which a structural member (a) (first cylindrical body) 1 and a resin structural member (b) (second cylindrical body) 2 are integrated.
  • a schematic diagram of an integrated molded product is shown, the structure of each is not limited to this.
  • the resin structural member (b) is essentially composed of a thermosetting resin
  • the shape change of each member due to heat input during joining is extremely small, so an integrated molded product with high dimensional accuracy can be obtained, and the structural member
  • the concentricity indicating the misalignment between the centers of the cross sections of (a) and the resin structural member (b) is 0.25 mm or less. Concentricity is measured by measuring the positions of three points on the outer diameter of each of the structural member (a) and the resin structural member (b) using a CNC three-dimensional measuring machine, and comparing the obtained center positions. be able to.
  • the resin structural member (b) may contain reinforcing fibers to improve mechanical properties.
  • reinforcing fibers include fibers selected from the same options as the fiber-reinforced thermosetting resin constituting the structural member (a) described above, but carbon fibers are preferred from the viewpoint of lightweight and mechanical properties. These fibers may be subjected to surface treatments such as treatment with a coupling agent, treatment with a sizing agent, and treatment with adhesion of additives.
  • the mass content of fibers present in 100% by mass of the resin structural member (b) is preferably 20 to 70% by mass, more preferably 25 to 70% by mass, particularly preferably 30 to 65% by mass. be. By setting the mass content of the fibers within the above range, a resin structural member (b) with high rigidity and good dimensional accuracy can be obtained.
  • the reinforcing fibers contained in the resin structural member (b) are preferably discontinuous reinforcing fibers from the viewpoint of moldability.
  • the mass average fiber length Lw of the reinforcing fibers is preferably 0.3 mm or more, more preferably 0.8 mm or more. The longer the mass average fiber length, the greater the effect of improving strength and rigidity, and in particular the remarkable effect of improving impact strength.
  • the upper limit of the mass average fiber length Lw is preferably 3.0 mm or less, more preferably 1.5 mm or less, and particularly preferably 1.0 mm or less.
  • the mass average fiber lengths of the resin structural member (b) of the present invention may not all be the same length, but may have a distribution of fiber lengths.
  • the resin structural member (b) has an overlapping region that overlaps the outer circumferential portion and/or inner circumferential portion of the cylindrical portion or columnar portion of the structural member (a). , is joined to the structural member (a) by thermal welding via a thermoplastic resin in at least a portion of the overlapping region.
  • the resin structural member (b) overlaps the outer circumferential surface and/or inner circumferential surface of the cylindrical portion of the structural member (a), which means the outer circumferential surface or the inner circumferential surface of the cylindrical portion of the structural member (a), Alternatively, it means that both surfaces thereof are in contact with at least a portion of the resin structural member (b).
  • the expression that the resin structural member (b) overlaps the outer circumferential surface of the columnar part of the structural member (a) means that the outer circumferential surface of the columnar part of the structural member (a) overlaps at least one part of the resin structural member (b). This means that the parts are in plane contact with each other.
  • the overlapping area means the area where they are in contact.
  • FIG. 9 shows an embodiment in which a joint 2 is joined to the outer peripheral surface of the structural member (a) 1 as a resin structural member (b).
  • the inner peripheral surface of the cylindrical resin structural member (b) is in contact with the resin structure member (b) so as to surround it. That is, the resin structural member (b) overlaps the structural member (a) around the entire circumference.
  • the resin structural member (b) may be in contact with only a part of the outer or inner peripheral surface of the structural member (a) rather than the entire circumference, but in order to develop strong bonding strength, the resin structural member (a) ) It is preferable that the circumferential length of the cylindrical part is in contact within a range of 50% or more and 100% (full circumference) or less, and it is preferable that the cylindrical part is in contact and joined at 100% (full circumference) to form a closed cross section. Particularly preferred. In addition, when joining the cylindrical part of the structural member (a), whether to overlap the outer peripheral surface or the inner peripheral surface and join the resin structural member (b) is determined depending on the intended member.
  • the integrated molded product can also include both a resin structural member (b) that overlaps and is joined to the outer peripheral surface and a resin structural member (b) that overlaps and joins the inner peripheral surface.
  • the thermoplastic resin is preferably present on the surface of the structural member (a) located on the structural member (a) side from the joint interface.
  • the state where the thermoplastic resin is present on the surface of the structural member (a) located on the structural member (a) side from the joint boundary surface means that the cylindrical portion of the structural member (a) is present in the cross section of the joint.
  • thermosetting resin constituting the structural member (a). It is preferable that it straddles the plastic resin region, that is, it is in contact with both the thermosetting resin and the thermoplastic resin region of the structural member (a).
  • the bonding strength between the structural member (a) and the resin structural member (b) of the present invention is preferably 7 MPa or more, more preferably 10 MPa or more.
  • the upper limit of the bonding strength is not particularly limited, it is preferably 100 MPa or less from the viewpoint of obtaining the integrated molded product of the present invention with good productivity.
  • an integral molded product consisting of a structural member (a) and a resin structural member (b) of the present invention can be produced by bringing the structural member (a) and the resin structure into contact with each other while at least one member is heated. It can be manufactured by joining member (b) by thermal welding.
  • the method of such heat welding is not particularly limited, and integration can be performed by hot plate welding, vibration welding, ultrasonic welding, far infrared heat welding, dielectric heat welding, laser welding, insert molding, outsert injection molding, etc. can.
  • the resin structural member (b) is essentially composed of a thermoplastic resin
  • insert molding is preferable since it is possible to manufacture a strongly joined integral molded product with high productivity.
  • the structural member (a) is inserted into the injection mold and the mold is clamped, and the thermoplastic resin of the resin structural member (b) is overlapped with the outer or inner peripheral part of the structural member (a).
  • the resin structural member (b) is molded and integrated by injection molding as follows. Further, after the structural member (a) and the resin structural member (b), at least one of which has a thermoplastic resin region on the surface, are molded in advance, the structural member (a) or the resin structural member (b) having the thermoplastic resin region is formed.
  • the structural member (a) and the resin structural member (b) are brought into contact with each other so as to overlap with the outer peripheral surface or inner peripheral surface of the structural member (a) in a heated state. ) may be joined by thermal welding.
  • a method includes far-infrared heat welding.
  • far-infrared heat welding after forming the structural member (a) and the resin structural member (b) in advance, the resin structural member (b) is attached to the outer peripheral part of the structural member (a) while the structural member (a) is heated. Alternatively, it can be manufactured by bringing it into contact so as to overlap with the inner circumference, cooling and solidifying it.
  • the structural member (a) is preferably heated with a far-infrared heater to a temperature higher than the temperature at which the thermoplastic resin contained in the resin structural member (b) melts and softens.
  • the integrally molded product may include, for example, a thermoplastic resin on at least a part of the outer peripheral surface or inner peripheral surface of the cylindrical part or columnar part.
  • a structural member (a) having a resin region and/or a resin structural member (b) having a thermoplastic resin region on at least a part of the surface is prepared, and in a state where the thermoplastic resin region is heated, the heating is performed.
  • the structural member (a) and the resin structural member (b) can be manufactured by a method in which the structural member (a) and the resin structural member (b) are brought into contact so as to overlap in a region including a thermoplastic resin region.
  • thermoplastic resin constituting the thermoplastic resin region of the structural member (a) or the resin structural member (b) it is preferable to heat the thermoplastic resin constituting the thermoplastic resin region of the structural member (a) or the resin structural member (b) to a temperature higher than that at which it softens, and more preferably to a temperature higher than a temperature at which it melts.
  • the integrally molded product of the present invention may include a structural member (a) and a resin structural member (b), wherein the resin structural member (b) has a cylindrical part or a columnar part of the structural member (a).
  • the thermoplastic resin is inserted into the injection mold so as to overlap the outer peripheral surface and/or inner peripheral surface of the part, and the thermoplastic resin is inserted between the overlapping structural member (a) and the resin structural member (b). It can also be manufactured by injection molding.
  • FIG. 10 shows that a second cylindrical body 2 as a resin structural member (b) is attached to the outer circumferential surface of a structural member (a) 1 as a first cylindrical body through an injection-molded thermoplastic resin 4.
