Integrated molded body and electronic device housing

Abstract

The utility model relates to an integrated molded body and an electronic equipment frame. The present invention relates to an integrated molded body in which a laminate (A), in which the front surface includes a design surface and the back surface includes a non-design surface, and a resin member (B), which includes discontinuous fibers and a thermoplastic resin, are joined and integrated, the resin member (B) being joined to at least a portion of the outer peripheral edge of the laminate (A). The laminate (A) has a sandwich structure in which a core layer is sandwiched between a surface layer and the surface layer, the surface layer is formed from a fiber-reinforced resin member containing continuous reinforcing fibers and a resin composition, the core layer is formed from any one selected from the group consisting of a film, a foam, and a porous base material, and the height difference (H) between the maximum height of the surface side and the minimum height of the surface side of the laminate (A) is 0-5 mm or less. A recessed portion recessed from the back side toward the front side is provided in a partial region of the back side. The present invention provides an integrally molded body having a shape such as a space in which a component is provided inside a product such as a frame, using a fiber-reinforced resin member.

Description

TECHNICAL FIELD

[0001] The utility model relates to the integrated molding body suitable for the purpose of light weight, high strength and high rigidity and thin walling as the parts of personal computer, OA equipment, mobile phone and the like, frame part. BACKGROUND

[0002] Currently, with the development of portability, electrical and electronic equipment such as personal computers, OA equipment, AV equipment, mobile phones, telephones, facsimile machines, household appliances, and toys are required to be smaller and lighter. To achieve small size and light weight, the miniaturization of the constituent parts inside the frame, the thinning of the frame, and the like can be cited.

[0003] Patent Document 1 describes that an integrated molding body is produced by joining a plate and a peripheral member separated from the plate by providing a joining resin to the outer peripheral edge portion of the plate, thereby reducing the amount of resin, reducing the warpage that can occur due to the shrinkage of the amount of resin, achieving thinning of the molding body, and as a preferred method, the plate has a stepped portion, and since the thickness of the portion near the periphery is thinner than other portions, the thickness of the entire molding body when overlapping and joining with other members can be reduced.

[0004] Patent Document 2 describes that a resin member containing discontinuous carbon fibers and a thermoplastic resin is interposed between a plate and a resin member to join the two, achieving high joining strength by the low shrinkage properties of the resin member present, and achieving thinning of the molding body by warpage reduction and smoothness of the joining boundary portion.

[0005] Patent Document 3 discloses a plate-shaped frame member having a surface and a back surface, the back surface including a first surface and a second surface having contour lines that meander and change in height with respect to the first surface, and the thickness from the meandering contour lines of the second surface to the surface is different from the thickness from the first surface to the surface.

[0006] Prior Art Documents

[0007] Patent Documents

[0008] Patent Document 1: International Publication No. 2018 / 110293

[0009] Patent Document 2: International Publication No. 2019 / 235299

[0010] Patent Document 3: Japanese Patent Application Publication No. 2014-50867 Utility Model Contents

[0011] Problems to be Solved by the Utility Model

[0012] However, for the integrated molded body described in Patent Documents 1 and 2, the space for the internal components increases due to the thinning of the wall, but simply reducing the thickness of the portion is not enough. In addition to thinning the frame, efforts are also needed in the design of the frame surface. In particular, since the shape of the thinnest part is parallel to the in-plane direction of the plate-shaped frame component, there is a limit to the thinning of the wall.

[0013] Regarding the frame component described in Patent Document 2, as in Patent Document 2... Figure 5 As shown, the frame component has stepped sections of varying thickness, thereby providing a high-strength laptop. However, the frame component described in Patent Document 2 uses a metal alloy such as magnesium alloy, which has limitations in terms of weight reduction. Although a frame component with the shape described in Patent Document 2 can be constructed from the sandwich structure described in Patent Document 1, it is difficult to make the continuous fibers follow the stepped shape. In the case of continuous reinforcing fibers, the distance between fibers increases when the continuous fibers are unidirectional, fiber cracking occurs, and in the case of fabric fibers, local openings are generated. In addition, areas of "resin enrichment" and pores are prone to occur. Furthermore, in this case, there are problems with mechanical strength and design performance.

[0014] In other words, in order to ensure space for the internal components, fiber-reinforced resin components with reinforcing fibers and resin are used. However, if a convex shape is formed on the design surface or a concave shape is formed on a non-design surface, the aforementioned problems of poor appearance, design defects, and inability to form a molded body may occur.

[0015] Therefore, the purpose of this invention is to provide an integral molded body with a shape that better ensures the internal component space of the frame and other products compared to conventional technologies, using fiber-reinforced resin components.

[0016] Methods for solving problems

[0017] To solve the above-mentioned problems, this utility model adopts the following structure. That is,

[0018] [1] An integrally molded body, wherein an integrally molded body is formed by joining and integrally bonding a laminate (A) having a front surface including a designed surface and a back surface including a non-designed surface with a resin component (B) comprising discontinuous fibers and thermoplastic resin, characterized in that,

[0019] The resin component (B) is bonded to at least a portion of the outer periphery of the laminate (A).

[0020] The laminate (A) has a sandwich structure in which a core layer is sandwiched between a surface layer.

[0021] The aforementioned surface layer is formed of a fiber-reinforced resin component comprising a continuous reinforcing fiber and a resin composition.

[0022] The aforementioned core layer is formed of any one selected from the group consisting of a film, a foam, and a porous substrate,

[0023] The difference in height (H) between the maximum height of the aforementioned surface side and the minimum height of the aforementioned surface side of the aforementioned layered body (A) is 0 to 5 mm or less,

[0024] A concave portion recessed from the back side toward the surface side is provided in a part of the aforementioned back side.

[0025] 〔2〕 The integrally molded body according to the aforementioned item 1, wherein at least a part of the aforementioned concave portion is curved.

[0026] 〔3〕 The integrally molded body according to the aforementioned item 1 or 2, wherein, when the difference in height between the maximum height of the aforementioned surface side and the minimum height of the aforementioned back side of the aforementioned layered body (A) is set as Tmax and the difference in height between the maximum height of the aforementioned surface side and the maximum height of the aforementioned back side of the aforementioned layered body (A) is set as Tmin,

[0027] The ratio Tmax / Tmin of Tmax to Tmin is 1.05 to 6.

[0028] 〔4〕 The integrally molded body according to any one of the aforementioned items 1 to 3, wherein, when the difference in height between the maximum height of the aforementioned surface side and the minimum height of the aforementioned back side of the aforementioned layered body (A) is set as Tmax and the difference in height between the maximum height of the aforementioned surface side and the maximum height of the aforementioned back side of the aforementioned layered body (A) is set as Tmin,

[0029] The difference Tmax-Tmin of Tmax to Tmin is 0.05 to 5.0 mm.

