JP2006167918A - Composite and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a composite capable of strongly thermally bonding a functional member such as a fixing implement or the like to a lightweight member without forming a through-hole to the lightweight member, in manufacturing the composite which is manufactured by strongly thermally bonding the functional member such as the fixing implement or the like to the lightweight member. <P>SOLUTION: The leading end of the rod-shaped part of the functional member, which is constituted so as to be thermally bonded to the lightweight member and has a rod-shaped part, is rotated to be pressed at least to the lightweight member and penetrated in the lightweight member and an attaching member to be allowed to pierce through the thermoplastic resin foam of the lightweight member. The leading end of the rod-shaped part is rotated and pressed in the state pressed to a base stand to melt the leading end of the rod-shaped part and the lightweight member to form an expanded locking part while the locking part is melted to be bonded to the lightweight member without being protruded from the lightweight member and/or the surface of the attaching member to fix the functional member. By this constitution, the functional member can be strongly thermally bonded to the lightweight member without forming the through-hole to the lightweight member and the attaching member. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a composite of a lightweight member having a single layer or a multilayer structure including a thermoplastic resin foam layer and a functional member, and a method of manufacturing a composite in which the lightweight member and the mounting member are fixed by the functional member, and Concerning the complex.

  A lightweight member having a single-layer or multilayer structure including a thermoplastic resin foam layer is lightweight and excellent in heat insulation and shock absorption, and thus is widely used in various applications.

  For example, a lightweight member can be used for a bath lid as a heat insulating material. Such a bath lid is more convenient to use if it can be folded. An easily foldable bath lid can be formed by attaching a connecting member having a hinge function so as to connect a plurality of lightweight members. In addition, other attachment members such as brackets and hooks can be attached to the lightweight member.

  To attach a mounting member such as a connecting member as described above to a lightweight member, the mounting member such as the connecting member is stacked on the lightweight member, and a hole is formed so as to penetrate both of them in that state, and a rivet or the like is fixed to the hole. The attachment member such as the connecting member may be fixed to the lightweight member by crushing or spreading the tip of the shaft portion of the fixture through the tool. In this way, the attachment member such as the connecting member and the lightweight member can be firmly fixed. However, if the size of the portion through which the fixing tool is passed is large, it is difficult to open the through hole, and even if the through hole can be opened. The length of the shaft portion of the fixture must be increased in accordance with the depth of the through hole, and the material cost of the fixture increases more than necessary. Furthermore, an operation for providing a through hole in advance at a predetermined position of a mounting member such as a lightweight member and a connecting member is required, which increases the number of work steps and is not efficient and increases the cost as a whole.

  In addition, in order to prevent the appearance of the attachment member such as the connecting member attached to the light weight member as much as possible, the light weight member should not be exposed on the surface opposite to the side through which the fixture is passed. It is better to attach the connecting member or the like to the lightweight member without opening a through hole. For example, a plastic fixture in the form of a rivet, for example, a mounting member such as a connecting member is stacked on a lightweight member, and the tip of the fixing device is heated to a softened state to attach the connecting member or the like. It can be carried out by a method in which the member is penetrated and the tip of the softened fixture is pressed and fused to the surface of the lightweight member. However, in such a method, since the lightweight member and the fixture are merely fused on a plane, a large adhesive force cannot be expected between them.

In addition, a single-layer or multi-layered lightweight member including a thermoplastic resin foam layer is a backing material that is integrally provided with the interior material on the back side of the automotive interior material in order to reduce the weight of the automobile and improve its thermal insulation. Used as. Thus, the interior material provided with the lightweight member usually has a clip attached to the lightweight member side, and is fixedly attached to the door panel of the automobile by fitting the clip into a predetermined hole of the door inner panel (Patent Document 1). reference.).
In this case, the clip needs to be attached to the lightweight member side, but the same problem as the attachment of the fixture to the lightweight member occurs as in the example of the bath lid described above.

  Furthermore, lightweight members having a single-layer or multi-layer structure including a thermoplastic resin foam layer are also used in cold storage boxes and parts passing-through boxes, etc. When attaching a printed plate or stamped plate, etc. using a fixture, there is a problem similar to the case where the fixture is attached to a lightweight member as shown in the example of the bath lid described above. .

JP-A-10-16055

  In view of the above-described problems, in manufacturing a composite in which a functional member such as a fixture is thermally bonded to a lightweight member, a method for manufacturing the composite in which the functional member such as a fixture is thermally bonded to the lightweight member, and The composite was previously filed (Japanese Patent Application No. 2003-270742). Although the composite in the previous method has fully achieved the original purpose, sometimes the adhesiveness is not sufficient, and the study is repeated to firmly bond the thermal adhesive strength between the functional member and the lightweight member. Invented.

