JP2008030288A - Resin sheet material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin sheet material which makes a resin molding of high rigidity be molded easily. <P>SOLUTION: The resin sheet material 1 includes a sheet material body 3 and a fiber sheet 5 which is arranged on at least one side of the sheet material body 3 and inserted into one side during pressurization molding. Sewing threads 9 penetrate the sheet material body 3 to fix the fiber sheet 5 to the sheet material body 3 by sewing. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a resin sheet material that is pressed by a mold and molded into a resin molded body.

  Conventionally, a molding method is known in which a resin sheet material is pressed with a molding die to be molded into a resin molded body.

For example, Patent Document 1 discloses a molding method in which a sheet material body and a glass mat as a reinforcing material are placed in a molding die and press molded in order to improve the rigidity of a resin molded body.
Japanese Patent No. 2866394

  However, in the molding method disclosed in Patent Document 1, since the sheet material body and the reinforcing material are separately set in the molding die, the sheet material body and the reinforcing material may be misaligned when the mold is closed. . If the reinforcing material is displaced in this manner, the resin molded body cannot be sufficiently rigid. Therefore, the sheet material main body and the reinforcing material must be arranged so as not to be displaced, and there is a problem that this arrangement work is troublesome and man-hours increase, and mass productivity is poor.

  The present invention has been made in view of the above points, and the object of the present invention is to achieve high mass productivity by easily molding a resin molded body having high rigidity by molding together with a fiber sheet as a reinforcing material. The object is to provide a resin sheet material.

  A resin sheet material according to a first aspect of the present invention is a resin sheet material that is pressed into a molded resin body by being pressed by a molding die, and is disposed on at least one side surface of the sheet material body and the sheet material body. The fiber sheet is inserted into the one side surface at the time of the pressure molding, and the sewing thread penetrates the sheet material body and sews the fiber sheet to the sheet material body.

  The resin sheet material according to the second aspect of the present invention is a resin sheet material that is pressed by a molding die and molded into a resin molded body, and is disposed between a plurality of sheet material bodies and the sheet material body, In the state where the fiber sheet is inserted between the sheet material main bodies during the pressure molding, and the fiber sheet is sandwiched between the sheet material main bodies, the adjacent sheet material main body and the fiber sheet are penetrated, It is comprised with the sewing thread | yarn which sews this adjacent sheet | seat material main body.

  In the resin sheet material according to the third aspect of the present invention, the fibers constituting the fiber sheet are oriented in the same direction as each other.

  As for the resin sheet material which concerns on 4th this invention, the fiber which comprises this fiber sheet is comprised by the textile form in the said fiber sheet.

  The resin sheet material according to the fifth aspect of the present invention is continuous so that the sewing thread is folded back on the front and back sides of the sheet material main body.

  According to the first invention, since the fiber sheet disposed on the side surface of the sheet material main body is sewn to the sheet material main body by the sewing thread, when placing the resin sheet material on the molding die, the sheet material main body And the fiber sheet can be arranged together without being displaced. For this reason, it is only necessary to arrange the sheet material body and the fiber sheet that are sewn together in the molding die as they are, and the arrangement work is extremely simple and does not lead to an increase in man-hours. Can be improved.

  Moreover, since the fiber sheet arrange | positioned at the side surface of a sheet material main body is inserted in this sheet material main body, the rigidity of a resin molding can be improved.

  Moreover, the rigidity of the required location of a resin molding can also be partially improved by sewing and inserting a fiber sheet in the arbitrary location of a sheet | seat body main body.

  Furthermore, since the sewing thread penetrates the sheet material body, the sewing thread adheres inside the sheet material body when the resin molded body is formed. The rigidity of the resin molded body can be improved by the sewing thread that is fixed inside the sheet material body.

  According to the second aspect, the adjacent sheet material bodies are sewn together with the sewing thread in a state where the fiber sheet is sandwiched between the sheet material bodies. For this reason, the sheet material main body and the fiber sheet can be arranged together in the mold without being displaced, so that the arrangement work is very simple, and the man-hour increase is not caused, and the mass productivity is increased. Can be improved.

  In addition, since the fiber sheet disposed between the sheet material bodies is inserted into the adjacent sheet material bodies, the fiber sheet is included inside the resin molded body, and the rigidity of the resin molded body is improved. Can do.

