Fiber-reinforced resin molded body and method for producing the same

Abstract

This fiber-reinforced resin molded body includes a semipreg 7 having a first thermoplastic resin adhered to the surface of a reinforcing fiber sheet and a second thermoplastic resin integrally molded therewith, wherein the semipreg 7 is shaped by pressing the second thermoplastic resin, the first thermoplastic resin is impregnated into the reinforcing fiber sheet by pressing the second thermoplastic resin, and the first thermoplastic resin and the second thermoplastic resin are integrated. Ribs 9 and 10 may be further provided on the surface opposite to the surface of the fiber-reinforced thermoplastic resin layer side of the fiber-reinforced resin molded body. This provides a fiber-reinforced resin molded body having high integrity between the resin and the reinforcing fibers, and a method for producing the same.

Description

Fiber Reinforced Resin Molded Body and Method for Producing the Same

[0001] The present invention relates to a fiber reinforced resin molded body in which a semi-prepreg is insert-molded and a method for producing the same.

[0002] Carbon fiber reinforced resin (CFRP: Carbon Fiber Reinforced Plastics) and glass fiber reinforced resin take advantage of features such as high strength and light weight, and are widely used in various sports goods such as golf club shafts and fishing rods, aircraft parts, automobile parts, ship parts, pressure vessels, etc., or are expected to be applied in the future. As general molding methods for fiber reinforced resins, for example, contact pressure molding methods such as hand lay-up method and spray-up method, continuous molding methods such as filament winding (FW) method, pultrusion method, and continuous lamination method are used to mold into the desired molded product. The matrix resin uses thermosetting resins such as epoxy resins and thermoplastic resins such as polypropylene resins. In addition, in order to enhance the affinity with the matrix resin, a sizing agent corresponding to the matrix resin is attached to the surface of the reinforcing fiber. As a conventional technique, Patent Document 1 proposes a molded body in which resin covers a part of a prepreg at the boundary between the prepreg and the resin. Patent Document 2 discloses a three-dimensional fiber reinforced resin molded body in which a chopped prepreg sheet material in which a matrix resin made of a thermoplastic resin is impregnated into reinforcing fibers and a base material made of a thermoplastic resin are integrally molded by laminating, and the thermoplastic resin of the base material is melted and solidified to form a molded body integrally molded with the chopped prepreg sheet material.

[0003] Japanese Unexamined Patent Application Publication No. 2022-118344 Japanese Unexamined Patent Application Publication No. 2023-048312

[0004] However, the fiber reinforced resin molded body of the conventional technique does not have sufficient integrality between the resin and the reinforcing fiber, and further improvement has been required. In particular, regarding a molded body having ribs on the back side, conventionally, molding (shaping) using a prepreg and rib molding are often performed in separate steps, and the manufacturing process has been time-consuming.

[0005] To solve the aforementioned conventional problems, the present invention provides a fiber-reinforced resin molded article in which semipreg is insert-molded, and a method for manufacturing the same, which has high integration between the resin and reinforcing fibers and can be molded more efficiently even when ribs are formed on the back surface.

[0006] One embodiment of the present invention relates to a fiber-reinforced resin molded article in which a semipreg, in which a first thermoplastic resin is attached to the surface of a reinforcing fiber sheet, and a second thermoplastic resin are integrally molded, wherein the semipreg is shaped by pressing the second thermoplastic resin, and the first thermoplastic resin is impregnated into the reinforcing fiber sheet by pressing the second thermoplastic resin, and the first thermoplastic resin and the second thermoplastic resin are integrated into a fiber-reinforced resin molded article.

[0007] Another embodiment of the present invention relates to a method for manufacturing a fiber-reinforced thermoplastic resin molded article, which includes placing a semipreg in which a first thermoplastic resin is attached to the surface of reinforcing fibers in a mold, injecting a second thermoplastic resin into the mold, pressing the semipreg with the injected second thermoplastic resin to shape the semipreg, impregnating the reinforcing fibers with the first thermoplastic resin by the pressing force of the injected second thermoplastic resin, cooling the mold to below the melting points of the first and second thermoplastic resins, and demolding the fiber-reinforced thermoplastic resin molded article in which the first thermoplastic resin and the second thermoplastic resin are integrated.