  • thermoplastic resin 4 only needs to be interposed between the outer circumferential surface and/or inner circumferential surface of the cylindrical part or columnar part of the structural member (a) and the surface of the resin structural member (b). It is not limited.
  • the thermoplastic resin species for injection molding in this case, the same resins as those described above as the thermoplastic resin constituting the resin structural member (b) can be used.
  • the thermoplastic resin for injection molding may contain reinforcing fibers in order to improve mechanical properties.
  • reinforcing fibers include fibers selected from the same options as the fiber-reinforced thermosetting resin constituting the structural member (a) described above, but carbon fibers are preferred from the viewpoint of lightweight and mechanical properties. These fibers may be subjected to surface treatments such as treatment with a coupling agent, treatment with a sizing agent, and treatment with adhesion of additives.
  • the integrated molded product of the present invention has a lightweight, highly rigid structural member (a) and a resin structural member (b) that can be connected, merged, branched, left in place, etc., and are firmly joined to the frame. It can be suitably used as a member forming a structure. Examples of such structures include the bodies and arms of industrial robots, the bodies and arms of automobiles, motorcycles, bicycles, aircraft, helicopters, drones, ships, submarines, and construction materials. In particular, from the viewpoint of rigidity and lightness, it is preferably used for flying objects such as aircraft, helicopters, and drones.
  • the length of the cylindrical portion or columnar portion of the structural member (a) is 0.05 m or more and 3 m or less. Particularly in the case of relatively small flying objects with a main body weight of 1000 kg or less, the influence of increased weight due to mechanical fastening such as bolts and fasteners is large, so the integrated molded product of the present invention can be particularly suitably used.
  • Example 1 Using "Toray Cap Prepreg” P3051S-30 and P3052S-12 manufactured by Toray Industries, Ltd., on a stainless steel mandrel with a tip outer diameter of 30 mm, a taper of 6.0/1000, and a length of 700 mm, the mandrel was When the longitudinal direction is set as the 0 degree axis, P3051S-30 was laminated so that the material angle was 0 degrees, and P3052S-12 was laminated so that the material angle was 60 degrees.
  • a polyamide film with a thickness of 70 ⁇ m obtained by hot pressing pellets of copolyamide resin (CM4000 manufactured by Toray Industries, Polyamide 6/66/610, melting point 150°C) was wrapped around the outside of the film, and then a wrapping tape ( A heat-resistant film tape (width: 10 mm) was wound around it with a tension of 3 kg, and heat molding was performed in a curing oven at 150° C. for 30 minutes. Thereafter, the mandrel was pulled out, the wrapping tape was removed, and the pipe was cut to obtain a pipe 1 having a thickness of 0.5 mm and a length of 500 mm.
  • CM4000 manufactured by Toray Industries, Polyamide 6/66/610, melting point 150°C was wrapped around the outside of the film, and then a wrapping tape ( A heat-resistant film tape (width: 10 mm) was wound around it with a tension of 3 kg, and heat molding was performed in a curing oven at 150° C. for 30 minutes. Thereafter, the mandrel
  • N 5 pieces
  • the joint part and pipe were held with a jig, and a tensile test was conducted at room temperature at a test speed of 0.5 mm/min using an Instron universal testing machine.
  • Example 2 Pipe 1 was obtained in the same manner as in Example 1. Next, using an injection molding machine (J350EIII manufactured by Japan Steel Works) set at a cylinder temperature of 280°C and a mold temperature of 80°C, long fiber pellets (TLP1060 manufactured by Toray Industries, Inc.), which are pellets of carbon fiber reinforced polyamide 6, were formed.
  • the joint shown in FIG. 1A was individually injection molded using this method. After heating the end of the pipe to a surface temperature of 230°C using a far-infrared heater, the joint is immediately heated to a pressure of 1 MPa for 15 seconds with the inner peripheral surface of the pipe touching 10 mm from the end of the outer peripheral surface of the pipe. 2A, and then cooled to produce an integrated molded product as shown in FIG. 2A.
  • J350EIII manufactured by Japan Steel Works
  • Example 3 Copolymerized polyamide resin (Toray CM4000, polyamide 6/66/610, melting point 150°C) was placed on a release-treated stainless steel mandrel with an outer diameter of 30 mm at the tip, a taper of 6.0/1000, and a length of 700 mm. After wrapping one round of polyamide film with a thickness of 70 ⁇ m obtained by hot pressing the pellets, we used "Torayka Prepreg" P3051S-30 and P3052S-12 manufactured by Toray Industries, Inc., and set the longitudinal direction of the mandrel as the 0 degree axis.
  • P3051S-30 was laminated so that the material angle was 0 degrees
  • P3052S-12 was laminated so that the material angle was 60 degrees.
  • wrapping tape heat-resistant film tape, width 10 mm
  • heat molding was performed in a curing oven at 150° C. for 30 minutes. Thereafter, the mandrel was pulled out, the wrapping tape was removed, and the pipe 2 was cut to obtain a pipe 2 having a thickness of 0.5 mm and a length of 500 mm.
  • Example 4 Pipe 1 was molded in the same manner as in Example 1. Next, a copolymerized polyamide resin (Toray CM4000, polyamide 6/66/610, melting point 150°C) was placed on a release-treated stainless steel mandrel with a tip outer diameter of 31 mm, a taper of 6.0/1000, and a length of 700 mm. ) pellets with a 70 ⁇ m thick polyamide film obtained by hot-pressing them for one turn, and then using Toray Industries, Inc.'s "Torecap Prepreg" P3051S-30 and P3052S-12, the longitudinal direction of all shafts was 0.
  • a copolymerized polyamide resin Toray CM4000, polyamide 6/66/610, melting point 150°C
  • the end of the pipe 1 is heated to a surface temperature of 230°C using a far-infrared heater, and then the pipe 3 is immediately heated for 15 seconds with the end of the outer peripheral surface of the pipe 1 touching the inner peripheral surface 10 mm from the end. It was pressed against the pipe 1 and then cooled to produce an integrated molded product as shown in FIG.
  • Example 5 After pipe 1 was molded in the same manner as in Example 1, pipe 4 was molded in the same manner as in Example 1 except that the outer diameter of the tip of the stainless steel mandrel was changed to 32 mm.
  • pipe 1 and pipe 4 were inserted into a mold using an injection molding machine (J350EIII manufactured by Japan Steel Works) set at a cylinder temperature of 280°C and a mold temperature of 80°C.
  • J350EIII manufactured by Japan Steel Works
  • a carbon fiber reinforced polyamide 6 pellet made by Toray Industries, Inc. is inserted.
  • the fiber pellets (TLP1060) were injection molded to obtain an integrated molded product as shown in FIG.