  Moreover, the rigidity of the required location of a resin molding can also be partially improved by sewing and inserting a fiber sheet in the arbitrary locations between sheet material main bodies.

  In addition, since the sewing thread penetrates the adjacent sheet material body and the fiber sheet, when the resin molded body is molded, the sewing thread is fixed in the sheet material body and the fiber sheet, and the rigidity of the resin molded body is increased. Can be further improved.

  According to the third aspect, since the fibers constituting the fiber sheet are oriented in the same direction, the bending rigidity and tensile rigidity of the resin molded body in the direction in which each fiber extends can be improved.

  Moreover, the direction with high bending rigidity and tensile rigidity of a resin molding can be set with the orientation direction of a fiber. For this reason, according to the use application of a resin molding, a use location, etc., a resin molding can be arrange | positioned in a direction with high bending rigidity and tensile rigidity.

  According to the fourth aspect, the fibers constituting the fiber sheet are configured in a textile form, that is, in the form of a braid, a knitted fabric, or a woven fabric. For this reason, when the fiber sheet is sewn to the sheet material body, the fiber sheet does not move, and the sewing work is easy.

  According to the fifth aspect, the sewing thread is continuous so as to be folded back on the front and back sides of the sheet material body. For this reason, since a continuous sewing thread adheres to the resin molded body when the resin molded body is molded, the rigidity of the resin molded body can be further improved.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
Embodiment 1 of the Invention
(Configuration of resin sheet material)
FIG. 1 shows a resin sheet material 1 according to Embodiment 1 of the present invention, and this resin sheet material 1 is pressed by a molding die described later to be molded into a resin molded body.

  The resin sheet material 1 includes a rectangular sheet material body 3 and fiber sheets 5 and 5 disposed on both side surfaces of the sheet material body 3.

  The sheet material body 3 is, for example, a thermosetting resin such as unsaturated polyester (UP), phenol resin (PF), or epoxy resin (EP), or a thermoplastic resin such as polypropylene resin (PP) or polyamide resin (PA). It becomes more. These resins may be mixed with reinforcing fibers such as carbon fibers and glass fibers.

  The fiber sheet 5 is composed of a plurality of fibers 7 such as chemical fibers and natural fibers, and these fibers 7 are oriented in the same direction on each of one side surface and the other side surface side of the sheet material body 3, and the fibers 7 They are in contact with each other or close to each other to form a sheet. The orientation directions of the fibers 7 are orthogonal to each other on one side and the other side of the sheet material body 3. Specifically, the fibers 7 of the fiber sheet 5 arranged on one side surface (upper surface in FIG. 1) of the sheet material body 3 are arranged along the longitudinal direction of the sheet material body 3, while the sheet material body 3. The fibers 7 of the fiber sheet 5 arranged on the other side surface (the lower surface in FIG. 1) are oriented along the width direction of the sheet material body 3.

  The fiber sheet 5 is sewn to the sheet material body 3 with a sewing thread 9 by an industrial sewing machine or the like. The sewing thread 9 passes through the sheet material body 3 and is continuous so as to be folded back on the front and back sides of the sheet material body 3.

  Specifically, for example, the sewing thread 9 penetrates the sheet material body 3 after passing through the sheet material body 3 and folded around the fibers 7 of the fiber sheet 5 on one side surface thereof. The fiber sheets 5, 5 are continuous along the width direction of the sheet material body 3 so as to extend to the other side surface and be folded back around the fibers 7 of the fiber sheet 5 on the other side surface side. (Surface) and other side (back) are sewn. The fiber sheets 5, 5 and the sheet material main body 3 are sewn together by sewing threads 9 at a plurality of positions at intervals in the longitudinal direction of the sheet material main body 3. The sewing thread 9 is made of a general material such as cotton, silk, or nylon.

(Molding of resin moldings)
Next, a method for molding a bumper beam 13 of an automobile as the resin molded body 11 with the resin sheet material 1 according to Embodiment 1 of the present invention will be described.

  In FIG. 3, the cross section of the shaping | molding die 21 which pressurizes the resin sheet material 1 and shape | molds the resin molding 11 is shown. The molding die 21 includes a lower fixed die 23 and an upper movable die 25 disposed to face the fixed die 23.

