JP2006001021A - Appearance part and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain an appearance part having excellent appearance commodity properties while having lightweight properties and high rigidity. <P>SOLUTION: The appearance part manufacturing method is characterized in that a base material 1A containing inorganic fibers and thermoplastic resin fibers is heated to melt the thermoplastic resin fibers and molded to obtain a molded base material 1 and a thermoplastic resin layer 7 is injection-molded on the surface 1a of the molded base material 1. Further, the processing of grooves 9 or slits 10 is applied to the surface 1a of the molded base material 1 and the thermoplastic resin layer 7 is injection-molded on the processed surface of the molded base material 1 to increase the rigidity of the appearance part 8 while suppressing the deformation thereof. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an external part and a method for manufacturing the same.

  For exterior materials such as automobiles, motorcycles, and buggies, for example, exterior bodies include thermoplastic resin injection-molded parts such as polypropylene, metal steel plate press parts, or thermosetting resin parts such as FRP (Fiber Reinforced Plastics). It is mainly used.

  Moreover, the member shape | molded from the base material containing an inorganic fiber and a resin fiber is used as interior materials for motor vehicles, such as a ceiling material and a door trim.

  An external part having a surface exposed to the outside and used for an exterior material such as an automobile, a motorcycle, or a buggy is required to be lightweight and highly rigid and have good appearance merchandise.

  In addition, it is an external part used for an interior material having a surface exposed to the inside, and for example, a part used for an interior material in an automobile interior is required to be lightweight, highly rigid, and to have good appearance merchandise. There is a case.

  The pressed part of the metal steel plate has a problem that the appearance merchantability is good, the rigidity is high, but the weight is heavy.

  In addition, since the thermoplastic injection molded part has low heat resistance, it is necessary to affix a heat insulating material such as aluminum foil on the inside of the part that requires heat resistance. There is a problem such as need.

Further, the thermosetting resin member has a problem in terms of recycling.
On the other hand, the molded base material molded from the base material containing the inorganic fiber and the resin fiber is light and highly rigid, but is inferior to the surface appearance merchantability, so that the interior material and the exterior material are required to have appearance merchantability. In order to improve the appearance merchantability, it is necessary to bond a fiber-based skin or a leather skin, and there is a problem that the bonding is troublesome.

  Therefore, the present invention is, for example, an exterior material whose surface is exposed to the outside of an automobile and an interior material whose surface is exposed to the interior of an automobile, i.e., an external part whose surface is externally visible, and has light weight and high rigidity. An object of the present invention is to provide an appearance part that has good appearance merchandise, is easy to manufacture, and is easy to recycle, and a method for manufacturing the same.

  In order to solve the above-mentioned problems, the invention described in claim 1 is characterized in that a thermoplastic resin layer is provided on the surface of a molded substrate formed from a substrate containing inorganic fibers and a thermoplastic resin. Appearance part.

  The invention according to claim 2 is an external part characterized in that a thermoplastic resin layer is provided on the surface of a molded substrate formed from a substrate containing inorganic fibers, a thermoplastic resin, and plant fibers.

  A third aspect of the invention is an external component according to the first or second aspect of the invention, wherein a groove or a slit is formed on the surface of the molding substrate.

  In the invention according to claim 4, the thermoplastic resin layer is formed on the surface of the molded substrate formed by heating the substrate containing inorganic fibers and the thermoplastic resin fibers to melt the thermoplastic resin fibers. It is a manufacturing method of an appearance part characterized by carrying out injection molding.

  The invention according to claim 5 is a method in which a thermoplastic resin is formed on the surface of a molded substrate formed by heating a substrate containing inorganic fibers, thermoplastic resin fibers, and plant fibers to melt the thermoplastic resin fibers. A method of manufacturing an external part, wherein a resin layer is injection-molded.

  The invention according to claim 6 is the invention according to claim 4 or 5, wherein after the thermoplastic resin is injected onto the molding substrate, the thermoplastic resin is compressed before the thermoplastic resin cools. It is a manufacturing method of the appearance component characterized.

  The invention according to claim 7 is the invention according to any one of claims 4 to 6, wherein a groove or slit processing is performed on the surface of the molding substrate, and the surface of the molding substrate subjected to the groove or slit processing. And a thermoplastic resin layer by injection molding.

  According to the present invention, since the appearance part is formed from the inorganic fiber and the thermoplastic resin fiber or these and the plant fiber, a lightweight and highly rigid appearance part can be obtained.

