Abstract
This study aims to develop the hybrid injection molding method combined with hot pressing for mass production of continuous carbon fiber reinforced thermoplastic (cFRTP) parts. A new type of heating system for hybrid injection molding was originally developed using near-infrared light and its linear drive carrier. The trial sample was a V-shape box type of shock absorber with light and high stiffness. The material used for skin layer was woven carbon fabric reinforced thermoplastic (woven-CF/PA66) laminate, which was formed by mold clamping process immediately after heating with near-infrared light inserted in die set. After the forming step, a short carbon fiber reinforced thermoplastics (short CF/PA66) was injection molded to form the grid-shaped rib-structure from within V-shape member. The 3D shape measurement of molded parts was evaluated by a digital image measurement robot system. The results shown the fusion bonding between woven CF/PA66 laminate formed thermally and short CF/PA66 injection-molded was significantly affected by heating time of woven CF/PA66 laminate, while the surface of skin layer was also thermally-deteriorated by overheating. Thus the heating conditions should be optimized to be satisfied the both fusion bonding strength and the surface quality.