  First, as shown in FIG. 3A, the resin sheet material 1 is placed on the molding surface 23 a of the fixed mold 23. In this case, the resin sheet material 1 is placed so that one side surface (the upper side in FIG. 1) faces the upper side of the fixed mold 23, and conversely, the one side surface is the lower side of the fixed mold 23. There are two placement methods, that is, the case where the placement is made so as to face the molding surface 23a side of the fixed mold 23.

  Next, as shown in FIG. 3B, the movable mold 25 is lowered, the mold 21 is closed, and the resin sheet material 1 is pressurized. Here, when the sheet material body 3 is made of a thermosetting resin, the temperature of the thermosetting resin is 15 ° C. to 20 ° C. in which the thermosetting resin is in a softened state and the curing reaction is difficult to accelerate. Thus, the mold temperature of the mold 21 is set to 110 ° C to 150 ° C. When the sheet material body 3 is made of a thermoplastic resin, the mold temperature of the mold 21 is set to 220 ° C to 300 ° C.

  The resin sheet material 1 is pressed by the fixed mold 23 and the movable mold 25 and is softened by heating from the molds 23 and 25, whereby the resin molded body 11 is molded. Along with the molding of the resin molded body 11, the fiber sheets 5 and 5 are inserted on both side surfaces of the sheet material body 3, and the sewing thread 9 penetrating the sheet material body 3 is fixed inside the sheet material body 3.

  After the resin sheet material 1 is solidified, the movable mold 24 is raised and the mold 21 is opened.

  In this way, the pair of resin molded bodies 11 are molded. The pair of resin molded bodies 11 are formed with flange portions 11a and 11a extending in the longitudinal direction at both ends in the width direction. As shown in FIG. It joins with each flange part 11a and 11a so that the hollow part 15 may be formed.

  Here, when the sheet material main body 3 is made of a thermosetting resin, the flange portions 11a and 11a are joined by joining with an adhesive or mechanical joining with screws or the like. On the other hand, when the sheet material body 3 is made of a thermoplastic resin, it can be performed by vibration or heat welding in addition to the bonding by the adhesive and the mechanical bonding.

  In this way, the pair of resin molded bodies 11 are joined to form the bumper beam 13. Here, when the bumper beam 13 is used so that the upper side in FIG. 2 is the front side of the vehicle, the fiber 7 of the fiber sheet 5 is on the surface side (upper side in FIG. 2) of the front resin molded body 11. The resin molded body 11 is oriented in the width direction, and on the back side (hollow part 15 side), the fibers 7 are oriented in the longitudinal direction (vehicle width direction) of the resin molded body 11. On the other hand, the fiber 7 of the fiber sheet 5 is oriented in the longitudinal direction on the front surface side (lower side in FIG. 2) of the resin molded body 11 on the rear side, and the fiber 7 is in the width direction on the back surface side (hollow portion 15 side). Oriented.

(Effect of Embodiment 1)
Since the resin sheet material 1 has the fiber sheets 5 and 5 disposed on both side surfaces of the sheet material body 3 sewn to the sheet material body 3 by the sewing thread 9, the resin sheet material 1 is disposed on the mold 21. In doing so, the sheet material body 3 and the fiber sheets 5 and 5 can be arranged together without being displaced. For this reason, the sheet material main body 3 and the fiber sheets 5 and 5 that are sewn together may be arranged in the forming die 21 as they are, and the arrangement work is very simple and the man-hours are not increased. Therefore, mass productivity can be improved.

  Further, since the sewing thread 9 penetrates the sheet material body 3, the sewing thread 9 is fixed inside the sheet material body 3 when the resin molded body 11 is formed. For this reason, in addition to the rigidity of the resin molded body 11 being improved by the fiber sheet 5, the rigidity of the resin molded body 11 can be further improved by the sewing thread 9 fixed in the sheet material body 3.

  Further, the fibers 7 constituting the fiber sheet 5 are oriented in the same direction. The orientation directions of the fibers 7 are perpendicular to each other on the one side surface side and the other side surface side of the sheet material body 3. For this reason, the bending rigidity of the resin molding 11 in both the longitudinal direction and the width direction of the sheet material body 3 can be improved. That is, when a collision load is applied to the upper surface of the bumper beam 13 (the upper side in FIG. 2 is the front of the automobile), the bumper beam 13 tends to bend in the longitudinal direction, but the resin molded body 11 has fibers in the same direction. Since the fiber sheet 5 oriented 7 is inserted, the bending rigidity is thereby improved, and the bumper beam 13 can be prevented from being damaged by the collision load.