  Furthermore, since it has a resin layer on the surface of the appearance part by resin molding, etc., and can be finished with good appearance merchandise, the fiber skin or leather skin tensioning process for improving the appearance merchandise as described above Can be easily manufactured.

  In addition, since the present invention contains inorganic fibers in the molding substrate, it has higher heat resistance than a single thermoplastic resin injection molded part such as polypropylene, and even a member having a heat source nearby can be molded. By attaching the surface of the material to the heat source, it is not necessary to apply heat insulating material.

Further, the use of plant fibers can reduce the weight of the external parts.
Furthermore, since a conventional thermosetting resin is not used, it is good for recycling.

  Furthermore, a groove or slit is formed on the surface of the molding base material, and injection molding of the resin on the surface of the molding base material increases the degree of adhesion with the molding base material by injecting the injection resin into the groove or slit portion. Since the injection resin forms a rib shape, it is possible to improve the rigidity of the appearance part and suppress deformation.

The best mode for carrying out the present invention will be described with reference to FIGS.
First, a base material 1A containing inorganic fibers and thermoplastic resin fibers is prepared. Moreover, it is good also considering what further contains vegetable fiber in this inorganic fiber and resin fiber as 1 A of base materials.

  Here, the inorganic fiber is a fiber mainly composed of an inorganic substance. Examples thereof include glass fiber, carbon fiber, basalt fiber, and alumina fiber.

  The thermoplastic resin fiber is a fiber made of a long-chain synthetic polymer mainly composed of a resin. Examples thereof include thermoplastic resin fibers such as polypropylene fibers, polyethylene fibers, and polyester fibers.

  Polyethylene fibers can be processed at low temperatures because of their low melting temperature, but they are less rigid than polypropylene fibers. Polyester fibers are difficult to process because of their high melting temperatures. Polypropylene fibers have a melting temperature between polyethylene fibers and polyester fibers, and have characteristics such as being easy to process for relatively high rigidity. Thermoplastic resin fibers can be used properly according to the shape of the external part, the intended use, and the like.

  The plant fiber is a natural fiber obtained from a plant. Examples include kenaf and sisal.

  Here, since the thermoplastic resin fibers are used as a binder for inorganic fibers, the ratio of the thermoplastic resin fibers in the base material is preferably 60 to 40%, and the ratio of the inorganic fibers is preferably 40 to 60%.

  Moreover, when using inorganic fiber and vegetable fiber as a base material, since the thermoplastic resin fiber is used as a binder for inorganic fiber and vegetable fiber, the blending ratio in the base material is the same as that for thermoplastic resin fiber as described above. It is preferable to make -40%, inorganic fiber 20-30%, and vegetable fiber 20-30%.

  A predetermined amount of the above-mentioned arbitrary inorganic fibers, thermoplastic resin fibers and plant fibers are weighed, and each fiber is cut to about 50 mm. The size of the cut can be set arbitrarily. The cut fibers are defibrated into cotton. During the defibrating operation, the fibers are mixed. The fibrillated fibers are stacked and entangled with a needle to make a mat-like substrate 1A as shown in FIG.

  Next, the mat-like substrate 1A is heated in a heating furnace, the thermoplastic resin fibers are melted, and the thermoplastic resin fibers are used as a binder in the molten state to perform a cooling press after the heating press. Compress to thickness. After the compression, the substrate board 1B is cut into a predetermined size to form a base board 1B as shown in FIG.

  Next, the substrate board 1B is heated again and then cooled to a desired shape. Thereafter, a part of the shape is scraped off and corrected (referred to as trimming) to obtain the molded substrate 1. An example of the shape of the molded substrate 1 is shown in FIG.

  Alternatively, the molded substrate 1 may be obtained by heating the mat-shaped substrate 1A to melt the thermoplastic resin and then performing cooling molding to a desired shape and then performing a trimming operation.

Further, the base board 1 </ b> B may be the molding base 1.
Next, a thermoplastic resin is injection-molded on the surface 1 a of the molding substrate 1.

The injection molding process will be described with reference to FIG.
First, the molding base 1 is attached to the molding base attachment portion 3 of the core plate 2 shown in FIG. 4A as shown in FIG.

  Next, the cavity plate 4 is moved in the X direction shown in FIG. 4 (c), and as shown in FIG. 4 (c), a space (cavity) in which injection molding is performed between the molding substrate surface 1a and the core plate. Stop at the position where 5 is formed.

