JP2010083153A - Vehicular large exterior component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin vehicular large exterior component having high dimensional accuracy and excellent design without necessity of a smoothing process in manufacturing. <P>SOLUTION: A coating material 3 is stacked on a base material 2 of the vehicular large exterior component 1. In this structure, a fiber material having a low linear expansion coefficient is mixed with the base material 2 to set a linear expansion coefficient equal to or smaller than 6×10<SP>-5</SP>/°C. The coating material 3 is formed by molding. The thermal shrinkage of the overall vehicular large exterior component 1 is suppressed by setting the linear expansion coefficient of the base material 2 small. Since the coating material 3 is formed by molding, the surface shapes of the coating material 3 and the vehicular large exterior component 1 are not influenced by the shape of a coating material side surface 20 of the base material 2. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a resin-made large-sized exterior component for a vehicle typified by a back door garnish and a side door garnish.

  A large-sized exterior part for a vehicle represented by a back door garnish or the like is disposed in the vehicle (see, for example, Patent Documents 1 to 3). These large vehicle exterior parts are generally made of a resin material in order to reduce the weight of the vehicle and reduce material costs.

  By the way, since the large-sized vehicle exterior component made of a resin material is a large-sized member, it greatly shrinks during molding. For this reason, the large vehicle exterior parts made of a resin material are inferior in dimensional accuracy. For example, when the large vehicle exterior part is a back door garnish, if the gap between another member (rear combination lamp, etc.) adjacent to the large vehicle exterior part and the large vehicle exterior part is excessive, this gap Since the rear side (front side) of the vehicle is visible, the design of the vehicle is impaired. In addition, if the gap between the large vehicle exterior component and the rear combination lamp is too small, the large vehicle exterior component and the rear combination lamp interfere with each other, making it impossible to install the large vehicle exterior component or the rear combination lamp on the vehicle. The door may not open (or close). For this reason, high dimensional accuracy is required for large exterior parts for vehicles.

In order to increase the dimensional accuracy of large exterior parts for vehicles made of resin materials, for example, fiber materials made of materials with a low coefficient of linear expansion such as glass fibers are blended with resin materials to suppress thermal shrinkage during molding. Is considered good. However, in this case, when the portion made of the resin material is thermally contracted, the fiber material is lifted, and an uneven shape is generated on the surface of the large vehicle exterior component. Moreover, fiber materials, such as glass fiber, may float from the resin material and jump out on the surface of a large vehicle exterior component. Therefore, in this case, there is a problem that it is difficult to obtain a large vehicle exterior part having excellent design. If the surface of the large vehicle exterior component is smoothed, such as sanding, a large vehicle exterior component with excellent design can be obtained. In this case, however, the manufacturing cost of the large vehicle exterior component increases. There's a problem. Accordingly, there is a need for a large-sized exterior component for a vehicle that is lightweight, excellent in design, and inexpensive to manufacture.
JP 2008-49859 A JP 2008-80915 A Japanese Utility Model Publication No. 1-68224

  This invention is made | formed in view of the said situation, and it aims at providing the resin-made large-sized exterior components for vehicles which are excellent in dimensional accuracy and designability, and do not require a smoothing process at the time of manufacture.

A large-sized exterior part for a vehicle that solves the above-described problem includes a base material made of a base material including a first resin material and a fiber material made of a material having a lower linear expansion coefficient than the first resin material. A coating material made of a coating material containing a second resin material and laminated on the substrate, and the linear expansion coefficient of the substrate is 6 × 10 ⁻⁵ / ° C. or less, and the coating The material is characterized by being molded.

  The large vehicle exterior component of the present invention preferably includes any of the following (1) to (4), and more preferably includes a plurality of (1) to (4).

  (1) The wall thickness of the covering material is 1.5 mm or more.

  (2) The average fiber diameter of the fiber material is 6 μm to 15 μm.

  (3) The average fiber length of the fiber material is 0.2 mm to 10 mm.

  (4) The covering material side surface of the base material has a concavo-convex shape having a peeling suppressing portion that protrudes in the direction of the covering material and extends in a direction intersecting with a longitudinal direction of the large-sized exterior part for a vehicle. The base material side surface has an uneven shape complementary to the covering material side surface of the base material.