[0008] The present invention relates to a fiber-reinforced resin molded article in which a semipreg, in which a first thermoplastic resin is attached to the surface of a reinforcing fiber sheet, and a second thermoplastic resin are integrally molded. The semipreg is shaped by the pressing of the second thermoplastic resin, and the first thermoplastic resin is impregnated into the reinforcing fiber sheet by the pressing of the second thermoplastic resin. Because the first thermoplastic resin and the second thermoplastic resin are integrated into the fiber-reinforced resin molded article, a molded article with high integration between the injection resin and the reinforcing fibers can be obtained. Furthermore, even when ribs are formed on the back surface, integral molding can be performed by injection molding.

[0009] Figure 1 is a schematic cross-sectional view of an injection molding apparatus according to one embodiment of the present invention. Figure 2 is a schematic perspective view of the molded product. Figure 3 is a schematic perspective view of the semipreg used in the molding. Figure 4 is a schematic cross-sectional view of the semipreg in the width direction. Figure 5 is a schematic perspective view showing the laminated state of the semipreg used in the molding. Figure 6 is a schematic cross-sectional view of the vicinity of the semipreg in a molded body according to one embodiment of the present invention. Figures 7A-D are cross-sectional photographs of a molded body according to Example 2 of the present invention, and Figures 7B-D are partially enlarged photographs of the cross-sectional photograph in Figure 7A (magnification 100x). Figures 8A-D are cross-sectional photographs of a molded body according to Comparative Example 2, and Figures 8B-D are partially enlarged photographs of the photograph in Figure 8A (magnification 100x).

[0010] The present invention relates to a fiber-reinforced resin molded article in which a semipreg, in which a first thermoplastic resin is attached to the surface of reinforcing fibers, and a second thermoplastic resin are integrally molded. Examples of reinforcing fibers include carbon fibers, aramid fibers, glass fibers, boron fibers, and high-molecular-weight polypropylene fibers. Among these, carbon fibers or aramid fibers are preferred.

[0011] The fiber-reinforced resin molded article of the present invention uses semipreg as the reinforcing fiber. Here, semipreg is, for example, a material in which continuous reinforcing fibers are opened and arranged in one direction, and thermoplastic resin powder is sprinkled on its surface and heat-fused to form a single unit. Unlike prepreg, semipreg is flexible, so it can be insert-molded into a predetermined shape along the mold during injection molding. The integration may occur within the fiber sheet or outside the fiber sheet. A commercially available example is semipreg manufactured by Kurabo Industries Ltd., trade name "Kurapower Sheet".

[0012] In the present invention, the fiber-reinforced resin molded article is formed in which the injected second thermoplastic resin presses against the semipreg, and the semipreg and the thermoplastic resin become integrated. That is, the thermoplastic resin injected by the injection pressure presses against and integrates with the first thermoplastic resin in the semipreg. As a result, the first thermoplastic resin is impregnated into the reinforcing fibers, resulting in a fiber-reinforced resin molded with high integration between the resin and the reinforcing fibers.

[0013] It is preferable that the first thermoplastic resin on the surface of the semipreg and the second thermoplastic resin of the fiber-reinforced resin molded body are compatible resins. Compatibility facilitates the integration of the semipreg and the injection-molded resin when melted. Compatible resins are those where both the first thermoplastic resin on the semipreg surface and the second injection-molded thermoplastic resin are from the same resin system. For example, this could be polyamide resins, polycarbonate resins, polypropylene resins, or ABS resins. Alternatively, resins with functional properties such as flame retardancy may also be used.

[0014] Preferably, ribs are integrally molded on the opposite side of the fiber-reinforced thermoplastic resin layer side of the fiber-reinforced resin molded body. Integrating the ribs, i.e., simultaneous molding, allows for efficient manufacturing and increases the strength of the molded body due to the ribs, making it useful for automotive parts, home appliance parts, electrical components, and the like.

[0015] The reinforcing fibers of the semipreg are sheets in which long fibers are arranged in one direction, and it is preferable that multiple sheets are laminated with the long fibers arranged in different directions. For example, it is preferable to laminate multiple semipreg sheets with long fibers arranged in one direction and semipreg sheets with fibers arranged in orthogonal directions. The number of laminated sheets can be any number, but four or more is preferable. This makes it possible to obtain a molded product with low angle dependence.