[0030] 〔5〕 The integrally molded body according to any one of the aforementioned items 1 to 4, wherein the aforementioned continuous reinforcing fiber has a form of unidirectional fiber in which filaments are aligned in one direction or a form of fabric in which filaments are combined in a warp-weft manner, and the distance between adjacent fibers is less than 2 mm.

[0031] 〔6〕 The integrally molded body according to any one of the aforementioned items 1 to 5, wherein the aforementioned porous substrate contains discontinuous fibers and a thermoplastic resin.

[0032] 〔7〕 The integrally molded body according to any one of the aforementioned items 1 to 6, wherein the surface of the aforementioned surface side of the aforementioned layered body (A) has a step portion formed of a thick wall portion having a large height, a thin wall portion having a small height, and a boundary portion connecting the aforementioned thick wall portion and the aforementioned thin wall portion,

[0033] The porosity of the core layer in the aforementioned thin wall portion is smaller than the porosity of the core layer in the aforementioned thick wall portion,

[0034] The aforementioned resin component (B) is not in contact with the aforementioned boundary portion but is joined to a portion of the aforementioned thin-walled portion.

[0035] [8] The integral molded body as described in [7], wherein the surface of the aforementioned boundary portion is inclined at an angle of 1 to 20° relative to the surface of the aforementioned thick-walled portion.

[0036] [9] The integral molded body as described in [7] or [8], wherein the porosity of the core layer in the thick-walled portion is 50% or more and 80% or less, and the porosity of the core layer in the thin-walled portion is 0% or more and less than 50%.

[0037]

[10] An integral molded body as described in any one of [1] to [9], used for an electronic device frame.

[0038]

[11] An electronic device frame, which is made using the integral molded body described in

[10] .

[0039] Here, "joining" simply means that the two components are in direct or indirect contact.

[0040] Effects of the utility model

[0041] According to this invention, fiber-reinforced resin components can be used to obtain an integrally molded body with a shape that prevents interference with internal parts when used in the case of a frame for applications such as personal computers. Attached Figure Description

[0042] Figure 1 The diagram shows the integrated molded body involved in this utility model. (A) is a perspective view, and (B) is a bottom view.

[0043] Figure 2 This is a top view of the integrated molded body involved in this utility model.

[0044] Figure 3 yes Figure 2 A rough cross-sectional view of A-A'.

[0045] Figure 4 It is used for molding with Figure 3 The cross-sectional view shown is a schematic cross-sectional view of the stamping die of the integral molded body.

[0046] Figure 5 yes Figure 4 The diagram shows a schematic cross-sectional view of the stamping die after stamping.

[0047] Figure 6 It is used for molding with Figure 3 The cross-sectional view shown is a schematic cross-sectional view of the injection mold of the integral molded body.

[0048] Figure 7 is Figure 6 is a cross-sectional view of the injection mold shown in

[0049] Figure 8 is a cross-sectional view of the integrated molded body.

[0050] Figure 9 is a cross-sectional view of the integrated molded body of the present application in the thickness direction, in which the laminate (A) is a sandwich structure composed of a surface layer (skin) and a core layer formed of a foamed body.

[0051] Figure 10 is an enlarged cross-sectional view showing the state of joining of the outer peripheral edge portion of the integrated molded body shown in Figure 9 , 11

[0052] Figure 11 is a cross-sectional view of the integrated molded body 10 formed of other components and the resin component (B) 30 and the laminate (A) 20.

[0053] Figure 12 is a cross-sectional view of an injection mold for molding an integrated molded body having a stepped portion at an end portion.

[0054] Figure 13 is a cross-sectional view of an integrated molded body having a stepped portion at an end portion.

[0055] Figure 14 is a cross-sectional view of the integrated molded body shown in Figure 13 .

[0056] Figure 15 is a cross-sectional view of an injection mold for molding an integrated molded body having a cross section shown in Figure 14 .

[0057] Figure 16 is a cross-sectional view showing the angle parameter of the integrated molded body shown in Figure 14 . DETAILED DESCRIPTION

[0058] Embodiments are described below using the drawings. Note that the present application is not limited to any of the drawings and the embodiments.

[0059] ​The integrated molded body 10 of this utility model is formed by bonding and integrating a laminate (A) with a designed surface on one side and a non-designed surface on the opposite side with a resin component (B) having discontinuous fibers and thermoplastic resin. The laminate (A) includes a fiber-reinforced resin component having reinforcing fibers and resin. The resin component (B) is disposed on at least a portion of the outer peripheral edge of the laminate (A), and preferably disposed on the entire circumference of the outer peripheral edge.

[0060] The perspective view, top view, and schematic cross-sectional view A-A' of the integrated molded body 10 involved in this utility model are shown respectively. Figure 1 , Figure 2 and Figure 3 .

[0061] The integrated molded body 10 of this utility model has a structure in which a resin component (B) 30 is disposed on the outer periphery of a laminate (A) 20. In the example of the above figure, the laminate (A) 20 is in the shape of a thin plate and has a designed surface and a non-designed surface on its back side.

[0062] At least a portion of the non-design surface has a concave shape extending from the non-design surface side towards the design surface side. Preferably, at least a portion of the concave shape is a curved surface; more preferably, the entire surface is curved, considering ease of molding. Viewed from above, it is preferable that at least 50% of the entire non-design surface is formed with a concave shape; more preferably, part or all of it is curved; and even more preferably, it is a continuously curved shape as described above. The aforementioned area is more preferably 80%, more preferably 90% or more, and particularly preferably formed throughout the entire area. As a preferred embodiment, a concave shape that continuously deepens from the periphery towards the center or offset from the center in the in-plane direction of the molded body can be cited, i.e., such as... Figure 3 As shown, one of the optimal methods is to form a curved concave portion across the entire area outside the design surface. In this case, it is preferable that the portion outside the concave portion is flat. It should be noted that, for the laminate (A) 20, Figure 2 The surface shown in the diagram Figure 3 The surface located at the top is the design surface.

[0063] In this utility model, such as Figure 3 As shown, the height difference H (mm) between the extension line extending inward from the maximum height portion of the design surface layer of the laminate (A) 20 and the extension line extending inward from the minimum height portion of the design surface layer is 0–5 mm. Here, the in-plane direction of the laminate (A) refers to, as... Figure 2The direction parallel to the horizontal cross section of the laminate when the laminate is placed on the water platform with the design surface side facing upward. If the height difference H (mm) is less than 0 mm, then in the case where the laminate (A) has a certain thickness, it can cause interference with the internal parts. On the other hand, if the height difference H (mm) is greater than 5 mm, then although it is a direction in which interference with the internal parts can be avoided in the case where the laminate (A) has a certain thickness, when viewed from the design surface side, the convex shape is conspicuous, and it can become disadvantageous in terms of appearance, and in addition, the fiber cracking and the opening described later can occur significantly.