  Next, as shown in FIG. 4D, a necessary amount of molten thermoplastic resin 7 is injected from the injection nozzle 6 into the space 5.

  Examples of the thermoplastic resin to be injected include thermoplastic resins such as polypropylene, acrylonitrile butadiene styrene copolymer, polyamide (nylon), polycarbonate, and polyethylene terephthalate. The injection resin can be properly used depending on the use environment of the external parts, the use site, or the customer's request.

  Next, as shown in FIG. 4E, the cavity plate 4 is further moved in the X direction, and the thermoplastic resin 7 injected into the space 5 is compressed at a high temperature, and then cooled. By performing the compression, the surface of the thermoplastic resin becomes extremely fine, and the appearance merchantability can be further improved. In addition, even if it does not have a compression process, an external appearance component with a favorable external appearance merchantability is obtained.

  Moreover, since the thermoplastic resin fiber is used for the molding base material 1 and the thermoplastic resin is used for the injection resin 7, when the thermoplastic resin is injected onto the surface of the molding base material 1 at high temperature and high pressure, the molding base material 1 is There is a risk of deformation. Therefore, it is desirable to inject the thermoplastic resin at a low pressure. When the injection of the thermoplastic resin is performed at a low pressure, it is difficult to uniformly injection-mold the injection thermoplastic resin 7 onto the surface 1a of the molding substrate 1. Therefore, after injecting the thermoplastic resin 7 at a low pressure, the injected thermoplastic resin 7 can be uniformly injection-molded on the molding substrate surface 1a by compressing the thermoplastic resin 7 in a high temperature state. .

Through these series of steps, the resin layer 7 is injection-molded on the molding substrate surface 1a.
Next, the cavity plate 4 is moved in the Y direction from the state of FIG. 4 (e) to be removed from the mold, and an external part 8 as shown in FIG. 4 (f) is obtained.

  In the said Example, although the shaping | molding base material surface 1a was formed in the plane, the groove | channel 9 which does not penetrate the front and back of the shaping | molding base material 1 in the shaping | molding base material surface 1a shown in the said FIG. The slit 10 may be processed. The molded substrate 1 subjected to the processing of the groove 9 or the slit 10 will be described with reference to FIGS.

  FIG. 5 is a perspective view of the molded base material 1 processed with the grooves 9, and FIG. 6 is a top view of the molded base material 1 processed with the grooves 9. FIG. 7 is a cross-sectional view taken along the line AA in which the thermoplastic resin layer 7 is injection-molded on the surface 1a of the molding base material that has been processed with the grooves 9 shown in FIG. FIG. 8 is a cross-sectional view taken along line AA of a molded base material obtained by subjecting the molded base material 1 of FIG. 5 to slit processing instead of the groove 9. FIG. 9 is a cross-sectional view at the same position as FIG. 7 of the appearance part in which a resin layer is injection-molded on the molding substrate surface 1a subjected to the slit processing shown in FIG. FIG. 10 is a perspective view of FIG. 9 cut at the central portion of the external part as viewed obliquely from below.

  A groove 9 that does not penetrate the front and back of the molding base 1 as shown in FIGS. 5 to 10 or the front and back of the molding base 1 as shown in FIGS. The slit 10 to be processed is simultaneously performed when the forming substrate 1 is formed from the substrate board 1B. In addition, you may process the groove | channel 9 or the slit 10 after shape | molding the shaping | molding base material 1. FIG.

  The groove 9 or the slit 10 forms a desired number at a desired interval. Although the cross section of the groove shown in FIGS. 5 to 7 is exemplified by a triangle, it may be formed in a desired shape such as a quadrangle or a semicircle. Although the grooves or slits are shown in parallel in the figure, the grooves or slits do not need to be provided in parallel, and can be provided at desired positions such as intersecting or V-shaped.

  By processing the groove 9 or the slit 10 on the molding substrate surface 1a, a part of the thermoplastic resin 7 injected on the surface enters the groove 9 or the slit 10 part. As a result, as shown in FIGS. 9 and 10, the rib 11 is formed integrally with the thermoplastic resin layer 7 to form a rib structure, and the rigidity strength of the external component 8 can be increased. By forming the rib structure, it is possible to reduce deformation due to warpage of the external parts. Further, by applying grooves or slits to the molding substrate surface 1a, the surface area of the molding substrate 1 is increased, and the contact area between the molding substrate surface 1a and the injection thermoplastic resin 7 is increased. The degree of adhesion between the material 1 and the injection thermoplastic resin 7 can be increased.