[0016] The mass per unit area (basis weight) of one sheet of the aforementioned semipreg is 50 to 300 g / m². 2 Preferably, and more preferably, 75 to 250 g / m² 2 And more preferably 100 to 200 g / m 2 This results in a lightweight and thin molded body.

[0017] It is preferable that a decorative film or functional film is further integrally molded onto the surface of the semipreg. In the case of a decorative film, if the semipreg is placed on the surface of the molded body, if the semipreg is made of carbon fiber, it will be limited to black and may cause irregularities in the surface appearance. However, if a decorative film is further integrally molded onto the surface of the semipreg, the appearance and design will be preferable. The decorative film is also called a decorative film or ornamental film. In the case of a functional film, if a functional film is further integrally molded onto the surface of the semipreg, various functions such as weather resistance can be imparted to the surface of the molded body. The decorative film and / or functional film are placed on one side of the semipreg in the molding die during injection molding, and the surface layer of the molded body obtained after injection molding is laminated and integrated at the same time as the molding of the molded body, thus completing the surface layer, which is very efficient. In addition, the surface layer may be buffed after molding to give it a glossy finish.

[0018] The method for manufacturing a fiber-reinforced thermoplastic resin molded article of the present invention includes the following steps: (1) Semipreg placement step: The semipreg is placed in the mold and the mold is closed. (2) Injection step: The second thermoplastic resin is injected into the mold, and the injected second thermoplastic resin presses the semipreg to shape the semipreg and impregnate the reinforcing fiber sheet with the first thermoplastic resin to integrate them. It is preferable that the second thermoplastic resin is injected so that it covers the entire surface of the semipreg in order to press the semipreg and impregnate the reinforcing fiber sheet with the first thermoplastic resin. The mold is heated to a temperature above the melting point of the first thermoplastic resin. The heating of the semipreg may be done before, during, or after the injection of the second thermoplastic resin. (3) Demolding step: The mold is cooled to a temperature below the melting point of the first and second thermoplastic resins, particularly below the glass transition temperature, and the molded article with the integrated semipreg is demolded.

[0019] The advantages of the present invention are as follows: (1) The final product is completed simply by inputting raw materials, simplifying the process and reducing costs. (2) Secondary processing (trimming, ribbing, bossing, decoration, etc.) is significantly reduced, leading to cost savings. (3) No auxiliary materials are required, further reducing costs. (4) There are relatively few restrictions on the molding temperature, and it is not affected by the heat resistance of the silicone sheet or film. (5) Molten resin impregnates the semipreg simultaneously with molding, and ribs can be added to the back side at the same time. (6) There is an anchoring effect due to the melting of the thermoplastic resin on the surface of the semipreg. (7) Various moldings such as foamed resin, sandwich panels, and pipes are possible, and further technological development can be expected.

[0020] Next, we will explain the differences between semipreg molded articles and prepreg molded articles. When semipreg is used, the interface where the first thermoplastic resin and the second thermoplastic resin are fused together is unclear. That is, in a semipreg molded article, the resin is not impregnated into the semipreg, and during injection molding, the first thermoplastic resin impregnates the entire semipreg, so the interface that comes into contact with the second thermoplastic resin during injection molding is fused together. When prepreg is used, the first thermoplastic resin and the second thermoplastic resin do not fused together, and the interface can be observed as a linear structure. That is, in a prepreg molded article, the resin is impregnated into the prepreg, and no resin is impregnated into the prepreg during injection molding, so the surface is already flat. Therefore, there is no room for the second thermoplastic resin during injection molding to penetrate into the first thermoplastic resin, and the interface is linear.

[0021] The following explanation will be given using the drawings. In the following drawings, the same reference numerals indicate the same part. Figure 1 is a schematic cross-sectional view of an injection molding apparatus 1 according to one embodiment of the present invention. This injection molding apparatus 1 has an upper mold (injection mold) 2 and a lower mold 3, and a semipreg 7 or semipreg laminate is placed along the bottom of the lower mold 3. Next, the upper mold 2 is brought close to the lower mold 3 to create a molding space 8 (cavity), and the heat from the lower mold 3 heats the surface of the semipreg 7 or semipreg laminate to above the melting point of the first thermoplastic resin. Next, molten resin is injected from the injection means 4 through the injection hole (sprue) 5 and gate 6. The injected second thermoplastic resin presses and shapes the semipreg or semipreg laminate, impregnates the reinforcing fiber sheet with the first thermoplastic resin, and further integrates the first thermoplastic resin and the second thermoplastic resin. Next, the mold is cooled and the molded body is demolded. Furthermore, the upper mold 2 may have spaces for ribs 9 and 10, and molten resin will spread into these spaces for ribs 9 and 10, resulting in integral molding.