[0064] The preferable range of the above height difference H (mm) differs depending on the position and purpose of use in the final product, but if the appearance and the like are considered, it is more preferable to be 4 mm or less, and more preferable to be 2 mm or less, and from the viewpoint of securing the internal part insertion space, there are cases where it is preferable to be 0 to 0.5 mm, and from the viewpoint of securing the internal part insertion space and the appearance, there are cases where it is more preferable to be 0 to 0.1 mm, and it is particularly preferable to be 0 mm, but if warping and measurement error are considered, it is in the range of 0 to 0.05 mm. From the viewpoint of valuing the securing of the internal part insertion space and giving the molded body a certain thickness, there are cases where it is preferable to be 1 mm or more. With respect to the convex shape of the design surface, the specific proportion of the area in which the convex shape portion is formed in the design surface when viewed from above is the same as the preferable proportion with respect to the concave shape portion in the non-design surface. As with the above concave shape portion in the non-design surface, it is preferable that at least a part of the area be a curved surface, and as with the non-design surface, a certain area is a curved surface, and a convex shape portion in which the height continuously increases from the periphery toward the center or from a position offset from the center in the in-plane direction of the molded body is a preferable mode, and as one of the most preferable modes, a convex shape portion in which one curved shape is formed in the entire area of the design surface as shown in FIGS. 1 to 3, for example, can be cited. Figure 3 As with the above concave shape portion in the non-design surface, it is preferable that at least a part of the area be a curved surface, and as with the non-design surface, a certain area is a curved surface, and a convex shape portion in which the height continuously increases from the periphery toward the center or from a position offset from the center in the in-plane direction of the molded body is a preferable mode, and as one of the most preferable modes, a convex shape portion in which one curved shape is formed in the entire area of the design surface as shown in FIGS. 1 to 3, for example, can be cited.

[0065] In addition, in the present application, the resin member (B) 30 is preferably formed throughout the entire circumference of the outer circumferential surface portion of the laminate (A) 20.

[0066] By forming the joint portion with the resin member (B) 30 throughout the entire circumference of the outer circumferential surface portion of the laminate (A) 20, it is possible to achieve high joint strength and thinning as a whole of the integrated molded body 10.

[0067] From the viewpoint of reducing warping of the integrated molded body 10, the resin member (B) 30 contains a reinforcing fiber, and the reinforcing fiber is a discontinuous fiber. The weight average fiber length of the discontinuous fiber is preferably 0.3 to 3 mm.

[0068] As a method of measuring the fiber length of the discontinuous fibers, for example, there is a method of extracting the discontinuous fibers directly from the integrally molded body and measuring by microscope observation. In the case where the resin is attached to the discontinuous fiber group, there are a method of dissolving the resin from the discontinuous fiber group using a solvent that dissolves only the resin attached to the discontinuous fiber group, filtering out the remaining discontinuous fibers, and measuring by microscope observation (dissolution method), a method of burning off only the resin in a temperature range in which the discontinuous fibers do not undergo oxidative degradation without a solvent that dissolves the resin, separating the discontinuous fibers, and measuring by microscope observation (burning-off method), and the like. Four hundred discontinuous fibers can be randomly selected from the discontinuous fiber group, the length thereof is measured in units of 1 μm by an optical microscope, and the fiber length and the proportion thereof are calculated.

[0069] Here, the continuous fiber and the discontinuous fiber in the present application are defined. The continuous fiber refers to a form in which the reinforcing fiber contained in the integrally molded body 10 is substantially continuously arranged over the entire length or width of the integrally molded body 10, and the discontinuous fiber refers to a reinforcing fiber that is intermittently broken. In general, in a unidirectional fiber-reinforced resin in which a reinforcing fiber is impregnated with a resin in one direction, the fiber in the unidirectional fiber-reinforced resin that is not cut into a pellet shape corresponds to the continuous fiber, and the fiber in an SMC (Sheet Molding Compound) substrate used in press molding, a pellet material containing a reinforcing fiber used in injection molding, and the like corresponds to the discontinuous fiber. The continuous fiber refers to a reinforcing fiber that is continuous over a length of 100 mm or more in at least one direction.

[0070] In addition, in the present application, a thermoplastic resin is contained in the resin member (B) 30, and is used together with the discontinuous fiber. By containing the discontinuous fiber, it is possible to improve the joining strength of the resin member (B) to the laminate (A) and to reduce the excess warping of the integrally molded body 10. The weight fiber content of the discontinuous fiber in the resin member (B) is preferably 1 to 60% by weight. If it is less than 1% by weight, there is a case where it becomes difficult to ensure the strength of the molded body, and if it is more than 60% by weight, there is a case where the filling of the resin member (B) 30 becomes insufficient in injection molding. From the viewpoint of moldability of the resin member (B) 30, it is preferably 5 to 55% by weight, more preferably 8 to 50% by weight, and further preferably 12 to 45% by weight.

[0071] In the integrated molded body of the present application, when the design surface side is set to a higher position and the non-design surface side is set to a lower position in the normal direction of the in-plane direction, the distance in the normal direction from the highest position (position of maximum height) in the design surface to the lowest position (position of minimum height) in the non-design surface of the laminate (A) is set to Tmax, and the distance in the normal direction from the position of maximum height in the design surface to the position of maximum height in the non-design surface is set to Tmin, the ratio Tmax / Tmin of Tmax to Tmin is preferably 1.05 to 6. If Tmax / Tmin is less than 1.05, the depth of the recess on the non-design surface side is sometimes insufficient. On the other hand, if Tmax / Tmin is greater than 6, the fibers contained in the layer on the non-design surface side generate tension in the in-plane direction during molding, and it can be impossible to follow the mold shape and form the desired shape. From the viewpoint of securing the internal space, the more preferable range on the lower limit side of the ratio is 1.1 or more, and further preferably 1.2 or more. From the viewpoint of more easily obtaining the desired shape, the more preferable range on the upper limit side of the ratio is 4.5 or less, and further preferably 3.2 or less.

[0072] In terms of the relationship between Tmax and Tmin, from the viewpoint of securing a certain amount of internal space in absolute terms, it is sometimes more effective to consider not only the ratio but also the difference, and the difference Tmax-Tmin is preferably 0.05 to 5.00 mm. From the viewpoint of securing the internal space, the more preferable range of the difference is 0.1 mm or more, and further preferably 0.2 mm or more. From the viewpoint of more easily obtaining the desired shape, the more preferable range on the upper limit side of the difference is 4.0 mm or less, and more preferably 2.5 mm or less.

