Long-fiber-reinforced resin composition and molded article thereof

Abstract

A long-fiber-reinforced resin composition including (A) a long-fiber-reinforced thermoplastic resin pellet including a thermoplastic resin, a modified polyolefin-based resin modified with an unsaturated carboxylic acid or its derivative and reinforcing fiber and satisfying (A-1) the melt index of the thermoplastic resin is 100-250 g / 10 min, (A-2) the relaxation time λ of the thermoplastic resin is 0.1 (sec) or less, (A-3) the content of the reinforcing fiber is 40-70 wt %, and (A-4) the content of the modified polyolefin-based resin is 1-5 wt %; and (B) a polyolefin-based resin satisfying (B-1) the melt index of the polyolefin-based resin is 20-70 g / 10 min, and (B-2) the relaxation time λ of the polyolefin-based resin is 0.23 (sec) or less; wherein the content of reinforcing fiber contained in (A) is 20-60 wt % relative to the total amount of the fiber-reinforced resin composition.

Description

TECHNICAL FIELD[0001]The invention relates to a long-fiber-reinforced resin composition and a molded article thereof.BACKGROUND ART[0002]A molded article formed of a long-fiber-reinforced resin composition is widely used as a module component of an automobile which requires a high strength. However, due to insufficient dispersion of reinforcing fibers contained in this long-fiber-reinforced resin composition, the reinforcing fibers may appear in the form of a mass at the surface of a module component. Therefore, module components composed of a long-fiber-reinforced resin composition are required to be used as a component of a part which does not need an excellent external appearance or are required to be used after coating the surface thereof.[0003]In order to solve the above-mentioned problems, a fiber-reinforced resin composition capable of improving the appearance of a molded article obtained therefrom is reported (Patent Document 1 and Patent Document 2).[0004]However, a molded ...

AI Technical Summary

Benefits of technology

[0057]In the long-fiber-reinforced thermoplastic resin pellet, the aspect ratio of the fibers in the composition is increased to allow a composition with a high strength to be obtained easily. Therefore, more significant advantageous effects are attained.

[0058]The long-fiber-reinforced thermoplastic resin pellet is normally in the shape of a column.

[0059]The pellet length of the long-fiber-reinforced thermoplastic resin pellet is preferably 4 mm to 8 mm, more preferably 5 mm to 7 mm. If the pellet length of the long-fiber-reinforced thermoplastic resin pellet is less than 4 mm, effects of improving rigidity, heat resistance and impact strength may be low, and the molded article may suffer sufficient warp deformation. If the pellet length of the long-fiber-reinforced thermoplastic resin pellet exceeds 8 mm, molding may become difficult.

[0060]In the invention, in the long-fiber-reinforced thermoplastic resin pellet, it is preferred that the reinforcing fibers having almost the same length (4 mm to 8 mm) be arranged in parallel with each other.

[0061]The long-fiber-reinforced thermoplastic resin pellet can be obtained easily by introducing a reinforcing fiber roving composed of several thousands fibers into an impregnation dice, allowing the molten polyolefin-based resin to be impregnated uniformly between the filaments, and cutting it into a necessary length.

[0062]For example, while supplying from an extruder a molten resin to an impregnation dice provided at the tip of an extruder, a continuous glass fiber bundle is passed through the dice so as to allow this glass fiber bundle to be impregnated with a molten resin. Thereafter, the glass fiber bundle is drawn through a nozzle, and then pelletized into a necessary length. Also, a method can be taken in which a polyolefin-based resin, unsaturated carboxylic acid or its anhydride, organic peroxides or the like are dry blended, and the resulting blend is put into a hopper of an extruder, whereby supply is conducted simultaneously with modification.

Problems solved by technology

However, due to insufficient dispersion of reinforcing fibers contained in this long-fiber-reinforced resin composition, the reinforcing fibers may appear in the form of a mass at the surface of a module component.

However, a molded article obtained from the above-mentioned fiber-reinforced resin composition does not have an appearance as excellent as one required as an automobile module component, for example.