[0022] Figure 2 is a schematic perspective view of a molded body 17 obtained by injection molding. 18 is the second thermoplastic resin that was injection molded. Since the semipreg laminate 16 is positioned near the surface of the molded body 17, the pattern of the semipreg is visible on the surface. If a different design is desired for the appearance, a decorative film may be integrally molded.

[0023] Figure 3 is a schematic perspective view of the semipreg 11 used in the present invention. The tows of the carbon fiber filaments 12 are opened and arranged in one direction, and bridge fibers 13 are arranged on the surface in various directions. In addition, the first thermoplastic resin 14 is melted and solidified and adheres to the vicinity of the surface of the semipreg 11, and the first thermoplastic resin 14 is not impregnated into the interior of the semipreg 11 or is only partially impregnated. The first thermoplastic resin 14 adheres and fixes the bridge fibers 13 to the surface of the semipreg 11. The thermoplastic resin 14 also acts as the matrix resin. Therefore, the semipreg is flexible and can be placed along the molding die even if the target molded product has an irregular shape.

[0024] When the semipreg is considered as 100% by volume, the volume percentage (Vf) of the reinforcing fibers is preferably 30 to 70% by volume, more preferably 40 to 65% by volume, and even more preferably 45 to 60% by volume. With these proportions, the material is flexible and can be placed along the mold even if the target molded product has an irregular shape, and under pressure, both the surface resin and the injection-molded resin can easily impregnate the entire fiber sheet. Furthermore, there are voids inside the prepreg, allowing the injected high-pressure molten resin (second thermoplastic resin) to penetrate into the reinforcing fiber portion, and the first thermoplastic resin and the second thermoplastic resin are molded together as one unit.

[0025] Figure 4 is a schematic cross-sectional view in the width direction of the semipreg 11 used in the present invention. Bridge fibers 13 are arranged in various directions on the surface of the opened carbon fiber sheet 12. The first thermoplastic resin 14 is melted and solidified and adheres to the vicinity of the surface of the carbon fiber sheet 12, and is either not impregnated into the interior of the carbon fiber sheet 12 or is only partially impregnated. The first thermoplastic resin 14 adheres and fixes the bridge fibers 13 to the surface of the carbon fiber sheet 12. There are also carbon fiber exposed areas 15 where the first thermoplastic resin 14 is attached and areas where it is not. The carbon fiber exposed areas 15 where the resin is not attached become passages through which air from inside the carbon fiber sheet escapes when it is molded into a fiber-reinforced resin molded product, and the resin on the surface easily impregnates the entire interior of the fiber sheet under pressure. As a result, the first thermoplastic resin 14 becomes the matrix resin of the carbon fiber sheet 12, and because there are voids in the carbon fiber sheet 12, the injected high-pressure molten resin (second thermoplastic resin 18) penetrates into the carbon fiber sheet 12 and is molded. As a result, the first thermoplastic resin 14 and the second thermoplastic resin 18 are integrated. In particular, if the first thermoplastic resin 14 and the second thermoplastic resin 18 are made of the same type of resin, such as a polyamide resin, they have good compatibility and are strongly molded as a single unit.

[0026] Figure 5 is a schematic perspective view showing the laminated state of the semipreg used in molding according to the present invention. In this example, four semipreg sheets 11a, 11b, 11c, and 11d are laminated and arranged in the order of 0° / 90° / 90° / 0° to form a semipreg laminate 16. This reduces angle dependence.

[0027] Figure 6 is a schematic cross-sectional view of the semipreg area of ​​an injection-molded body 17 according to one embodiment of the present invention. In this example, the semipreg sheets 11b and 11c are arranged in the length direction (left-right direction in the viewer's perspective), and the semipreg sheets 11a and 11d are arranged in the width direction (depth direction in the viewer's perspective). This results in a molded body with low angle dependence. 17 is an injection-molded thermoplastic resin. Note that in Figure 6, the thickness of the semipreg sheets 11a-11d is 0.35 mm, and the thickness of the injection-molded thermoplastic resin 17 is 2.65 mm.

