JP2001138814A - Upper lid structure for storing space - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an upper lid structure for a storing space that does not require appearance measures and can reduce cost. SOLUTION: An end surface of a window part 10 is hidden by a longitudinal wall of a recessed part 7 left after notching formation, so that special appearance measures are not required, differently from the prior art.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an upper cover structure for a storage space.

[0002]

2. Description of the Related Art Spare tire pans and tool storage spaces provided in a luggage room of an automobile generally include:
It is covered from above by a resin upper lid structure called luggage floorboard. As this type of luggage floorboard, for example, there is known a luggage floorboard in which a resin core sheet having a plurality of cylindrical embossed portions is sandwiched by resin skin sheets to form a three-layer structure (Japanese Patent Laid-Open Publication No. 9
-76381).

[0003] This type of luggage floorboard firstly
The heated resin sheet is formed into an embossed shape by roller molding to produce a raw material of a core sheet. Then, the heated skin sheets are simultaneously bonded to both surfaces of the core sheet, and a sheet having the same cross-sectional shape as that of the resin board is obtained in a raw state. Next, the raw material is punched and cut into a product shape by a big mold, and a window for punching a lower storage space is punched and formed at the center thereof.

[0004]

However, according to such a conventional technique, a window is punched and formed at the center of the upper lid structure by a big mold. The cross-sectional shape of the cut embossed portion is exposed, and the appearance is poor. Conventionally, it has been necessary to employ an overlock structure for sewing and hiding the end face, or to attach a nonwoven fabric tape to the end face for hiding, thereby increasing the number of working steps. Also, it is necessary to take countermeasures against the appearance of the peripheral end face of the upper lid structure.

The present invention has been made by paying attention to such a conventional technique, and an object thereof is to provide an upper lid structure for a storage space which does not require any appearance countermeasures.

[0006]

According to the first aspect of the present invention,
A structure in which a skin sheet made of a thermoplastic resin is joined to at least the upper surface of a core sheet made of a thermoplastic resin having a plurality of embossed portions. An upper lid structure, wherein the core sheet is a vacuum-formed product formed in advance according to a product shape, and a window portion is formed by cutting out a bottom surface of a concave portion formed in a predetermined region, and a window of a skin sheet is formed. An opening was formed in a portion corresponding to the portion.

According to the first aspect of the invention, since the cross-sectional shape of the embossed portion is hidden by the concave vertical wall left after the notch is formed on the end face of the window, a special appearance countermeasure as in the prior art is provided. There is no need to do this, and costs can be reduced.

[0008] In the second aspect of the present invention, no embossed portion is formed on the periphery of the core sheet.

According to the second aspect of the present invention, since the embossed portion is not formed on the periphery of the core sheet, the appearance of the end face of the periphery of the core sheet is good.

According to a third aspect of the present invention, the skin sheet is joined to the lower surface of the core sheet, and the lower skin sheet is cut out together with the bottom surface of the concave portion of the core sheet.

According to the third aspect of the present invention, since the skin sheets are bonded to both sides of the core sheet, the overall strength of the upper cover structure is improved, and the luggage floor board of an automobile can be used.
It is suitable when used for a part to which a load is applied.

According to the invention of claim 4, a step is formed in the vertical wall of the concave portion, and a cover having a shape corresponding to the window is placed on the step.

According to the fourth aspect of the present invention, since the window can be covered with the cover, dust and the like do not enter the storage space from the window.

According to the fifth aspect of the present invention, a groove having the same depth as the embossed portion is formed at the periphery of the core sheet during vacuum forming, and the outer edge of the core sheet is cut at the bottom of the groove.

According to the fifth aspect of the present invention, since the peripheral end face of the upper lid structure is hidden by the vertical wall of the groove left after cutting, it is not necessary to take a special appearance measure as in the related art. And cost reduction.

In the invention according to claim 6, the core sheet and the skin sheet are formed of a recyclable resin material.

According to the sixth aspect of the present invention, since the core sheet and the skin sheet are formed of a recyclable resin material, the waste material of the resin board is melted and reused by the reducer to reduce resources. Effective utilization and cost reduction can be achieved.

[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of the present invention will be described below with reference to FIGS. The luggage floorboard 1 as the “top cover structure” according to this embodiment has a three-layer structure, as shown in FIG. That is, the luggage floorboard 1 of this embodiment includes a core sheet 3 having a large number of cylindrical embossed portions 2 and skin sheets 4 and 5 joined to upper and lower surfaces thereof, respectively. The luggage floor board 1 covers a storage space (not shown) for storing spare tire pans and tools provided in a luggage room of an automobile from above.

First, a method for manufacturing the core sheet 3 will be described first. The core sheet 3 is made of polypropylene (thermoplastic synthetic resin) and manufactured by a vacuum forming method. That is, the heated and softened polypropylene sheet is covered with a vacuum forming mold (not shown), and air from the mold and the sheet is exhausted from a number of holes formed in the mold by a vacuum pump. , An embossed shape is provided, and a square concave portion 7 is formed at the center. A step 8 is formed on the vertical wall of the recess 7.
In this way, in vacuum forming, the mold is inexpensive and the shape can be easily changed because it is merely brought into close contact with the mold. Further, the resin sheet does not bend at an acute angle, the thickness of the resin constituting the core sheet 3 is uniform, and high strength is obtained.

