TW202012219A - Composite molded article provided with fittings, vehicle step provided with fittings, and method for producing composite molded article provided with fittings - Google Patents

Abstract

A composite molded article provided with fittings, the composite molded article having exceptional lightness as well as exceptional pull-out strength of the fittings. A composite molded article provided with fittings is equipped with: a composite molded article having a foamed particle molded article comprising a plurality of foamed thermoplastic resin particles heat-fused to each other and a skin material comprising a thermoplastic resin hollow molded article, the foamed particle molded article being formed inside the skin material and bonded to the inner surface of the skin material; fittings for fitting the composite molded article to another part; and fastening members that penetrate the skin material and the fittings and fasten the fittings to the skin material. The skin material has a plurality of heating medium supply pipe tracks formed by heating medium supply pipes, and the fittings are fitted between two heating medium supply pipe tracks. The distance between two heating medium supply pipe tracks is 400 mm or less, and the distance between a fitting and one heating medium supply pipe track from among the two heating medium supply pipe tracks is 180 mm or less.

Description

Method for manufacturing composite molded body with mounting tool, boarding pedal with mounting tool and composite molded body with mounting tool

The present invention relates to a composite molded body with a mounting tool and a manufacturing method thereof, in particular to a composite molded body with a mounting tool used as a boarding pedal and a manufacturing method thereof.

In general, in high-height vehicles such as cargo trucks or some sport utility vehicles, in order to facilitate the loading and unloading and the good loading and unloading of goods, they are used in front doors, rear doors, or back doors. A pedal for getting on and off the vehicle or for pedaling is provided below the opening. Regarding this pedal, resin molded bodies have recently been used. The pedal of the resin molded body has a pedal composed of a blow molded body having a hollow portion. In order to improve the mechanical strength and the like, the pedal composed of the conventional blow-molded body has a rib structure and is thick, and as a result, the product is heavy.

On the other hand, there is known a composite molded body including an expanded particle molded body formed by molding a hollow resin skin material and expanded particles filled therein. The method for manufacturing this composite molded body proposes a method such as Patent Documents 1 and 2 in which a softened parison formed by extruding a resin melt of a thermoplastic resin is blow-molded in a molding die to form a hollow Blow-molded body, a foamed particle filling tube is driven into the wall of the hollow blow-molded body, and the hollow blow-molded body is filled with thermoplastic resin foamed particles, after which, the hollow blow-molded body is similarly inserted The heating medium supply pipe in the wall portion supplies steam to the hollow blow-molded body to heat the expanded particles filled in the hollow blow-molded body to fuse the expanded particles with each other to form the expanded particle molded body, and the expanded particles The molded body is fused with the inner surface of the hollow blow molded body. Here, in consideration of the appearance of the produced composite molded body, the number of the above-mentioned expanded particle filling tube and heating medium supply tube is designed to be as small as possible, and a composite molded body with few such tube marks is formed.

The bending rigidity of the composite molded body obtained by this manufacturing method is superior to that of the hollow blow molded body only. Even if the skin thickness of the skin material is thin and lightweight, it can be prepared with the hollow blow molded only. A molded body composed of a molded body having bending rigidity equal to or higher than that of the molded body. Therefore, the composite molded body has excellent bending rigidity and light weight, and has been used in various applications in recent years. Prior technical literature Patent Literature

Patent Literature 1: Japanese Patent Publication No. Hei 06-166112 Patent Document 2: Japanese Patent Publication No. 2008-273117

Problems to be solved by invention

However, when the thickness of the skin material of the above-mentioned composite molded body is thin, when the mounting tool is mounted on the composite molded body, there is a problem that the mounting strength, specifically, the strength of the pulling-out of the mounting tool from the composite molded body tends to decrease.

The present invention has been made in view of the above-mentioned problems with the prior art, and its object is to propose a composite molded body with an attachment and a method of manufacturing the same, which are excellent in lightness and excellent in the pull-out strength of the attachment. Means to solve problems

In order to achieve the above object, the present invention is a composite molded body with a mounting tool described in the following [1] to [8] and a manufacturing method thereof. [1] A composite molded body with an attachment, comprising: a composite molded body having a foamed particle molded body composed of a plurality of thermoplastic resin foamed particles fused with each other by heating and a skin material composed of a thermoplastic resin hollow molded body , The expanded particle shaped body is formed inside the skin material and adhered to the inner surface of the skin material; a mounting tool for mounting the composite shaped body to other objects; and a fastening member that penetrates the skin Material and the mounting tool, and the mounting tool is fastened to the skin material; the skin material has a plurality of heating medium supply tube marks formed by a heating medium supply tube for supplying the hollow filling of the thermoplastic resin The heating medium of the thermoplastic resin expanded particles in the hollow part of the molded body is heated and fused; the mounting tool is installed between two heating medium supply pipe marks; the distance between the two heating medium supply pipe marks is 400 mm or less; the installation The distance from one of the two heating medium supply pipe marks is 180 mm or less. [2] The composite molded body with an attachment as described in [1] above, wherein when the attachment is pulled out, the load at the time of peeling off the skin material and the expanded particle molded body is 1.5 kN or more. [3] The composite molded body with attachment as described in [1] or [2] above, wherein the average thickness of the skin material is 1 to 4 mm. [4] The composite molded body with attachment as described in any one of [1] to [3] above, wherein the skin material is a hollow blow molded body composed of a fiber-reinforced thermoplastic resin containing reinforcing fibers in the thermoplastic resin . [5] The composite molded article with a fixture as described in [4] above, wherein the content of the reinforcing fiber in the fiber-reinforced thermoplastic resin is 10 to 30% by weight. [6] The composite molded body with attachment as described in [4] or [5] above, wherein the thermoplastic resin is a polypropylene resin. [7] The composite molded body with attachment as described in any one of [1] to [6] above, wherein the expanded particle molded body is formed of thermoplastic resin expanded particles with an apparent density of 30 to 150 kg/m ³ body. [8] The composite molded article with an attachment as described in [7] above, wherein the expanded particle molded article is a polypropylene resin expanded particle molded article. [9] A boarding pedal with an attachment, which is composed of a composite molded body with an attachment as described in any one of [1] to [8] above and is installed below a door opening of a vehicle body. [10] A method for manufacturing a composite molded body with an attachment, the composite molded body with an attachment includes a composite molded body, and an installation for fixing the composite molded body to other objects The manufacturing method of the composite molded body with the mounting tool includes: a first process, which fills the hollow portion of the thermoplastic resin hollow molded body with thermoplastic resin foam particles, and inserts two or more heating medium supply tubes into the thermoplastic In the resin hollow molded body, the heating medium is supplied from the heating medium supply pipe, whereby the filled expanded particles are heated and fused with each other to form an expanded particle molded body, and the inner surface of the thermoplastic resin hollow molded body and the expanded particle molded body Bonding to obtain a composite molded body of a skin material composed of a hollow molded body of a thermoplastic resin and a foamed particle molded body located inside the skin material; and a second process in which a fastening member penetrates through the skin material and is installed Buckle the buckling member after the tool and fix the mounting tool to the composite shaped body to obtain a composite shaped body with a mounting tool and a mounting tool attached to the composite shaped body; in the first process , Insert the two heating medium supply pipes so that the distance between the two heating medium supply pipes is 400 mm or less, through the part where the composite molded body of the mounting tool is installed, and heat the part and the two One of the medium supply tubes is heated by heating the medium supply tube such that the distance of the heating medium supply tube is 180 mm or less into the thermoplastic resin hollow molding body. Effect of invention