The present invention has the following features: (1) A single layer or multilayer structure lightweight member including a thermoplastic resin foam layer is brought into contact with a base so that it can be thermally bonded to the lightweight member and has a rod-shaped portion. Rotate and press the tip of the rod-shaped part of the member against the lightweight member to enter the lightweight member, penetrate the tip of the rod-shaped part through at least the thermoplastic resin foam layer of the lightweight member, and press the functional member against the base side A method of manufacturing a composite, wherein the tip of the rod-shaped portion is melted at the state of being pressed to form a bulge locking portion, and the functional member is fixed to the lightweight member by the locking portion,
(2) A single-layer or multi-layered lightweight member including a thermoplastic resin foam layer and a mounting member are stacked and brought into contact with the base, and are configured to be thermally bondable to the lightweight member and have a shape having a rod-shaped portion. The tip of the rod-shaped portion of the functional member is rotated and pressed to at least the lightweight member, and the attachment member and the lightweight member enter in this order, and the tip of the rod-shaped portion penetrates at least the thermoplastic resin foam layer of the mounting member and the lightweight member. In addition, the functional member is pressed against the base and further rotated and pressed to melt the tip of the rod-shaped portion to form a bulging latching portion, and the functional member is fixed to the lightweight member by the latching portion. And a method for producing a composite, characterized by fixing the mounting member and
(3) A single-layer or multilayer structure lightweight member including a thermoplastic resin foam layer and a mounting member are stacked to be configured to be heat-bondable to the lightweight member and to have a rod-shaped functional member rod shape Rotate and press at least the light-weight member to the light-weight member, and enter the light-weight member and the attachment member in this order, and pass the light-weight member through the light-weight member, but press the functional member against the attachment member. In this state, it is further rotated and pressed to melt the tip of the rod-shaped portion to form a bulge locking portion, and the functional member is fixed to the lightweight member and the mounting member by the locking portion to fix the lightweight member and the mounting member. The present invention relates to a method for producing a composite.

Furthermore, the present invention includes (6) a lightweight member having a single layer or multilayer structure including a thermoplastic resin foam layer, and a functional member configured to be thermally bonded to the lightweight member and having a rod-like portion. The rod-shaped portion has a distal end formed at least at the end of the thermoplastic resin foam layer of the lightweight member to form a bulging engagement portion, and the functional portion is lightweight by the engagement portion. A composite characterized by being fixed to a member,
(7) A composite comprising a single-layer or multi-layered lightweight member including a thermoplastic resin foam layer, a mounting member, and a functional member configured to be thermally bonded to the lightweight member and having a rod-like portion. And forming a locking portion having a bulge in which the tip of the rod-shaped portion penetrates at least the thermoplastic resin foam layer of the lightweight member, and the functional member becomes a lightweight member by the locking portion. The present invention relates to a composite body characterized by being fixed and fixing a lightweight member and an attachment member.

(1) A composite formed by fixing a functional member to a lightweight member having a single-layer or multilayer structure including a thermoplastic resin foam layer obtained by the production method of the present invention has a light-weight tip at the rod-shaped portion of the functional member. Penetrate at least the thermoplastic resin foam layer of the member, melt the tip of the rod-shaped portion to form a bulge locking portion at the tip of the rod-shaped portion, and fix the functional member to the lightweight member by the locking portion Therefore, a composite in which the functional member is firmly fixed to the thermoplastic resin foam layer is provided.
(2) Further, in a composite formed by fixing a single-layer or multi-layer lightweight member including a thermoplastic resin foam layer and a mounting member with a functional member, the tip of the rod-shaped portion of the functional member is The mounting member and at least the thermoplastic resin foam layer of the lightweight member are penetrated, the tip of the rod-shaped portion is melted to form a bulging locking portion, and the functional member is fixed to the lightweight member by the locking portion. Since the lightweight member and the attachment member are fixed, a composite body in which the lightweight member and the attachment member are firmly fixed by the functional member is provided.
(3) Also, in a composite formed by fixing a single-layer or multi-layered lightweight member including a thermoplastic resin foam layer and a mounting member with a functional member, the tip of the rod-shaped portion of the functional member is The lightweight member is penetrated but not penetrated to the attachment member, and the functional member is pressed against the attachment member, and further rotated and pressed to melt the tip of the rod-like portion to form a bulge engagement portion. Since the functional member is fixed to the lightweight member and the attachment member and the lightweight member and the attachment member are fixed, a composite in which the lightweight member and the attachment member are firmly fixed by the functional member is provided.
(4) Since the functional member has a space portion at the tip of the rod-shaped portion, it can be easily melted by rotation pressing to form a swollen locking portion, and can be attached to the lightweight member by the functional member and the lightweight member, or the functional member. A composite in which the member is more firmly fixed is obtained.
(5) Since the functional member has a taper that becomes thicker from the tip of the rod-shaped portion toward the other end, it is possible to easily enter the foam layer without making a hole in the foam layer or the attachment member in advance. it can.
(6) Furthermore, the composite of the present invention is such that the end of the rod-shaped part forms a locking part having a bulge through at least the thermoplastic resin foam layer of the lightweight member. Thus, the functional member is fixed to the lightweight member, so that the functional member is more firmly fixed to the lightweight member.
(7) Furthermore, the composite of the present invention is such that the end of the rod-shaped part forms a locking part having a bulge through at least the thermoplastic resin foam layer of the lightweight member, and the locking part Thus, the functional member is fixed to the light weight member and the light weight member and the mounting member are fixed, so that the light weight member and the mounting member are firmly fixed by the functional member.