  The large vehicle exterior component of the present invention has a base material and a covering material. The base material (base material) includes a first resin material and a fiber material having a smaller linear expansion coefficient than the first resin material. For this reason, the linear expansion coefficient of the base material in the large vehicle exterior component of the present invention is small. For this reason, a base material does not heat-shrink easily and is excellent in dimensional accuracy. Moreover, since the coating | covering material in the large sized exterior component for vehicles of this invention is being fixed to the base material which is hard to heat-shrink, it is hard to heat-shrink. For this reason, the large-sized exterior component for vehicles according to the present invention is difficult to thermally shrink as a whole and has excellent dimensional accuracy. Therefore, the large vehicle exterior component of the present invention is unlikely to impair the design of the vehicle.

  Moreover, the coating material is laminated | stacked on the base material in the large sized exterior component for vehicles of this invention. For this reason, in the base material, the surface on the coating material side (hereinafter simply referred to as the coating material side surface of the base material) is covered with the coating material. Therefore, the large-sized exterior component for a vehicle according to the present invention is excellent in design because the uneven shape on the coating material side surface of the base material is hidden by the coating material. In addition, since the coating material is laminated on the base material, it is necessary to smooth the surface of the base material on the coating material side and the surface of the large vehicle exterior component when manufacturing the large vehicle exterior component of the present invention. Absent. For this reason, the large vehicle exterior component of the present invention can be manufactured at low cost.

  Furthermore, since the base material and the covering material (covering material) include a resin material, the large vehicle exterior component of the present invention is lightweight.

  The surface shape of the covering material in the large vehicle exterior component of the present invention having the above (1) is more unlikely to be affected by the uneven shape of the surface of the base material on the covering material side. For this reason, the large-sized exterior parts for vehicles of the present invention provided with the above (1) are further excellent in design.

  The vehicular large-sized exterior component of the present invention having at least one of the above (2) to (3) can sufficiently suppress the thermal shrinkage of the base material by sufficiently increasing the size of the fiber material, and can be used as a coating material. However, it is difficult to be affected by the uneven shape of the surface of the base material on the coating material side. Therefore, the large vehicle exterior component of the present invention including at least one of the above (2) to (3) is further excellent in dimensional accuracy and further excellent in design.

  According to the large vehicle exterior component of the present invention having the above (4), even when the linear expansion coefficient of the coating material is relatively small (when the thermal shrinkage amount of the coating material and the thermal shrinkage amount of the base material are greatly different) The base material and the covering material are hardly peeled off. For this reason, the large vehicle exterior component of the present invention having the above (4) is excellent in design and increases the degree of freedom in selecting the coating material.

  Hereinafter, the large-sized exterior parts for vehicles of the present invention are explained concretely.

Example 1
The large vehicle exterior part of Example 1 is a back door garnish. The large vehicle exterior component of Example 1 includes the above (1) to (4). FIG. 1 is a front view schematically showing the large vehicle exterior component of the first embodiment. FIG. 2 is a cross-sectional view schematically showing a state in which the large vehicle exterior component of the first embodiment is cut at the position AA in FIG.

  As shown in FIG. 1, the large-sized exterior component 1 for a vehicle according to the first embodiment is attached to a back door 9 of the vehicle with the longitudinal direction thereof being directed in the left-right direction. Rear combination lamps 90 are disposed on the left and right of the large vehicle exterior component 1. The large vehicle exterior component 1 and the rear combination lamp 90 are close to each other.

As shown in FIG. 2, the large vehicle exterior component 1 includes a base material 2 and a covering material 3. The base material is made of a mixed material of PA as the first resin material and glass fiber as the fiber material. Specifically, the base material is formed by mixing 40 parts by mass of the first resin material and 60 parts by mass of the fiber material. The linear expansion coefficient of the first resin material is 12 × 10 ⁻⁵ / ° C., and the linear expansion coefficient of the fiber material is 2 × 10 ⁻⁵ / ° C. Therefore, the linear expansion coefficient of the fiber material is lower than the linear expansion coefficient of the first resin material. The average fiber diameter of the fiber material is about 10 μm, and the average fiber length is about 0.5 mm. The linear expansion coefficient of the whole substrate 2 is 4 × 10 ⁻⁵ / ° C., and is 6 × 10 ⁻⁵ / ° C. or less. The thickness of the base material 2 excluding the peeling suppression portion described later is substantially constant (2.5 mm).