According to the composite molded body with an attachment and the manufacturing method thereof according to the present invention described above, since the composite molded body is manufactured, a heating medium supply tube is inserted through a portion of the skin material where the attachment is installed, and is located near the portion (180 mm or less) Position) Insert the heating medium supply tube to heat the foamed particles filled, so even if the thickness of the skin material is thin, the peel strength of the skin material and the foamed particle molded body around the place where the fixture is installed can be increased , And the light-weight and strong pull-out strength of the mounting tool installed in this part.

[Forms for carrying out the invention]

Hereinafter, an embodiment of the composite molded body with an attachment and the manufacturing method of the present invention will be described in detail based on the drawings.

FIG. 1 is a perspective view showing an embodiment of a composite molded body with a mounting device of the present invention, that is, a boarding pedal from diagonally above, and FIG. 2 is a perspective view showing the boarding pedal from diagonally below. In addition, FIG. 3 is an enlarged cross-sectional view of a portion along the line A-A of FIG. 1 (the portion where the mounting tool is mounted). As shown in these figures, the boarding pedal 1 is formed as a composite molded body with an attachment, which includes a composite molded body 10, and is fixed to the composite molded body 10 and used to install the composite molded body 10 on Three mounting tools 50 for other objects. In addition, when a composite molded body with a mounting tool is used as a boarding pedal, the upper surface of the composite molded body in the state of being mounted on the vehicle body (the upper surface in the vertical direction of the vehicle body) is called the upper surface, and the composite The lower surface of the molded body (the lower surface of the vehicle body in the vertical direction) is called the lower surface.

The composite molded body 10 is composed of a skin material 11 and an expanded particle molded body 12. The skin material 11 is composed of a thermoplastic resin, and is molded with a thermoplastic resin hollow molded body having a hollow portion (hereinafter referred to as a “hollow molded body”). The expanded particle molded body 12 is composed of plural thermoplastic resin expanded particles (hereinafter referred to as "expanded particles") that are heated and fused to each other. The expanded particle shaped body 12 is formed in the hollow portion of the skin material 11. The expanded particle shaped body 12 is adhered to the inner surface of the skin material 11. The expanded particle molded body 12 is formed by filling the hollow portion of the hollow molded body with expanded particles and heating and fusing the expanded particles with each other. The heat fusion of the expanded particles is performed by inserting the heating medium supply tube into the hollow molded body and supplying the heating medium from the heating medium supply tube to the hollow portion. Furthermore, by supplying the heating medium from the heating medium supply pipe to the hollow portion, the skin material 11 and the expanded particle molded body 12 are adhered. The above-mentioned mounting tool 50 is fixed to the composite molded body 10 with a snap member 51. The fastening member 51 penetrates and fastens the attachment 50 to the skin material 11. In addition, the skin material 11 has a blow pipe mark 13, a foam particle filling pipe mark 14, and a heating medium supply pipe mark 15. The blow tube mark 13 is formed by a blow tube that supplies air to the hollow portion when manufacturing the skin material 11 described above. The foaming particle filling tube mark 14 is formed by a foaming particle filling tube that fills the hollow portion of the skin material 11 with the foaming particles. The heating medium supply pipe mark 15 is formed by a heating medium supply pipe for supplying the medium for heating the foamed particles filled to the hollow portion. The boarding pedal 1 of the illustrated embodiment has two blow molding tube marks 13, one expanded particle filling tube mark 14, and nine heating medium supply tube marks 15.

In addition, in the hollow molded body constituting the skin material 11, the first wall 11a and the second wall 11b are fused to each other only at these peripheral edges to form a hollow portion. That is, the hollow molding system is formed by fusing the first wall 11a and the second wall 11b only at the periphery, and there is no inside of the hollow molded body where the first wall 11a and the second wall 11b are abutted and fused at a position other than the periphery Ribs. In addition, the hollow molded body may have a rib structure within a range where weight reduction can be achieved.