  In the present invention, a lightweight member having a single layer or a multilayer structure including a thermoplastic resin foam layer, or a lightweight member and an attachment member are overlapped and brought into contact with a base so as to be thermally bonded to the lightweight member and formed into a rod shape. The tip of the rod-shaped portion of the functional member having a shape having a portion (hereinafter, also simply referred to as “the rod-shaped portion tip”) is rotationally pressed against the lightweight member or the mounting member to enter the mounting member and the lightweight member, and the rod-shaped portion At least the thermoplastic resin foam layer of the lightweight member (hereinafter sometimes simply referred to as “foam layer”) is passed through the tip, and further pressed against the base to further rotate the tip of the rod-like portion and the lightweight member. The present invention relates to a composite manufacturing method and a composite in which a softening / melting is performed to form a bulge locking portion at a tip of a rod-shaped portion, and a functional member is fixed to a lightweight member or a mounting member.

The present invention will be described in detail with reference to the drawings.
1 and 2 show an example of the functional member 1 according to the present invention, FIG. 1 is an external perspective view of the functional member 1, FIG. 2 (1) is a top view of the functional member 1, and FIG. ) Is a side view, and FIG. 2 (3) is a bottom view. As shown in FIGS. 1 and 2 (1) to 2 (3), the functional member 1 in the present invention protrudes laterally from the central axis of the rod-shaped portion 11 at one end of the rod-shaped portion 11. The head 12 has a diameter larger than the diameter. Examples of the shape of the head 12 include a semispherical shape, a columnar shape, and a cylindrical shape. Among these, a columnar shape and a cylindrical shape that are excellent in appearance even when jumping out from the surface of the lightweight member 2 are preferable. The rod-shaped part 11 has a taper that becomes thicker from the tip part toward the other end part (head side). In the head 12, a receiving hole 13 of a rotating shaft protruding portion is formed from the center of the head 12 toward the tip of the rod-like portion 11, and a space portion 14 such as a hole is formed at the tip of the rod-like portion 11. Note that the receiving hole 13 formed in the head 12 may communicate with the tip of the rod-like portion 11 to form an opening at the tip. With such a configuration, it is easy to melt and bulge and form a locking portion by rotational pressing, and a more firmly fixed composite can be obtained.

  An explanatory diagram of a rotating device for rotating the functional member 1 is shown in FIG. 7 as an example of a device used for spin welding. The rotating device 9 includes a rotating means (motor) 7 and a movement adjusting means, and includes a columnar head 5 connected to a rotating shaft 4 connected to the motor and movable up and down. Is provided with a protruding portion 6 having a shape that can be fitted into the receiving hole 13 of the head 12 of the functional member 1. In addition, the front-end | tip part of this head 5 can also be designed and used for the shape which can fit the head 12 itself of the functional member 1. FIG. For example, the shape of the head 12 of the functional member 1 is formed in a polygonal shape, and a depressed portion is formed in the vicinity of the tip of the head 5 so that the head 12 of the functional member 1 is fitted. While forming the inner peripheral edge into a polygonal shape corresponding to the shape of the head 12, it is also possible to form a protrusion having a shape that can be fitted into the receiving hole 13 of the rod-like part at the center.

  The rotating device 9 may be any device that can rotate and stop the functional member 1, and for example, an electric drill or a drilling machine can be appropriately employed. For example, when an electric drill is adopted as the rotating device 9, the protrusion 6 attached to the tip of the head 5 attached to the rotary shaft of the electric drill is designed to be fitted according to the shape of the receiving hole 13 of the functional member 1. Then, the method of the present invention can be easily performed. Note that it is preferable that the rotating device 9 includes a clutch mechanism because this mechanism can easily manage torque management of the functional member 1 and rotation and stop of the rotating shaft of the rotating device 9. When carrying out the method of the present invention using such a rotating device 9, the base 8 is arranged at a predetermined position, and the lightweight member 2 or the lightweight member 2 and the mounting members 31, 32 are placed on the base. The functional member 1 is rotationally pressed and attached to a required portion by being placed horizontally and stacked.

  The schematic diagram which shows the partial cross section for demonstrating the state of the melt-bonding of the functional member 1 in this invention is shown in FIGS. FIG. 3 (1) shows an embodiment in which the functional member 1 is fixed to the lightweight member 2, and FIG. 3 (2) shows a multilayered lightweight member 2 having a synthetic resin layer 22 on one surface of the lightweight member 2. The example which fixed the functional member 1 is shown. FIG. 3 (3) shows an example in which the lightweight member 2 has a multilayer structure having the synthetic resin layers 22 on both surfaces, and the head 12 of the functional member 1 is flush with the surface of the lightweight member 2. In FIG. 3, all penetrate the foam layer 21 of the lightweight member 2 but do not protrude, and the bulging locking portion 15 is formed at the distal end portion of the functional member 1 in the lightweight member 2.