[0073] Further, in the present application, the laminate (A) 20 is a sandwich structure having at least a surface layer and a core layer sandwiched inside the surface layer, and the surface layer has a thermoplastic resin or a thermosetting resin or a combination thereof in addition to continuous reinforcing fibers. By making the laminate (A) 20 a sandwich structure, the surface layer and each layer (skin layer) constituting the surface layer easily follow the convex shape of the convex shape portion in which a part of the laminate (A) 20 is raised toward the design surface side. By making the surface layer and each layer (skin layer) constituting the surface layer easily follow the convex shape, the occurrence of fiber cracking and opening of the continuous fibers described above can be suppressed, and a high design integrated molded body can be obtained. Note that in the case of using unidirectional fibers and in the case of using a fabric, the spacing between adjacent continuous fibers is preferably less than 2 mm, and further preferably less than 1 mm. In some cases, it is desirable that the spacing between adjacent continuous fibers is 0 mm, but in reality, there are many cases where a spacing of 0.01 mm or more, and 0.1 mm or more depending on the type of fiber, etc. exists between the fiber bundles. In the case where adjacent fibers are not parallel to each other, the spacing can be set as the distance in the perpendicular direction to the reference direction, which is the lengthwise direction of one of the fibers. In the case where the integrated molded body is rectangular in plan view, in the case where the fibers are arranged along either of the longitudinal and lateral edges of the molded body, the direction of either of the longitudinal and lateral edges of the molded body can be set as the reference direction. In the case where the resin constituting the surface layer is a thermosetting resin, particularly from the viewpoint of high strength and high rigidity, the following configuration is preferable, i.e., a thermoplastic resin layer is further provided on the outer surface of the surface layer in the non-design surface, and the resin member (B) 30 is also arranged on the thermoplastic resin layer and forms an overlapping portion with the laminate (A), and the laminate (A) 20 and the resin member (B) 30 are joined at the overlapping portion via the thermoplastic resin layer. In this manner, the thermoplastic resin of the resin member (B) 30 and the thermoplastic resin of the thermoplastic resin layer are fused and solidified to form a joint structure, and a higher joint strength is achieved as an integrated molded body 10. The fused and solidified joint structure refers to a joint structure in a state where the members are fused by heat and solidified by cooling.

[0074] In addition, as the reinforcing fiber contained in the laminate (A) 20 and the resin member (B) 30 of the present application, an aluminum fiber, a brass fiber, a stainless steel fiber, a metal fiber, a polyacrylonitrile-based fiber, a rayon-based fiber, a lignin-based fiber, a carbon fiber, a graphite fiber, a glass fiber, a silicon carbide fiber, a silicon nitride fiber, an aramid fiber, a poly-p-phenylene benzobisoxazole (PBO) fiber, a polyphenylene sulfide fiber, a polyester fiber, an acrylic fiber, a polyamide fiber, an aromatic polyamide fiber, a polyaramid fiber, a polyethylene fiber, a silicon carbide fiber, a silicon nitride fiber, an alumina fiber, a boron fiber, or the like can be used. These reinforcing fibers can be used alone or in combination with two or more. These fiber raw materials can be subjected to surface treatment. As the surface treatment, a coating treatment of a metal, a treatment using a coupling agent, a treatment using a sizing agent, an additive attachment treatment, or the like can be mentioned.

[0075] In addition, as the material of the continuous reinforcing fiber used in the laminate (A) 20, a carbon fiber or a graphite fiber is preferable from the viewpoints of specific strength, specific rigidity, and light weight, and a polyacrylonitrile (PAN)-based carbon fiber, a rayon-based carbon fiber, a lignin-based carbon fiber, a pitch-based carbon fiber, or the like having excellent specific strength and specific rigidity is preferably used. In the present application, a polyacrylonitrile (PAN)-based carbon fiber is preferable from the viewpoints of cost and processability. As the reinforcing fiber used in the resin member (B) 30, a carbon fiber or a glass fiber is preferable from the viewpoint of the strength of the resin member (B) 30. A glass fiber is more preferable, and by using a glass fiber for the resin member (B) 30, the resin member (B) 30 can be given a function as an electric wave permeable member.

[0076] In addition, in the case where the reinforcing fiber is a carbon fiber, the density of the carbon fiber is 1.6 g / cm 3 2.0 g / cm 3 From the viewpoint of improvement in rigidity, 1.8 g / cm 3 2.0 g / cm 3 2.0 g / cm 3 2.5 g / cm 3 From the viewpoint of cost, 2.0 g / cm 3 2.3 g / cm 3 In the present application, a polyacrylonitrile (PAN)-based carbon fiber having excellent processability is preferable.

[0077] In view of the lightness, any one of the film, the foamed body, and the porous substrate is used as the core layer, and a sandwich structure in which the core layer is sandwiched by the surface layers (skin layers) is formed.

[0078] In terms of the rigidity of the sandwich structure, the tensile elastic modulus of the continuous reinforcing fiber in the laminate (A) 20 is preferably 200 to 1000 GPa, and in terms of the handleability of the prepreg, a tensile elastic modulus in the range of 400 to 900 GPa can be more preferably used. In the case where the tensile elastic modulus of the continuous reinforcing fiber is less than 200 GPa, there is a case where the rigidity of the sandwich structure is poor, and in the case where it is greater than 1000 GPa, the crystallinity of the carbon fiber needs to be improved when the continuous reinforcing fiber is a carbon fiber, and it is difficult to manufacture the carbon fiber. If the tensile elastic modulus of the continuous reinforcing fiber is in the aforementioned range, the rigidity of the sandwich structure is further improved, and the manufacturability of the carbon fiber is improved, and it is preferable in this respect. Note that the tensile elastic modulus of the continuous reinforcing fiber can be measured by the wire bundle tensile test described in JIS R7301-1986.

[0079] Further, in the present application, as described above, the laminate (A) 20 is a sandwich structure in which the surface layers and the core layer are layered, and the surface layers each formed of the continuous reinforcing fiber and the resin are preferably layered in two or more layers. The layered structure in each of the surface layers can be freely set and layered in view of the desired rigidity, thickness, strength, and the like.

[0080] In terms of the thickness of the laminate (A), the thickness of the surface layers and the layers (skin layers) constituting the surface layers is preferably 0.05 to 1.00 mm. In terms of the degree of freedom of the laminate design, it is further preferably 0.05 to 0.20 mm.

[0081] In addition, in the laminate (A) 20, a fiber fabric base material can also be used. The fiber fabric base material is a base material in which continuous fiber bundles in which continuous fibers are integrated in bundles of 1000 are set as warp and weft and 2 groups of the yarns are crossed using a loom. The continuous fiber bundle integrated in bundles of 1000 is generally referred to as 1K, in the case of 3000, as 3K, and in the case of 12000, as 12K. As the fiber used in the fiber fabric base material, the above-described kinds of fibers can be used alone or in combination of two or more. As the kind of fabric, at least one fabric selected from plain weave, twill weave, satin weave (Japanese: sashi-zo-shi), and satin weave (Japanese: shu-shi) is preferable. The fiber pattern of the fiber fabric base material has a characteristic, and thus the fiber pattern having the characteristic can be highlighted, and by using the fiber fabric in the outermost layer (design surface side), the shape pattern of the fabric of the continuous fibers can be highlighted, and a brand-new surface pattern can be presented. With respect to the continuous fiber bundle, 1K to 24K is preferable, and from the viewpoint of stability of the fiber pattern at the time of processing, 1K to 6K is more preferable.