[0028] The present invention will be specifically described using the following examples. However, the present invention is not construed to be limited to the following examples. Various parameters were measured using the following methods: <Bending modulus> Measured according to JIS K7171:2016. <Maximum load> Measured according to JIS K7171:2016. <Bending strength> Measured according to JIS K7171:2016. <Deflection> Measured according to JIS K7171:2016. <Bending strain> Measured according to JIS K7171:2016.

[0029] (Example 1) <Semipreg> Semipreg manufactured by Kurabo Industries Ltd., product name "Kurapower Sheet": A semipreg in which continuous carbon fibers are arranged in one direction, with a powder of the first thermoplastic resin (polyamide 12) melted and fixed to the surface, mass of one sheet: 125 g / m 2 Density 1.82, volume percentage of carbon fiber (Vf) 50% by mass, number of layers 4 (0° / 90° / 90° / 0°), total mass 500 g / m 2A semipreg with a total thickness of 0.35 mm was used. <Injection Resin> Polyamide 66 (glass fiber content 15%) was used as the second thermoplastic resin. <Molding Conditions> (1) Mold temperature: 200°C (2) Demolding temperature: 40°C (3) Resin melting temperature: 300°C (4) Injection pressure: 80 MPa (5) Hold time: 5 minutes (6) Upper mold (injection mold) temperature: 80°C Under the above conditions, the molded body 17 shown in Figure 2 was molded. One molding cycle was 8 minutes and 40 seconds. The dimensions and physical properties of this molded body are shown in Table 1. The data in Table 1 are the average values ​​for n=5 tests.

[0030] (Comparative Example 1) The procedure was carried out in the same manner as in Example 1, except that semipreg was not inserted. The results are summarized in Table 1.

[0031]

[0032] As a result, Example 1 showed approximately 2.8 times higher flexural modulus, approximately 2.3 times higher maximum load, and approximately 2.4 times higher flexural strength compared to Comparative Example 1. This is because of the high degree of integration between the resin and reinforcing fibers.

[0033] (Example 2) <Semipreg> Semipreg manufactured by Kurabo Industries Ltd., product name "Kurapower Sheet": A semipreg in which continuous carbon fibers are arranged in one direction, with a powder of the first thermoplastic resin (polycarbonate) melted and fixed to the surface, mass of one sheet: 135 g / m 2 Density 1.82, volume percentage of carbon fiber (Vf) 50% by mass, number of layers 2 (0° / 90°), total mass 270 g / m 2 A semipreg with a total thickness of 0.17 mm was used. <Injection Resin> Polyamide 66 (glass fiber content 15%) was used as the second thermoplastic resin. <Molding Conditions> (1) Mold temperature: 300°C (2) Demolding temperature: 40°C (3) Resin melting temperature: 300°C (4) Injection pressure: 80 MPa (5) Hold time: 1 minute (6) Upper mold (injection mold) temperature: 80°C Under the above conditions, the molded body 17 shown in Figure 2 was molded. One molding cycle took 5 minutes and 40 seconds.

[0034] (Comparative Example 2) The procedure was carried out in the same manner as in Example 2, except that a prepreg was used instead of a semipreg. The prepreg used was made by impregnating a sheet of only carbon fiber from the semipreg used in Example 2 with the thermoplastic resin used in Example 2. The injection molding conditions were as follows: <Molding conditions> (1) Mold temperature: 300°C (2) Demolding temperature: 40°C (3) Resin melting temperature: 300°C (4) Injection pressure: 80 MPa (5) Hold time: 1 minute (6) Upper mold (injection mold) temperature: 80°C The molding conditions were the same as in Example 2, but the prepreg was placed in the mold and softened before molding was performed with injection pressure. Except for the softening mentioned above, it was the same as in Example 2.