  The covering material 3 is made of PA (second resin material) as a material (covering material). The base material 2 and the covering material 3 are integrally molded (two-color molding). Specifically, the base 2 is formed by forming a cavity for the base material 2 in the two-color mold, and then the cavity for the covering material 3 is formed in the two-color mold in which the base 2 is arranged. The covering material 3 was molded on the covering material side surface 20 of the material 2. The wall thickness of the covering material 3 excluding the filling portion described later is substantially constant (about 1.5 mm).

  As shown in FIG. 3, the base material 2 has a plurality of peeling suppressing portions 21. Therefore, the coating material side surface 20 of the substrate 2 has an uneven shape. Each peeling suppression part 21 protrudes in the coating | covering material 3 direction, and is extended in the direction orthogonal to the longitudinal direction of the large sized exterior component 1 for vehicles. The protrusion height of each peeling suppression part 21 is about 1.3 mm, and the width is about 1.2 mm. The distance between adjacent peeling suppression portions 21 is about 40 mm. The base material side surface 30 of the covering material 3 has an uneven shape complementary to the covering material side surface 20 of the base material 2. In other words, the covering material 3 has a plurality of filling portions 31 that protrude in the direction of the base material 2 and extend in a direction perpendicular to the longitudinal direction of the large vehicle exterior component 1. Each filling portion 31 is disposed in a gap between adjacent peeling suppression portions 21 and fills a gap between adjacent peeling suppression portions 21. The adjacent peeling suppressing part 21 and the filling part 31 are welded at the time of two-color molding.

  In the large vehicle exterior component 1 of the first embodiment, the base material 2 is covered with the covering material 3. For this reason, the uneven | corrugated shape of the coating | covering material side surface 20 of the base material 2 is not visually recognized from the surface side of the large sized exterior component 1 for vehicles. Further, since the covering material 3 is molded, the surface shape of the covering material 3 is hardly affected by the uneven shape of the covering material side surface 20 of the base material 2. Furthermore, since the base material 2 includes a fiber material having a low expansion coefficient, it is difficult to thermally shrink, and the entire large vehicle exterior component 1 is also difficult to thermally shrink. For this reason, the large-sized exterior component 1 for vehicles of Example 1 is excellent in dimensional accuracy. Therefore, the large vehicle exterior component 1 of Example 1 is excellent in dimensional accuracy and design. In addition, as described above, the covering material side surface 20 of the base material 2 is covered with the covering material 3, and the surface of the covering material 3 is not easily affected by the uneven shape of the covering material side surface 20 of the base material 2. Furthermore, it is not necessary to smooth the covering material side surface 20 of the base material 2 and the surface of the covering material 3. For this reason, the large-sized exterior part 1 for vehicles of Example 1 is excellent in design property, and can be manufactured cheaply.

  Moreover, the large-sized exterior component 1 for vehicles of Example 1 can fix the coating | covering material 3 firmly by the base material 2 by providing the peeling suppression part 21 in the base material 2. FIG. For this reason, the thermal contraction of the covering material 3 can be more reliably inhibited by the base material 2, and the thermal contraction of the entire large vehicle exterior component 1 can be suppressed. Moreover, peeling of the base material 2 and the coating | covering material 3 resulting from a thermal contraction can be suppressed with high reliability by inhibiting the thermal contraction of the coating | covering material 3 with high reliability.

  In addition, the 1st resin material and 2nd resin material in the large sized exterior component 1 for vehicles of Example 1 are materials with comparatively low compatibility. However, the base material 2 and the covering material 3 can be firmly integrated by providing the base material 2 with the peeling suppressing portion 21 and providing the covering material 3 with the filling portion 31. Also by this, the base material 2 and the covering material 3 in the large vehicle exterior component 1 of Example 1 are difficult to peel off.

  Moreover, since the peeling suppression part 21 is extended in the direction crossing with the longitudinal direction of the large sized exterior component 1 for vehicles, the thermal contraction of the coating | covering material 3 in the longitudinal direction of the large sized exterior component 1 for vehicles can be suppressed especially effectively. Therefore, the large vehicle exterior component 1 of the first embodiment is particularly excellent in dimensional accuracy in the longitudinal direction.

  Furthermore, the large vehicle exterior component 1 of the first embodiment is formed in two colors. For this reason, the large-sized exterior component 1 for vehicles of Example 1 can be manufactured by the base material 2 and the coating | covering material 3 being integrated firmly, and with few man-hours.

(Example 2)
The large vehicle exterior component of the second embodiment is a back door garnish, and is the same as the large vehicle exterior component of the first embodiment except for the shapes of the peeling prevention portion 21 and the filling portion 31. The large vehicle exterior component of Example 2 includes the above (1) to (4). FIG. 3 is a cross-sectional view schematically showing a state in which the large vehicle exterior component of the second embodiment is cut at the same position as AA in FIG.