  • Structural member (a) (first cylindrical body) 2 Resin structural member (b) (joint, pedestal, rib or second cylindrical body) 3 Overlap area 4 Thermoplastic resin

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Abstract

本発明は、筒状部または柱状部を有する繊維強化熱硬化性樹脂構造部材と、別の樹脂構造部材とが接合されてなる一体化成形品を、生産性よく、かつ強固な接合状態で作製することを課題とする。　上記課題を解決するための本発明は、繊維強化熱硬化性樹脂から本質的になる、筒状部または柱状部を有する構造部材（ａ）と、樹脂構造部材（ｂ）とが接合されてなる一体化成形品であって、前記樹脂構造部材（ｂ）は、前記構造部材（ａ）の筒状部または柱状部の外周面および／または内周面とオーバーラップするオーバーラップ領域を有し、該オーバーラップ領域の少なくとも一部において前記構造部材（ａ）と熱可塑性樹脂を介して接合されてなる一体化成形品である。

Description

一体化成形品および一体化成形品の製造方法
　本発明は、筒状部または柱状部を有する繊維強化熱硬化性樹脂構造部材と、別の樹脂構造部材とが接合されてなる一体化成形品に関する。
　繊維強化複合材料は力学特性、軽量性に優れた材料であり、航空機や自動車、産業用機器などの部材をはじめとして広く用いられている。このような用途においては、繊維強化複合材料を主骨格とするフレーム構造を採用する場合がある。この場合、繊維強化複合材料から成るフレーム材の一部に連結あるいは着脱が可能な部材を形成する必要があるが、そのような部材は、比較的形状が複雑であるため、射出成形などで別途製造し、接着剤やボルトを用いてフレーム材に固定することが一般的であった。例えば、特許文献１では繊維強化樹脂製のパイプの接合部にボルト加工を行い、接合部材と機械的に接合する方法が開示されている。また特許文献２には炭素繊維強化樹脂製のパイプと継手を接着剤で接合した構造体が開示されている。
特開平１１－３５０５９２号公報 特開昭６２－２９５３７２号公報
　しかし、特許文献１に記載の方法では、パイプのボルト加工により強度低下の懸念があるとともに、ボルトそのものによる重量増といった課題も存在した。また特許文献２で開示されている方法についても、接合状態が接着剤塗布の状態に依存することが接合の信頼性を低下させる要因となるとともに、接着材塗布による重量増の課題も存在した。また、いずれの方法においても、工程数が多くなるために生産性が低下するという課題は避けられなかった。
　本発明の目的は、軽量かつ高剛性の一体化成形品を、生産性よく、かつ強固な接合状態で作製することにある。
　上述の課題を解決する本発明は、以下である。
　繊維強化熱硬化性樹脂から本質的になる、筒状部または柱状部を有する構造部材（ａ）と、樹脂構造部材（ｂ）とが接合されてなる一体化成形品であって、前記樹脂構造部材（ｂ）は、前記構造部材（ａ）の筒状部または柱状部の外周面および／または内周面とオーバーラップするオーバーラップ領域を有し、該オーバーラップ領域の少なくとも一部において前記構造部材（ａ）と熱可塑性樹脂を介して接合されてなる一体化成形品。
　本発明によれば、軽量かつ安定した接合状態の一体化成形品を、生産性良く製造することができる。
樹脂構造部材（ｂ）としての継手の例を示す模式図である。 図１に示す継手を構造部材（ａ）と接合した一体化成形品の例を示す模式図である。 樹脂構造部材（ｂ）としての台座の例を示す模式図である。 図３に示す台座を構造部材（ａ）と接合した一体化成形品の例を示す模式図である。 樹脂構造部材（ｂ）としてのリブの例を示す模式図である。 図５に示すリブを構造部材（ａ）と接合した一体化成形品の例を示す模式図である。 樹脂構造部材（ｂ）としての第二の筒状体の例を示す模式図である。 図７に示す第二の筒状体を構造部材（ａ）と接合した一体化成形品の例を示す模式図である。 構造部材（ａ）と樹脂構造部材（ｂ）の接合部の一例を示す断面図である。 構造部材（ａ）と樹脂構造部材（ｂ）の間に熱可塑性樹脂をインサート成形した一体化成形品の例を示す模式図である。 構造部材（ａ）と樹脂構造部材（ｂ）の間に熱可塑性樹脂をインサート成形した一体化成形品の接合部の断面の一例を示す透視図である。
　以下に、本発明の好ましい実施の形態について説明する。
　本発明に係る一体化成形品は、繊維強化熱硬化性樹脂から本質的になり、少なくとも一部に筒状部または柱状部を有する構造部材（ａ）と、別の樹脂構造部材（ｂ）とが接合されてなる一体化成形品である。なお、本発明において、ある材料から本質的になる、とは、当該材料を主要な成分として含有し、典型的には当該材料のみから構成されるが、発明の効果を失わない限りにおいてその他の成分を含んでもよいことを意味する。
　本発明における構造部材（ａ）の繊維強化熱硬化性樹脂に含まれる繊維は、一般的に強化繊維として用いられるものを用いることができる。例えば、ガラス繊維、ポリアクリロニトリル系、レーヨン系、リグニン系、ピッチ系の炭素繊維（黒鉛繊維を含む）、チタン酸カリウィスカ、酸化亜鉛ウィスカ、炭酸カルシウムウィスカ、ワラステナイトウィスカ、硼酸アルミウィスカ、アラミド繊維、アルミナ繊維、炭化珪素繊維、セラミック繊維、アスベスト繊維、石コウ繊維、金属繊維などが挙げられ、この中でもガラス繊維、ポリアクリロニトリル系およびピッチ系の炭素繊維が好ましく、軽量性と力学特性の観点からポリアクリロニトリル系およびピッチ系の炭素繊維がより好ましく、ポリアクリロニトリル系の炭素繊維が特に好ましい。
　構造部材（ａ）に含まれる繊維はサイジング剤で表面処理を行っていることが力学特性向上の観点から好ましい。サイジング剤としては多官能エポキシ樹脂、アクリル酸系ポリマー、多価アルコール、ポリエチレンイミンなどが挙げられ、具体的にはグリセロールトリグリシジルエーテル、ジグリセロールポリグリシジルエーテル、ポリグリセロールポリグリシジルエーテル、ソルビトールポリグリシジルエーテル、アラビトールポリグリシジルエーテル、トリメチロールプロパントリグリシジルエーテル、ペンタエリスリトールポリグリシジルエーテルなどの脂肪族多価アルコールのポリグリシジルエーテル、ポリアクリル酸、アクリル酸とメタクリル酸との共重合体、アクリル酸とマレイン酸との共重合体、あるいはこれらの２種以上の混合物、ポリビニルアルコール、グリセロール、ジグリセロール、ポリグリセロール、ソルビトール、アラビトール、トリメチロールプロパン、ペンタエリスリトール、アミノ基を１分子中により多く含むポリエチレンイミン等が挙げられ、これらの中でも、反応性の高いエポキシ基を１分子中に多く含み、かつ水溶性が高く、繊維への塗布が容易なことから、グリセロールトリグリシジルエーテル、ジグリセロールポリグリシジルエーテル、ポリグリセロールポリグリシジルエーテルが本発明では好ましく用いられる。
　サイジング剤は、繊維１００質量部に対して０．０１～５質量部含有していることが好ましく、０．１～２質量部含有していることがより好ましい。
　構造部材（ａ）に含まれる繊維は連続繊維であることが好ましい。ここで、本明細書における連続繊維とは、１０ｍｍ以上の長さを有する繊維を意味し、この長さを有する限りにおいて必ずしも部材全体にわたって連続した繊維である必要はなく、途中で分断されていてもよい。連続繊維の形態としては、例えば、繊維束を織り込んだクロス織物や、フィラメント、ブレイド、フィラメント束、紡績糸等を一方向に引き揃えた形態が挙げられる。また、これらのうち２種以上の強化繊維の形態を併用して構造部材（ａ）を形成することもできる。