The outer shape of the hollow molded body constituting the skin material 11 is formed as an elongated plate-shaped body attached below the door opening of the vehicle body. Specifically, it is formed into a plate-like body of about 2000×200×100 mm. The hollow molded body has a pedal portion 20 and a mounting portion 21 and is formed into an approximately L-shaped cross section. The pedal portion 20 is in the form of an approximately flat plate that extends from below the door opening to approximately the outside in the horizontal direction while being attached to the vehicle body. The attachment portion 21 is formed to protrude upward in the widthwise inner side (vehicle body side) of the pedal portion 20. The first wall 11 a forms the upper surface of the pedal portion 20. On the first wall 11a, a concave-convex slide-down preventing portion 22 that prevents the passenger from sliding when the foot is placed is extended in the longitudinal direction. A lower surface of the pedal portion 20 is formed on the second wall 11b. On the second wall 11b, mounting portions 23 are formed at a plurality of locations as mounting portions (metal rods) 50 for fixing the vehicle body. In the illustrated embodiment, concave mounting portions 23 are formed in three places.

The blow molding tube marks 13, the foamed particle filling tube marks 14, and the heating medium supply tube marks 15 are preferably formed on the second wall 11b formed on the lower surface of the pedal portion 20 in consideration of appearance. In the boarding pedal 1 of the illustrated embodiment, two blow molding tube marks 13, one expanded particle filling tube mark 14, and nine heating medium supply tube marks 15 are all shown in FIG. Second wall 11b.

Thermoplastic resins such as polypropylene-based resins, polyethylene-based resins, and polystyrene-based resins can be used as the material for forming the skin material 11, that is, the hollow molded body. Among them, polypropylene resin is preferred because of its excellent balance between mechanical strength and heat resistance. In addition, from the viewpoint of improving strength and bending rigidity, the skin material 11 is preferably composed of a fiber-reinforced thermoplastic resin containing reinforcing fibers in the thermoplastic resin. Among them, the skin material 11 is preferably made of a fiber-reinforced polypropylene-based resin containing reinforcing fibers in the polypropylene-based resin. The content of the reinforcing fiber in the fiber-reinforced thermoplastic resin is preferably 10 to 30% by weight, and preferably 12 to 20% by weight. With the content of the reinforcing fiber being 10% by weight or more, the skin material 11, that is, the hollow molded body has more excellent bending rigidity. With the content of reinforcing fibers being 30% by weight or less, the hollow molded body can be easily formed.

In addition, the hollow molded body of the skin material 11 may have a multilayer structure. For example, the outer layer may be composed of fiber-reinforced thermoplastic resin, and the inner layer may be composed of a fiber-reinforced thermoplastic resin containing less reinforcing fiber than the outer layer or a thermoplastic resin not containing reinforcing fiber. When using such a multi-layered hollow molded body, by using the same type of thermoplastic resin as the expanded particles and the hollow molded body filled in the hollow portion, the two can be firmly fused, and the bending rigidity of the composite molded body can be improved . In particular, the outer layer is preferably composed of fiber-reinforced polypropylene resin, and the inner layer is preferably composed of a fiber-reinforced polypropylene resin containing less reinforcing fiber than the outer layer or a polypropylene-based resin not containing reinforcing fiber. By using such a multi-layered hollow molded body, when the expanded particles filled in the hollow portion are polypropylene-based resins, the expanded particle molded body 12 and the hollow molded body can be stably fused, and the composite molded body can be further improved Bending rigidity. In addition, the content of the reinforcing fibers at this time may be as long as the content of the entire reinforcing fibers of the multilayer is within the above range.

Examples of the polypropylene-based resin include random copolymer polypropylene (r-PP) and block copolymer polypropylene (h-PP), propylene-ethylene random copolymer or propylene-ethylene-butene random copolymer, etc. b-PP) or a mixture of these. In addition, block copolymer polypropylenes are not only block copolymers such as propylene-ethylene block copolymers, but also those that polymerize propylene in the presence of olefin-based thermoplastic elastomers or olefin-based rubbers, and combine polypropylene and olefin-based thermoplastic elastomers. Or olefin rubber kneading. In addition, examples of the types of the reinforcing fibers include inorganic fiber materials such as glass fiber, glass wool, and carbon fiber; and organic fiber materials such as cellulose nanofiber.

The thickness of the skin material 11 that is the hollow molded body is considered to be both strength and lightness, so the average thickness is preferably 1 to 4 mm, and preferably 1.5 to 3 mm. When the average thickness is less than 1 mm, the strength is insufficient. On the other hand, when the average thickness exceeds 4 mm, lightness is impaired. In addition, the average body thickness (average thickness) of the hollow molded body is measured as follows. The vertical cross-section in the longitudinal direction at a total of three positions selected from the vicinity of the longitudinal center portion and the longitudinal end portions of the hollow molded body was used for thickness measurement. For the vertical cross-sections at each position, the thickness in the thickness direction (thickness of the wall) of the six vertical cross-sections was measured at equal intervals along the circumferential direction of each vertical cross-section. The obtained eighteen thickness values were arithmetically averaged, and the average value was the average thickness of the hollow molded body.

The foamed-particle molded body 12 filled with the hollow part of the skin material 11, that is, the hollow molded body, and located inside the skin material 11 may be a polypropylene-based resin, a polyethylene-based resin, a polystyrene-based resin, or a polyolefin-based resin Composite resin with polystyrene resin, polyurethane foam as the base resin. The type of resin constituting the expanded particle molded body 12 is preferably the same as the resin of the hollow molded body, that is, the skin material 11. For example, when the hollow molded body is formed of a polypropylene-based resin, it is preferable to use a foamed particle molded body using the polypropylene-based resin as a base resin. By making the type of resin constituting the expanded particle molded body 12 the same kind of resin as the skin material 11, that is, the resin of the hollow molded body, the fusion between the skin material 11 and the expanded particle molded body 12 can be improved. Thus, a composite molded body 10 having more excellent bending rigidity is obtained.

