JP2009166421A - Resin panel with foamed sealing material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin panel, the foamed sealing material of which does not separate from its concave groove, easily and certainly, and also at low cost. <P>SOLUTION: A liquid foaming resin material is allowed to foam and harden within the concave groove 19 of a plate body 15, so that the foamed sealing material 11 swells above the surface of the plate body 15. A plurality of penetrating holes 27 are formed at the bottom surface 19a of the concave groove 19 in a longitudinal direction with respect to the groove with intervals. At a portion of the side surface 19b of the concave groove 19 that corresponds to each of the penetrating holes 27, a plurality of holder strips 29 jut out toward the internal side of the groove, the holder strips 29 being provided with intervals in a longitudinal direction with respect to the groove in a manner that the holder strips 29 are buried in the foamed sealing material 11. A part of the foamed sealing material 11 is engaged into each of the penetrating holes 27 so as to secure the foamed sealing material 11 to each of the holder strips 29. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an improvement in a resin panel with a foam seal material, and more particularly to a measure for preventing the foam seal material from being detached.

  Patent Document 1 discloses a door in which a metal door outer panel and a resin door inner panel of an automobile are joined to each outer peripheral edge portion with a foam sealant interposed therebetween. In Patent Document 1, a groove groove is formed in the outer peripheral edge portion of the panel main body constituting the main body of the door inner panel, and a foamed sealing material is accommodated in the groove groove so as to bulge on the surface of the panel main body. ing. And in the state which joined the said door outer panel and the door inner panel, the sealing performance between both panels is ensured by pinching and compressing the said foaming sealing material by both panels.

In addition, in Patent Document 1 described above, surface treatment such as corona discharge treatment, plasma treatment, flame treatment, primer treatment, etc. is performed around at least the concave groove of the panel body of the door inner panel for the purpose of improving adhesion. There is a statement that the foamed sealing material is not separated from the groove.
JP 2003-335134 A (paragraph 0035 column, paragraph 0069 column, FIG. 3)

  However, as in the above-mentioned Patent Document 1, if the surface treatment is performed on the surface of the panel body, a large-scale facility is required, resulting in an increase in cost. Immediately after the surface treatment, the liquid foamed resin raw material is recessed. If it is not injected into the groove, the effect of the surface treatment is reduced, and the foamed sealing material cannot be accommodated so as not to leave the groove.

  On the other hand, in order to prevent the foaming seal material from detaching from the groove groove, if the locking piece protrudes toward the groove inner side on the side surface of the groove groove and is buried in the foam seal material, The panel body formed with the locking piece as an undercut portion cannot be removed. Therefore, in order to avoid this, the mold portion located between the locking piece and the bottom surface of the groove has to be configured with a slide mold, and the mold structure is complicated as much as the slide mold is necessary. As a result, equipment costs will rise.

  The present invention has been made in view of this point, and an object of the present invention is to provide a resin panel in which the foamed sealing material is not detached from the groove, easily and reliably and at a low cost.

  In order to achieve the above object, the present invention is characterized in that the foamed sealing material is accommodated in the groove so as not to be detached without applying a special surface treatment and adopting a slide mold. .

  Specifically, the present invention includes a resin panel body having a groove on the surface, and a foam sealing material formed by expanding and curing a liquid foam resin material in the groove to bulge on the surface of the panel body. Based on the premise of a resin panel with a foam sealant provided with the following, the following solutions were taken.

  That is, in the first aspect of the present invention, a plurality of through holes are formed on the bottom surface of the concave groove at intervals in the longitudinal direction of the groove, and each of the through holes on the side surface of the concave groove is formed. In the hole corresponding portion, a plurality of locking pieces are protruded toward the inside of the groove at intervals in the longitudinal direction of the groove so as to be buried in the foamed sealing material. A part of the material is inserted and locked to the locking pieces.

  According to a second aspect of the present invention, in the above premise, a plurality of through holes are formed in a side surface of the concave groove at intervals in the groove longitudinal direction, and the foam seal is provided in each through hole. A part of the material is inserted and locked to the periphery of each of the through holes.

  According to a third aspect of the present invention, in the above premise, the foamed sealing material protrudes outward from the groove and is entirely welded to the surface of the panel body and compressed into a flat shape. The plurality of tab portions are formed integrally with a gap in the longitudinal direction of the groove.

  According to a fourth aspect of the present invention, in the above premise, a plurality of concave portions that are recessed toward the outer side of the groove are formed on the side surface of the concave groove at intervals in the longitudinal direction of the groove, and the foam sheet A plurality of tab portions, which are fitted into the respective concave portions and the corresponding peripheral portions of the concave portions are welded to the surface of the panel main body and are compressed into a flat shape, are integrated with a gap in the longitudinal direction of the groove. It is characterized by being formed.

