Carbon fiber-reinforced resin molded body and manufacturing method thereof
AssigneeNissan Motor Co., Ltd.
InventorsTakashi Oda, Katsumi Morohoshi
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Abstract
A carbon fiber-reinforced resin molded body of the present invention derives from kneaded materials of a thermoplastic resin and a carbon fiber and includes at least a three-dimensional complex shaped region and a substantially flat plate-shaped region arranged in a profile direction. Fluidity of the kneaded materials at predetermined temperature is such that fluidity of the kneaded material forming the substantially flat plate-shaped region is lower than fluidity of the kneaded material forming the three-dimensional complex shaped region, which makes it unlikely to cause defects in ribs, posses, and other portions. Thus, a carbon fiber-reinforced resin molded body with low cost and high strength can be provided.
Claims8
A carbon fiber-reinforced resin molded body deriving from kneaded materials of a thermoplastic resin and a carbon fiber, comprising
- at least a three-dimensional complex shaped region and a substantially flat plate-shaped region, wherein
- fluidity of the kneaded materials at a predetermined temperature is such that the fluidity of the kneaded material forming the substantially flat plate-shaped region is lower than the fluidity of the kneaded material forming the three-dimensional complex shaped region;
- the three-dimensional complex shaped region and the substantially flat plate-shaped region do not overlap each other in a thickness direction of the carbon fiber-reinforced resin molded body but arranged in an in-plane direction thereof;
- and
- a fiber content of the carbon fiber is in a range of 50 to 60 wt %,
- wherein an average fiber length in the kneaded material forming the three-dimensional complex shaped region is smaller than an average fiber length in the kneaded material forming the substantially flat plate-shaped region, and
- wherein the average fiber length in the kneaded material forming the three-dimensional complex shaped region satisfies an expression (1)
- 0.5 (mm)≤average fiber length (mm)≤50 (mm)/aspect ratio (1)
- where the aspect ratio in the expression (1) is rib height (mm)/rib thickness (mm) or boss height (mm)/boss diameter (mm) of a rib or a boss formed in the carbon fiber-reinforced resin molded body and is more than 1 and 50 or less.
A method of manufacturing a carbon fiber-reinforced resin molded body containing a thermoplastic resin and a carbon fiber comprising a step of disposing a plurality of kneaded materials, containing the thermoplastic resin and the carbon fiber and varying in fluidity at a predetermined temperature, on a mold and compression-molding the kneaded materials, wherein:
- the mold includes a region with a three-dimensional complex shaped region and a substantially flat plate-shaped region;
- fluidity of the kneaded material disposed in the substantially flat plate-shaped region is lower than fluidity of the kneaded material disposed in the three-dimensional complex shaped region;
- and
- the three-dimensional complex shaped region and the substantially flat plate-shaped region are disposed so as not to overlap each other in a thickness direction of the carbon fiber-reinforced resin molded body but to be arranged in an in-plane direction thereof;
- and
- a fiber content of the carbon fiber is in a range of 50 to 60 wt %,
- wherein an average fiber length in the kneaded material forming the three-dimensional complex shaped region is smaller than an average fiber length in the kneaded material forming the substantially flat plate-shaped region, and
- wherein the average fiber length in the kneaded material forming the three-dimensional complex shaped region satisfies an expression (1)
- 0.5 (mm)≤average fiber length (mm)≤50 (mm)/aspect ratio (1)
- where the aspect ratio in the expression (1) is rib height (mm)/rib thickness (mm) or boss height (mm)/boss diameter (mm) of a rib or a boss formed in the carbon fiber-reinforced resin molded body and is more than 1 and 50 or less.
Dependencies are inferred from the claim text.