The polypropylene resin constituting the expanded particles is preferably a propylene homopolymer, a propylene-ethylene random copolymer, a propylene-butene random copolymer, or a propylene-ethylene-butene random copolymer. In addition, for the expanded particles, a resin in which the surface of the core layer made of a foamed layer, that is, a polypropylene-based resin in a foamed state can be used to exhibit a melting temperature or softening temperature lower than the melting temperature of the polypropylene-based resin forming the core layer Coated multilayer structured expanded particles, or expanded particles composed of a base resin containing a polypropylene resin polymerized with a metallocene-based polymerization catalyst. By using these foamed particles, the foamed particles can be fused with each other with a lower heating medium heating pressure.

The apparent density of the expanded particle shaped body 12 is not particularly limited, and the apparent density generally used can be widely used. From the viewpoint of excellent balance between lightness and mechanical strength, 30 to 150 kg/m ^{3 is} preferred, and 30 to 150 120kg/m ³ is preferred, and 35-90kg/m ³ is particularly preferred. In addition, the apparent density of the expanded particle molded body 12 refers to the value of the weight of the expanded body divided by the volume of the expanded body. The volume of the foam can be obtained from a method of measuring the amount of increase in the water level when the foam sinks in water (submerged water method) or the like. The apparent density of the expanded particle molded body 12 located inside the skin material 11 can be determined by, for example, measuring the weight of a sample cut from the expanded particle molded body and having a predetermined volume, and dividing the weight by the volume. In addition, the ratio of the weight of the expanded particle molded body 12 to the weight of the hollow molded body constituting the skin material 11 is preferably 0.2 to 0.5, and preferably 0.25 to 0.35 in consideration of both strength and lightness. .

An attachment 50 is attached to the composite molded body 10 as described above. The mounting tool 50 only needs to be an accessory that can mount the composite molded body 10 to other objects such as a vehicle body, and the specific structure is not limited. In addition, the material of the mounting tool 50 can also be widely used with strong metal. The boarding pedal 1 of the illustrated embodiment is a mounting tool (iron rod) 50 of a vehicle body, and is attached to a mounting portion 23 formed on a second wall 11b with a snap member (blind rivet) 51. In fixing the fixture 50 to the composite molded body 10, it is preferable to use a rivet for the fastening member 51 from the viewpoint of making the pull-out strength strong. The installation method of the mounting tool 50 is not limited to riveting. For example, bolts and nuts can be used as the fastening member 51. At this time, by embedding the embedded nut in the composite molded body 10 in advance and fastening the embedded nut with the bolt, the mounting tool 50 can be fixed. In addition, the blind rivet has a rivet body fastened to the object and a mandrel for fastening the rivet body. In the installation using blind rivets, first, the rivet body is inserted into the composite molded body 10 via the attachment 50. Secondly, with the rivet body fixed, the mandrel formed integrally with the rivet body is pulled out to break, so that a part of the rivet body is flexed, and the flexed part is inside the composite molded body 10 (foam The skin material 11) on the particle shaped body side is hooked, and the rivet body is fastened. Thereby, the mounting tool 50 can be mounted on the composite molded body 10. For blind rivets, hollow rivets (POP Rivets) or hollow HC rivets (POP HC Rivets) manufactured by Japan POP RIVETS AND FASTENERS Co., Ltd. can be suitably used. Especially when buckling a part of the rivet body, the buckling part expands into a flat shape, and the rivet body is fastened by the way of surface pinching, so that even if the number is small, it can be installed in the composite forming The pull-out strength of the mounting tool 50 of the body 10 is strong, so it is better to use hollow HC rivets (POP HC Rivets).

The installation tool 50 is installed between two adjacent heating medium supply pipe marks 15. The distance between the two heating medium supply tube marks 15 is 400 mm or less. The distance between the mounting tool 50 mounted on the composite molded body 10 and one of the two heating medium supply tube marks 15 is 180 mm or less. When manufacturing the composite molded body 10, the heating medium supply pipe is inserted at a position where the distance between the two heating medium supply pipes is 400 mm or less and the distance between one heating medium supply pipe and the mounting section 23 is 180 mm or less through the mounting section 23 To cuticle material 11. By manufacturing in this way, two adjacent heating medium supply tube marks 15 are located at a distance of 400 mm or less across the mounting tool 50, and at least one of the heating medium supply tube marks 15 is located at a distance of 180 mm or less from the mounting tool 50 s position. The heating medium supply tube is inserted at a position close to the mounting portion 23 (at a position of 180 mm or less) to heat-mold the filled expanded particles, whereby the fusion state of the skin material 11 and the expanded particle shaped body 12 around the mounting portion 23 Improve, peel strength increases. Therefore, the pull-out strength of the mounting tool 50 mounted on the mounting portion 23 is strong. From this viewpoint, the distance between the mounting tool 50 and one of the two adjacent heating medium supply pipe marks 15 is preferably 150 mm or less, and particularly preferably 130 mm or less. From the same viewpoint, the distance between the two adjacent heating medium supply tube marks 15 is preferably 350 mm or less, and more preferably 300 mm or less. In addition, from the viewpoint of stably fixing the fixture 50, the distance between the fixture 50 and one of the two adjacent heating medium supply pipe marks 15 is preferably about 30 mm or more. 50mm or more is preferable. In addition, from the viewpoint of easily obtaining a composite molded body having a good surface condition, the distance between the two heating medium supply tube marks 15 is preferably about 100 mm or more, preferably 150 mm or more, and more preferably 180 mm or more . In addition, from the viewpoint of improving the pull-out strength of the mounting tool 50, the mounting tool 50 is preferably fixed to the composite molded body 10 close to either side of the two heating medium supply tube marks 15 described above. In addition, the distance between the mounting tool 50 and the other heating medium supply pipe mark 15 of the two heating medium supply pipe marks 15 is preferably 200 mm or less, preferably 180 mm or less, and particularly preferably 160 mm or less. In addition, connect the center points of the two heating medium supply tube marks 15 located near the mounting tool 50 with a straight line, and the point where the straight line intersects the side end of the mounting tool 50 as the midpoint of the line segment at both ends As the center point of the mounting tool 50, the distance between the center point of the mounting tool 50 and the center point of the heating medium supply pipe mark 15 is the distance between the mounting tool 50 and the heating medium supply pipe mark 15. In the boarding pedal 1 of the illustrated embodiment, the distance a shown in FIG. 2 is 120 mm, the distance b is 160 mm, the distance c is 60 mm, the distance d is 140 mm, the distance e is 120 mm, and the distance f The distance is 180mm.