　構造部材（ａ）は、繊維強化熱硬化性樹脂からなるプリプレグシートを積層して成形した積層構造を有する成形体であることが好ましい。プリプレグシートが強化繊維を一方向に引き揃えられた形態である場合には、強化繊維の角度を概ね０°方向、概ね±４５°方向、概ね９０°方向などを併用した積層構成とすることが好ましく、上記以外の角度の層構成が含まれていてもよい。
　構造部材（ａ）１００質量％中に存在する繊維の質量含有率は２０～７０質量％であることが好ましく、より好ましくは２５～７０質量％であり、特に好ましくは３０～６５質量％である。繊維の質量含有率を上記の範囲とすることで、高剛性かつ良寸法精度の構造部材（ａ）を得ることができる。
　構造部材（ａ）の繊維強化熱硬化性樹脂を構成する熱硬化性樹脂の種類は特に制限はなく、例えば不飽和ポリエステル樹脂、ビニルエステル樹脂、エポキシ樹脂、フェノール（レゾール型）樹脂、ユリア・メラミン樹脂、ポリイミド樹脂等や、これらの共重合体、変性体、および、これらの少なくとも２種をブレンドした樹脂があげられる。これらの中でも、剛性、強度に優れることから、エポキシ樹脂を主成分とする熱硬化性樹脂が成形品の力学特性の観点からより好ましい。なお熱硬化性樹脂中における主成分とは、熱硬化性樹脂における成分比率が、６０質量％以上を占めることをいう。
　また繊維強化熱硬化性樹脂には用途等に応じ他の充填材や添加剤を含有してもよい。例えば、エラストマーあるいはゴム成分、無機充填材、難燃剤、導電性付与剤、抗菌剤、防虫剤、防臭剤、着色防止剤、離型剤、帯電防止剤、可塑剤、着色剤、顔料、染料、発泡剤、制泡剤、カップリング剤などが挙げられる。
　本発明において、構造部材（ａ）は、少なくとも一部に筒状部または柱状部を有する部材である。ここで、柱状とは筒状部において中空が存在しない中実の形状を意味する。典型的には、構造部材（ａ）は、全体として柱状や筒状をなす形状であることができる。あるいは、構造部材（ａ）は、筒状部または柱状部と、それ以外の形状部分とを併せ持つ形態であってもよい。さらに、筒状部を有する場合、筒状部の肉厚が変化する偏肉の形態であってもよい。構造部材（ａ）の筒状部または柱状部は湾曲していてもよい。
　構造部材（ａ）が筒状部を有する場合、筒状形態の開口面と平行な断面（以下、単に構造部材（ａ）の「断面」という場合、構造部材（ａ）の筒状部における筒状形態の開口面と平行な断面を指すものとする）の径に対し、開口面と垂直な方向の長さがより長い、管状であることが、軽量、高剛性の観点から好ましい。この場合、管状部の長手方向の長さは特に制限はないが、０．０５ｍ以上であることが好ましく、より好ましくは０．１ｍ以上、特に好ましくは０．１５ｍ以上である。また、ドローン等のフレーム構造を構成するフレーム材として用いることを想定すると、３ｍ以下であることが好ましく、より好ましくは２ｍ以下、特に好ましくは１ｍ以下である。構造部材（ａ）が、全体として筒状をなす筒状体であることは本発明の好ましい態様であり、全体として管状をなす部材、すなわちパイプ状の部材であることは、本発明の特に好ましい態様である。
　構造部材（ａ）の筒状部または柱状部の断面形状は特に制限がないが、円形または矩形であることが好ましい。また、構造部材（ａ）の筒状部または柱状部の断面積は２０ｍｍ２以上が好ましく、より好ましくは５０ｍｍ２以上である。また３００ｍｍ２以下が好ましく、より好ましくは２００ｍｍ２以下である。構造部材（ａ）が上記断面積の範囲である場合は高剛性の一体化成形品を生産性よく得ることができる。
　構造部材（ａ）は、熱硬化性樹脂から本質的になるものであるが、外周面および／または内周面の少なくとも一部、典型的には樹脂構造部材（ｂ）と接合する部分に、その表面に露出した熱可塑性樹脂領域を有していると、樹脂構造部材（ｂ）との熱溶着により、熱可塑性樹脂を介して構造部材（ａ）と樹脂構造部材（ｂ）とが接合した状態、特に、後述するような、接合境界面より構造部材（ａ）側に位置する構造部材（ａ）の表面に熱可塑性樹脂が存在する状態を容易に形成することができる。このような熱可塑性樹脂領域は、典型的には構造部材（ａ）の表面に薄く設けられ、その厚みは通常１～３００μｍであり、５０～１５０μｍがより好ましい。
　構造部材（ａ）の筒状部または柱状部が円形断面を有し、その外周面に熱可塑性樹脂領域が存在する場合は、筒状部または柱状部の中心軸から最外層までの距離Ｌａと、筒状部または柱状部の中心軸から熱硬化性樹脂と熱可塑性樹脂領域の界面までの距離Ｌｂが、下記式（１）の関係を満たすことが好ましい。
０．９≦Ｌｂ／Ｌａ≦０．９９９９（１）
　このような熱可塑性樹脂領域の形態は、構造部材（ａ）の筒状部または柱状部の内周面または外周面の表面に熱可塑性樹脂が露出した領域を形成している限り特に限定はないが、例えば、層状、スポット状、網目状、格子状など例示することができる。
　また、このような熱可塑性樹脂領域を構成する熱可塑性樹脂としては、ポリオレフィン樹脂、ポリエステル樹脂、ポリアミド樹脂、ポリカーボネート樹脂、ポリフェニレンスルフィド樹脂、ポリイミド樹脂、ポリアミドイミド樹脂、ポリエーテルイミド樹脂、ポリエーテルケトン樹脂、ポリエーテルエーテルケトン樹脂、ポリエーテルケトンケトン樹脂、ポリアリレート樹脂などが好ましい。
　熱可塑性樹脂領域を構成する熱可塑性樹脂の線膨張係数は６０℃から１５０℃の測定温度範囲において、高い接合強度が得られるという観点において、６０ｐｐｍ／℃以上であることが好ましく、７０ｐｐｍ／以上がより好ましく、また２００ｐｐｍ／℃以下であることが好ましく、１５０ｐｐｍ以下であることがより好ましい。
　構造部材（ａ）に熱可塑性樹脂領域が存在する場合、構造部材（ａ）の熱硬化性樹脂と熱可塑性樹脂領域の界面が凹凸形状を形成していることが、高い接合強度が得られる観点から好ましい。ここで、界面が凹凸形状を形成しているとは、熱硬化性樹脂と熱可塑性樹脂領域の境界面が平らではなく、熱硬化性樹脂側に窪んでいる形態と熱可塑性樹脂領域側に窪んでいる形態が混在する境界面を形成していることを示している。この場合の窪みの深さは、１～２００μｍであることが好ましく、より好ましくは１０～１００μｍである。
　本発明において、構造部材（ａ）の製造方法は特に限定されない。構造部材（ａ）が筒状体である場合、製造方法としては、フィラメントワインディング法やシートワインディング法等により、熱硬化性樹脂を含浸させた強化繊維を引きそろえたプリプレグ等を、所定の張力を付加しながらマンドレルに巻き付けて賦形した後に硬化する方法や、賦形型を使用した内圧成形、あるいはプレス成形で賦形したのちに硬化する方法などが挙げられる。構造部材（ａ）の外周面または内周面の少なくとも一部に熱可塑性樹脂領域を形成する方法としては、上記方法において、最初もしくは最後に少なくとも一層分、熱可塑性樹脂からなるフィルムを巻き付けて、熱硬化性樹脂と一体化して硬化する方法を挙げることができる。