  Also, the resin molded body 11 of the bumper beam 13 is pressed toward the hollow portion 15 side by the collision load and tries to bend. The fiber sheet in which the fibers 7 are oriented in the width direction is formed on the resin molded body 11. Since 5 is inserted, the bending rigidity is thereby improved, and damage to the bumper beam 13 due to the collision load can be prevented.

  Further, the bumper beam 13 has the fiber sheet 5 in which the fibers 7 are oriented in the longitudinal direction inserted in the rear surface of the automobile in each resin molded body 11 as described above. For this reason, when a collision load is applied to the upper surface of the bumper beam 13, the fibers 7 are respectively oriented in the longitudinal direction on the surfaces of the resin molded bodies 11 that are bent and protruded. 11, the bending rigidity is further improved, and the bumper beam 13 can be further prevented from being damaged by the collision load.

Further, the sewing thread 9 is continuous so as to be folded back on the front and back sides of the sheet material body 3. For this reason, since the continuous sewing thread 9 adheres to the resin molded body 11, the rigidity of the resin molded body 11 can be further improved.
<< Embodiment 2 of the Invention >>
Next, the resin sheet material 1 according to Embodiment 2 of the present invention will be described in detail with reference to FIG. The same components as those in FIGS. 1 to 3 are denoted by the same reference numerals, and detailed description of the same portions as those in the first embodiment is omitted.

  As shown in FIG. 4, the resin sheet material 1 according to the second embodiment includes two sheet material bodies 3 and 3, and the fiber sheet 5 is disposed between the sheet material bodies 3 and 3. Different from the resin sheet material 1 according to the first embodiment.

  In the fiber sheet 5, the fibers 7 are oriented along the rectangular longitudinal direction of the sheet material body 3.

  The sewing thread 9 penetrates one sheet material body 3, the fiber sheet 5, and the other sheet material body 3 in a state where the fiber sheet 5 is sandwiched between the sheet material bodies 3 and 3, and the other sheet material body 3, after passing through the other sheet material body 3, the fiber sheet 5, and the one sheet material body 3, the sheet material body 3 has a width direction so as to be folded on the one sheet material body 3 side. The sheet material bodies 3 and 3 are sewn together continuously.

  Other configurations are the same as those of the first embodiment.

  When the resin sheet material 1 is pressed and molded, the fiber sheet 5 is inserted into the adjacent (one and the other) sheet material bodies 3 and 3.

  According to the resin sheet material 1 of the second embodiment, in addition to having the same effects as those of the first embodiment, the fiber sheets 5 arranged between the sheet material bodies 3 and 3 are adjacent to each other. 3 and 3, the fiber sheet 5 is contained inside the resin molded body 11, and the rigidity of the resin molded body 11 can be further improved.

In the second embodiment, the sewing thread 9 is continuous so as to be folded back on the front and back sides of the sheet material main body 3. For example, as shown in FIG. The adjacent sheet material bodies 3 and 3 may be sewn together. At this time, the sewing thread 9 penetrates the sheet material main bodies 3 and 3 and the fiber sheet 5 at each location, and is folded on one side of the sheet material main body 3 (the lower side in FIG. 5). 3 and 3 and the fiber sheet 5 are extended to the other side surface (upper side in FIG. 5), and both ends are connected and fastened to each other side surface side. The effect similar to Embodiment 2 can be obtained also by sewing in this way.
<< Other Embodiments >>
In addition, the above-mentioned embodiment is an illustration of this invention, Comprising: This invention is not limited to this example.

  For example, the following configuration may be used.

  That is, in each of the above embodiments, the fibers 7 constituting the fiber sheet 5 are arranged in the same direction, but the fibers 7 may be configured in a textile shape, that is, in the form of a braid, knitted fabric, or woven fabric. By configuring the fiber 7 in a textile shape, when the fiber sheet 5 is sewn to the sheet material bodies 3 and 3, the fiber sheet 5 does not move and the sewing work is easy.