  According to a fifth aspect of the present invention, in the fourth aspect of the present invention, a protrusion having a bulging portion at the tip is integrally projected on the bottom surface of each concave portion so as to be buried in each tab portion. It is characterized by.

  According to the first aspect of the present invention, a part of the foam sealing material is locked to a plurality of locking pieces at positions spaced in the longitudinal direction of the groove, and the anchor effect is exhibited. Even if the surface is not specially treated, the foamed sealing material can be securely stored so that it does not leave the groove, and the large-scale equipment required for the surface treatment is not required, reducing costs. be able to. Moreover, it is also possible to make it difficult to remove the foamed sealing material from the concave groove due to the anchor effect by inserting a part of the foamed sealing material into the plurality of through holes.

  Further, when molding the panel body, a protrusion is provided on the molding surface of the first split mold for molding the surface side of the panel body corresponding to the groove forming portion, while the back side of the panel body is molded. A molding die in which a plurality of projections for forming through holes are formed on the molding surface of the second split mold so as to slidably slide on the side surfaces of the projections when the mold is closed. Is prepared and a space for forming a locking piece is formed between the tip of each of the protrusions and the molding surface of the first split mold when the mold is closed. Thus, the situation where the molded panel body cannot be removed is avoided. Therefore, a slide mold for avoiding this is unnecessary, and the panel main body, and thus the resin panel with the foam sealant can be easily and reliably manufactured at a low cost with a simple mold having a mold structure.

  According to the invention of claim 2, a part of the foam sealing material is fitted into a plurality of through holes formed in the side surface of the groove and locked to the periphery of each through hole, thereby exhibiting an anchor effect. Therefore, as in the case of claim 1, the foam sealing material can be reliably accommodated in the groove so as not to be detached without special surface treatment on the surface of the panel body, and the surface. Large equipment necessary for processing is unnecessary, and the cost can be reduced.

  Further, when molding the panel body, a protrusion is provided on the molding surface of the first split mold for molding the surface side of the panel body corresponding to the groove forming portion, while the back side of the panel body is molded. The groove forming portion of the molding surface of the second split mold is partially bulged corresponding to the plurality of through-holes, and the bulge and the side surfaces are slid in the mold closed state. By preparing a molding die projecting so as to fit and molding the panel main body, it is possible to avoid a situation in which the molded panel main body can be removed after the molding by eliminating a portion serving as an undercut portion. Therefore, as in the case of claim 1, a slide mold for avoiding this is not required, and a panel body, and thus a resin panel with a foam sealant, can be easily and reliably manufactured at a low cost with a simple mold structure. can do.

  According to the invention of claim 3, since the plurality of tab portions of the foam sealing material are welded to the surface of the panel body at positions spaced in the longitudinal direction of the groove and compressed into a flat shape. As in 1, it is possible to securely store the foamed sealing material in the groove so that it does not separate from the surface of the panel body without any special surface treatment, and large-scale equipment necessary for the surface treatment. Is unnecessary, and the cost can be reduced.

  Further, when molding the panel body, a protrusion is provided on the molding surface of the first split mold for molding the surface side of the panel body corresponding to the groove forming portion, while the back side of the panel body is molded. By preparing a molding die with a grooved part corresponding to the groove forming part of the molding surface of the second split mold and molding the panel body, the part that becomes the undercut part is eliminated after molding. The situation where the molded panel body cannot be removed is avoided. Therefore, as in the case of claim 1, a slide mold for avoiding this is not required, and a panel body, and thus a resin panel with a foam sealant, can be easily and reliably manufactured at a low cost with a simple mold structure. can do.

  According to the invention of claim 4, the plurality of tab portions of the foam sealing material are welded to the surface of the panel body at the periphery of the plurality of recessed portions at positions spaced in the groove longitudinal direction and compressed into a flat shape. Therefore, as in the case of Claim 1 (Claim 3), the foamed sealing material must be securely stored in the groove so as not to be detached even if the surface of the panel body is not subjected to special surface treatment. In addition, large-scale equipment necessary for the surface treatment is unnecessary, and the cost can be reduced. Moreover, it is also possible to make it difficult for the foamed sealing material to be detached from the groove groove by inserting a tab portion into the plurality of recessed portions to exert an anchor effect.