　本発明における樹脂構造部材（ｂ）は、本質的に熱可塑性樹脂で構成される部材であることができる。この場合、熱可塑性樹脂に特に制限はなく、例えば、ポリエチレン、ポリプロピレンなどのポリオレフィン樹脂、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート（ＰＥＮ）、ポリブチレンナフタレート（ＰＢＮ）、液晶ポリエステル等のポリエステル樹脂、ポリカプロアミド（ナイロン６）、ポリヘキサメチレンアジパミド（ナイロン６６）、ポリペンタメチレンアジパミド（ナイロン５６）、ポリヘキサメチレンセバカミド（ナイロン６１０）、ポリヘキサメチレンドデカミド（ナイロン６１２）、ポリウンデカンアミド（ナイロン１１）、ポリドデカンアミド（ナイロン１２）、ポリカプロアミド／ポリヘキサメチレンアジパミドコポリマー（ナイロン６／６６）、ポリカプロアミド／ポリヘキサメチレンテレフタルアミドコポリマー（ナイロン６／６Ｔ）、ポリヘキサメチレンアジパミド／ポリヘキサメチレンテレフタルアミドコポリマー（ナイロン６６／６Ｔ）、ポリヘキサメチレンアジパミド／ポリヘキサメチレンイソフタルアミドコポリマー（ナイロン６６／６Ｉ）、ポリヘキサメチレンアジパミド／ポリヘキサメチレンイソフタルアミド／カプロアミドコポリマー（ナイロン６６／６Ｉ／６）、ポリヘキサメチレンテレフタルアミド／ポリヘキサメチレンイソフタルアミドコポリマー（ナイロン６Ｔ／６Ｉ）、ポリヘキサメチレンテレフタルアミド／ポリドデカンアミドコポリマー（ナイロン６Ｔ／１２）、ポリヘキサメチレンアジパミド／ポリヘキサメチレンテレフタルアミド／ポリヘキサメチレンイソフタルアミドコポリマー（ナイロン６６／６Ｔ／６Ｉ）、ポリヘキサメチレンテレフタルアミド／ポリ－２－メチルペンタメチレンテレフタルアミドコポリマー（ナイロン６Ｔ／Ｍ５Ｔ）、ポリノナメチレンテレフタルアミド（ナイロン９Ｔ）などのポリアミド樹脂、ポリカーボネート樹脂、ポリフェニレンスルフィド（ＰＰＳ）樹脂、ポリアセタール樹脂またはポリオキシメチレン樹脂、ポリイミド（ＰＩ）樹脂、ポリアミドイミド（ＰＡＩ）樹脂、ポリエーテルイミド樹脂、ポリスルフォン樹脂、ポリエーテルケトン（ＰＥＫ）樹脂、ポリエーテルエーテルケトン（ＰＥＥＫ）樹脂、ポリエーテルケトンケトン（ＰＥＫＫ）樹脂、ポリテトラフルオロエチレン樹脂、ポリアリレート（ＰＡＲ）樹脂、および、これらの少なくとも２種類をブレンドした樹脂などが挙げられる。なかでもポリオレフィン樹脂、ポリエステル樹脂、ポリアミド樹脂、ＰＰＳ樹脂が好ましい。
　また、構造部材（ａ）と樹脂構造部材（ｂ）の接合強度の観点から、構造部材（ａ）が熱可塑性樹脂領域を有する場合は、熱可塑性樹脂領域を構成する熱可塑性樹脂と、樹脂構造部材（ｂ）の構造部材（ａ）と接合される領域、すなわち後述するオーバーラップ領域において樹脂構造部材（ｂ）の表面に存在する熱可塑性樹脂は、同種であることが好ましい。
　樹脂構造部材（ｂ）が本質的に熱可塑性樹脂で構成される場合、樹脂構造部材（ｂ）は継手、台座またはリブのいずれかの部材であることが好ましい。典型的には、継手は、２つの筒状部または柱状部を繋ないだり、方向を変えたり、太さの異なる筒状部または柱状部同士を連結したり、３つ以上の筒状部または柱状部を合流したり分岐させたりするための部材である。台座は、筒状部または柱状部を受け止めて据えおくための部材である。また、リブは、板状突起を形成することにより筒状部または柱状部の強度、剛性を向上させるための部材である。本発明においては、これらの筒状部のうち少なくとも１つが前述の筒状部を有する構造部材（ａ）であり、好ましい態様においてはそれらの全てが前述の筒状部である。図１Ａ～Ｄには代表的な継手、図２Ａ～Ｄには構造部材（ａ）（筒状体）と継手が一体化した一体化成形品、図３Ａ～Ｂには代表的な台座、図４Ａ～Ｂには構造部材（ａ）（筒状体）と台座が一体化した一体化成形品、図５には代表的なリブ、図６Ａ～Ｂには構造部材（ａ）（筒状体）とリブが一体化した一体化成形品の模式図を示すがそれぞれの構造はこれに限定されるものではない。
　また、樹脂構造部材（ｂ）は、本質的に熱硬化性樹脂で構成される部材であってもよい。この場合、熱硬化性樹脂は特に制限はなく、構造部材（ａ）と同様に、例えば、不飽和ポリエステル樹脂、ビニルエステル樹脂、エポキシ樹脂、フェノール（レゾール型）樹脂、ユリア・メラミン樹脂、ポリイミド樹脂等や、これらの共重合体、変性体、および、これらの少なくとも２種をブレンドした樹脂があげられる。これらの中でも、剛性、強度に優れることから、エポキシ樹脂を主成分とする熱硬化性樹脂が成形品の力学特性の観点からより好ましい。さらに用途等に応じ他の充填材や添加剤を含有してもよい。例えば、エラストマーあるいはゴム成分、無機充填材、難燃剤、導電性付与剤、抗菌剤、防虫剤、防臭剤、着色防止剤、離型剤、帯電防止剤、可塑剤、着色剤、顔料、染料、発泡剤、制泡剤、カップリング剤などが挙げられる。
　本発明において樹脂構造部材（ｂ）が本質的に熱硬化性樹脂で構成される場合には、樹脂構造部材（ｂ）は、その表面の少なくとも一部に熱可塑性樹脂が露出した熱可塑性樹脂領域を有していてもよい。これにより、構造部材（ａ）および樹脂構造部材（ｂ）が熱可塑性樹脂領域を介して両者を熱溶着で接合することが可能になる。より好ましい態様においては、構造部材（ａ）と樹脂構造部材（ｂ）の双方がこのような熱可塑性樹脂領域を有し、構造部材（ａ）の熱可塑性樹脂領域と樹脂構造部材（ｂ）の熱可塑性樹脂領域とが熱溶着により接合される。構造部材（ａ）と樹脂構造部材（ｂ）の双方が熱可塑性樹脂領域を有する場合、両者の接合強度の観点から、構造部材（ａ）と樹脂構造部材（ｂ）の双方が熱可塑性樹脂領域を構成する熱可塑性樹脂種は同種であることが好ましい。
　このような熱可塑性樹脂領域は、典型的には樹脂構造部材（ｂ）の表面に薄く設けられ、その厚みは通常１～３００μｍであり、５０～１５０μｍがより好ましい。また、熱可塑性樹脂領域の形態は、樹脂構造部材（ｂ）の表面に熱可塑性樹脂が露出した領域を形成している限り特に限定はないが、例えば、層状、スポット状、網目状、格子状など例示することができる。
　樹脂構造部材（ｂ）が本質的に熱硬化性樹脂で構成される場合、樹脂構造部材（ｂ）は、筒状体であることが好ましい。典型的には、筒状体とは、構造部材（ａ）の筒状部または柱状部とは長さ、径、厚みなどが異なる筒状体である。図７には代表的な筒状体、図８には構造部材（ａ）（第一の筒状体）１と、樹脂構造部材（ｂ）（第二の筒状体）２が一体化した一体化成形品の模式図を示すが、それぞれの構造はこれに限定されるものではない。
　樹脂構造部材（ｂ）が本質的に熱硬化性樹脂から構成される場合、接合時の入熱による各部材の形状変化が極めて小さいため、高い寸法精度の一体化成形品が得られ、構造部材（ａ）と樹脂構造部材（ｂ）の断面の中心ずれを示す同心度は０．２５ｍｍ以下であることが好ましい。同心度はＣＮＣ三次元測定機を用いて、構造部材（ａ）および樹脂構造部材（ｂ）それぞれの外径３点の位置を測定し、それより得られた中心位置を比較することで測定することができる。
　樹脂構造部材（ｂ）は、力学特性を向上するために、強化繊維を含有していてもよい。強化繊維としては、前述の構造部材（ａ）を構成する繊維強化熱硬化性樹脂と同様の選択肢から選択される繊維が挙げられるが、軽量性と力学特性の観点からは炭素繊維が好ましい。これらの繊維には、カップリング剤による処理、サイジング剤による処理、添加剤の付着処理などの表面処理が施されていても良い。
　樹脂構造部材（ｂ）１００質量％中に存在する繊維の質量含有率は２０～７０質量％であることが好ましく、より好ましくは２５～７０質量％であり、特に好ましくは３０～６５質量％である。繊維の質量含有率を上記の範囲とすることで、高剛性かつ良寸法精度の樹脂構造部材（ｂ）を得ることができる。