[0082] As the resin used in the surface layer 100 and the core layer 110 constituting the sandwich structure included in the laminate (A) 20, any of a thermoplastic resin or a thermosetting resin can be used. The resin included in the resin member (B) 30 is a thermoplastic resin, and among the thermoplastic resins, there is no particular limitation, and any of the thermoplastic resins exemplified below can be used. For example, a thermoplastic resin selected from the group consisting of polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, polyethylene naphthalate (PEN resin), liquid crystal polyester resin, and the like polyester resin; polyethylene (PE resin), polypropylene (PP resin), polybutylene resin, and the like polyolefin resin; polyoxymethylene (POM) resin, polyamide (PA) resin, polyphenylene sulfide (PPS) resin, and the like polyarylene sulfide resin; polyketone (PK) resin, polyether ketone (PEK) resin, polyether ether ketone (PEEK) resin, polyether ketone ketone (PEKK) resin, polyether nitrile (PEN) resin, polytetrafluoroethylene resin, and the like fluorine-based resin; crystalline resin such as liquid crystal polymer (LCP); styrene-based resin, and polycarbonate (PC) resin, polymethyl methacrylate (PMMA) resin, polyvinyl chloride (PVC) resin, polyphenylene ether (PPE) resin, polyimide (PI) resin, polyamide-imide (PAI) resin, polyether-imide (PEI) resin, polysulfone (PSU) resin, polyether sulfone resin, polyacrylate (PAR) resin, and the like amorphous resin, and phenol-based resin, phenoxy-based resin, and polystyrene-based resin, polyurethane-based resin, polybutadiene-based resin, polyisoprene-based resin, and acrylonitrile-based resin, and the like thermoplastic elastomer, and copolymers and modified products thereof, and the like can be used.

[0083] Among them, from the viewpoint of light weight of the obtained molded product, it is preferable to use a polyolefin resin, from the viewpoint of strength, it is preferable to use a polyamide resin, from the viewpoint of surface appearance, it is preferable to use an amorphous resin such as a polycarbonate resin, a styrene-based resin, a modified polyphenylene ether-based resin, from the viewpoint of heat resistance, it is preferable to use a polyarylene sulfide resin, and from the viewpoint of continuous use temperature, it is preferable to use a polyether ether ketone resin. The exemplified thermoplastic resins can also contain impact resistance improvers such as elastomers or rubber components, other fillers, and additives, without affecting the purpose of the present application. As examples thereof, inorganic fillers, flame retardants, conductivity imparting agents, nucleating agents, ultraviolet absorbers, antioxidants, vibration dampers, antibacterial agents, insect repellents, deodorants, coloration preventing agents, heat stabilizers, release agents, antistatic agents, plasticizers, lubricants, colorants, pigments, dyes, foaming agents, defoaming agents, or coupling agents can be mentioned.

[0084] In the case where the resin constituting the laminate (A) 20 is a thermosetting resin, an unsaturated polyester resin, a vinyl ester resin, an epoxy resin, a phenol resin (Resol type), a urea-melamine resin, a polyimide resin, a maleimide resin, a benzoxazine resin, or the like can be preferably used. These can also be applied to a resin obtained by blending two or more kinds. Among them, an epoxy resin is particularly preferable from the viewpoint of the mechanical properties and heat resistance of the molded body. In the case where an epoxy resin is used, in order to exhibit the excellent mechanical properties thereof, it is preferable to include the epoxy resin as a main component of the resin used, and specifically, it is preferable to include 60% by weight or more with respect to the resin composition.

[0085] In the case where a foam having a void is used as the core layer 110, as a material thereof, a polyurethane resin, a phenol resin, a melamine resin, an acrylic resin, a polyethylene resin, a polypropylene resin, a polyvinyl chloride resin, a polystyrene resin, an acrylonitrile-butadiene-styrene (ABS) resin, a polyetherimide resin, or a polymethacrylimide resin can be appropriately used. Specifically, in order to ensure light weight, it is preferable to use a resin having a smaller apparent density than the skin layer, and particularly, a polyurethane resin, an acrylic resin, a polyethylene resin, a polypropylene resin, a polyetherimide resin, or a polymethacrylimide resin can be preferably used.

[0086] In addition, in the present application, from the viewpoint of the joint strength of the integrated molded body 10, it is preferable to be configured to have an embedded portion into which the resin member (B) 30 of a part of the core layer as a foam porous base material enters.

[0087] Next, the manufacturing method of the integrated molded body of the present application will be described. As described above, the molded body of the present application is obtained by integrating the resin member (B) 30 to the laminate (A) 20, and the laminate (A) 20 has a sandwich structure in which a core layer is sandwiched by surface layers, but as the fiber reinforced resin member constituting the surface layer having a continuous reinforcing fiber and a resin composition, for example, a prepreg having unidirectional fibers is used for the surface layer, and the laminate is stacked in a prescribed configuration on both sides of the core layer, and is molded using a press molding method or the like, whereby the laminate (A) 20 can be obtained. In this press molding, from the viewpoint of mold shape followability (prevention of fiber cracking or the like) of the reinforcing fiber resin member, the mold temperature is preferably 110 to 200°C. In addition, from the viewpoint of impregnation of the resin into the inter-fiber space of the surface layer and the core, the press pressure is preferably 1 to 6 MPa. In addition, it is also effective to preheat the stacked base material before being put into the press, and from the viewpoint of impregnation of the resin into the inter-fiber space of the surface layer and the core, the preheating time is preferably 30 to 120 seconds.

[0088] In the present application, preferably, the laminate (A) has a stepped portion at least in a part of the end portion, the stepped portion is composed of a thick wall portion forming a high surface in the stepped portion, a boundary portion forming a boundary surface connecting the high surface and a low surface of the stepped portion, and a thin wall portion having a core layer with a lower void ratio than that of the core layer in the thick wall portion, and the resin member (B) is engaged with at least a part of the thin wall portion without being engaged with the boundary portion.

[0089] Figure 13 An embodiment of the present application shows an integrated molded body, Figure 14 An embodiment of the present application shows an integrated molded body, Figure 13 A schematic cross-sectional view of the integrated molded body in the thickness direction as viewed along the A-A' line of Figure 13In the sandwich structure 1 composed of the core layer 3 and the skin layer 2 in the core layer 3, the core layer 3 is composed of the discontinuous fiber 4 and the thermoplastic resin of the matrix resin, and a void 5 of a certain size is formed in the core layer 3. A joining portion 6 is provided at least in a part of the end portion of the sandwich structure 1, and a resin member (B) 7 is injection-molded to be joined to the joining portion 6, thereby constituting an integrated molded body 10. A stepped portion 11 is provided at least in a part of the end portion of the sandwich structure 1, and the stepped portion 11 is composed of a thick wall portion 8 forming a high face 8a in the stepped portion 11, a boundary portion 9 forming a boundary face 9a connecting the high face 8a and a low face 10a of the stepped portion 11, and a thin wall portion 140 having a core layer 3b having a lower void ratio than the core layer 3a in the thick wall portion 8. The stepped portion is preferably provided in a non-design face. The resin member (B) 7 is joined to at least a part of the thin wall portion 140 without contacting the boundary face 9a. In the integrated molded body 10, the joining area can be increased compared to a case where the resin member (B) is joined only to the side face flat portion of the sandwich structure, and an effect of improving the joining strength can be obtained.