  In the first embodiment, the fiber sheet 5 is disposed on both side surfaces of the sheet material body 3, but the fiber sheet 5 may be disposed only on one side surface of the sheet material body 3.

  Further, in Embodiment 1 described above, the orientation direction of the fibers 7 is set to be orthogonal to each other on the one side surface side and the other side surface side of the sheet material body 3, but may be aligned in the same direction. In this case, the bending rigidity of the resin molded body 11 in the extending direction (orientation direction) of the fibers 7 can be further improved.

  Thus, the direction with high bending rigidity of the resin molding 11 is set by the orientation direction of the fiber 7. For this reason, the resin molding 11 can be arrange | positioned in a direction with high bending rigidity according to the use application of the resin molding 11, a use location, etc. FIG.

  Moreover, in the said Embodiment 1, although the fiber sheet 5 has been arrange | positioned over the both sides | surfaces of the sheet material main body 3, it is in arbitrary positions partially in arbitrary locations of the sheet material main body 3 as needed. It may be arranged. Depending on the application of the molded resin body 11 to be molded, the fiber sheet 5 is sewn and inserted into an arbitrary portion of the sheet material body 3 to partially improve the rigidity of the necessary portion of the resin molded body 11. Can be made.

  Moreover, in each said embodiment, in order to improve the bending rigidity of the bumper beam 13, the bumper beam 13 was shape | molded by the resin molding 11, but the resin molding 11 improves the bending rigidity in this way. By setting the orientation of not only the body 11 but also the fibers 7 of the fiber sheet 5 in the tensile direction, the resin molded body 11 with improved tensile rigidity can be molded.

  Further, in Embodiment 2 described above, the sewing thread 9 is fastened by tying both ends together at each location, but each end may be tied like a ball knot so as not to come off the sheet material body 3.

  Moreover, in each said embodiment, although the resin molding 11 was shape | molded by the shaping | molding method using the shaping | molding die 21 which consists of the fixed mold | type 23 and the movable mold | type 25, you may shape | mold by the shaping | molding method by hydraulic forming. That is, in a state in which the resin sheet material 1 is wound around the entire outer peripheral surface of an expandable core having a hollow portion and disposed in a mold, a liquid is pressurized and supplied to the inside of the core. The resin molded body 11 may be molded by expanding the resin sheet 1 and pressing the resin sheet material 1 against the molding surface of the mold.

  As described above, the present invention is useful for a resin sheet material that is pressed by a molding die and molded into a resin molded body.

It is a perspective view of the resin sheet material which concerns on Embodiment 1 of this invention. It is a perspective view of the bumper beam shape | molded by the resin sheet material. It is sectional drawing of the shaping | molding die which shape | molds a resin molding, (a) shows the state by which the resin sheet material is arrange | positioned, (b) shows the state by which the resin molding was shape | molded. It is a perspective view of the resin sheet material which concerns on Embodiment 2 of this invention. It is a perspective view of the resin sheet material which concerns on other embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Resin sheet material 3 Sheet material main body 5 Fiber sheet 7 Fiber 9 Sewing thread 11 Resin molding 21 Mold

Claims (5)

A resin sheet material that is pressed by a molding die and molded into a resin molded body,
A sheet material body;
A fiber sheet that is disposed on at least one side surface of the sheet material main body and is inserted into the one side surface during the pressure molding;
A resin sheet material comprising: a sewing thread that penetrates the sheet material body and sews the fiber sheet to the sheet material body. A resin sheet material that is pressed by a molding die and molded into a resin molded body,
A plurality of sheet material bodies;
A fiber sheet that is placed between the sheet material bodies and inserted into each sheet material body during the pressure molding,
In a state where the fiber sheet is sandwiched between the sheet material main bodies, the adjacent sheet material main body and the fiber sheet, and a sewing thread that sews the adjacent sheet material main bodies. Characteristic resin sheet material. In the resin sheet material according to claim 1 or 2,
The fiber sheet is a resin sheet material in which the fibers constituting the fiber sheet are oriented in the same direction. In the resin sheet material according to claim 1 or 2,
The fiber sheet is a resin sheet material in which fibers constituting the fiber sheet are formed in a textile shape. In the resin sheet material according to any one of claims 1 to 4,
A resin sheet material, wherein the sewing thread is continuous so as to be folded back on the front and back sides of the sheet material main body.

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