  4 (1), (2), and (3) show an aspect in which the attachment member 3 is fixed to the lightweight member 2 with the functional member 1, and penetrates the foam layer 21 of the lightweight member 2 but does not protrude and is lightweight. A bulging locking portion 15 is formed at the tip of the functional member 1 in the member 2. 4 (1) shows an example in which the plate-like member 31 is fixed to one surface of the lightweight member 2 as the attachment member 3 with the functional member 1, and FIG. 4 (2) is another example of FIG. 4 (1). A mode (modification) is shown, an example in which the light-weight member 2, the attachment member 3, and the light-weight member 2 are stacked in this order and the plate-like member 31 is fixed as the attachment member 3 with the functional member 1, and FIG. An example in which a hook 32 is fixed as the member 3 with the functional member 1 is shown.

FIGS. 5 (1) and (2) show a mode in which the attachment member 3 is fixed to the lightweight member 2 with the functional member 1, and FIG. 5 (1) shows the tip of the functional member 1 penetrating the foam layer. Does not penetrate through the mounting member 3, the tip of the functional member 1 does not protrude, and the foam layer and the locking member 15 are formed in the mounting member 3. The functional member 1 is fixed by melting and bonding to the attachment member 3, and the lightweight member 2 and the attachment member 3 are fixed by the functional member 1.
FIG. 5B shows an example in which a U-shaped corner member 33 is fixed to the end portion of the lightweight member 2 as the attachment member 3 by the functional member 1. In addition, the attachment member 3 as used in this specification means what is attached to the lightweight member 2. FIG.
In FIG. 3 and FIG. 4 described above, the example in which the bulge locking portion 15 does not protrude from the surface of the lightweight member 2 has been described. As an example of the case where the bulge locking portion 15 protrudes from the surface of the lightweight member 2, the functional member 1 can be fixed to the lightweight member 2 by providing a recess 81 on the base as shown in FIG. 6. . When the bulge latching part 15 does not protrude from the surface of the lightweight member 2, it can be set as the composite excellent in an external appearance.

  In the present invention, the functional member 1 is thermally bonded to a desired location as follows. The functional member 1 is rotated about the central axis of the rod-shaped portion 11 as a rotation axis by the rotation of the rotary shaft 4, the head 5 and the protrusion 6 attached to the motor 7 of the rotating device 9 shown in FIG. The tip of one rod-shaped portion 11 is pressed against a predetermined portion of the lightweight member 2, and heat is generated by friction between the rod-shaped portion 11 of the functional member 1 and the lightweight member 2 at the contact portion between the lightweight member 2 and the functional member 1. The above portion of the lightweight member 2 is softened or melted, and the tip of the rod-like portion 11 enters the foam layer 21 of the lightweight member 2 like a screw. When the tip of the rod-shaped part 11 is advanced to a required depth, preferably at least until it penetrates the foam layer 21 and is pressed and rotated in this state, the foam layer of the lightweight member 2 is softened / melted, and the base against the pressing force is reduced. Resin around the rod-shaped portion 11 that rotates due to the reaction of the base is engulfed to form a swollen locking portion 15. Thereafter, the rotation of the functional member 1 is stopped, the bulge locking portion 15 formed by softening / melting is cooled and solidified, and the functional member 1 is thermally bonded and fixed to the lightweight member 2. In this case, the timing at which the protrusion 6 of the head 5 is detached from the functional member 1 may be immediately after the rotation of the functional member 1 is stopped or after the bulge locking portion 15 is cooled and solidified.

  For example, the functional member 1 can be attached to the lightweight member 2 in a state where the lightweight member 2 is erected. In such a case, the functional member 1 is brought into contact with a receiving base (base) that resists pressing that causes the rod-shaped portion of the functional member 1 to enter the surface opposite to the surface on which the functional member 1 is attached. Is rotated and pressed to melt the tip of the rod-shaped portion 11 and the lightweight member 2 to form a bulging locking portion, and the locking portion of the functional member 1 can be fixed to the lightweight member 2.

In the case where the lightweight member 2 and the functional member 1 are heat-sealed using the rotating device 9, the rotational speed is preferably 1000 to 6000 ppm, although it depends on the materials of the functional member 1 and the lightweight member 2. 5000 ppm is more preferable, and 2000 to 4000 ppm is more preferable. As feed, 1-5 mm / sec is preferable and 1-3 mm / sec is more preferable. The maximum load is preferably 80 to 200N, more preferably 100 to 180N, and still more preferably 100 to 150N.
Furthermore, the above conditions depend on the apparent density of the foam layer and the rigidity of the functional member 1, but if the apparent density of the foam layer is high, the friction between the functional member 1 and the lightweight member 2 may increase or the rotational speed Tends to be lower, and the feed rate is slower due to the higher density.

  The bulge locking portion 15 thus formed exhibits an anchor effect, and the lightweight member 2 and the functional member 1 are firmly fixed. Further, by pressing and rotating with the rod-shaped portion 11 entering a desired depth, a bulge locking portion 15 is formed at the distal end portion of the rod-shaped portion 11 and the resin around the rod-shaped portion 11 other than the distal end portion is also formed. It also has the effect of strengthening the adhesion between the lightweight member 2 and the functional member 1 by softening / melting with frictional heat and adhering to the rod-like portion 11. Note that the resin constituting the foam layer in the lightweight member 2 is softened or melted during the press entry, and flows into the space portion 14 such as a hole provided at the tip of the rod-like portion 11 of the functional member 1 to be solidified. A functional member and a lightweight member, or a composite in which the lightweight member and the mounting member are more firmly fixed by the functional member.