The embossed portion 2 is not formed on the periphery of the core sheet 3 which is the end of the luggage floor board 1, and the groove 6 having the same depth as the embossed portion 2 is formed along the outer shape of the product shape. Is done. Then, the center of the bottom of the groove 6 is cut by a laser processing machine along the product shape.

Next, the skin sheets 4, 5 are also cut from a large raw material by a laser processing machine along the product shape. The skin sheets 4, 5 are also made of polypropylene (thermoplastic synthetic resin) and can be easily cut by a laser. The upper skin sheet 4 has an opening 9 having a shape corresponding to the recess 7.
Are formed. Then, the core sheet 3 and the skin sheets 4, 5 are heated with hot air to soften their surfaces, and
The recess 7 and the opening 9 are joined so that they match. Since the concave portion 7 and the groove portion 6 have the same depth as the embossed portion 2, the lower surfaces thereof are the same surface, and the lower skin sheet 5 can be securely joined in a close contact state. After the joining, a decorative sheet such as a nonwoven fabric may be provided on the upper surface of the upper skin sheet 4 or a pattern such as a grained pattern may be formed.

Then, the bottom portion of the concave portion 7 and the lower skin sheet 5 joined thereto are cut out by a laser to form a window portion 10. The window 10 is provided with a cover 11 that is placed on the step 8 and covers the window 10. The cover 11 can prevent dust from entering the storage space.

The luggage floorboard 1 thus obtained has a three-layer structure and a high overall strength, so that there is no problem even if heavy luggage is placed on the luggage floorboard 1 without being deformed and stepped on by the occupants' feet. In addition, since the end face of the window 10 is hidden by the vertical wall of the concave portion 10 left after the notch is formed, it is not necessary to take a special appearance measure as in the related art, and the cost can be reduced. Similarly, since the peripheral end face of the luggage floor board 1 is hidden by the vertical wall of the groove 6 left after the cutting, there is no need to take special appearance measures as in the related art.
In this respect, cost reduction can be achieved.

Further, the core sheet 3 and the skin sheets 4, 5
However, since it is formed of recyclable polypropylene, the waste material of the luggage floorboard 1 is melted by a reducer and reused, whereby effective use of resources and cost reduction can be achieved.

In the above description, polypropylene is used as an example of the thermoplastic synthetic resin. However, the present invention is not limited to this.
Other olefin-based resins can also be used.
Further, the core sheet 3 is not limited to the one in which the columnar embossed portion 2 is formed as in the present embodiment, and may have a waveform-curved shape. Various shapes may be used.

Furthermore, the luggage floorboard 1 is taken as an example of the "top cover structure", but any top cover structure such as a console box or a glove box may be used.

[0027]

According to the present invention, the end face of the window is hidden by the concave vertical wall left after the notch is formed, so that it is not necessary to take any special appearance measures as in the prior art.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a core sheet.

FIG. 2 is an enlarged perspective view of a partial cross section showing a core sheet.

FIG. 3 is a sectional view showing a core sheet.

FIG. 4 is a sectional view showing a state where the core sheet is cut from a groove.

FIG. 5 is an exploded perspective view showing the upper lid structure.

FIG. 6 is a perspective view showing an upper lid structure.

FIG. 7 is a sectional view showing a window portion of the upper lid structure.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Resin board 2 Emboss part 3 Core sheet 4, 5 Skin sheet 6 Groove part 7 Concave part 8 Step part 9 Opening 10 Window part 11 Cover

 ──────────────────────────────────────────────────の Continuing on the front page (72) Inventor Takahiro Hasegawa 33, Onna, Atsugi-shi, Kanagawa Prefecture Inside the company (72) Inventor Norihisa Nemoto 33, Onna, Atsugi-shi, Kanagawa Prefecture F, Japan Terms (Reference) 3D022 BA01 BB01 BC11

Claims (6)

[Claims] 1. A structure in which a thermoplastic resin skin sheet is joined to at least the upper surface of a thermoplastic resin core sheet having a plurality of embossed portions, and a window portion is formed on a part of the core sheet to view a lower storage space. An upper lid structure for a storage space, wherein the core sheet is a vacuum-formed product formed in advance according to the product shape, and the window portion is formed by cutting out a bottom surface of a concave portion formed in a predetermined area. An upper lid structure for a storage space, wherein an opening is formed in a portion corresponding to a window of a skin sheet. 2. The upper cover structure for a storage space according to claim 1, wherein an embossed portion is not formed on a peripheral edge of the core sheet. 3. The upper cover structure for a storage space according to claim 1, wherein a skin sheet is joined to a lower surface of the core sheet, and the lower skin sheet is a bottom surface of a concave portion of the core sheet. An upper lid structure for a storage space, wherein the upper lid structure is cut out together with a part. 4. The upper lid structure for a storage space according to claim 1, wherein a step is formed in the vertical wall of the recess, and the step corresponds to a window. An upper cover structure for a storage space, wherein a cover is placed. 5. The upper lid structure for a storage space according to claim 1, wherein a groove portion having the same depth as the embossed portion is formed in a peripheral edge of the core sheet during vacuum forming. An upper lid structure for a storage space, wherein an outer edge of a sheet is cut at a bottom of the groove. 6. The upper lid structure for a storage space according to claim 1, wherein the core sheet and the skin sheet are formed of a recyclable resin material. Top lid structure for storage space.