  Furthermore, when molding the panel body, the first split mold forming surface that molds the surface side of the panel body is provided with protrusions and protrusions for forming the recesses corresponding to the groove forming positions, On the other hand, the panel body is prepared by preparing a molding die in which a concave portion and a concave portion for forming a concave portion are formed corresponding to the concave groove forming portion of the molding surface of the second split mold for molding the back side of the panel main body. By molding, the situation where the panel main body molded without the portion that becomes the undercut portion after molding cannot be removed is avoided. Also, when compressing the tab part and welding the foam seal material to the panel body, the foam seal material is less repelled by the recessed part provided in the panel body against the compression. It is strongly compressed at the periphery and can be reliably welded. Therefore, as in the case of claim 1, a slide mold for avoiding this is not required, and a panel body, and thus a resin panel with a foam sealant, can be easily and reliably manufactured at a low cost with a simple mold structure. can do.

  According to the invention which concerns on Claim 5, an anchor effect is exhibited also by the bulging part of protrusion front-end | tip, it makes it difficult to detach | leave a tab part further from a recessed part, and makes it difficult to detach | leave a foaming sealing material from a grooved groove | channel further. Can do.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
FIG. 6 is a cross-sectional view of the lower end portion of the side door 1 of the automobile. The side door 1 includes a metal door main body 7 including a door outer panel 3 and a door inner panel 5, and the door inner panel 5 of the door main body 7 includes a resin panel with a foam sealing material according to Embodiment 1 of the present invention. A carrier plate (door module plate) 9 is attached via a foam seal material 11, and a resin door trim 13 is attached to the door inner panel 5 so as to cover the carrier plate 9 from the vehicle interior side. The carrier plate 9 is attached between the door inner panel 5 and the door trim 13.

  The carrier plate 9 is formed of, for example, a thermoplastic resin in which fibers such as glass fibers are mixed, and a guide rail for raising and lowering the window glass, a motor, a pull handle, a speaker, and the like are attached to the carrier plate 9.

  The carrier plate 9 includes a plate main body 15 as a resin panel main body which is the main body. An elongated bulging portion 17 is formed over the entire periphery of the outer peripheral surface of the plate body 15 on the vehicle interior side, and the outer peripheral surface of the outer surface of the plate main body 15 corresponding to the bulging portion 17. In this case, one groove groove 19 is formed over the entire circumference, and the foamed sealing material 11 is accommodated in the groove groove 19 as shown in FIG. The foamed sealing material 11 is formed by foaming and hardening a liquid foamed resin raw material in the groove 19 to swell on the surface of the plate body 15.

  In addition, a plurality of circular boss-shaped attachment portions 21 are provided adjacent to the outer peripheral edge portion of the plate body 15 (inside the groove 19) so as to be integrally adjacent to each other at a predetermined interval. In each of the attachment portions 21, a bolt insertion hole 21a for fastening is formed so as to penetrate the plate body 15.

  Then, the carrier plate 9 is overlaid on the door inner panel 5 so that the bolt insertion holes 21a of the mounting portions 21 correspond to the plurality of bolt insertion holes 5a formed at the opening peripheral edge of the door inner panel 5, The carrier plate 9 is attached to the door inner panel 5 by inserting the bolt 23 from the vehicle interior side into the bolt insertion holes 21a and 5a and screwing the bolt 23 into the weld nut 25 welded to the outer side surface of the door inner panel 5. (See FIG. 6).

  As shown in FIGS. 1 to 4, a plurality of rectangular through holes 27 are formed on the bottom surface 19 a of the concave groove 19 (the bulging top surface 17 a of the bulging portion 17). It is formed in a zigzag pattern at intervals in the longitudinal direction of the groove so as to be in contact with the side surface 17b) of the protruding portion 17. Further, at a position corresponding to each through-hole 27 on the side surface 17b of the concave groove 19, a plurality of rectangular locking pieces 29 are spaced in a staggered manner in the longitudinal direction of the groove so as to be buried in the foamed sealing material 11. And projecting integrally toward the inside of the groove. A part of the foamed sealing material 11 is fitted into each of the through holes 27, and the fitting part 11 a is locked to the locking pieces 29.

  As described above, in the first embodiment, a part of the foam seal material 11 is locked to the plurality of locking pieces 29 at positions spaced in the groove longitudinal direction to exert the anchor effect. Without special surface treatment on the surface of the plate main body 15, the foamed sealing material 11 can be reliably accommodated so as not to be separated into the groove 19, and large equipment necessary for the surface treatment is unnecessary. Cost can be reduced. Further, the foamed sealing material 11 can be made difficult to be detached from the groove 19 due to the anchor effect that a part of the foamed sealing material 11 (inserted portion 11 a) is inserted into the plurality of through holes 27. .

