US 11,794,385 B2
Integrally molded body
Takafumi Suzuki, Ehime (JP); Yuichiro Sento, Ehime (JP); Naokichi Imai, Ehime (JP); Mitsushige Hamaguchi, Nagoya (JP); and Masato Honma, Ehime (JP)
Assigned to TORAY INDUSTRIES, INC., Tokyo (JP)
Appl. No. 16/641,447
Filed by Toray Industries, Inc., Tokyo (JP)
PCT Filed Aug. 24, 2018, PCT No. PCT/JP2018/031339
§ 371(c)(1), (2) Date Feb. 24, 2020,
PCT Pub. No. WO2019/044693, PCT Pub. Date Mar. 7, 2019.
Claims priority of application No. 2017-166841 (JP), filed on Aug. 31, 2017; and application No. 2017-166842 (JP), filed on Aug. 31, 2017.
Prior Publication US 2020/0198193 A1, Jun. 25, 2020
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 45/00 (2006.01); B29C 45/14 (2006.01); B32B 27/08 (2006.01); C08J 5/24 (2006.01)
CPC B29C 45/0025 (2013.01) [B29C 45/14631 (2013.01); B32B 27/08 (2013.01); C08J 5/24 (2013.01); B32B 2262/10 (2013.01); B32B 2307/546 (2013.01); B32B 2307/7376 (2023.05); C08J 2363/00 (2013.01); Y10T 428/24994 (2015.04); Y10T 428/249933 (2015.04)] 16 Claims
OG exemplary drawing
 
1. An integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated,
the substrate for reinforcement (a) covering a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b),
a ratio of thickness Ta of the substrate for reinforcement (a) to thickness T of a weldline part of the integrally molded body satisfying relational expression:
in a case of Ea≠Ebw,
Ta/T≤((Ebw−√(Ea·Ebw))/(Ebw−Ea))
in a case of Ea=Ebw,
Ta/T≤0.5
wherein, Ta: Thickness of substrate for reinforcement (a),
T: Thickness of the weldline part of integrally molded body,
Ea: Flexural modulus of substrate for reinforcement (a) in width direction of the weldline, and
Ebw: Flexural modulus of the weldline of injection molding body (b) in width direction of the weldline,
wherein the substrate for reinforcement (a) covers a part of the injection molding body (b), such that when the integrally molded body is arranged such that a surface of the substrate for reinforcement (a) is placed in the horizontal direction and facing upward and projected from above, the substrate for reinforcement (a) having 50% or less and 5% or more of a projected area of the integrally molded body, and
wherein:
(i) the substrate for reinforcement (a) is in a form of a sheet or a tape of randomly dispersed discontinuous fibers (a1),
(ii) the substrate for reinforcement (a) is substantially isotropic, and
(iii) the substrate for reinforcement (a) does not have a weldline.
 
9. An integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated,
the thickness of the substrate for reinforcement (a) being 0.25 mm or less,
the substrate for reinforcement (a) covering a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b),
wherein the substrate for reinforcement (a) covers a part of the injection molding body (b), such that when the integrally molded body is arranged such that a surface of the substrate for reinforcement (a) is placed in the horizontal direction and facing upward and projected from above, the substrate for reinforcement (a) having 50% or less and 5% or more of a projected area of the integrally molded body, and
wherein:
(i) the substrate for reinforcement (a) is in a form of a sheet or a tape of randomly dispersed discontinuous fibers (a1),
(ii) the substrate for reinforcement (a) is substantially isotropic, and
(iii) the substrate for reinforcement (a) does not have a weldline.
 
10. An integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated,
the substrate for reinforcement (a) covering a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b),
wherein the substrate for reinforcement (a) covers a part of the injection molding body (b), such that when the integrally molded body being arranged such that a surface of the substrate for reinforcement (a) is placed in the horizontal direction and facing upward and projected from above, the substrate for reinforcement (a) having 50% or less and 5% or more of a projected area of the integrally molded body,
a ratio Ea/Eb of flexural modulus Ea of the substrate for reinforcement (a) to flexural modulus Eb of the injection molding body (b) in a non-weldline part being 0.7 to 1.3, and
wherein:
(i) the substrate for reinforcement (a) is in a form of a sheet or a tape of randomly dispersed discontinuous fibers (a1),
(ii) the substrate for reinforcement (a) is substantially isotropic, and
(iii) the substrate for reinforcement (a) does not have a weldline.