[0090] In the integrated molded body 10 according to the embodiment, as shown in Figure 14 , the resin member (B) 7 is joined to at least a part of the thin wall portion 140 having the core layer 3b having a lower void ratio (including a case where there is no void) than the core layer 3a in the thick wall portion 8, Figure 14 , and the lower face side is formed as a design face. The joining portion 6 can be provided over the entire circumference of the sandwich structure 1, or can be provided only at necessary portions in the circumferential direction of the sandwich structure 1. The provision can be determined according to the use of the integrated molded body 10.

[0091] As for the manufacturing method, the configuration in which the resin member (B) 7 is joined to at least a part of the thin wall portion 140 without contacting the boundary face 9a in the integrated molded body 10 is formed, for example, in a manner shown in Figure 12 , in contrast to Figure 15 . As shown in Figure 14 , the sandwich structure 1 after the molding is arranged in a mold 12, and the resin member (B) 7 is injected into the mold 12, and an intercepting structure portion 13 is arranged on the inner face side of the mold 12 integrally with the mold 12 or separately from the mold 12, and the intercepting structure portion 13 intercepts the resin R in such a manner that the resin R is joined to only a part of the side face 140b and the upper face 140a of the thin wall portion 140 without contacting the boundary face 9a. In this way, by injection in such a manner that the resin R is joined to only a part of the thin wall portion 140, the following problem can be eliminated to reliably obtain a desired design face, that is, a problem that the design face is not formed in a desired shape due to the resin member (B) 7 being joined to the boundary face 9a. Figure 12As shown, the heat of the injected resin R is transferred to the core layer 3 in the boundary portion 9 and the thick wall portion 8, and the amount of shrinkage of the core layer at the time of cooling becomes large in the region in which the voids in the core layer 3 are relatively many, and a defective condition such as deformation caused by sink marks accompanying the shrinkage of the core layer can occur on the design surface side of the integrated molded body thus molded. That is, the integrated molded body 10 that is capable of thin and lightweight can be obtained in which the resin member (B) 7 is joined with high joining strength and no defective condition occurs on the design surface side. At the thin wall portion 140, the void ratio of the core layer is reduced and the strength is improved and the thin wall portion 140 is thinned, and thus the thickness of the resin member (B) 7 can be made uniform with the thickness of the thick wall portion 8, that is, a configuration in which the thickness of the thick wall portion 8 and the thickness of the portion formed of only the resin member (B) 7 joined via the joining portion 6 have the same thickness can be made, and the thickness of the integrated molded body 10 can be made uniform in the range of the entire body. Alternatively, with respect to the entire body of the integrated molded body 10 including the resin member (B) 7, a thickness and a shape in a prescribed range can also be formed. As a result, the entire body of the integrated molded body 10 can be made thin and lightweight.

[0092] As the void ratio of the core layer 3 in the region in which the thick wall portion 8 is formed in the integrated molded body 10 as described above, it is preferably 50% or more and 80% or less, and as the void ratio of the core layer 3 in the region in which the thin wall portion 140 is formed, it is preferably 0% or more and less than 50%. By providing a certain void in the core layer and changing the void ratio thereof, a desired thickness can be formed. The void ratio of the core layer 3 in the region in which the thick wall portion 8 is formed is preferably 52 to 78%, more preferably 58 to 75%, and further preferably 60 to 70%. If the void ratio is less than 50%, a certain height in the thick wall portion 8 cannot be ensured, and there is a case in which the effect of improving the joining strength of the sandwich structure body 1 and the resin member (B) 7 becomes weak. If the void ratio is more than 80%, there is a case in which the strength of the sandwich structure body 1 is insufficient. In addition, the void ratio of the core layer 3 in the region in which the thin wall portion 140 is formed is preferably 0 to 45%, more preferably 0 to 40%, and further preferably 0 to 35%. If the void ratio is 50% or more, a certain height difference between the thick wall portion 8 cannot be ensured, and there is a case in which the effect of improving the joining strength of the sandwich structure body 1 and the resin member (B) 7 becomes weak.

[0093] The parameters related to each shape in the integrated molded body 10 as described above are preferably set as described below. Figure 16 Each shape parameter is shown in the table, and first, it is preferable that the boundary surface 9a of the boundary portion 9 has an angle θ of 1 to 20° with respect to the in-plane direction of the thick wall portion 8. Note that in the case in which the angle θ is 90°, the boundary surface 9a of the boundary portion 9 stands up perpendicularly from the thin wall portion 140, but the present mode also holds in this case. The angle θ (°) is more preferably 2 to 10°, and further preferably 3 to 8°.

[0094] The integrated molded body according to the present application is suitable for a top plate or the like of an electronic device frame such as a notebook personal computer, and the length of one side thereof is preferably 200 mm to 500 mm. If the length of one side is 400 mm or less, the integrated molded body according to the present application can be more suitably applied.

[0095] The upper limit and the lower limit of the numerical range described above can be arbitrarily combined.

[0096] Examples

[0097] Hereinafter, the integrated molded body according to the present application will be specifically described based on examples, but the following examples do not limit the present application. The measurement methods used in the examples are described below.

[0098] (1) Measurement of flatness of integrated molded body

[0099] The height of the thickness direction of the top plate (laminate (A) 20) and the height of the resin member (B) 30 from the horizontal surface were measured using a three-dimensional measuring device in the state where the design surface side of the box-shaped integrated molded body produced in the examples and comparative examples was facing upward. For the measurement points, the design surface was positioned at a higher position in the normal direction of the above-described surface direction, and the maximum position and the minimum position of the height of the design surface of the laminate (A) 20 were determined, and one measurement was performed for each of these two positions. Then, in the state where the non-design surface side of the integrated molded body was facing upward, the design surface was similarly positioned at a higher position in the normal direction, and one measurement was performed for each of the maximum position and the minimum position of the height of the non-design surface. The obtained values were evaluated based on the following criteria. A is pass, and B is fail.

[0100] A: The appearance of the design surface side of the laminate (A) 20 did not have appearance defects such as fly-off, fiber cracking, and fiber meandering.

[0101] B: The appearance of the design surface side of the laminate (A) 20 had appearance defects such as fly-off, fiber cracking, and fiber meandering.

