Method for manufacturing a molded body and molded body

Abstract

To provide a method for manufacturing a molded body that can prevent leakage of the molding material when performing transfer molding on an insert made of multiple components. [Solution] A method for manufacturing a molded article comprising: preparing a pre-molded case comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member; and transferring a resin onto the pre-molded case.

Claims

1. A pre-molded case is provided, comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member. Transfer molding of resin onto the aforementioned pre-molded case, A method for manufacturing a molded article, including [a specific component].

2. To provide a first member having a first through hole and a second member having a second through hole, A third member is prepared with a thermoplastic material arranged around it, The third member is inserted into the first and second through holes so that the thermoplastic material is positioned between the first and second members, thereby forming a pre-molded case prototype assembly. Transfer molding a resin onto the pre-molded case precursor assembly, wherein the thermoplastic material is heated to soften or melt during the transfer molding, and the first member and the second member are pressed together with the thermoplastic material to form a pre-molded case in which at least a portion of the gap formed by the first through hole, the second through hole and the third member is sealed by the thermoplastic material. A method for manufacturing a molded article, including [a specific component].

3. The method according to claim 2, wherein heating of the thermoplastic material, pressing of the first member and the second member with the thermoplastic material, or both thereof, is performed via molten resin injected during the transfer molding.

4. The method according to any one of claims 1 to 3, wherein the first member and the second member are joined together by the thermoplastic material.

5. The method according to any one of claims 1 to 3, wherein the thermoplastic material mainly comprises an amorphous thermoplastic resin.

6. The method according to claim 5, wherein the amorphous thermoplastic resin is at least one selected from the group consisting of thermoplastic epoxy resins and phenoxy resins, the thermoplastic epoxy resin is a polymer of (a) a bifunctional epoxy resin monomer or oligomer and (b) a bifunctional compound having two identical or different functional groups selected from the group consisting of phenolic hydroxyl groups, carboxyl groups, mercapto groups, isocyanate groups and cyanate ester groups (excluding polyhydroxy polyethers synthesized from bisphenol compounds and epichlorohydrin), and the phenoxy resin is a polyhydroxy polyether synthesized from bisphenol compounds and epichlorohydrin.

7. The method according to claim 5, wherein the thermoplastic material comprises an epoxy equivalent of 1,600 g / eq. or more, or an amorphous thermoplastic resin that does not contain epoxy groups.

8. The method according to any one of claims 1 to 3, wherein the first member has a convex structure around the first through hole, and the second member has a concave structure that fits into the convex structure.

9. A pre-molded case comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member, The resin molded on the aforementioned pre-molded case, A molded body containing a certain material.

Images