  As described above, in the method of the present invention, the foam layer 21 and the functional member 1 in the lightweight member 2 have thermal adhesiveness, and the functional member 1 includes the rod-shaped portion 11. Since the bulge locking portion 15 can be formed with the tip entering the foam layer and the foam layer and the functional member 1 can be heat-sealed, the fixing force of the functional member 1 is large.

  Further, since the lightweight member 2 includes the foam layer, while the functional member 1 is rotated, the tip of the rod-like portion 11 is pressed against an arbitrary portion of the lightweight member 2 to generate heat at that portion and soften or melt, When the tip of the rod-shaped portion 11 enters the inside of the foam layer, the foam layer is easily melted to reduce the volume, so that the rod-shaped portion 11 can easily enter the foam layer.

  Further, when the functional member 1 is thermally bonded to the lightweight member 2, the tip of the rod-shaped portion 11 is made to rotate while the functional member 1 is rotated about the central axis of the rod-shaped portion 11 of the functional member 1. In order to heat and soften or melt the portion by pressing against an arbitrary location, and to thermally bond the functional member 1 to the lightweight member 2 by allowing the tip of the rod-shaped portion 11 to enter the foam layer 21, It is not necessary to make a hole in the lightweight member 2 in advance, and the functional member 1 can be efficiently fixed to the lightweight member 2.

  In the present invention, the attachment member 3 is stacked on the surface of the lightweight member 2, and the attachment member 3 is fixed to the lightweight member 2 by passing through the attachment member 3 and thermally bonding the functional member 1 to the lightweight member 2. it can. In this case, for example, the attachment member 3 is overlapped at a required position of the lightweight member 2 and brought into contact with the base 8, and the rod-like portion 11 of the functional member 1 is rotated and pressed to penetrate the attachment member 3. The lightweight member 2 is made to enter in order, and the foam layer 21 of the lightweight member 2 is softened in the same manner as described above by penetrating the foam layer 21 at a desired depth, preferably at least through the foam layer 21 as described above. / Attaching member by melting and inflating the resin around the rod-like portion 11 rotated by the reaction of the base against the pressing force to form a swollen engagement portion 15 and thermally bond the functional member 1 to the lightweight member 2 3 is firmly fixed to the lightweight member 2. Thereby, the synthetic resin hinge of the lightweight member 2 can be attached, for example, and the several lightweight member 2 can be connected so that folding is possible. Further, by attaching a hook shape, it can be connected to another member through this. In addition, if a hole is made in the attachment member 3 in advance, the location where the functional member 1 is rotated and pressed becomes clear, so that the workability is excellent. In this case, when the diameter of the rod-shaped portion 11 of the functional member 1 is smaller than the hole of the mounting member 3, the tip of the rod-shaped portion 11 of the functional member 1 is rotated and pressed by the lightweight member 2.

  In the present invention, the lightweight member 2 may form either a multilayer structure including a thermoplastic resin foam layer or a single layer structure of a thermoplastic resin foam. A resin layer (synthetic resin layer) 22 may be formed on the surface. In addition, surface materials such as paper, woven fabric, and non-woven fabric may be formed. These surface materials such as synthetic resin layer, paper, woven fabric, and non-woven fabric may be either single-sided or double-sided. The foam layer may be a multilayer in which two different foam layers are laminated. If the non-foamed thermoplastic resin layer (synthetic resin layer) 22 is configured to be thermally bonded to the functional member 1, the functional member 1 or the mounting member 3 can be more firmly fixed.

  In this invention, when the lightweight member 2 forms the multilayer structure which has the synthetic resin layer 22 on the surface, the rod-shaped part 11 of the functional member 1 penetrates the synthetic resin layer 22 on the surface of the lightweight member 2, and furthermore, rod-shaped When the tip of the portion 11 enters the inside of the lightweight member 2, a composite formed by bonding the functional member 1 to the lightweight member 2 is formed. For example, by using a lightweight member 2 that forms a multilayer structure with the surface being a synthetic resin layer, in the composite, a synthetic resin layer that is hard on the surface of the lightweight member 2 so as to surround the rod-like portion 11 of the functional member 1 22, even if a lateral force is applied to the functional member 1 by reinforcing the periphery of the functional member 1, the synthetic resin layer 22 effectively prevents the functional member 1 from falling sideways. The functional member 1 is more firmly fixed to the lightweight member 2.

  Here, if the synthetic resin layer 22 present on the surface of the lightweight member 2 is too thin, the reinforcing effect of the functional member 1 is small, and if it is too thick, the rod-like portion 11 of the functional member 1 becomes the synthetic resin layer. There is a possibility that the foam layer cannot pass through 22. From such a viewpoint, the thickness of the synthetic resin layer 22 to be present on the surface of the lightweight member 2 is preferably about 0.02 mm to 5.0 mm, more preferably 0.07 mm to 3.0 mm, and 0.1 mm to 2.0 mm. Is more preferable.