　樹脂構造部材（ｂ）が比較的複雑な形状である場合には、樹脂構造部材（ｂ）に含まれる強化繊維は、不連続の強化繊維であることが成形加工性の観点で好ましい。この場合、強化繊維の質量平均繊維長Ｌｗは０．３ｍｍ以上であることが好ましく、０．８ｍｍ以上がより好ましい。質量平均繊維長は長い程、強度、剛性の向上効果が高く、特に衝撃強度に対して著しい向上効果が得られる。質量平均繊維長Ｌｗの上限は３．０ｍｍ以下であることが好ましく、１．５ｍｍ以下であることがさらに好ましく、１．０ｍｍ以下であることがとりわけ好ましい。この範囲の質量平均繊維長Ｌｗとすることで強度、剛性と加工性のバランスが良好となる。本発明の樹脂構造部材（ｂ）の質量平均繊維長は、全て同一の長さではなく、繊維長の分布をもっていてもよい。炭素繊維の質量平均繊維長は、次の手法により求められる。すなわち、樹脂構造部材（ｂ）からサンプルを切り出し、この切り出した試験片を、樹脂構造部材（ｂ）に含まれる熱可塑性樹脂が可溶な溶剤に２４時間浸漬し、樹脂成分を溶解させる。樹脂成分が溶解された試験片を、顕微鏡にて、１００倍の倍率で観察する。この観察において、視野内の繊維の中の任意の４００本について、それぞれの繊維長Ｌｉを測定し、次式に基づき算出する。
質量平均繊維長Ｌｗ＝（ΣＬｉ２）／（ΣＬｉ）。
　本発明の一体化成形品において、樹脂構造部材（ｂ）は、構造部材（ａ）の筒状部または柱状部の外周部および／または内周部とオーバーラップするオーバーラップ領域を有しており、オーバーラップ領域の少なくとも一部において、構造部材（ａ）と熱可塑性樹脂を介して熱溶着により接合されている。樹脂構造部材（ｂ）が構造部材（ａ）の筒状部の外周面および／または内周面とオーバーラップする、とは、構造部材（ａ）の筒状部の外周面または内周面、あるいはその両面と、樹脂構造部材（ｂ）の少なくとも一部とが面で接していることを意味する。また、樹脂構造部材（ｂ）が構造部材（ａ）の柱状部の外周面とオーバーラップする、とは、構造部材（ａ）の柱状部の外周面と、樹脂構造部材（ｂ）の少なくとも一部とが面で接していることを意味する。そして、オーバーラップ領域とは、その接している領域を意味する。図９は、構造部材（ａ）１の外周面に樹脂構造部材（ｂ）として継手２を接合した実施形態であるが、この実施形態では、構造部材（ａ）の外周面を全周に渡り取り囲むように筒状の樹脂構造部材（ｂ）の内周面が接している。すなわち、樹脂構造部材（ｂ）は構造部材（ａ）とその全周においてオーバーラップしている。樹脂構造部材（ｂ）は構造部材（ａ）の外周面または内周面の全周ではなく、一部のみで接していてもよいが、強固な接合強度を発現するために、構造部材（ａ）の筒状部の周長の５０％以上、１００％（全周）以下の範囲で接していることが好ましく、１００％（全周）で接して接合して閉断面をなしていることが特に好ましい。なお、構造部材（ａ）の筒状部と接合する場合、外周面、内周面のいずれとオーバーラップさせて樹脂構造部材（ｂ）を接合するかは、目的とする部材に応じて決定されるべき事項であるが、生産性の観点からは、構造部材（ａ）の筒状部の外周面とオーバーラップさせて接合することが好ましい。また、一体化成形品は、外周面とオーバーラップして接合する樹脂構造部材（ｂ）と、内周面とオーバーラップして接合する樹脂構造部材（ｂ）の両方を備えることもできる。
　構造部材（ａ）と樹脂構造部材（ｂ）との接合部においては、接合境界面より構造部材（ａ）側に位置する構造部材（ａ）の表面に、熱可塑性樹脂が存在することが好ましい。ここで、接合境界面より構造部材（ａ）側に位置する構造部材（ａ）の表面に熱可塑性樹脂が存在する状態とは、当該接合部の断面において、構造部材（ａ）の筒状部または柱状部の外周をなす線を接合境界面とし、それよりも構造部材（ａ）側に熱可塑性樹脂が存在している状態を指す。
　本発明の構造部材（ａ）と樹脂構造部材（ｂ）との接合部においては、構造部材（ａ）に含まれる繊維の一部が、構造部材（ａ）を構成する熱硬化性樹脂と熱可塑性樹脂領域とを跨ぐ状態で、すなわち構造部材（ａ）の熱硬化性樹脂および熱可塑性樹脂領域の両方と接していることが好ましい。このような接合構造を形成することで、繊維補強効果により強固な接合状態を形成することができる。
　本発明の構造部材（ａ）と樹脂構造部材（ｂ）の接合強度は７ＭＰａ以上であることが好ましく、１０ＭＰａ以上であることがより好ましい。接合強度の上限について特に限定されないが生産性良く本発明の一体化成形品が得られる観点から１００ＭＰａ以下であることが好ましい。
　本発明の構造部材（ａ）と樹脂構造部材（ｂ）からなる一体化成形品は、一例として、少なくとも一方の部材が加熱された状態で両者を接触させることにより構造部材（ａ）と樹脂構造部材（ｂ）とを熱溶着により接合することにより製造することができる。このような熱溶着の方法は特に限定されず、熱板溶着、振動溶着、超音波溶着、遠赤外線加熱溶着、誘電加熱溶着、レーザー溶着、インサート成形、アウトサート射出成形などにより一体化することができる。
　樹脂構造部材（ｂ）が本質的に熱可塑性樹脂で構成される場合は、インサート成形は、特に強固に接合した一体化成形品を生産性よく製造することができる点で好ましい。インサート成形では構造部材（ａ）を射出成形金型内にインサートした状態で型締めを行い、樹脂構造部材（ｂ）の熱可塑性樹脂を構造部材（ａ）の外周部または内周部とオーバーラップするように射出成形することで樹脂構造部材（ｂ）を成形、一体化する。また、少なくとも一方が表面に熱可塑性樹脂領域を有する構造部材（ａ）と樹脂構造部材（ｂ）を予め成形した後、当該熱可塑性樹脂領域を有する構造部材（ａ）または樹脂構造部材（ｂ）が加熱された状態で前記樹脂構造部材（ｂ）を前記構造部材（ａ）の外周面または内周面とオーバーラップするよう接触させることにより、前記構造部材（ａ）と前記樹脂構造部材（ｂ）とを熱溶着により接合してもよい。このような方法としては、遠赤外線加熱溶着が挙げられる。遠赤外線加熱溶着では、構造部材（ａ）と樹脂構造部材（ｂ）をそれぞれ予め成形した後、構造部材（ａ）を加熱した状態で樹脂構造部材（ｂ）が構造部材（ａ）の外周部または内周部とオーバーラップするように接触させ、冷却、固化することで製造することができる。構造部材（ａ）は遠赤外線ヒーターで樹脂構造部材（ｂ）に含まれる熱可塑性樹脂が溶融、軟化する温度以上の状態に加熱することが好ましい。
　樹脂構造部材（ｂ）が本質的に熱硬化性樹脂で構成される場合は、一体化成形品は、一例として、筒状部または柱状部の外周面または内周面の少なくとも一部に熱可塑性樹脂領域を有する構造部材（ａ）、および／または、表面の少なくとも一部に熱可塑性樹脂領域を有する樹脂構造部材（ｂ）を準備し、該熱可塑性樹脂領域が加熱された状態で、該加熱された熱可塑性樹脂領域を含む領域で前記構造部材（ａ）と前記樹脂構造部材（ｂ）とがオーバーラップするように接触させる方法により製造することができる。このような熱溶着の方法は特に限定されず、熱板溶着、振動溶着、超音波溶着、遠赤外線加熱溶着、誘電加熱溶着、レーザー溶着などが利用できる。このとき、構造部材（ａ）または樹脂構造部材（ｂ）の熱可塑性樹脂領域を構成する熱可塑性樹脂が軟化する温度以上に加熱することが好ましく、溶融する温度以上に加熱することがより好ましい。
　また、本発明の一体化成形品は、他の例として、構造部材（ａ）および樹脂構造部材（ｂ）を、前記樹脂構造部材（ｂ）が前記構造部材（ａ）の筒状部または柱状部の外周面および／または内周面とオーバーラップするように射出成形金型内にインサートした状態で、オーバーラップしている構造部材（ａ）と樹脂構造部材（ｂ）の間に熱可塑性樹脂を射出成形する方法によっても製造することができる。図１０は、第一の筒状体である構造部材（ａ）１の外周面に、樹脂構造部材（ｂ）として第二の筒状体２が、射出成形された熱可塑性樹脂４を介して接合した実施形態の模式図であり、図１１はその接合部の断面図である。熱可塑性樹脂４は構造部材（ａ）の筒状部または柱状部の外周面および／または内周面と、樹脂構造部材（ｂ）の表面との間に介在していればよく、この図に限定されるものではない。この場合の射出成形用の熱可塑性樹脂種としては、樹脂構造部材（ｂ）を構成する熱可塑性樹脂として前述した樹脂と同様の樹脂を用いることができる。また、射出成形用の熱可塑性樹脂は、力学特性を向上するために、強化繊維を含有していてもよい。強化繊維としては、前述の構造部材（ａ）を構成する繊維強化熱硬化性樹脂と同様の選択肢から選択される繊維が挙げられるが、軽量性と力学特性の観点からは炭素繊維が好ましい。これらの繊維には、カップリング剤による処理、サイジング剤による処理、添加剤の付着処理などの表面処理が施されていても良い。