[0102] (Material composition example 1) PAN-based unidirectional prepreg

[0103] A prepreg (Toray (Shanghai) Co., Ltd. "Torayca" (registered trademark) prepreg, type P3252S-15, epoxy resin, thickness 0.14 mm) in which PAN-based carbon fibers were arranged in one direction was used.

[0104] (Thermoplastic film)

[0105] A polyester resin film having a thickness of 0.05 mm was obtained using a polyester resin ("Hytrel" (registered trademark) manufactured by Toray-DuPont (K.K.). This was used as a thermoplastic film.

[0106] (Glass fiber reinforced polycarbonate resin (Material composition example 3)

[0107] A compounded pellet of a glass fiber reinforced polycarbonate ("Panlite" (registered trademark) GXV-3545WI (manufactured by Teijin Kasei (K.K.)) (GF reinforced polycarbonate resin) was used.

[0108] (Short carbon fiber bundle (Material composition example 4)

[0109] A short carbon fiber bundle having a fiber length of 6 mm was obtained by cutting a PAN-based carbon fiber ("Torayca" (registered trademark), type T700SC, manufactured by Toray (K.K.)) using a machine-knife.

[0110] (Preparation of carbon fiber mat (Material composition example 5)

[0111] A 1.5 mass% aqueous solution of a surfactant ("Sodium n-Dodecylbenzenesulfonate" (product name), manufactured by Wako Pure Chemical Industries (K.K.)) 100 liters was stirred to prepare a pre-foamed dispersion liquid. The short carbon fiber bundle obtained in Material composition example 4 was added to the dispersion liquid, which was stirred and then fed into a papermaking machine having a papermaking surface of 400 mm in length and 400 mm in width, and dewatered by suction, and then dried at a temperature of 150°C for 2 hours to obtain a carbon fiber mat. The obtained mat was in a good dispersed state.

[0112] (Preparation of polypropylene resin film (Material composition example 6)

[0113] A dry-blended resin was obtained by dry-blending 90 mass% of an unmodified polypropylene resin ("Prime Polypro" (registered trademark) J105G, melting point 160°C, manufactured by PRIME POLYMER (K.K.)) and 10 mass% of an acid-modified polypropylene resin ("ADMER" (registered trademark) QE510, melting point 160°C, manufactured by Mitsui Chemicals (K.K.)), and a polypropylene resin film was obtained using the dry-blended resin.

[0114] (Expanded resin core layer (Material composition example 7)

[0115] An uncrosslinked low-expansion polypropylene sheet "EFCELL" (registered trademark) (2-fold expansion) (manufactured by Furukawa Electric Industries (K.K.)) was used.

[0116] (Carbon fiber core (Material composition example 8)

[0117] The carbon fiber mat obtained in Material Composition Example 5 and the polypropylene resin film obtained in Material Composition Example 6 were stacked in the order of [polypropylene resin film / carbon fiber mat / polypropylene resin film] to be used as the material used in the core layer.

[0118] (Comparative Example 1)

[0119] The PAN-based unidirectional prepreg obtained in Material Composition Example 1, the thermoplastic adhesive film obtained in Material Composition Example 2, and the carbon fiber core obtained in Material Composition Example 8 were each adjusted to a size of 400 mm square, and stacked in the order of [PAN-based unidirectional prepreg 0° / PAN-based unidirectional prepreg 90° / polypropylene resin film / carbon fiber mat / polypropylene resin film / PAN-based unidirectional prepreg 90° / PAN-based unidirectional prepreg 0° / thermoplastic adhesive film] in a sandwiched structure. The stack was sandwiched with a release film, and, in order to set a concave shape to the non-design surface of the stack and a convex shape to the design surface, a heating press mold having a concave-convex shape shown in Table 1 was used. The stack was placed on the mold, and the mold was closed. The stack was heated and pressed at 3 MPa. After 1 minute from the start of pressurization, a spacer having a thickness of 1.15 mm was inserted into the mold as a thickness adjustment, and the mold gap was enlarged by 1.15 mm. Figure 4 , Figure 5 The stack was placed on the mold, and the mold was closed. The stack was heated and pressed at 3 MPa. After 1 minute from the start of pressurization, a spacer having a thickness of 1.15 mm was inserted into the mold as a thickness adjustment, and the mold gap was enlarged by 1.15 mm. Figure 10

[0120] After 4 more minutes, the mold was opened, and the stack was quickly placed on the surface of a cooling press mold having the same shape as the heating press mold, with the surface temperature of the mold set to 40°C. The stack was cooled and pressed at 3 MPa.

[0121] After 5 minutes, the molded product was taken out of the press mold, and a sandwiched structure body having a thickness of 1.7 mm in the thick wall portion, a thickness of 0.7 mm in the thinnest portion in the joint portion, and an angle θ of 15 degrees in the inclined surface of the step portion was obtained. The sandwiched structure body obtained in this manner was heated to 180°C in a hot air oven, quickly placed on the surface of a cooling press mold having a surface temperature of 40°C, and cooled and pressed at 3 MPa. Note that, in order to set a concave shape to the non-design surface of the stack and a convex shape to the design surface, a concave-convex shape shown in Table 1 was provided on the cooling press mold. In addition, as a thickness adjustment, a spacer having a thickness of 1.15 mm was inserted into the mold. After 5 minutes, the molded product was taken out of the press mold, and a stack (A) 20 having a thickness of 1.15 mm in the thick wall portion and a thickness of 0.7 mm in the joint portion was obtained.

[0122] Next, in Figure 6 ​In the mold shown, the laminate (A) 20 to which the thermoplastic film is attached, which is processed to have a size of 300 mm x 200 mm square in plan view, is aligned and arranged with the design surface side as the lower mold side. After the upper mold is placed and the mold is closed, the glass fiber reinforced polycarbonate resin of Material Composition Example 3 is injection molded at 150 MPa, a cylinder temperature of 320°C, a mold temperature of 120°C, and a diameter of the resin discharge port of φ 3 mm, using an injection molding machine (omitted from the drawing) for the laminate (A) 20 in the mold as a whole, to produce Figure 10 , 11 the integrated molded body 10 shown in the schematic view.

[0123] The characteristics of the integrated molded body are summarized in Table 1. Although the resulting integrated molded body 10 formed a concave shape from the non-design surface side to the design surface side in the desired area of the laminate (A) 20, there were undercuts, fiber cracks, and fiber meandering on the design surface.

[0124] (Example 1)

[0125] In Comparative Example 1, a convex shape portion having the same curved shape as the mold shown in Figure 4 , 5 and the height shown in Table 1 was provided on the non-design surface side, and a flat-shaped mold was used for both heating and cooling stamping on the design surface side, and the other conditions were the same as in Comparative Example 1, whereby an integrated molded body 10 was produced.

[0126] The characteristics of the integrated molded body are summarized in Table 1. The resulting integrated molded body 10 formed a concave shape from the non-design surface side to the design surface side in the desired area of the laminate (A) 20, and there were no undercuts, fiber cracks, or other appearance defects on the design surface, resulting in a molded product with a good appearance and high design.