  In order to form such a through hole 27 and a locking piece 29 in the concave groove 19 of the plate body 15, a forming die 31 as shown in FIG. 7 is used. The mold 31 includes a first split mold 33 that molds the front side of the plate body 15 and a second split mold 35 that molds the back side of the plate body 15. On the molding surface 33a of the first split mold 33, a single protrusion 37 is integrally provided corresponding to the forming position of the concave groove 19, and the protrusion 37 has a U-shape. Cutout portions (not shown) are formed in a staggered manner in the longitudinal direction so as to correspond to the respective locking pieces 29.

  On the other hand, a cavity 39 corresponding to the thickness of the plate body 15 is formed on the molding surface 35 a of the second split mold 35, and a recess 39 a is formed on the bulging portion 17 on the outer peripheral edge of the cavity 39. Correspondingly, it is formed over the entire circumference. In addition, a plurality of protrusions 41 for forming the through holes 27 are integrally formed in a staggered manner on the bottom surface of the concave portion 39a so as to correspond to the positions where the concave grooves 19 are formed. When the mold 31 is in the closed state, the protrusion 37 of the first split mold 33 and the side surfaces thereof slide against each other. Further, in this mold closed state, a space 39 b for forming the locking piece 29 is formed between the tip of each projection 41 and the molding surface 33 a of the first split mold 33.

  Then, with the mold 31 in the closed state, the thermoplastic resin (for example, polypropylene resin) mixed with the glass fiber or the like as described above is injected and filled into the cavity 39 from the injection machine, as shown in FIGS. As described above, the plate body 15 having the concave groove 19 in which a plurality of through holes 27 are formed in the bottom surface 19a and a plurality of locking pieces 29 project from the side surface 19b is formed. A liquid foamed resin raw material is injected into the groove groove 19 of the plate main body 15, and the liquid foamed resin raw material is foamed and cured in the groove groove 19 and swells on the surface of the plate main body 15, thereby expanding the foam sealing material 11. Is accommodated in the groove 19.

  In the plate body 15 molded in this way, each through hole 27 corresponds to the lower side of each locking piece 29, so that after the molding, each locking piece 29 is formed as an undercut portion. The situation where the plate body 15 cannot be removed can be avoided. Therefore, a slide mold for avoiding this is unnecessary, and the plate main body 15 and, consequently, the resin carrier plate 9 with the foamed sealing material can be easily and reliably manufactured at a low cost with a simple mold having a mold structure. .

(Embodiment 2)
8 and 9 show the carrier plate 9 according to the second embodiment, and FIGS. 10 and 11 show the plate body 15 respectively. A plurality of rectangular through holes 27 are formed on the side surface 19b of the concave groove 19 of the plate body 15 (side surface 17b of the bulging portion 17), and the bottom surface 19a of the concave groove 19 (the bulging top surface of the bulging portion 17). 17a) is formed in a staggered pattern with a gap in the longitudinal direction of the groove. In addition, rectangular cutouts 17c are formed in the side surface 17b of the bulging part 17 corresponding to the through holes 27 so as to open the through holes 27 laterally and downward. A part of the foamed sealing material 11 is inserted into each through hole 27, and the inserted part 11 a faces the notch 17 c and engages with the periphery of each through hole 27. The rest of the configuration is the same as that of the first embodiment (see FIGS. 5 and 6).

  As described above, in the second embodiment, a part of the foam seal material 11 is fitted into the plurality of through holes 27 formed in the side surface 17b of the concave groove 19 and is engaged with the periphery of each through hole 27. Therefore, the same anchor effect as in the first embodiment can be obtained, and the foamed sealing material 11 can be reliably accommodated in the concave groove 19 without performing a special surface treatment on the surface of the plate body 15. In addition, large-scale equipment necessary for the surface treatment is unnecessary, and the cost can be reduced.

  In order to form such a through hole 27 in the concave groove 19 of the plate body 15, a forming die 31 as shown in FIG. 12 is used. The mold 31 includes a first split mold 33 that molds the front side of the plate body 15 and a second split mold 35 that molds the back side of the plate body 15. On the molding surface 33 a of the first split mold 33, a single protrusion 37 is integrally provided so as to correspond to the concave groove 19 forming portion.

  On the other hand, a cavity 39 corresponding to the thickness of the plate body 15 is formed on the molding surface 35 a of the second split mold 35, and a concave portion 39 a corresponds to the bulging portion 17 on the outer peripheral edge of the cavity 39. Thus, it is formed over the entire circumference. A plurality of projections 43 for forming the through holes 27 and the notches 17c are integrally formed in a staggered manner on the bottom surface of the concave portion 39a so as to correspond to the portions where the concave grooves 19 are formed. In the mold closed state of the mold 31, the protrusions 37 of the first split mold 33 and the respective side surfaces slide against each other.