In addition, when the mounting tool 50 is pulled out, the load when the skin material 11 and the expanded particle shaped body 12 are peeled off is preferably 1.5 kN or more, preferably 1.8 kN or more, and particularly preferably 2.0 kN or more. When the load when peeling the skin material 11 and the expanded particle molded body 12 is within the aforementioned range, the pull-out strength of the mounting tool 50 mounted on the mounting portion 23 is strong, and it is a highly reliable composite molded body with mounting tool. In addition, the load at the time when the skin material 11 and the expanded particle molded body 12 are peeled off when the attachment 50 is pulled out can be measured as follows using, for example, a tensile tester. First, the composite molded body with a mounting tool is fixed to a jig for tensile testing (for load measurement), and in the tensile test, the mounting tool 50 and the tensile testing machine are fixed so as to align the skin material 11 and the expanded particles An equal load is applied in the direction perpendicular to the fusion surface of the molded body 12. Next, a tensile load is applied by a tensile tester at a predetermined speed, a tensile test is performed, and the load at the time of peeling the skin material 11 from the expanded particle molded body 12 is measured, whereby the load at the time of peeling can be obtained. In addition, in the tensile test, when the skin material 11 is peeled off from the expanded particle molded body 12, the temporary reduction in the load of displacement appears as a displacement-load curve, so the reduction of this load can be obtained as The load at the time of standard stripping.

The boarding pedal 1 with a mount composed of the above-mentioned composite molded body with a mount can be manufactured by a manufacturing method having a first process and a second process in which the hollow portion of the thermoplastic resin hollow molded body is filled with a thermoplastic resin Foam particles, two or more heating medium supply tubes are inserted into the thermoplastic resin hollow molding body, and the heating medium is supplied from the heating medium supply tube, thereby heating and fusing the filled foam particles to form foam particles Body, and the inner surface of the thermoplastic resin hollow molded body is bonded to the foamed particle molded body to obtain a composite molded body of a skin material composed of the thermoplastic resin hollow molded body and the foamed particle molded body located inside the skin material; The second process is to fasten the fastening member through the skin material and the mounting tool after fastening the fastening member, and fix the mounting tool to the composite molded body, thereby obtaining a composite molding body and a mounting tool fixed to the composite molded body Composite molded body with mounting tools.

In the first process, first, a cylindrical parison or two-piece parison in a softened state formed by pressing a melt of a thermoplastic resin from a stamper is held by a split forming die (forming die 60), and then, The blow molding tube 61 is driven into the parison, and pressurized gas such as air (hereinafter also referred to as blow molding air) is blown into the parison through the blow molding tube 61. Thereby, the parison expands in the die hole of the forming die 60 and is pressed against the inner wall of the forming die 60, whereby the parison is shaped to form a hollow shaped body (forming). In this blow molding process, during the blowing of blow air, it is preferable to evacuate from the side of the forming mold 60 so that the parison closely adheres to the inner wall of the forming mold. At this time, forming the hollow molded body more easily reflects the shape of the molding die faithfully. For example, the slip prevention portion 22 formed on the upper surface of the pedal portion 20 of the skin material 11 and the mounting portion 23 formed on the lower surface are formed with good accuracy.

Here, in the case of the skin material 11 composed of a multilayered hollow molded body, for example, the thermoplastic resin and the reinforcing fiber forming the outer layer are supplied to an extruder to form a molten state to obtain a molten resin for forming an outer layer. Regarding the inner layer, the thermoplastic resin forming the inner layer is supplied to an extruder to form a molten state to obtain a molten resin for forming an inner layer. In addition, as for the outer layer and the inner layer, not only the thermoplastic resin but also the reinforcing fiber is supplied to the extruder to be in a molten state as necessary. Then, a method of extruding the layered product from the die provided by the extruder (co-extrusion method) is carried out by combining and depositing the thermoplastic resin (molten resin) in the molten state forming the inner layer and the outer layer in the die. To obtain a parison with a multi-layer structure, the parison with a multi-layer structure may be shaped using the forming mold 60 described above.

Next, in the forming mold 60, thermoplastic resin foamed particles are filled in the formed hollow body, that is, the formed skin material 11. The filling process of the expanded particles is shown in FIG. 4, and the expanded particle filling tube 62 can be provided by the molding die 60 for blow molding. After the blow molding, the hollow molded body is cooled and solidified from the outside of the hollow molded body The expanded particle filling tube 62 is driven into the inside (hollow portion), and the expanded particle filling tube 62 is filled into the expanded particles together with the compressed air. The filling of the expanded particles is preferably performed when the hollow molded body is in a softened state. In this way, by filling the hollow molded body with the expanded particles, the expanded particle molded body 12 formed by fusing the expanded particles with the heating medium and the inner surface of the hollow molded body as the skin material 11 can be more reliably fused.

Next, a heating medium is supplied to the expanded particles filled in the hollow molded body, and the expanded particles are heated and fused with each other. As shown in FIG. 4, the heating medium supply process can be performed by inserting the heating medium supply tube 63 provided in the molding die 60 for blow molding into the hollow molded body, and heating the heating medium through the inserted heating medium supply tube 63 (For example, steam) is supplied to the hollow molded body and is performed. In the heating medium supply process, the expanded particles heated by the supplied heating medium are fused with each other to form the expanded particle shaped body 12. Furthermore, while the formation of the expanded particle molded body 12 is proceeding, the inner surface of the skin material 11, that is, the hollow molded body, and the portion of the expanded particle molded body 12 that contacts the inner surface are fused.