  In the present invention, the rod-like portion 11 of the functional member 1 is not limited to the truncated cone shape, and may be formed in a columnar shape or a cylindrical shape. If the rod-shaped portion 11 is not a columnar shape or a cylindrical shape that is formed in an axisymmetric manner, when the rod-shaped portion 11 is rotated and pressed into the lightweight member 2, the periphery of the lightweight member 2 and the rod-shaped portion 1 A large gap is likely to occur between and the functional member 1 is likely to wobble. Note that the columnar portion 11 tends to have a larger adhesive force than the rod-shaped portion 11 is formed in a truncated cone shape having a taper that becomes thicker from the tip portion toward the other end portion. However, when the functional member 1 itself is large and the diameter of the rod-shaped portion is large, it is preferable that the shape has a taper because it is easy to press and enter.

In the present invention, the material of the functional member 1 is not particularly limited as long as it can be thermally bonded to the lightweight member, but is preferably composed of a thermoplastic resin that can be thermally bonded to the lightweight member.
Since the functional member 1 is made of a thermoplastic resin, the thermal adhesive force with the thermoplastic resin foam layer constituting the lightweight member 2 can be increased. However, since the thermoplastic resin constituting the functional member 1 and the thermoplastic resin constituting the thermoplastic resin foam layer of the lightweight member 2 need to have thermal adhesiveness, they are thermally bonded to each other. It is more preferable that the force is large. In addition, when the functional member 1 is made of a thermoplastic resin, rust does not occur as compared with the iron functional member 1, so that the composite does not generate rust even if it is used in a place with a lot of moisture or moisture. This is preferable because it does not occur.

  The thermoplastic resin constituting the foam layer of the lightweight member 2 and the thermoplastic resin constituting the functional member 1 are not particularly limited as long as they have thermal adhesiveness to each other, but both thermoplastic resins are the same. It is desirable that the main monomer component is the same among the monomer components which are thermoplastic resins or form the thermoplastic resin. Thermoplastic resins include propylene homopolymers, propylene resins such as copolymers with other monomers based on propylene, ethylene homopolymers, copolymers with other monomers based on ethylene Examples thereof include ethylene resins such as styrene, homopolymers of styrene, styrene resins such as copolymers with other monomers mainly composed of styrene, thermoplastic polyester resins, polyphenylene ether resins, polyacetal resins, and the like.

  Moreover, when the thermoplastic resin which comprises the foam layer of the lightweight member 2 contains the thermoplastic resin which has a functional group, it can be thermally bonded also to a metal. For example, a thermoplastic resin having a functional group obtained by graft polymerization of maleic anhydride to polystyrene or polyolefin, styrene or olefin as a main component, and α or β unsaturated carboxylic acid such as acrylic acid, methacrylic acid, maleic acid or fumaric acid However, the ionomer, which is a cross-linked metal salt, is easily heat-bonded to the metal. In this case, the functional member 1 may be made of metal as long as the functional member 1 rotates and presses to melt the tip of the rod-like portion and the lightweight member 2 to form the bulging engagement portion. In addition, as a thermoplastic resin of the non-foamed thermoplastic resin layer (synthetic resin layer) 22, the same thermoplastic resin as the thermoplastic resin which comprises a foam layer is mentioned.

  In the present invention, the functional member 1 may not include the head 12 as long as the functional member 1 can be pressed against the lightweight member 2 while rotating the tip of the rod-shaped portion 11. Moreover, the functional member 1 may have a portion (hereinafter, also referred to as a collar portion) in which a collar-like object projecting in the lateral direction is formed at an arbitrary position excluding the tip of the rod-shaped portion 11. .

The apparent density of the foam layer in the lightweight member 2 of the present invention is preferably 0.3 to 0.014 g / cm ³ . Poor light weight is less than 0.3 g / cm ^3, the functional member 1 even more preferably from 0.18 g / cm ³ or more it is necessary to select a strong rigidity, 0.11 g / cm ³ or more and more preferable. Meanwhile, the upper limit is, the rigidity of the lightweight component 2, more preferably 0.016 g / cm ³ or less from the balance of the strong fixing of the weight member 2 with functional member 1, more preferably 0.02 g / cm ³ or less .
The apparent density of the foam layer described above means the apparent overall density defined by JIS K7222 (1999).

Since the functional member 1 is provided with a head portion and a heel portion projecting in the lateral direction, when the other member is fixed to the lightweight member 2 using this, the other member is detached from the lightweight member 2. There is an advantage that it becomes difficult.
In addition, when the functional member 1 is provided with a flange projecting in the lateral direction to form a portion further protruding on the collar, when fixing the other member and the lightweight member 2, Without sticking between the flange and the lightweight member 2, the rod-shaped portion 11 is rotated to the flange to enter the thermoplastic resin foam layer and thermally bonded, and then another member is bonded to the protruding portion. If possible, it is preferable because the functional component 1 can be stably fixed to the lightweight member 2 by the collar portion, and another member can be fixed to the protruding portion of the functional member 1. An example of this is a clip.