  Then, with the mold 31 closed, the cavity 39 is injected and filled with a thermoplastic resin (for example, polypropylene resin) mixed with the above glass fiber or the like from the injection machine, as shown in FIGS. As described above, the plate body 15 having the groove 19 having the plurality of through holes 27 formed on the side surface 19b and the plurality of notches 17c formed on the side surface 17b of the bulging portion 17 is formed. . A liquid foamed resin raw material is injected into the groove groove 19 of the plate main body 15, and the liquid foamed resin raw material is foamed and cured in the groove groove 19 and swells on the surface of the plate main body 15, thereby expanding the foam sealing material 11. Is accommodated in the groove 19.

  In the plate body 15 thus molded, there is no portion that becomes an undercut portion after molding, and it is possible to avoid a situation in which the molded plate body 15 cannot be removed. Therefore, as in the first embodiment, a slide mold for avoiding this is not necessary, and the plate body 15 and, consequently, the resin carrier plate 9 with the foam sealant can be easily and reliably formed with a simple mold structure. It can be manufactured at low cost.

(Embodiment 3)
13, 14 and 19 show the carrier plate 9 according to the third embodiment, FIGS. 15 and 16 show the plate body 15, and FIGS. 17 and 18 show the foamed resin raw material in the groove 19 of the plate body 15. Each of the foamed states is shown. The concave groove 19 of the plate body 15 does not have the through hole 27 and the locking piece 29 as in the first and second embodiments. Instead, the foamed sealing material 11 is spaced apart in the longitudinal direction of the groove such that a plurality of semicircular tab portions 45 protrude from the concave groove 19 toward the outside (inside the plate body 15). They are integrally formed (see FIG. 19). The entire tab portion 45 is welded to the surface of the plate body 15 and compressed into a flat shape, and is harder than the non-compressed portion of the foam seal material 11. 17 and 18, 45 ′ indicates a protruding portion of the foamed sealing material 11 before compression. In FIG. 18, reference numeral 47 denotes an ultrasonic welding jig for compressing the protruding portion 45 '. Instead of the ultrasonic welding jig 47, the protruding portion 45 ′ may be compressed using, for example, a heat trowel or the like. The same applies to the following embodiments. The rest of the configuration is the same as that of the first embodiment (see FIG. 6).

  As described above, in the third embodiment, the plurality of tab portions 45 of the foam sealing material 11 are welded to the surface of the plate body 15 by the ultrasonic welding jig 47 at a position spaced in the longitudinal direction of the groove, and are flattened. In the same manner as in the first aspect, the foamed sealing material 11 can be reliably accommodated in the concave groove 19 without being subjected to a special surface treatment on the surface of the plate body 15. At the same time, large-scale equipment necessary for the surface treatment is unnecessary, and the cost can be reduced.

  When molding the plate body 15, although not shown, a molding die including a first split mold 33 that molds the front side of the plate body 15 and a second split mold 35 that molds the back side of the plate body 15. 31 is used (see FIGS. 7 and 12). However, only one protrusion 37 is integrally provided on the molding surface 33a of the first split mold 33 so as to correspond to the formation position of the concave groove 19, and the protrusion 37 includes an embodiment. There is no notch like 1. Further, the cavity 39 having the concave portion 39a is only formed on the molding surface 35a of the second split die 35 corresponding to the thickness of the plate body 15, and the bottom surface of the concave portion 39a is implemented on the bottom surface. There are no projections 41 as in the first embodiment and projections 43 for forming the notch 17c as in the second embodiment.

  Therefore, even if the plate body 15 is molded using such a mold 31, it is not possible to make a portion that becomes an undercut portion after molding, and it is possible to avoid a situation in which the molded plate body 15 cannot be removed. it can. Therefore, as in the first embodiment, a slide mold for avoiding this is not necessary, and the plate body 15 and, consequently, the resin carrier plate 9 with the foam sealant can be easily and reliably formed with a simple mold structure. It can be manufactured at low cost.

(Embodiment 4)
20 and 21 show the carrier plate 9 according to the fourth embodiment, FIGS. 22 and 23 show the plate body 15, and FIGS. 24 and 25 show the foamed resin material foamed in the groove 19 of the plate body 15. Each is shown. Similar to the third embodiment, the concave groove 19 of the plate body 15 does not have the through-hole 27 and the locking piece 29 as in the first and second embodiments. Instead, as in the third embodiment, the foamed sealing material 11 has a plurality of semicircular tab portions 45 that protrude from the concave groove 19 toward the outside (inside the plate body 15). It is integrally formed with a space in the longitudinal direction. 24 and 25, 45 'shows the protrusion part of the foaming sealing material 11 before compression. In FIG. 25, 47 is an ultrasonic welding jig for compressing the protruding portion 45 '.