In the process of supplying the heating medium in the first process described above, in the present invention, the two heating medium supply pipes 63 are installed with the mounting tool 50 therebetween so that the distance between the two heating medium supply pipes is 400 mm or less. The part (mounting portion 23) of the composite molded body 10 is inserted, and the heating medium supply tube 63 is placed so that the distance between the mounting portion 23 and one of the two heating medium supply tubes is 180 mm or less 63 is inserted into the hollow body to heat it. Thereby, the fusion state of the skin material 11 and the expanded particle molded body 12 around the mounting portion 23 is good, the peeling strength is improved, and the pulling strength of the mounting tool 50 mounted on the mounting portion 23 is strong. From this viewpoint, the distance between the mounting portion 23 and one of the two heating medium supply pipes 63 is preferably 150 mm or less, and particularly preferably 130 mm or less. In addition, in the above-mentioned first process, it is preferable to insert the heating medium supply pipe 63 into the hollow molded body to heat it so that the distance between the two heating medium supply pipes 63 is 350 mm or less, the two heating The distance between the media supply tubes 63 is preferably 320 mm or less. In addition, from the viewpoint of stably fixing the mounting tool 50, the distance between the mounting portion 23 and one of the two heating medium supply tubes 63 is preferably about 30 mm or more, and more preferably 50 mm or more. In addition, from the viewpoint of easily obtaining a composite molded body with a good surface condition, in the above-mentioned first process, the heating medium is supplied so that the distance between the two heating medium supply tubes 63 is 100 mm or more It is better to insert the tube 63 into the hollow forming body to heat it. The distance between the two heating medium supply tubes 63 is preferably 150 mm or more, and more preferably 180 mm or more. In addition, from the viewpoint of further improving the pull-out strength of the mounting tool 50, the mounting portion 23 is preferably close to either side of the two heating medium supply tube marks 15 described above. In addition, in the first process, the heating medium supply pipe 63 is inserted into the hollow molded body such that the distance from the other heating medium supply pipe 63 of the two heating medium supply pipes 63 is 200 mm or less. heating. The distance to the other heating medium supply pipe 63 of the two heating medium supply pipes 63 is preferably 180 mm or less, and particularly preferably 160 mm or less. In addition, the center points of the two heating medium supply tubes 63 located near the mounting portion 23 are connected by a straight line, and the midpoint of the line segment at both ends is taken as the point where the straight line intersects the side end of the mounting portion 23 The center point of the portion 23, the distance between the center point of the mounting portion 23 and the center point of the heating medium supply pipe 63 is the distance between the mounting portion 23 and the heating medium supply pipe 63.

As shown in FIG. 4, the manufacturing apparatus of the composite molded body includes an extruder, a stamper (these are not shown), and a molding die 60 for molding. The molding die 60 is provided with a blow tube 61 for supplying blow air to blow-mold the parison in a softened state to form a hollow molded body, and filled with expanded particles to fill the formed hollow molded body with expanded particles. A pipe 62 and a heating medium supply pipe 63 for supplying a heating medium that heats and fuses the filled expanded particles with each other. In addition, this FIG. 4 shows the above-mentioned heating medium supply process, in which the heating medium supply pipe 63 is inserted into the hollow molding body which is the skin material 11. The blow molding tube 61, the foamed particle filling tube 62, and the heating medium supply tube 63 are each configured to be insertable into the forming mold 60. The blow molding tube 61 is configured to supply blow air, the expanded particle filling tube 62 is configured to supply expanded particles, and the heating medium supply tube 63 is configured to supply heating medium (for example, steam). The forming mold 60 shown in the figure is formed as a split forming mold. The forming mold piece 60a forming the first wall 11a side forming the upper surface of the skin material 11 and the forming mold forming the second wall 11b side forming the lower surface The sheet 60b constitutes. The blow molding tube 61, the expanded particle filling tube 62, and the heating medium supply tube 63 are all disposed on the molding die piece 60b that molds the second wall 11b side forming the lower surface of the skin material 11. As a result, the composite molded body 10 is the blow molded tube mark 13, the expanded particle filled tube mark 14, and the heating medium supply tube mark 15 are all present on the lower surface which is difficult to see from the outside, and a composite molded body with excellent appearance can be manufactured 10.

Next, in the second process, the mounting tool 50 is fixed to the composite molded body 10 manufactured in the first process. The mounting tool 50 can be installed by arranging a mounting tool (for example, a metal rod) 50 on the mounting portion 23 formed in the composite molded body 10, and a fastening member (blind rivet) 51 to penetrate the skin material 11 and the mounting tool 50 It is inserted into the mounting portion 23 in a manner such that the fastening member (blind rivet) 51 is fastened and fixed. The fastening member 51 is preferably a rivet, and the installation method of the mounting tool 50 is not limited to this. For example, nuts and bolts can be used for the fastening member 51. In this case, the embedded nut can be embedded in the composite molded body 10 in advance, and the embedded nut can be fastened to the bolt to attach the mounting tool. 50Installed on the composite molded body 10.

As described above, the described composite molded body with a mounting tool of the present invention, that is, the boarding pedal 1 with a mounting tool can be mounted on the vehicle body by the mounting tool 50 with a fastener such as a bolt. Furthermore, in a state where the boarding pedal 1 is mounted on the vehicle body, the passenger can easily get on or off the vehicle by placing their feet on the pedal portion 20 of the skin material 11 that is the hollow molded body. At this time, since the boarding pedal 1 of the present invention is composed of a composite molded body 10 composed of a skin material 11 composed of a hollow molded body and an expanded particle molded body 12 located inside the skin material 11, it has sufficient rigidity. It can suppress the occurrence of defects such as deformation and damage. In addition, the energy absorption performance of the expanded particle molded body 12 located inside the boarding pedal 1 is a pedal with good cushioning performance at the time of impact. Furthermore, since the skin material 11, that is, the hollow molded body, is reinforced by the foamed particle molded body 12 located inside, without a rib structure, the first wall 11 a forming the upper surface and the second wall 11 b forming the lower surface It is formed as a hollow molded body that is fused to each other at the periphery of these, so that the weight of the boarding pedal 1 can be reduced. The lightening of the boarding pedal 1 can also reduce the labor during the installation work of the boarding pedal 1.