  Next, examples according to the manufacturing process will be described.

  The base material is 40 to 60% glass fiber and 60 to 40% polypropylene fiber. A substrate mat is formed from the substrate. The base mat is heated to a temperature at which the polypropylene fibers melt, compressed to a predetermined thickness, and formed into a base board. The substrate board is heated and then cooled to form a molded substrate. Here, if necessary, grooves or slits are applied to the surface of the molding substrate simultaneously with the molding of the molding substrate. Polypropylene is injected onto the surface of the molding substrate and compression molded before the resin cools to produce an external part.

  The base material is 40 to 60% carbon fiber and 60 to 40% polypropylene fiber. A substrate mat is formed from the substrate. The base mat is heated to a temperature at which the polypropylene fibers melt, compressed to a predetermined thickness, and formed into a base board. The substrate board is heated and then cooled to form a molded substrate. Here, if necessary, grooves or slits are applied to the surface of the molding substrate simultaneously with the molding of the molding substrate. Polypropylene is injected onto the surface of the molding substrate and compression molded before the resin cools to produce an external part.

  The base material is 20-30% carbon fiber, 60-40% polypropylene fiber, and 20-30% kenaf fiber. A substrate mat is formed from the substrate. The base mat is heated to a temperature at which the polypropylene fibers melt, compressed to a predetermined thickness, and formed into a base board. The substrate board is heated and then cooled to form a molded substrate. Here, if necessary, grooves or slits are applied to the surface of the molding substrate simultaneously with the molding of the molding substrate. Polyamide is injected onto the surface of the molding substrate and compression molded before the resin cools down to produce an external part.

  The base material is 20-30% carbon fiber, 40-60% polypropylene fiber, and 20-30% sisal fiber. A substrate mat is formed from the substrate. The base mat is heated to a temperature at which the polypropylene fibers melt, compressed to a predetermined thickness, and formed into a base board. The substrate board is heated and then cooled to form a molded substrate. Here, if necessary, grooves or slits are applied to the surface of the molding substrate simultaneously with the molding of the molding substrate. Polyethylene terephthalate is injected onto the surface of the molding substrate and compression molded before the resin cools to produce an external part.

The perspective view which shows a base material mat. The perspective view which shows a base material board. The perspective view which shows the example of a shape of the shaping | molding base material of this invention. Schematic which shows the injection molding process of this invention. The perspective view which gave the groove process to the surface of the shaping | molding base material. The top view which gave the groove process to the shaping | molding base material surface shown in FIG. FIG. 6 is a cross-sectional view taken along line AA in which the surface of the forming base material shown in FIG. 5 is grooved. FIG. 6 is a cross-sectional view taken along line AA in which slit processing is performed on the surface of the forming base material in FIG. 5 instead of grooves. Sectional drawing of the same position as FIG. 7 of the external appearance component which carried out the injection molding of the resin layer on the surface 1a of the shaping | molding base material 1 which gave the slit process shown in FIG. The perspective view which cut | disconnected the center part in the external appearance component which looked at FIG. 9 from diagonally downward.

Explanation of symbols

1 Molding Base Material 5 Cavity 6 Injection Port 7 Thermoplastic Injection Resin 9 Groove 10 Slit

Claims (7)

An external part characterized in that a thermoplastic resin layer is provided on the surface of a molded base material formed from a base material containing inorganic fibers and a thermoplastic resin. An external part characterized in that a thermoplastic resin layer is provided on the surface of a molded base material formed from a base material containing inorganic fiber, thermoplastic resin and vegetable fiber. The external part according to claim 1 or 2, wherein a groove or a slit is formed on a surface of the molding substrate. A base material containing inorganic fibers and thermoplastic resin fibers is heated to melt the thermoplastic resin fibers, and then a thermoplastic resin layer is injection molded on the surface of the molded base material. Manufacturing method of appearance parts. Heating a substrate containing inorganic fibers, thermoplastic resin fibers and plant fibers to melt the thermoplastic resin fibers and then injection-molding a thermoplastic resin layer on the surface of the molded substrate. A method of manufacturing a featured external part. 6. The method of manufacturing an external part according to claim 4, wherein the thermoplastic resin is compressed after the thermoplastic resin is injected onto the molding substrate and before the thermoplastic resin cools. 7. A groove or slit process is performed on the surface of the molding substrate, and a thermoplastic resin layer is injection-molded on the surface of the molding substrate subjected to the groove or slit process. The manufacturing method of the external components as described in 2.