[0127] (Example 2)

[0128] In Comparative Example 1, the mold shown in Figure 4 , 5 was used, but the height of the concave shape portion on the design surface side and the convex shape portion on the non-design surface side was as shown in the mold of Table 1 for both heating and cooling stamping, and the other conditions were the same as in Comparative Example 1, whereby an integrated molded body 10 was produced.

[0129] The characteristics of the integrated molded body are summarized in Table 1. The resulting integrated molded body 10 formed the desired shape as in Example 1, and was a molded product with a good appearance.

[0130] (Example 3)

[0131] In Comparative Example 1, the mold shown in Figure 4 ,5 The same curved shape as the mold is shown, but the height of the concave shape portion on the design surface side and the convex shape portion on the non-design surface side is as shown in Table 1, and the same conditions as Comparative Example 1 are used for both heating press and cooling press, whereby an integrated molded body 10 is manufactured.

[0132] The characteristics of the integrated molded body are summarized in Table 1. The resulting integrated molded body 10 forms the desired shape as in Example 1, and is a molded product with good appearance.

[0133] (Example 4)

[0134] The PAN-based unidirectional prepreg obtained in Material Composition Example 1, the thermoplastic adhesive film obtained in Material Composition Example 2, and the foamed resin core layer obtained in Material Composition Example 7 are each adjusted to a size of 400 mm square, and are stacked in the order of [PAN-based unidirectional prepreg 0° / PAN-based unidirectional prepreg 90° / foamed resin core layer / PAN-based unidirectional prepreg 90° / PAN-based unidirectional prepreg 0° / thermoplastic adhesive film], and an integrated molded body is manufactured in the same manner as in Example 1, except for this, whereby an integrated molded body 10 having a thickness of 1.15 mm and a plate thickness of 1.05 mm in the central portion is obtained. The characteristics of the integrated molded body 10 are summarized in Table 1. The resulting integrated molded body 10 forms a concave shape from the non-design surface side to the design surface side in the desired area of the stacked body (A) 20, and there is no appearance defect such as undercuts or fiber cracking on the design surface, and a molded product with high design and good appearance is obtained.

[0135] [Table 1]

[0136]

[0137] Industrial applicability

[0138] The integrated molded body of the present application can be effectively used for automobile interior and exterior decoration, electrical and electronic equipment frames, bicycles, sports goods structural materials, aircraft interior decoration materials, transportation cases, and the like.

[0139] Explanation of reference numerals

[0140] 1 sandwich structure

[0141] 2 surface layer (skin layer)

[0142] 3, 3a, 3b, 110 core layer

[0143] 4 discontinuous fibers

[0144] 5 voids

[0145] 6 joint portion

[0146] 7, 30 resin part (B)

[0147] 8, 150 thick wall portion

[0148] 8a high surface

[0149] 9, 160 boundary portion

[0150] 9a boundary surface

[0151] 10 integrally molded body

[0152] 10a low surface

[0153] 11 step portion

[0154] 12 mold

[0155] 13 intercepting configuration portion

[0156] 20 laminate (A)

[0157] 21 Tmax

[0158] 22 Tmin

[0159] 40 concave shape formed on a non-design surface of the laminate (A)

[0160] 50 Figure 3 lower surface of the press mold at the A-A' cross section position

[0161] 60 Figure 3 convex shape provided on the upper surface of the press mold at the A-A' cross section position

[0162] 70 Figure 3 upper surface of the injection mold at the A-A' cross section position

[0163] 80 Figure 3 lower surface of the injection mold at the A-A' cross section position

[0164] 130 other part

[0165] 140 thin wall portion

[0166] 170 thermoplastic resin layer

[0167] H height difference

[0168] R resin

[0169] Tmax height difference between the maximum height of the front side and the minimum height of the back side of the laminate (A)

[0170] Tmin height difference between the maximum height of the front side and the maximum height of the back side of the laminate (A)

Claims

1. A monolithic molded body, comprising a laminate (A) having a designed surface on one side and a non-designed surface on the other side, and a resin component (B) comprising discontinuous fibers and thermoplastic resin, integrally formed by joining and integrating the two parts, characterized in that, The resin component (B) is bonded to at least a portion of the outer periphery of the laminate (A). The laminate (A) has a sandwich structure in which a core layer is sandwiched between a surface layer. The surface layer is formed of a fiber-reinforced resin component comprising a continuous reinforcing fiber and a resin composition. The core layer is formed from any one selected from membranes, foams, and porous substrates. The height difference (H) between the maximum height and the minimum height of the surface of the laminate (A) is less than 0 to 5 mm. A portion of the back side has a concave shape that is recessed from the back side to the front side.

2. The integrally molded body as described in claim 1, wherein, At least a portion of the concave portion is bent.

3. The integrally molded body as described in claim 1, wherein, When the height difference between the maximum height on the front side and the minimum height on the back side of the laminate (A) is set as Tmax, and the height difference between the maximum height on the front side and the maximum height on the back side of the laminate (A) is set as Tmin, The ratio of Tmax to Tmin, Tmax / Tmin, is 1.05 to 6.

4. The integrally molded body as described in claim 1, wherein, When the height difference between the maximum height on the front side and the minimum height on the back side of the laminate (A) is set as Tmax, and the height difference between the maximum height on the front side and the maximum height on the back side of the laminate (A) is set as Tmin, The difference between Tmax and Tmin, Tmax-Tmin, is 0.05 to 5.0 mm.

5. The integrally molded body as described in claim 1, wherein, The continuous reinforcing fiber has the form of a unidirectional fiber formed by spinning yarns in one direction or the form of a fabric formed by combining yarns in a longitudinal and transverse manner, with the spacing between adjacent fibers being less than 2 mm.

6. The integrally molded body as described in claim 1, wherein, The porous substrate comprises discontinuous fibers and thermoplastic resin.

7. The integrally molded body as described in claim 1, wherein, The laminate (A) has a stepped portion on its outer surface, formed by a thick-walled portion with a large height, a thin-walled portion with a small height, and a boundary portion connecting the thick-walled portion and the thin-walled portion. The porosity of the core layer in the thin-walled portion is less than that of the core layer in the thick-walled portion. The resin component (B) is not in contact with the boundary portion but is joined to a portion of the thin-walled portion.

8. The integrally molded body as described in claim 7, wherein, The surface of the boundary portion is inclined at an angle of 1 to 20° relative to the surface of the thick-walled portion.

9. The integrally molded body as described in claim 7 or 8, wherein, The porosity of the core layer in the thick-walled portion is 50% to 80%, and the porosity of the core layer in the thin-walled portion is 0% to less than 50%.

10. The integrally molded body as claimed in claim 1, wherein, The integrated molded body is used for the frame of electronic devices.

11. An electronic device frame, characterized in that, The electronic device frame is made using the integral molded body as described in claim 10.

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