Molding method and apparatus of fiber filler reinforced resin molded article

Abstract

In a molding method of a fiber filler reinforced resin molded article, in which a reinforcement fiber and a resin are plasticized and kneaded in a material supply cylinder including a screw with an anti counterflow portion, and the resin with the reinforcement fiber mixed therewith is injected into a cavity of a mold, the reinforcement fiber is mixed with the resin in the cylinder at a portion downstream of the anti counterflow portion of the screw, and a physical foaming agent is supplied into the cylinder at a portion downstream of the anti counterflow portion. Accordingly, there can be provided a molding method or apparatus of a fiber filler reinforced resin molded article that can improve properties by preventing the reinforcement fiber from being broken.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side view showing an entire structure of a fiber filler reinforced resin injection molding apparatus according to a first embodiment of the present invention, FIG. 1B is a sectional view showing a cylinder inside of a plasticizing pushing portion, and FIG. 1C is a sectional view showing a structure of a major portion of the cylinder inside of the plasticizing pushing portion.

FIG. 2 is a partially sectional view showing a GF supply unit with a seal structure that prevents a leakage of a foaming agent at the GF supply portion in the first embodiment.

FIG. 3 is a side view showing an entire structure of a fiber filler reinforced resin injection molding apparatus according to a second embodiment.

FIG. 4 is an explanatory diagram showing a schematic structure of a device to compensate a leakage of a physical foaming agent at a GF supply portion of a filler reinforced resin injection molding apparatus according to a third embodiment.

FIG. 5A a view showing an attachment state of a mixing nozzle, and FIG. 5B is a sectional view of a major portion of the mixing nozzle.

FIG. 6A is a sectional view showing a cylinder inside of a metering injecting portion with a supersonic oscillator (or an electromagnetic-wave oscillator) of a vibration adding device, and FIG. 6B is a sectional view showing an attachment state of an agitating plate in the cylinder inside of the metering injecting portion.

FIG. 7 is a sectional view of a mold in which the mixing nozzle and a similar agitating device are provided at a hot runner portion.

FIG. 8 is a side view of a foaming-agent supply portion in which a porous member is disposed at an inside wall of a supply nozzle.

FIG. 9 is a side view showing a seal structure with a resilient member as a modified embodiment.

Claims

1. A molding method of a fiber filler reinforced resin molded article, in which a reinforcement fiber and a resin are plasticized and kneaded in a material supply cylinder including a screw with an anti counterflow portion, and the plasticized resin with the reinforcement fiber mixed therewith is injected into a cavity of a mold, wherein the reinforcement fiber is mixed with the resin in the cylinder at a portion downstream of the anti counterflow portion of the screw, and a physical foaming agent is supplied into the cylinder at a portion downstream of the anti counterflow portion of the screw.

2. A molding method of a fiber filler reinforced resin molded article of claim 1, wherein the physical foaming agent is a super critical fluid.

3. A molding method of a fiber filler reinforced resin molded article of claim 1, wherein the reinforcement fiber is mixed with the resin in the cylinder at a portion that is located downstream of said supply portion of the physical foaming agent.

4. A molding method of a fiber filler reinforced resin molded article of claim 1, wherein the reinforcement fiber is provided independently so as to be mixed with the resin.

5. A molding method of a fiber filler reinforced resin molded article of claim 4, wherein the reinforcement fiber is provided in a form of a continuous fiber to the cylinder, and the provided continuous fiber is cut into pieces by the screw, whereby the reinforcement fiber is mixed with the resin in the cylinder.

6. A molding method of a fiber filler reinforced resin molded article of claim 1, wherein mixing and dispersion of the reinforcement fiber in the resin is promoted in a resin flow path from the supply portion of the physical foaming agent to the cavity of the mold.

7. A molding method of a fiber filler reinforced resin molded article of claim 1, wherein the resin with the physical foaming agent supplied thereto and the reinforcement fiber mixed therewith is collected temporarily, transmitted to an injection unit, metered for molding, and then supplied to the cavity of the mold via the injection unit.

8. A molding apparatus of a fiber filler reinforced resin molded article, in which a reinforcement fiber and a resin are plasticized and kneaded in a material supply cylinder including a screw with an anti counterflow portion, and the plasticized resin with the reinforcement fiber mixed therewith is injected into a cavity of a mold, the molding apparatus comprising: a reinforcement-fiber mixing portion where the reinforcement fiber is mixed with the resin in the cylinder, the mixing portion being downstream of the anti counterflow portion of the screw; anda foaming-agent supply portion where a physical foaming agent is supplied into the cylinder, the supply portion being downstream of the anti counterflow portion of the screw.

9. A molding apparatus of a fiber filler reinforced resin molded article of claim 8, wherein the physical foaming agent is a super critical fluid.

10. A molding apparatus of a fiber filler reinforced resin molded article of claim 8, wherein the reinforcement fiber is mixed with the resin in the cylinder at a portion that is located downstream of said supply portion of the physical foaming agent.

11. A molding apparatus of a fiber filler reinforced resin molded article of claim 8, wherein the reinforcement fiber is provided independently so as to be mixed with the resin.

12. A molding apparatus of a fiber filler reinforced resin molded article of claim 11, wherein the reinforcement fiber is provided in a form of a continuous fiber to the cylinder, and the provided continuous fiber is cut into pieces by the screw, whereby the reinforcement fiber is mixed with the resin in the cylinder.

13. A molding apparatus of a fiber filler reinforced resin molded article of claim 8, wherein there is provided a mixing-dispersion promoting device to promote mixing and dispersion of the reinforcement fiber in the resin in a resin flow path from the supply portion of the physical foaming agent to the cavity of the mold.

14. A molding apparatus of a fiber filler reinforced resin molded article of claim 8, wherein the resin with the physical foaming agent supplied thereto and the reinforcement fiber mixed therewith is collected temporarily, transmitted to an injection unit, metered for molding, and then supplied to the cavity of the mold via the injection unit.

15. A molding apparatus of a fiber filler reinforced resin molded article of claim 8, wherein there is provided a seal device to seal an inside from an outside of the cylinder at the reinforcement-fiber mixing portion.

16. A molding apparatus of a fiber filler reinforced resin molded article of claim 8, wherein there is provided a flow-amount detecting device that is provided in a leakage path of the physical foaming agent leaking from the reinforcement-fiber mixing portion and detects an amount of leakage of the physical foaming agent, and the physical foaming agent is configured to be supplemented from the foaming-agent supply portion according to the leakage amount thereof detected by the flow-amount detecting device.