In particular, when the composite molded body with the mounting tool of the present invention, that is, the boarding pedal 1 is manufactured in the composite molded body 10, the heating medium supply pipe 63 is inserted through the mounting portion 23 of the skin material 11 and is near the mounting portion 23 (Position of 180 mm or less) Insert the heating medium supply tube 63 to heat-mold the filled foamed particles, whereby even if the thickness of the skinned material 11 is thin, the skinned material 11 and foamed particles around the mounting portion 23 can be increased The peel strength of the molded body 12 is strong in the pull-out strength of the attachment 50 attached to the attachment portion 23. Therefore, the boarding pedal is lightweight and can be stably mounted on the vehicle body by the mounting tool 50. Examples

Next, the present invention will be described in more detail by showing Examples and Comparative Examples. However, the present invention is not limited by this embodiment at all.

A composite molded body with a mounting tool (boarding pedal) was produced. The composite molded body with a mounting tool was shaped as shown in FIG. 1. The approximate dimensions were that the length of the composite molded body was 2000 mm and the width of the pedal portion was 160 mm. The thickness of the pedal part is 80mm, and the height of the mounting part is 120mm.

The above-mentioned composite molded body (boarding pedal) is produced by the following method. First, will be glass fibers (fiber length 0.8mm) to 15% by weight blending ratio of the added polypropylene block copolymer (MFR: 1.0g / 10 min, density: 1.0g / cm ³⁾ is supplied to an inner diameter of 65mm The extruder was heated and kneaded at 210°C to form a molten resin. Next, the molten resin was filled into a reservoir (set temperature of 210° C.), and the molten resin was pressed into a cylindrical shape from the reservoir by a die to form a parison in a softened state. The parison is held by a split mold arranged just below the stamper. In addition, the mold temperature was adjusted to 70°C. Then, blow the blow-in tube, blow 0.50 MPa (G: gauge pressure) of pressurized air into the parison from the blow tube, and at the same time, reduce the pressure between the outer surface of the parison and the inner surface of the mold to The shape of the die hole of the mold was shaped to form a hollow molded body with an average body thickness of 3.5 mm. In addition, in the molding of the hollow molded body, a molding die having a molding die hole having the same size as the schematic size of the boarding pedal described above was used. One tube with an outer diameter of 20 mm was used for the expanded particle filling tube, two tubes with an outer diameter of 4 mm were used for the blow molding tube, and nine tubes with an outer diameter of 8 mm were used for the heating medium supply tube. In addition, the tubes are arranged in a positional relationship as shown in FIG. 2 in the forming die.

Next, in the softened hollow molded body, the nine heating medium supply tubes are inserted from one of the divided molds to the other divided mold, and the gas in the hollow portion of the hollow molded body is discharged from the heated medium supply tube, thereby, While adjusting the pressure of the hollow part of the hollow molded body to 0.18 MPa (G), while inserting the foamed particle filling tube into the hollow molded body, the polypropylene resin using propylene-ethylene random copolymer as the base resin is foamed The particles (apparent density 60 kg/m ³ ) are filled through the expanded particle filling tube. After the expanded particles are filled, the four heating medium supply tubes A group out of the nine heating medium supply tubes inserted into the hollow molding body are exhausted, and the other five heating medium supply tubes B group are supplied with 0.4 MPa ( G) Steam for 10 seconds. Next, while exhausting gas from the heating medium supply pipe group B, 0.4 MPa (G) of steam was supplied from the heating medium supply pipe group A for 10 seconds. Finally, 0.4 MPa (G) of steam was supplied from all the heating medium supply tubes A and B for 8 seconds to heat and fuse the expanded particles to each other, and fuse the inner surface of the hollow molded body with the expanded particles. After that, the molded body was cooled until the pressure of the surface pressure gauge attached to the mold was 0.05 MPa (G), the heating medium supply tube was pulled out, the mold was opened, and the composite molded body was obtained by demolding from the mold.

The obtained composite molded body had the above-mentioned approximate size, the average skin thickness of the skin material was 3.5 mm, and the apparent density of the expanded particle molded body was 45 kg/m ³ .

Using a hollow rivet, the mounting tool (iron rod) was mounted on the composite molded body manufactured as described above so that the distance from the heating medium supply pipe mark was the value shown in Table 1. In addition, in Examples 1 to 4 and Comparative Example 1, six hollow rivets (POP Rivets) were used for one mounting tool: AD-64-TL A-30-MC manufactured by Japan POP RIVETS AND FASTENERS Co., Ltd. installation. In addition, in Example 5, two hollow HC rivets (POP HC Rivets) were used for one mounting tool: SHC-52M76 manufactured by Japan POP RIVETS AND FASTENERS Co., Ltd. and mounted.

With respect to the composite molded body with attachments manufactured as described above, the load at the time of peeling off the skin material and the expanded particle molded body (load at the time of peeling) when each attachment was pulled out was measured. In addition, the measurement of the load at the time of peeling used a tensile tester (a universal tester for tension: manufactured by ORIENTEC), and was performed by the following method. The composite molded body with a mounting tool mounted at a distance from the heating medium supply pipe mark as shown in Table 1 was fixed to the load measuring jig so that the mounting tool was the upper surface (the lower surface of the pedal was the upper surface). The holes in the four corners of the mounting tool are connected to the four steel cables of the tensile testing machine. During the tensile test, the mounting tool and the tensile testing machine are fixed to form the skin material and the foam particles. An equal load is applied in the direction perpendicular to the fusion surface of the body. Next, a tensile test was performed by applying a tensile load at a speed of 20 mm/min by a tensile test machine. In this tensile test (n=3), the arithmetic average value of the load when the skin material was peeled from the expanded particle molded body was obtained, and let this arithmetic average value be the load at the time of peeling at the time of pulling out.