　本発明の一体化成形品は、軽量、高剛性の構造部材（ａ）に接続、合流、分岐、据え置きなどを行うことができる樹脂構造部材（ｂ）が強固に接合されていることから、フレーム構造を形成する部材として好適に使用することができる。このような構造体としては、産業用ロボットのボディーおよびアーム、自動車、バイク、自転車、航空機、ヘリコプター、ドローン、船舶、潜水艇などのボディーおよびアーム、建築資材などが挙げられる。特に、剛性、軽量性の観点から、航空機、ヘリコプター、ドローンなどの飛翔体に好ましく用いられる。飛翔体の性能向上の観点から構造部材（ａ）の筒状部または柱状部の長さが０．０５ｍ以上、３ｍ以下の一体化成形品がより好ましい。特に本体重量が１０００ｋｇ以下の比較的小型の飛翔体ではボルト、ファスナーなど機械締結による重量増の影響が大きいことから、本発明の一体化成形品を特に好適に用いることができる。
　以下に実施例を示し、本発明をさらに具体的に説明するが、本発明は実施例の記載によって何ら限定されるものではない。
　（実施例１）
　先端外径３０ｍｍ、テ－パ－６．０／１０００、長さ７００ｍｍの、離型処理したステンレス製マンドレルに、東レ（株）製”トレカプリプレグ”Ｐ３０５１Ｓ－３０およびＰ３０５２Ｓ－１２を使用し、マンドレル長手方向を０度軸とした場合、Ｐ３０５１Ｓ－３０を材料角度０度に、Ｐ３０５２Ｓ－１２を材料角度６０度となるように積層させた。さらにその外側に共重合ポリアミド樹脂（東レ製ＣＭ４０００、ポリアミド６／６６／６１０、融点１５０℃）のペレットを熱プレスして得られた厚み７０μｍのポリアミドフィルムを１周分巻き付けた後、ラッピングテープ（耐熱性フィルムテープ、幅１０ｍｍ）を張力３ｋｇで巻きつけて、１５０℃の硬化炉で３０分間加熱成形を行った。この後、マンドレルを抜き取り、ラッピングテ－プを除去した後、切断して、厚み０．５ｍｍ、長さ５００ｍｍのパイプ１を得た。その後、シリンダー温度２８０℃、金型温度８０℃に設定した射出成形機（日本製鋼所製Ｊ３５０ＥＩＩＩ）を用いて、射出成形用金型に当該パイプをインサートし、東レ（株）製長繊維ペレット（ＴＬＰ１０６０）を用いて、パイプの外周面の端部から１０ｍｍの領域の外周面と接触するように図１Ａに示す継手を射出成形し、図２Ａに示すような一体化成形品を製造した。
　得られた一体化成形品Ｎ＝５個について、１．５ｍの高さから継手が下方となるように落下させ、その時のパイプと継手の接合状態を目視で確認する落下試験を実施した。その結果、５個ともに接合部に変化は見られず良好な接合状態が維持されていた。
　得られた一体化成形品Ｎ＝５個について、継手部分とパイプを治具で把持して、インストロン製万能試験機を用いて、室温下、試験速度０．５ｍｍ／分で引張試験を実施したところ、Ｎ＝５平均の接合強度は４５ＭＰａであり、良好な接合状態であった。
　（実施例２）
　実施例１と同様にパイプ１を得た。次いで、シリンダー温度２８０℃、金型温度８０℃に設定した射出成形機（日本製鋼所製Ｊ３５０ＥＩＩＩ）を用いて、炭素繊維強化ポリアミド６のペレットである東レ（株）製長繊維ペレット（ＴＬＰ１０６０）を用いて図１Ａに示す継手を単独で射出成形した。パイプの端部を遠赤外線ヒーターで用いて表面温度が２３０℃まで加熱したのち、パイプの外周面の端部から１０ｍｍとその内周面が接する状態で、直ちに継手を１ＭＰａの圧力で１５秒間パイプに押し当て、その後冷却して図２Ａに示すような一体化成形品を製造した。
　実施例１と同様に一体化成形品の落下試験を実施した結果、５個ともに接合部に変化は見られず良好な接合状態が維持されていた。
　実施例１と同様に接合強度を評価したところ、４１ＭＰａであり、良好な接合状態であった。
　（実施例３）
　先端外径３０ｍｍ、テ－パ－６．０／１０００、長さ７００ｍｍの、離型処理したステンレス製マンドレルに、共重合ポリアミド樹脂（東レ製ＣＭ４０００、ポリアミド６／６６／６１０、融点１５０℃）のペレットを熱プレスして得られた厚み７０μｍのポリアミドフィルムを１周分巻き付けた後、東レ（株）製”トレカプリプレグ”Ｐ３０５１Ｓ－３０およびＰ３０５２Ｓ－１２を使用し、マンドレル長手方向を０度軸とした場合、Ｐ３０５１Ｓ－３０を材料角度０度に、Ｐ３０５２Ｓ－１２を材料角度６０度となるように積層させた。さらにその外側にラッピングテープ（耐熱性フィルムテープ、幅１０ｍｍ）を張力３ｋｇで巻きつけて、１５０℃の硬化炉で３０分間加熱成形を行った。この後、マンドレルを抜き取り、ラッピングテ－プの除去した後、切断して厚み０．５ｍｍ、長さ５００ｍｍのパイプ２を得た。
　次いで、シリンダー温度２８０℃、金型温度８０℃に設定した射出成形機（日本製鋼所製Ｊ３５０ＥＩＩＩ）を用いて、炭素繊維強化ポリアミド６のペレットである東レ（株）製長繊維ペレット（ＴＬＰ１０６０）を用いて、図５に示すようなリブを単独で射出成形した。
　パイプの端部の内周面を遠赤外線ヒーターにより表面温度２３０℃まで加熱したのち、加熱されたパイプの内周面に直ちにリブを１ＭＰａの圧力で１５秒間押し当て、その後冷却して図６に示すような一体化成形品を製造した。
　得られた一体化成形品Ｎ＝５個について、１．５ｍの高さからリブ接合部が下方となるように落下させ、その時のパイプとリブの接合状態を目視で確認する落下試験を実施した。その結果、５個ともに接合部に変化は見られず良好な接合状態が維持されていた。
　（実施例４）
　実施例１と同様にパイプ１を成形した。次いで、先端外径３１ｍｍ、テ－パ－６．０／１０００、長さ７００ｍｍの、離型処理したステンレス製マンドレルに、共重合ポリアミド樹脂（東レ製ＣＭ４０００、ポリアミド６／６６／６１０、融点１５０℃）のペレットを熱プレスして得られた厚み７０μｍのポリアミドフィルムを１周分巻き付けた後、東レ（株）製”トレカプリプレグ”Ｐ３０５１Ｓ－３０およびＰ３０５２Ｓ－１２を使用し、オールシャフト長手方向を０度軸とした場合、Ｐ３０５１Ｓ－３０を材料角度０度に、Ｐ３０５２Ｓ－１２を材料角度６０度となるように積層させた。さらにその外側にラッピングテープ（耐熱性フィルムテープ、幅１０ｍｍ）を張力３ｋｇで巻きつけて、１５０℃の硬化炉で３０分間加熱成形を行った。この後、マンドレルを抜き取り、ラッピングテ－プを除去した後、切断して厚み０．５ｍｍ、長さ５００ｍｍのパイプ３を得た。
　その後、パイプ１の端部を遠赤外線ヒーターで用いて表面温度が２３０℃まで加熱したのち、パイプ１の外周面の端部から１０ｍｍとその内周面が接する状態で、直ちにパイプ３を１５秒間パイプ１に押し当て、その後冷却して図８に示すような一体化成形品を製造した。
　得られた一体化成形品Ｎ＝５個について、１．５ｍの高さからパイプ３が下方となるように落下させ、その時の接合状態を目視で確認する落下試験を実施した。その結果、５個ともに接合部に変化は見られず良好な接合状態が維持されていた。
　得られた一体化成形品Ｎ＝５個について、ミツトヨ製ＣＮＣ三次元測定機ＣＲＹＳＴＡ　Ａｐｅｘ　Ｓ９１０８を用いて、パイプ１およびパイプ３それぞれの外径３点の位置を測定して得られた中心位置を比較して同心度を評価したところ、同心度は０．１６ｍｍと高い寸法精度であった。