[0035] Cross-sectional observations were performed on parts of the molded articles of Example 2 and Comparative Example 2. The cross-sectional observations were performed using a digital microscope (Keyence Corporation, model: VHX series) at a magnification of 100x. Cross-sectional photographs of Example 2 are shown in Figures 7A-D. Figures 7B-D are magnified photographs of Figure 7A. Cross-sectional photographs of Comparative Example 2 are shown in Figures 8A-D. Figures 8B-D are magnified photographs of Figure 8A. In Figures 7B-D of Example 2, the second thermoplastic resin 17 has penetrated into the semipreg 15. In particular, in Figure 7D, it can be observed that the second thermoplastic resin 17 has seeped out beyond the semipreg 15 to the outside. In contrast, in Figures 8B-D of Comparative Example 2, a linear interface 19 is seen at the boundary between the first thermoplastic resin and the second thermoplastic resin, and the second thermoplastic resin 17 has not impregnated the prepreg 18. From the cross-sectional observations of Example 2 and Comparative Example 2, it can be confirmed that in Example 2, the second thermoplastic resin is impregnated into the semipreg sheet. In Comparative Example 2, the second thermoplastic resin was hardly impregnated into the prepreg sheet, and an interface 19 existed at the boundary between the fiber-reinforced resin sheet and the matrix resin. From the above, the superiority of Example 2 is clear.

[0036] The fiber-reinforced resin molded articles of the present invention have high physical properties due to the high integration of the resin and reinforcing fibers, and are useful for various sporting goods, aircraft parts, automobile parts, home appliance parts, electrical components, ship parts, pressure vessels, and the like.

[0037] 1. Injection molding apparatus 2. Upper mold (injection mold) 3. Lower mold 4. Injection means 5. Injection hole (sprue) 6. Gate 7, 11, 11a-11d. Semipreg 8. Molding space (cavity) 9, 10. Ribs 12. Carbon fiber filament 13. Bridge fiber 14. First thermoplastic resin 15. Carbon fiber exposed portion 16. Semipreg laminate 17. Molded body 18. Injection-molded second thermoplastic resin 19. Prepreg 20. Interface

Claims

1. A fiber-reinforced resin molded article in which a semipreg, having a first thermoplastic resin attached to the surface of a reinforcing fiber sheet, and a second thermoplastic resin are integrally molded, wherein the semipreg is shaped by the pressing of the second thermoplastic resin, and the first thermoplastic resin is impregnated into the reinforcing fiber sheet by the pressing of the second thermoplastic resin, and the first thermoplastic resin and the second thermoplastic resin are integrated into a fiber-reinforced resin molded article.

2. The fiber-reinforced thermoplastic resin molded body according to claim 1, wherein ribs are further arranged on the opposite side of the semipreg side of the fiber-reinforced resin molded body.

3. The fiber-reinforced thermoplastic resin molded article according to claim 1 or 2, wherein the reinforcing fibers of the semipreg are sheets in which continuous fibers are arranged in one direction, and a plurality of such sheets are laminated with the continuous fibers arranged in different directions.

4. The fiber-reinforced thermoplastic resin molded article according to any one of claims 1 to 3, wherein a decorative film is further laminated and integrated onto the surface of the semipreg.

5. The fiber-reinforced thermoplastic resin molded article according to any one of claims 1 to 4, wherein the first thermoplastic resin and the second thermoplastic resin are both resins of the same system.

6. The fiber-reinforced thermoplastic resin molded article according to any one of claims 1 to 5, wherein both the first thermoplastic resin and the second thermoplastic resin are polyamide resins.

7. The fiber-reinforced resin molded article according to any one of claims 1 to 6, wherein the first thermoplastic resin is present near the surface of the semipreg and a portion of it is impregnated into the semipreg.

8. The fiber-reinforced resin molded article according to any one of claims 1 to 7, wherein when the semipreg is 100% by volume, the volume ratio of the reinforcing fibers: Vf is 30 to 70% by volume.

9. A method for manufacturing a fiber-reinforced resin molded article using the fiber-reinforced resin molded article described in any one of claims 1 to 8, comprising: placing a semipreg in which a first thermoplastic resin is attached to the surface of reinforcing fibers on a mold; injecting a second thermoplastic resin into the mold; pressing the semipreg with the injected second thermoplastic resin to shape the semipreg, and impregnating the reinforcing fibers with the first thermoplastic resin by the pressing force of the injected second thermoplastic resin; cooling the mold to below the melting points of the first and second thermoplastic resins; and demolding the fiber-reinforced thermoplastic resin molded article in which the first thermoplastic resin and the second thermoplastic resin are integrated.

10. The method for producing a fiber-reinforced thermoplastic resin molded article according to claim 9, wherein the second thermoplastic resin is injected over the entire surface on the injection side of the semipreg.

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