The results are shown in Table 1. In addition, in Table 1, the center points of the two heating medium supply pipe marks located near the installation tool are connected with a straight line, and the point where the straight line intersects the side end of the installation tool is the middle of the line segment at both ends The point is used as the center point of the mounting tool. The distance between the center point of the mounting tool and the center point of the heating medium supply pipe mark is the distance from one of the heating medium supply pipe marks and the other heating medium supply pipe mark. Distance.

產業上之可利用性[Table 1]

Industrial availability

According to the present invention, since it is possible to provide a composite molded body with an attachment which is excellent in lightness and excellent in the pull-out strength of the attachment, it can be widely used as, for example, a cargo truck or a part of a sports utility vehicle. The pedal of a taller vehicle.

1: boarding pedal 10: Composite molded body 11: Skin material 11a: the first wall 11b: Second wall 12: Expanded particle molding 13: Blow molding tube marks 14: Foam particles fill the tube marks 15: Heating medium supply pipe mark 20: Pedal 21: Installation Department 22: Slipping prevention section 23: Installation Department 50: mounting tool 51: Fastening member 60: forming mold 60a: Forming die piece 60b: Forming die piece 61: blow molded tube 62: Expanded particle filled tube 63: heating medium supply tube a: distance b: distance c: distance d: distance e: distance f: distance

FIG. 1 is a perspective view showing an embodiment of a composite molded body with an attachment, that is, a boarding pedal of the present invention, from diagonally above. FIG. 2 is a perspective view showing the boarding pedal shown in FIG. 1 from diagonally below. FIG. 3 is an enlarged cross-sectional view of the portion (the portion where the mounting tool is installed) along the line A-A of FIG. 1. 4 is a cross-sectional view conceptually showing a part of a manufacturing apparatus of a composite molded body.

1: boarding pedal

11: Skin material

11a: the first wall

11b: Second wall

13: Blow molding tube marks

14: Foam particles fill the tube marks

15: Heating medium supply pipe mark

20: Pedal

21: Installation Department

23: Installation Department

50: mounting tool

51: Fastening member

a: distance

b: distance

c: distance

d: distance

e: distance

f: distance

Claims (10)

A composite molded body with mounting equipment, including: A composite molded body having an expanded particle molded body composed of a plurality of thermoplastic resin expanded particles fused with each other and a skin material composed of a thermoplastic resin hollow molded body, the expanded particle molded body formed inside the skin material And adhere to the inner surface of the skin material; A mounting tool for mounting the composite molded body to other objects; and A buckling member penetrating the skin material and the mounting tool to buckle the mounting tool to the skin material; The skin material has a plurality of heating medium supply tube marks formed by a heating medium supply tube for heating and fusing thermoplastic resin foam particles filled in the hollow portion of the thermoplastic resin hollow molded body Heating media The installation tool is installed between two heating medium supply pipe marks; The distance between the two heating medium supply tube marks is less than 400mm; The distance between the mounting tool and one of the two heating medium supply pipe marks is 180 mm or less. For example, in the patent application, the composite molded body with attachments in item 1, where, When the attachment is pulled out, the load at the time of peeling off the skin material and the expanded particle molded body is 1.5 kN or more. For example, the composite molded body with attachments of item 1 or 2 of the patent application scope, where, The average thickness of the skin material is 1~4mm. For example, in the patent application, the composite molded body with attachments of item 1 or item 2, where, The skin material is a hollow blow molded body composed of a fiber-reinforced thermoplastic resin containing reinforcing fibers in a thermoplastic resin. For example, the composite molded body with mounting equipment according to item 4 of the patent scope, in which The content of reinforcing fibers in the fiber-reinforced thermoplastic resin is 10 to 30% by weight. For example, the composite molded body with mounting equipment according to item 4 of the patent scope, in which The thermoplastic resin is a polypropylene resin. For example, the composite molded body with a mounting device as claimed in item 1 or 2 of the patent scope, wherein the expanded particle molded body is a thermoplastic resin expanded particle molded body with an apparent density of 30 to 150 kg/m ³ . For example, the composite molded body with mounting equipment of item 7 of the patent scope, in which The expanded particle molded body is a polypropylene resin expanded particle molded body. A boarding pedal with a mounting tool, which is composed of a composite molded body with a mounting tool as described in any one of claims 1 to 8 and is installed below a door opening of a vehicle body. A method for manufacturing a composite shaped body with a mounting tool, the composite shaped body with a mounting tool includes a composite shaped body, and a mounting tool fixed to the composite shaped body and used to install the composite shaped body to other objects, the attached The manufacturing method of the composite molded body of the mounting tool includes: In the first process, the hollow portion of the thermoplastic resin hollow molded body is filled with thermoplastic resin foam particles, two or more heating medium supply tubes are inserted into the thermoplastic resin hollow molded body, and the heating medium is supplied from the heating medium supply tube, so that The filled thermoplastic resin foam particles are heated and fused with each other to form a foamed particle molded body, and the inner surface of the thermoplastic resin hollow molded body is adhered to the foamed particle molded body to obtain a skin material and a thermoplastic resin hollow molded body. The composite molded body of the expanded particle molded body inside the skin material; and The second process is to fix the mounting tool to the composite molded body by passing the fastening member through the skin material and the mounting tool to fasten the mounting member to obtain the composite molded body and the composite molded body A composite molded body with a mounting tool attached to the mounting tool; In this first process, the two heating medium supply pipes are inserted so that the distance between the two heating medium supply pipes is 400 mm or less through the part where the composite molded body of the mounting tool is installed, and the The heating medium supply tube is inserted into the thermoplastic resin hollow molding body so that the distance between the part and one of the two heating medium supply tubes is 180 mm or less.

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