  However, in the fourth embodiment, unlike the third embodiment, a plurality of recessed portions 49 that are recessed toward the outer side of the groove (inside the plate main body 15) are spaced apart in the groove longitudinal direction on the side surface 19b of the groove 19. It is formed with a gap. Reference numeral 17 d denotes a bulging side wall portion that bulges outward corresponding to the recessed portion 49. A plurality of tab portions 45 are fitted into the respective recessed portions 49 in the foamed sealing material 11, and the peripheral portions corresponding to the peripheral portions of the recessed portions 49 are welded to the surface of the plate body 15 and compressed into a flat shape. It is harder than the non-compressed portion of the foamed sealing material 11. Moreover, the foaming sealing material 11 in the recessed part 49 is also compressed. The rest of the configuration is the same as that of the first embodiment (see FIG. 6).

  As described above, in the fourth embodiment, the plurality of tab portions 45 of the foam sealing material 11 are ultrasonically welded to the surface of the plate body 15 at the periphery of the plurality of recessed portions 49 at positions spaced in the longitudinal direction of the groove. Since it is welded by the jig 47 and compressed into a flat shape, the foamed sealing material 11 can be formed into the concave groove 19 without subjecting the surface of the plate body 15 to a special surface treatment as in the case of claim 1 (claim 3). In addition to being able to be surely accommodated so as not to be disengaged, large-scale equipment necessary for the surface treatment is unnecessary, and the cost can be reduced. Further, the foam seal material 11 can be made difficult to be detached from the groove 19 by inserting the tab portion 45 into the plurality of recessed portions 49 to obtain an anchor effect.

  When molding the plate body 15, although not shown, a molding die including a first split mold 33 that molds the front side of the plate body 15 and a second split mold 35 that molds the back side of the plate body 15. 31 is used (see FIGS. 7 and 12). However, on the molding surface 33 a of the first split mold 33, a single protrusion 37 having a protrusion corresponding to the recessed portion 49 is integrally protruded corresponding to the formation position of the groove 19. However, the protrusion 37 does not have a notch as in the first embodiment. A cavity 39 having a concave portion 39 a is formed on the molding surface 35 a of the second split mold 35 corresponding to the thickness of the plate body 15, and the concave portion 39 a corresponds to the concave portion 49. It only has a wide portion, and there is no projection 41 as in the first embodiment and projection 43 for forming the notch portion 17c as in the second embodiment on the bottom surface of the concave portion 39a.

  Therefore, even if the plate body 15 is molded using such a mold 31, it is not possible to make a portion that becomes an undercut portion after molding, and it is possible to avoid a situation in which the molded plate body 15 cannot be removed. it can. Further, when the tab portion 45 is compressed and the foam seal material 11 is welded to the plate body 15, the foam seal material 11 is less repelled by the recessed portion 49 provided in the plate body 15 against the compression. 11 is strongly compressed to the periphery of the recessed portion 49 of the plate body 15 and can be reliably welded. Therefore, as in the first embodiment, a slide mold for avoiding this is not necessary, and the plate body 15 and, consequently, the resin carrier plate 9 with the foam sealant can be easily and reliably formed with a simple mold structure. It can be manufactured at low cost.

(Embodiment 5)
26, 27 and 28 show the carrier plate 9 according to the fifth embodiment, FIGS. 29 and 30 show the plate main body 15, and FIGS. 31 and 32 show the foamed resin material in the concave groove 19 of the plate main body 15. Each of the foamed states is shown. Similar to the third embodiment, the concave groove 19 of the plate body 15 does not have the through-hole 27 and the locking piece 29 as in the first and second embodiments. Instead, like the third and fourth embodiments, a plurality of semicircular tab portions 45 protrude from the concave groove 19 toward the outside (inside the plate body 15) in the foamed sealing material 11. Are integrally formed at intervals in the groove longitudinal direction. In FIG. 31 and FIG. 32, 45 'shows the protrusion part of the foaming sealing material 11 before compression. In FIG. 32, 47 is an ultrasonic welding jig for compressing the protruding portion 45 '.