　（実施例５）
　実施例１と同様にパイプ１を成形したのち、ステンレス製マンドレルの先端外径３２ｍｍに変えた以外は実施例１と同様にパイプ４を成形した。
　次いで、シリンダー温度２８０℃、金型温度８０℃に設定した射出成形機（日本製鋼所製Ｊ３５０ＥＩＩＩ）を用いて、金型内にパイプ１およびパイプ４をインサートした。この時、パイプ１の外周面の端部から１０ｍｍがパイプ４の内部に入る位置でインサートされており、パイプ１とパイプ４の間に炭素繊維強化ポリアミド６のペレットである東レ（株）製長繊維ペレット（ＴＬＰ１０６０）を射出成形して、図１０に示すような一体化成形品を得た。
　実施例４と同様に一体化成形品の落下試験を実施した結果、５個ともに接合部に変化は見られず良好な接合状態が維持されていた。
　実施例４と同様に一体化成形品の同心度を評価したところ、同心度は０．１２ｍｍであり高い寸法精度であった。
　（比較例１）
　実施例２と同様に、パイプ１および継手を作製した。２液型エポキシ接着剤（タカダ化学品製（株）製スワンボンド４０００）を用いて、等量の割合の２液を室温で均一に混合した後、ただちにパイプ１の端部から１０ｍｍの外周面に塗布してパイプ１の外周面の端部から１０ｍｍとその内周面が接する状態で、継手をパイプ１に嵌合させて万力で固定し、２５℃、２４時間接合させ、一体化成形品を製造した。
　実施例１と同様に一体化成形品の落下試験を実施した結果、５個中２個の接合部にクラックが見られた。
　実施例１と同様に接合強度を評価したところ、５ＭＰａであった。
　（比較例２）
　実施例４と同様に、パイプ１およびパイプ３を作製した。比較例１と同様の方法で２液型エポキシ接着剤（タカダ化学品製（株）製スワンボンド４０００）を用いて、一体化成形品を製造した。
　実施例４と同様に一体化成形品の落下試験を実施した結果、５個中３個の接合部にクラックが見られた。
　実施例４と同様に一体化成形品の同心度を評価したところ、同心度は０．９２ｍｍであった。
１　構造部材（ａ）（第一の筒状体）
２　樹脂構造部材（ｂ）（継手、台座、リブまたは第二の筒状体）
３　オーバーラップ領域
４　熱可塑性樹脂
 

Claims (16)

  1. 　繊維強化熱硬化性樹脂から本質的になる、筒状部または柱状部を有する構造部材（ａ）と、樹脂構造部材（ｂ）とが接合されてなる一体化成形品であって、前記樹脂構造部材（ｂ）は、前記構造部材（ａ）の筒状部または柱状部の外周面および／または内周面とオーバーラップするオーバーラップ領域を有し、該オーバーラップ領域の少なくとも一部において前記構造部材（ａ）と熱可塑性樹脂を介して接合されてなる一体化成形品。
  2. 　前記構造部材（ａ）と前記樹脂構造部材（ｂ）とが接合する部分において、接合境界面より構造部材（ａ）側に位置する前記構造部材（ａ）の表面に前記熱可塑性樹脂が存在する、請求項１に記載の一体化成形品。
  3. 　前記構造部材（ａ）の前記筒状部または柱状部が、その外周面および／または内周面の表面に露出した熱可塑性樹脂領域を有し、該熱可塑性樹脂領域の熱可塑性樹脂を介して前記構造部材（ａ）と、前記樹脂構造部材（ｂ）とが接合されてなる、請求項２に記載の一体化成形品。
  4. 　前記熱可塑性樹脂領域を構成する熱可塑性樹脂の線膨張係数が６０ｐｐｍ／℃以上、２００ｐｐｍ／℃以下である、請求項３に記載の一体化成形品。
  5. 　前記構造部材（ａ）に含まれる繊維が連続繊維であり、前記構造部材（ａ）を構成する熱硬化性樹脂と前記熱可塑性樹脂領域の両方と接している、請求項３に記載の一体化成形品。
  6. 　前記構造部材（ａ）の筒状部または柱状部が、円形断面を有し、前記構造部材（ａ）の中心軸から最外層までの距離Ｌａと中心軸から前記熱硬化性樹脂と前記熱可塑性樹脂領域の界面までの距離Ｌｂが式（１）の関係を満たす、請求項３に記載の一体化成形品。
    ０．９≦Ｌｂ／Ｌａ≦０．９９９９　（１）
  7. 　前記樹脂構造部材（ｂ）が本質的に熱可塑性樹脂からなる射出成形部材であるか、または、前記樹脂構造部材（ｂ）が本質的に熱硬化性樹脂からなるとともに表面の少なくとも一部に熱可塑性樹脂領域を有する部材である、請求項１～６のいずれかに記載の一体化成形品。
  8. 　前記構造部材（ａ）と前記樹脂構造部材（ｂ）の接合強度が７ＭＰａ以上、１００ＭＰａ以下である、請求項１～６のいずれかに記載の一体化成形品。
  9. 　前記樹脂構造部材（ｂ）が、前記オーバーラップ領域において、前記筒状部または柱状部の周長の５０％以上、１００％以下の範囲で接合されてなる、請求項１～６のいずれかに記載の一体化成形品。
  10. 　前記構造部材（ａ）が全体として管状をなす部材である、請求項１～６のいずれかに記載の一体化成形品。
  11. 　前記樹脂構造部材（ｂ）、が本質的に熱可塑性樹脂からなる継手、台座、リブのいずれかである、請求項１～６のいずれかに記載の一体化成形品。
  12. 　前記樹脂構造部材（ｂ）が、本質的に熱硬化性樹脂からなる筒状体であり、前記構造部材（ａ）と前記樹脂構造部材（ｂ）の同心度が０．２５ｍｍ以下である、請求項１～６のいずれかに記載の一体化成形品。
  13. 　請求項１～６のいずれかに記載の一体化成形品を含むフレーム構造。
  14. 　請求項１～６のいずれかに記載の一体化成形品を含む飛翔体。
  15. 　前記構造部材（ａ）の長さが０．０５ｍ以上、３ｍ以下である、および／または、本体重量が１０００ｋｇ以下である、請求項１４に記載の飛翔体。
  16. 　繊維強化熱硬化性樹脂から本質的になる、筒状部または柱状部を有する構造部材（ａ）と、樹脂構造部材（ｂ）とが接合されてなる一体化成形品の製造方法であって、下記（１）～（３）のいずれかの方法により前記構造部材（ａ）と前記樹脂構造部材（ｂ）とを熱溶着により接合する、一体化成形品の製造方法。
    （１）前記構造部材（ａ）を射出成形金型内にインサートした状態で、前記樹脂構造部材（ｂ）を前記構造部材（ａ）の外周面および／または内周面とオーバーラップするよう射出成形する。
    （２）少なくとも一方が表面に熱可塑性樹脂領域を有する構造部材（ａ）と樹脂構造部材（ｂ）を予め成形した後、当該熱可塑性樹脂領域を有する構造部材（ａ）または樹脂構造部材（ｂ）が加熱された状態で前記樹脂構造部材（ｂ）を前記構造部材（ａ）の外周面または内周面とオーバーラップするよう接触させる。
    （３）前記構造部材（ａ）および前記樹脂構造部材（ｂ）を、前記樹脂構造部材（ｂ）が前記構造部材（ａ）の外周面および／または内周面とオーバーラップするように射出成形金型内にインサートした状態で、オーバーラップしている前記構造部材（ａ）と前記樹脂構造部材（ｂ）の間に熱可塑性樹脂を射出成形する。
     
PCT/JP2023/010371 2022-03-22 2023-03-16 一体化成形品および一体化成形品の製造方法 Ceased WO2023182158A1 (ja)

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WO2026071057A1 (ja) * 2024-09-30 2026-04-02 東レ株式会社 フレーム構造体、飛翔体およびフレーム構造体の製造方法

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WO2026071057A1 (ja) * 2024-09-30 2026-04-02 東レ株式会社 フレーム構造体、飛翔体およびフレーム構造体の製造方法

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