  In the composite of the present invention, it is preferable that the rod-shaped portion 11 other than the locking portion 15 in the functional member 1 is fused to the lightweight member 2. In the case of such a composite body in which the functional member 1 is fixed to the lightweight member 2, the functional member 1 is firmly fixed to the lightweight member 2. Further, in the case of a composite in which the lightweight member 2 and the attachment member 3 are fixed by the functional member 1, the lightweight member 2 and the attachment member 3 can be more firmly fixed by the functional member 1. As said method, since the method of rotating and pressing can be formed easily, it is a preferable aspect.

  In the present invention, the functional member 1 is used as a fixture such as a rivet for fixing another attachment member 3 such as a connecting member or a name plate to the lightweight member 2, or the functional member 1 is used as another member. By using it as a fixing tool such as a clip for fixing, there is an advantage that other members can be fixed to the lightweight member 2 more easily and firmly. Also, as shown in FIGS. 8 and 9, the functional member 1 has a relatively large head and the head has a semispherical shape, for example, a bottom portion such as a returnable box or a storage box. Since it can be used as a leg part of a returnable box or a storage box by attaching a plurality of parts to the required locations, it is convenient for movement. In the embodiment of FIG. 9, the functional member 1 is firmly fixed by the lightweight member 2 as compared to the embodiment of FIG. 8.

  In addition, since the composite formed by the present invention is a composite with a higher fixing force between the lightweight member 2 and the functional member 1, the lid of the bath, the backing material of the automobile interior material, the return box and the storage box It can be suitably used depending on the use of the sign plate or the like or as a leg part.

Example 1 and Example 2
A plate-like lightweight member 2 (of the lightweight member 2) in which a non-foamed layer made of a mixture of polypropylene and high-density polyethylene is integrally bonded to the entire surface of a foam layer made of polypropylene having a melting point (melting peak temperature) of 159 ° C. A thickness of 20 mm, a non-foamed layer (polypropylene resin) thickness of 0.75 mm, a foam layer thickness of 18.5 mm, and an apparent density of the foam layer of 0.03 g / cm ³ ), A functional member 1 (made of polypropylene having a melting point (melting peak temperature) 162 ° C.) having a head portion 12 and a rod-shaped portion 11 is prepared, and a receiving hole formed at the central position of the head portion of the functional member 1 The tip of the head provided in the rotating means is fitted and fixed, and the rod-shaped portion 11 of the functional member 1 is rotated at a rotation speed (rpm) as shown in Table 1 with the rod-shaped portion 11 of the functional member 1 as the central axis. Ahead Is rotated against the lightweight member 2 with the feed (falling speed) (mm / second) shown in Table 1 and stopped when 25 mm has entered from the surface of the lightweight member 2, and the rod-like portion 11 of the functional member 1 is stopped. The tip was melted by 5 mm, the functional member 1 was removed from the head, and a composite of the functional member 1 and the lightweight member 2 was obtained. At that time, the functional member 1 penetrates the lightweight member 2, and the tip of the rod-like portion of the functional member 1 is formed to be the same surface as the surface of the lightweight member 2.
The melting peak temperature is a value measured by heat flux DSC using “when measuring the melting temperature after performing a certain heat treatment” as a condition adjustment of the specimen according to JIS K 7121 1987. is there. At this time, the heating rate in the condition adjustment of the test piece and the test was set to 10 ° C. per minute, and the cooling rate in the condition adjustment of the test piece was set to minus 10 ° C. per minute.

Reference example 1
A composite of the functional member 1 and the lightweight member 2 was obtained under the same conditions as in the example except that the functional member 1 was stopped at the center in the thickness direction of the foam layer of the lightweight member 2.

The size and shape of the functional member 1 used in Example 1, Example 2, and Reference Example 1 are represented by A in the shape column of Table 1.
In Table 1, the shape is A, the functional member 1 is provided with a rod-shaped portion 11 formed in a columnar shape having a length of 30 mm and a diameter of 5 mm, and a diameter (a rod-shaped portion of the rod-shaped portion is opened from the head 12 to the tip of the rod-shaped portion 11. It has a hole with a diameter of 5 mm and a depth of 30 mm (having the same central axis as the central axis), and a cylindrical shape with a diameter (having the same central axis as the central axis of the rod-shaped portion 11) of 10 mm and a height of 2.5 mm And a hexagonal receiving hole having a diameter of 5 mm is formed at the center of the head.

  The composite obtained as described above was left in a room at 23 ° C. for 48 hours, and then the maximum load when the functional member 1 was pulled out of the composite at a speed of 2 mm / min was measured. The results are shown in Table 1.

(Table 1)

    As a result of Table 1, since the functional member 1 penetrates the foam layer of the lightweight member 2 and forms the bulging engagement portion 15, the maximum load greatly exceeds 60 N in any of the examples and shows a large maximum load. It was proved that the fixing strength of the functional member 1 and the lightweight member 2 in the obtained composite was large.