  Further, in the fifth embodiment, as in the fourth embodiment, a plurality of recessed portions 49 that are recessed toward the outer side of the groove (inner side of the plate body 15) are formed on the side surface 19b of the groove 19 in the longitudinal direction of the groove. Are formed at intervals, but in each recessed portion 49, a stepped portion 51 is formed that is located above the bottom surface 19 a of the groove 19, and the top surface of the stepped portion 51 is the bottom surface of the recessed portion 49. And the point that the projection 53 having the bulging portion 53a at the tip is integrally projected on the top surface of the stepped portion 51, which is different from the fourth embodiment. In addition, the bulging part 53a of this protrusion 53 does not exist before the tab part 45 compression (refer FIG.29 and FIG.30). Reference numeral 17 d denotes a bulging side wall portion that bulges outward corresponding to the recessed portion 49.

  In the fifth embodiment, a plurality of tab portions 45 are fitted into the respective recessed portions 49 in the foamed sealing material 11, and the peripheral portions corresponding to the peripheral portions of the recessed portions 49 are ultrasonically welded to the surface of the plate body 15. It is welded by the jig 47 and compressed into a flat shape, and is harder than the non-compressed portion of the foam seal material 11. Moreover, the foaming sealing material 11 in the recessed part 49 is also compressed. At the time of this welding, the tip of the projection 53 is crushed by the ultrasonic welding jig 47 to form a bulging portion 53 a, and the projection 53 is buried in each tab portion 45. The rest of the configuration is the same as that of the first embodiment (see FIG. 6).

  As described above, in the fifth embodiment, the plurality of tab portions 45 of the foam sealing material 11 are ultrasonically welded to the surface of the plate body 15 at the periphery of the plurality of recessed portions 49 at positions spaced in the longitudinal direction of the groove. Since it is welded by the jig 47 and compressed into a flat shape, the foamed sealing material 11 is recessed without applying any special surface treatment to the surface of the plate body 15 as in claim 1 (claims 3 and 4). While being able to be surely accommodated in the groove 19 so as not to be detached, large-scale equipment necessary for the surface treatment is unnecessary, and the cost can be reduced. Further, the foam seal material 11 can be made difficult to be detached from the groove 19 by inserting the tab portion 45 into the plurality of recessed portions 49 to obtain an anchor effect. Furthermore, the anchor effect is also exerted by the bulging portion 53 a at the tip of the protrusion 53, making it difficult for the tab portion 45 to be further detached from the recessed portion 49, and making the foamed sealing material 11 more difficult to separate from the groove 19. .

  When molding the plate body 15, although not shown, a molding die including a first split mold 33 that molds the front side of the plate body 15 and a second split mold 35 that molds the back side of the plate body 15. 31 is used (see FIGS. 7 and 12). However, on the molding surface 33a of the first split mold 33, a single ridge 37 having a protrusion corresponding to the concave portion 49 (including the stepped portion 51 and the protrusion 53) is formed in the groove 19 forming portion. Correspondingly, the protrusions are only integrally formed, and the protrusions 37 do not have the notches as in the first embodiment. A cavity 39 having a concave portion 39a is formed on the molding surface 35a of the second split die 35 corresponding to the thickness of the plate body 15, and the concave portion 39a is formed on the concave portion 49 (upper step). 51 and the protrusion 53 (including the protrusion 53), and the protrusion 41 as in the first embodiment and the protrusion for forming the notch 17c as in the second embodiment are formed on the bottom surface of the recess 39a. There is no 43.

  Therefore, even if the plate body 15 is molded using such a mold 31, it is not possible to make a portion that becomes an undercut portion after molding, and it is possible to avoid a situation in which the molded plate body 15 cannot be removed. it can. Therefore, as in the first embodiment, a slide mold for avoiding this is not necessary, and the plate body 15 and, consequently, the resin carrier plate 9 with the foam sealant can be easily and reliably formed with a simple mold structure. It can be manufactured at low cost.

  In addition, in said embodiment, although the case where the resin-made panel with a foam seal material was the carrier plate 9 of the side door of a motor vehicle was shown, it can apply also to other panels for vehicles, and panels other than a motor vehicle. It is.

  The present invention is useful for a resin panel in which a foamed sealing material is accommodated so as not to leave the groove.

