# US 10,479,005 B2 · Composite molded article and method for producing the same

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- Number: US 10,479,005 B2
- Document ID: US10479005B2
- Status: Granted
- Kind: B2
- Application number: 15/771,425
- Filed: 2016-10-27
- Published: 2018-11-15
- Granted: 2019-11-19
- Earliest claimed: 2015-10-29
- Assignees: Asahi Kasei Kabushiki Kaisha
- Applicants: Asahi Kasei Kabushiki Kaisha
- Inventors: Hideaki Ichiki; Taiga Saito; Yuo Umei
- Web page: https://patentgrep.com/patent/US10479005B2

## CPC

- B29C 45/0005: {using fibre reinforcements}
- B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)}
- B29C 45/14221: {by tools, e.g. cutting means}
- B29C 45/14786: {Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/10: characterised by a fibrous {or filamentary} layer reinforced with filaments
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/281: {comprising polyimides}
- B32B 27/286: {comprising polysulphones; polysulfides}
- B32B 27/288: {comprising polyketones}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/322: {comprising halogenated polyolefins, e.g. PTFE}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B29K 2077/00: Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material
- B29K 2105/08: of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K 2105/0881: {unidirectional}
- B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K 2309/08: Glass
- B29K 2995/0077: Yield strength; Tensile strength
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/26: Polymeric coating
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/101: Glass fibres
- B32B 2262/103: Metal fibres
- B32B 2262/105: Ceramic fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/732: Dimensional properties
- B32B 2605/00: Vehicles
- 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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

## Abstract

A composite molded article (3) containing: a thermoplastic resin continuous fiber composite material (1) containing a continuous reinforcement fiber (A) and a thermoplastic resin (B); and a thermoplastic resin composition (2), wherein the thermoplastic resin continuous fiber composite material (1) is bonded to the thermoplastic resin composition (2) via a bonding surface, and a bonded part between the thermoplastic resin continuous fiber composite material (1) and the thermoplastic resin composition (2) has a tensile strength which is 0.35 times or more as strong as a tensile strength of the thermoplastic resin composition (2).

## Claims

### Claim 1

A composite molded article comprising:
a thermoplastic resin continuous fiber composite material comprising a continuous reinforcement fiber (A) and a thermoplastic resin (B); and
a thermoplastic resin composition,
wherein the thermoplastic resin continuous fiber composite material is bonded to the thermoplastic resin composition via a bonding surface,
wherein a bonded part between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a tensile strength which is 0.35 times or more as strong as a tensile strength of the thermoplastic resin composition,
wherein the bonded part between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a convexo-concave structure where the material and the composition are mixed with each other, and
wherein a length L of an interface at the bonding surface between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition; and a thickness t of the composite molded article satisfy a relation of L>1.8t.

### Claim 2 (depends on 1)

The composite molded article according to claim 1, wherein the bonded part between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a tensile strength which is 0.5 times or more as strong as the tensile strength of the thermoplastic resin composition.

### Claim 3 (depends on 1)

The composite molded article according to claim 1, wherein the bonded part between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a tensile strength which is 1.0 time or more as strong as the tensile strength of the thermoplastic resin composition.

### Claim 4 (depends on 1)

The composite molded article according to claim 1, wherein the thermoplastic resin composition comprises a non-continuous reinforcement material.

### Claim 5 (depends on 1)

The composite molded article according to claim 1, wherein the length L and the thickness t satisfy a relation of L>2.0t.

### Claim 6 (depends on 1)

The composite molded article according to claim 1, wherein the interface is formed by the continuous reinforcement fiber (A) comprised in the thermoplastic resin continuous fiber composite material and the non-continuous reinforcement material comprised in the thermoplastic resin composition.

### Claim 7 (depends on 1)

The composite molded article according to claim 1, wherein the continuous reinforcement fiber (A) is at least one selected from the group consisting of a glass fiber, a carbon fiber, an aramid fiber, a super strong polyethylene fiber, a polybenzazole fiber, a liquid crystal polyester fiber, a polyketone fiber, a metal fiber and a ceramic fiber.

### Claim 8 (depends on 1)

The composite molded article according to claim 1, wherein the thermoplastic resin (B) is at least one selected from the group consisting of a polyolefin resin, a polyamide resin, a polyester resin, a polyether ketone, a polyether ether ketone, a polyether sulfone, a polyphenylene sulfide, a thermoplastic polyetherimide and a thermoplastic fluororesin.

### Claim 9 (depends on 1)

The composite molded article according to claim 1, wherein the thermoplastic resin (B) is a thermoplastic resin fiber.

### Claim 10 (depends on 1)

The composite molded article according to claim 1, wherein the thermoplastic resin continuous fiber composite material as a raw material is a fabric-shaped material.

### Claim 11

A method for producing a composite molded article comprising a thermoplastic resin continuous fiber composite material comprising a continuous reinforcement fiber (A) and a thermoplastic resin (B), and a thermoplastic resin composition, wherein the thermoplastic resin continuous fiber composite material is bonded to the thermoplastic resin composition via a bonding surface, the method comprising:
a step of shaping the thermoplastic resin continuous fiber composite material in a mold;
a step of injecting the thermoplastic resin composition into the mold; and
a step of bonding the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition,
wherein a bonded part between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a tensile strength which is 0.35 times or more as strong as a tensile strength of the thermoplastic resin composition,
wherein the bonded part between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a convexo-concave structure where the material and the composition are mixed with each other, and
wherein a length L of an interface at the bonding surface between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition; and a thickness t of the composite molded article satisfy a relation of L>1.8t.

### Claim 12 (depends on 11)

The method for producing the composite molded article according to claim 11, wherein a bonded part between the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a convexo-concave structure where the material and the composition are mixed with each other.

### Claim 13 (depends on 11)

The method for producing the composite molded article according to claim 11, wherein an injection pressure or an injection-holding pressure applied when the thermoplastic resin composition is injected or held in the mold is equal to a press pressure applied when the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition are compressed and molded.

### Claim 14 (depends on 11)

The method for producing the composite molded article according to claim 11, wherein, after the thermoplastic resin composition is injected into the mold, the injection-holding pressure, which is equal to the press pressure applied when the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition are compressed and molded, is continuously applied until the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition has a temperature which is a solidification temperature −10° C., or less.

### Claim 15 (depends on 11)

The method for producing the composite molded article according to claim 11, further comprising, after the step of injecting the thermoplastic resin composition into the mold, a step of compressing and molding the thermoplastic resin continuous fiber composite material and the thermoplastic resin composition in the mold having a temperature equal to or higher than the melting point of the thermoplastic resin (B).

### Claim 16 (depends on 15)

The method for producing the composite molded article according to claim 15, wherein a temperature of the mold in the step of injecting the thermoplastic resin composition into the mold is equal to or lower than the melting point of the thermoplastic resin (B).

### Claim 17 (depends on 11)

The method for producing the composite molded article according to claim 11, further comprising, after the step of shaping the thermoplastic resin continuous fiber composite material in the mold, a step of compressing and molding the thermoplastic resin continuous fiber composite material in the mold having a temperature equal to or higher than the melting point of the thermoplastic resin (B).

### Claim 18 (depends on 17)

The method for producing the composite molded article according to claim 17, wherein, in the step of injecting the thermoplastic resin composition into the mold, the injection is carried out when a temperature of the mold is equal to or higher than the melting point of the thermoplastic resin (B).