The external appearance perspective view which shows one example of the functional member 1 in this invention is shown. The explanatory view of functional member 1 shown in Drawing 1 is shown. (1) is a top view of the functional member 1. (2) is a side view of the functional member 1. (3) is a bottom view of the functional member 1. The schematic diagram which shows the partial cross section which shows the bulging latching | locking part 15 in the functional member 1 of this invention is shown. (1) shows an embodiment in which the functional member 1 is fixed to the lightweight member 2, and (2) shows the functional member 1 in the multilayered lightweight member 2 having the synthetic resin layer 22 on one surface of the lightweight member 2. An example of fixing is shown. (3) is a multilayer structure having the synthetic resin layers 22 on both surfaces of the lightweight member 2, and shows an example in which the head of the functional member 1 is flush with the surface of the lightweight member 2. The schematic diagram which shows the partial cross section in which the bulging latching | locking part 15 in the functional member 1 of this invention is formed in the foaming layer is shown. (1) shows the example which fixed the plate-shaped attachment member 31 with the functional member 1, (2) shows the example of another embodiment of (1). (3) shows an example in which the hook 32 is fixed by the functional member 1 as an attachment member. The schematic diagram which shows the partial cross section in which the bulging latching | locking part 15 in the functional member 1 of this invention is formed in the foam layer and the attachment member is shown. (1) shows an example in which the light weight member 2 and the attachment member 3 are fixed by the functional member 1 by forming a bulging and engaging portion 15 in the foam layer of the lightweight member 1 and the plate-like attachment member 31. (2) shows an example in which a U-shaped corner member 33 is fixed to the end of the lightweight member 2 as the attachment member 3 by the functional member 1. An example in which the bulge locking portion 15 protrudes from the surface of the lightweight member 2 is shown. It is explanatory drawing which shows one example of the apparatus which attaches the functional member 1 to the lightweight member 2 in this invention. An example of a comparative example in which the functional member 1 is attached to the bottom portion of a returnable box or a storage box and used as a leg portion of the returnable box or the storage box is shown. An example of an embodiment of the present invention in which the functional member 1 is attached to a bottom portion of a returnable box or a storage box and used as a leg portion of the returnable box or the storage box is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Functional member 11 Rod-shaped part 12 Head 13 Receiving hole 14 Space part 15 Swelling locking part 2 Light weight member 21 Foam layer 22 Synthetic resin layer 3, 31, 32, 33 Mounting member 4 Rotating shaft 5 Head 6 Protruding part 7 Motor 8 Base 81 Recess 9 Rotating device

Claims (7)

  A light-weight member having a single-layer or multi-layer structure including a thermoplastic resin foam layer is brought into contact with the base, and the tip of the rod-shaped portion of the functional member is configured to be thermally bonded to the light-weight member and has a rod-shaped portion. The lightweight member is rotated and pressed to enter the lightweight member, the tip of the rod-shaped portion is penetrated at least through the thermoplastic resin foam layer of the lightweight member, and the functional member is further pressed against the base side. And a tip of the rod-shaped portion is melted to form a bulge locking portion, and the functional member is fixed to the lightweight member by the locking portion.   A single-layer or multilayer structure lightweight member including a thermoplastic resin foam layer and a mounting member are stacked and brought into contact with a base so that the functional member can be thermally bonded to the lightweight member and has a rod-shaped portion. The tip of the rod-shaped portion is rotated and pressed at least on the lightweight member, the attachment member and the lightweight member are entered in this order, and the tip of the rod-shaped portion is passed through the attachment member and at least the thermoplastic resin foam layer of the lightweight member. In a state where the functional member is pressed against the base side, it is further rotated and pressed to melt the tip of the rod-shaped portion to form a bulge locking portion, and the functional member is fixed to the lightweight member by the locking portion and attached to the lightweight member. A method for producing a composite, comprising fixing a member.   A light-weight member having a single-layer or multi-layer structure including a thermoplastic resin foam layer and an attachment member are stacked to be configured to be thermally bonded to the light-weight member, and the tip of the rod-shaped portion of the functional member having a rod-shaped portion At least the lightweight member is rotated and pressed to enter the lightweight member and the mounting member in this order, and the tip of the rod-shaped portion is penetrated through the lightweight member, but the functional member is pressed against the mounting member without penetrating the mounting member. Further, by rotating and pressing, the tip of the rod-shaped portion is melted to form a bulge locking portion, and the functional member is fixed to the lightweight member and the mounting member by the locking portion, and the lightweight member and the mounting member are fixed. A method for producing a composite.   The method for producing a composite according to any one of claims 1 to 3, wherein the functional member has a space at the tip of the rod-shaped portion.   The method for producing a composite according to any one of claims 1 to 3, wherein the functional member has a taper that becomes thicker from the tip of the rod-shaped portion toward the other end.   A composite comprising a lightweight member having a single-layer or multilayer structure including a thermoplastic resin foam layer, and a functional member having a shape having a rod-shaped portion while being thermally bondable to the lightweight member, The front end of the portion penetrates at least the thermoplastic resin foam layer of the lightweight member to form an engaging portion having a bulge, and the functional member is fixed to the lightweight member by the engaging portion. And the complex. A composite comprising a light-weight member having a single-layer or multi-layer structure including a thermoplastic resin foam layer, a mounting member, and a functional member configured to be thermally bonded to the light-weight member and having a rod-like portion. The rod-shaped portion has a distal end that penetrates at least the thermoplastic resin foam layer of the lightweight member to form a bulging engaging portion, and the functional member is fixed to the lightweight member by the engaging portion and is light. A composite comprising a member and an attachment member fixed.

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