It is a perspective view equivalent to the cross section in the AA line of FIG. It is sectional drawing in the AA line of FIG. 5 (arrow line view in the BB line of FIG. 1). It is a perspective view which shows the concave groove surrounding part of the plate body of the carrier plate which concerns on Embodiment 1. FIG. It is sectional drawing in CC line of FIG. It is the front view which looked at the carrier plate which concerns on Embodiment 1 from the vehicle compartment outer side. It is sectional drawing which shows the lower end part of the side door of the motor vehicle to which the carrier plate which concerns on Embodiment 1 was applied. FIG. 5 is a cross-sectional view of a molding die corresponding to FIG. 4 in the first embodiment. FIG. 3 is a diagram corresponding to FIG. It is an arrow line view in the DD line | wire of FIG. FIG. 4 is a diagram corresponding to FIG. 3 of the second embodiment. It is an arrow view in the EE line of FIG. FIG. 12 is a cross-sectional view of a molding die corresponding to FIG. 11 in Embodiment 2. It is a perspective view equivalent to the cross section in the FF line of FIG. It is an arrow line view in the GG line of FIG. FIG. 4 is a diagram corresponding to FIG. 3 of the third embodiment. It is an arrow line view in the HH line | wire of FIG. In Embodiment 3, it is a perspective view which shows the state which the foaming resin raw material foamed in the grooved groove | channel of a plate main body. It is an arrow line view in the II line | wire of FIG. FIG. 6 is a diagram corresponding to FIG. 5 of the third embodiment. FIG. 14 is a diagram corresponding to FIG. 13 of the fourth embodiment. It is sectional drawing in the JJ line of FIG. FIG. 16 is a diagram corresponding to FIG. 15 of the fourth embodiment. It is an arrow line view in the KK line | wire of FIG. FIG. 18 is a diagram corresponding to FIG. 17 of the fourth embodiment. It is an arrow line view in the LL line | wire of FIG. FIG. 14 is a diagram corresponding to FIG. 13 of the fifth embodiment. It is an arrow view in the MM line | wire of FIG. It is sectional drawing in the NN line | wire of FIG. FIG. 22 is a view corresponding to FIG. 22 of the fifth embodiment. It is an arrow line view in the OO line of FIG. FIG. 25 is a view corresponding to FIG. 24 of the fifth embodiment. It is an arrow line view in the PP line of FIG.

Explanation of symbols

9 Carrier plate (panel)
11 Foam sealing material 15 Plate body (panel body)
19 concave groove 19a concave groove bottom surface 19b concave groove side surface 27 through hole 29 locking piece 45 tab portion 49 concave portion 53 protrusion 53a bulging portion

Claims (5)

A resin with a foam sealing material, comprising: a resin panel body having a groove on the surface; and a foam sealing material in which the liquid foam resin raw material is foamed and cured in the groove to bulge on the surface of the panel body. Panel made of,
A plurality of through holes are formed on the bottom surface of the concave groove at intervals in the longitudinal direction of the groove, and a plurality of locking holes are provided at the corresponding portions of the through holes on the side surface of the concave groove. Projected toward the inside of the groove with an interval in the groove longitudinal direction so that the piece is buried in the foam sealant,
A resin panel with a foam seal material, wherein a part of the foam seal material is fitted into each through-hole and is retained by each of the retaining pieces. A resin with a foam sealing material, comprising: a resin panel body having a groove on the surface; and a foam sealing material in which the liquid foam resin raw material is foamed and cured in the groove to bulge on the surface of the panel body. Panel made of,
A plurality of through holes are formed on the side surface of the concave groove at intervals in the longitudinal direction of the groove,
A resin panel with a foam seal material, wherein a part of the foam seal material is fitted into each through hole and is locked to the periphery of each through hole. A resin with a foam sealing material, comprising: a resin panel body having a groove on the surface; and a foam sealing material in which the liquid foam resin raw material is foamed and cured in the groove to bulge on the surface of the panel body. Panel made of,
The foamed sealing material has a plurality of tab portions that protrude outward from the concave groove and are welded to the surface of the panel body and compressed into a flat shape with a gap in the longitudinal direction of the groove. A resin panel with a foam sealant, characterized by being integrally formed. A resin with a foam sealing material, comprising: a resin panel body having a groove on the surface; and a foam sealing material in which the liquid foam resin raw material is foamed and cured in the groove to bulge on the surface of the panel body. Panel made of,
On the side surface of the groove, a plurality of recessed portions that are recessed toward the outer side of the groove are formed at intervals in the groove longitudinal direction,
In the foam sheet material, a plurality of tab portions, which are fitted into the respective recessed portions and the corresponding peripheral portions of the recessed portions are welded to the surface of the panel main body and compressed into a flat shape, are spaced apart in the longitudinal direction of the groove. A resin panel with a foam sealant, which is integrally formed by opening. In the resin panel with a foam seal material according to claim 4,
A resin panel with a foam sealant, characterized in that a protrusion having a bulging portion at the tip is integrally projected on the bottom surface of each recessed portion so as to be buried in each tab portion.

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