Resin-molded member and method for manufacturing the same

Abstract

A method of manufacturing a resin-molded member includes: an insert member forming step of forming an insert member (10, 50) by a 3D printer that layers a base resin containing continuous fibers; a positioning step of positioning the insert member (10, 50) in a cavity (C, C10) of a mold for injection molding; and a resin portion forming step of forming a resin portion (9, 39) integrated with the insert member (10, 50) by filling a resin for injection molding into the cavity (C, C10). The insert member (10, 50) is disposed on a surface of a weld portion (W1, W2) formed on the resin portion (9, 39) by the resin portion forming step, and the continuous fibers of the insert member (10, 50) are oriented in a direction that spans the weld portion (W1, W2).

Claims

1. A method for manufacturing a resin molded part, comprising: The insert component forming process involves using a 3D printer to laminate a base resin containing continuous fibers to form the insert component. The positioning process involves positioning the inserted component within the cavity of the injection molding mold. The resin part molding process involves filling the cavity with injection molding resin to form a resin part that is integrated with the insertion component. In the resin forming process, the insert member is disposed on the surface of the welded portion formed on the resin portion, and the continuous fibers of the insert member are oriented in a direction that crosses the welded portion.

2. The method for manufacturing a resin molded part as described in claim 1, wherein, The shape of the mold surface of the injection molding mold is transferred to the insert component by using the resin pressure when filling the cavity with the injection molding resin.

3. A resin-molded component, comprising: Insertion component, which is laminated with a base resin containing continuous fibers; The resin portion is integrally formed with the insertion component. The insertion member is disposed on the surface of the weld portion formed on the resin portion. The continuous fibers of the insert are oriented in a direction that crosses the weld.

4. The resin molded part as claimed in claim 3, wherein, The insertion component is disposed on the surface of the resin part and has the shape of the mold surface of the injection molding mold for shaping the resin part transferred onto it.

5. The resin molded part as claimed in claim 3, wherein, The base resin is any one of the following: the same resin as the resin portion, a resin that is compatible with the resin portion, and a resin with a lower melting point compared to the resin portion.

6. The resin molded part as claimed in claim 3, wherein, The resin portion contains short fibers.

7. The resin molded part as claimed in claim 3, wherein, The insertion component includes a first insertion component and a second insertion component. The continuous fibers contained in the first insertion component are different from those contained in the second insertion component.

8. The resin molded part as claimed in claim 7, wherein, One of the first insertion component and the second insertion component comprises aramid continuous fibers. The first insertion component and the other of the second insertion component comprise continuous carbon fibers or continuous glass fibers.

9. The resin molded part as claimed in claim 3, wherein, The insertion component has multiple layers. The orientation of the continuous fibers in each layer is consistent.

10. The resin molded part as claimed in claim 3, wherein, The insertion component has a first layer and a second layer that overlaps with the first layer. The orientations of the continuous fibers in the first layer and the second layer are different.

11. The resin molded part as claimed in claim 3, wherein, The resin molded component is a resin gear with a central hole for a rotating shaft to pass through and teeth on its outer peripheral surface. The insertion component includes a first insertion component and a second insertion component. The inner circumferential surface of the hole is formed by the first insertion member, and the surface of the tooth is formed by the second insertion member. The first insertion component comprises continuous carbon fibers or continuous glass fibers. The second insert comprises continuous aramid fibers.

12. The resin molded part as claimed in claim 3, wherein, The resin molding component is a spring guide having a cylindrical portion and a butterfly-shaped spring support portion that expands outward from the cylindrical portion. The insertion component is arranged around the entire circumference of the outer periphery of the spring support.

13. The resin molded part as claimed in claim 3, wherein, The resin molding component is a spring guide having a cylindrical portion and a butterfly-shaped spring support portion that expands outward from the cylindrical portion. The insertion component is disposed at the connection between the cylindrical portion and the spring support portion.

14. The resin molded part as claimed in claim 12 or 13, wherein, The insert contains continuous aramid fibers.

15. The resin molded part as claimed in claim 12 or 13, wherein, The insert contains continuous glass fibers or continuous carbon fibers.

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