  The base material and the covering material in the large vehicle exterior component 1 of the second embodiment are the same as those of the first embodiment. The large vehicle exterior component 1 of the second embodiment is insert-molded. Specifically, the base material 2 molded in advance was placed in the cavity of the injection mold, and the coating material 3 was molded on the coating material side surface 20 of the base material 2. The thickness of the covering material 3 is substantially constant (about 2 mm).

  The protrusion height of each peeling suppression part 21 is about 1 mm, and the width is about 1 mm. The distance between adjacent peeling suppression portions 21 is about 40 mm. Each filling portion 31 of the covering material 3 is disposed in a gap between adjacent peeling suppression portions 21 and fills a gap between adjacent peeling suppression portions 21. The adjacent peeling suppressing portion 21 and the filling portion 31 are welded during insert molding.

  The large vehicle exterior part 1 of Example 2 is excellent in dimensional accuracy and designability like the large vehicle exterior part 1 of Example 1, and does not require a smoothing process during production. 3 can be firmly integrated with each other and can be manufactured with less man-hours.

  The covering material 3 in the large vehicle exterior component 1 of the present invention can be molded by a method such as injection molding. The covering material 3 may be laminated on the base material 2 by a method such as adhesion, welding, press molding, or the like, which is previously molded. Or you may mold integrally with the base material 2 by methods, such as insert molding and two-color molding. In any case, if the surface of the covering material 3 is molded, the surface shape of the covering material 3 is hardly affected by the surface shape of the base material 2.

As the fiber material, one having a linear expansion coefficient of 2.5 × 10 ⁻⁵ / ° C. or less is preferable, and one having a linear expansion coefficient of 2.0 × 10 ⁻⁵ / ° C. or less is more preferable. By using a fiber material having a linear expansion coefficient of 2.0 × 10 ⁻⁵ / ° C. or less, the linear expansion coefficient of the base material 2 can be effectively reduced. Shrinkage can be effectively suppressed.

The linear expansion coefficient of the covering material 3 is not particularly limited, but is preferably 12 × 10 ⁻⁵ / ° C. or less. In the case where a material having low compatibility with the base material is used as the coating material and the coating material 3 does not have the peeling suppressing portion 21, it is more preferably 7.0 × 10 ⁻⁵ / ° C. or less. preferable.

  The peeling suppressing portion 21 preferably extends in a direction intersecting the longitudinal direction of the large vehicle exterior component 1, and more preferably extends in a direction orthogonal to the longitudinal direction of the large vehicle exterior component 1.

  As the first resin material, it is preferable to select a resin material having a low linear expansion coefficient and high strength such as PBT, PA, PP, and PET. As the second resin material, it is preferable to select a material such as ABS, PA, PBT, PP or the like. As the first resin material and the second resin material, it is preferable to select materials that are highly compatible with each other. However, as described above, the peeling suppression portion 21 is provided on the base material 2 and the filling portion 31 is provided on the covering material 3. In this case, the compatibility of the first resin material and the second resin material is not particularly limited.

  The protrusion height, width, and interval of the peeling suppressing portion 21 are not particularly limited. In order to effectively suppress the heat shrinkage of the covering material 3 and the large vehicle exterior component 1, it is preferable that the protrusion height of the peeling suppressing portion 21 is 40% or more of the thickness of the covering material 3. In consideration of the influence on the surface shape of the covering material 3, it is preferable that the protrusion height of the peeling suppressing portion 21 is 60% or less of the thickness of the covering material 3.

1 is a front view schematically illustrating a large-sized exterior part for a vehicle according to a first embodiment. It is sectional drawing which represents typically a mode that the large sized exterior component for vehicles of Example 1 was cut | disconnected in the AA position in FIG. It is sectional drawing which represents typically a mode that the large sized exterior component for vehicles of Example 2 was cut | disconnected in the same position as AA in FIG.

Explanation of symbols

1: Large exterior part for vehicle 2: Base material 3: Coating material 20: Coating material side surface 21: Peeling suppression part 30: Base material side surface 31: Filling part

Claims (5)

A base material made of a base material including a first resin material and a fiber material made of a material having a lower linear expansion coefficient than the first resin material;
A covering material made of a covering material containing a second resin material and laminated on the base material,
The linear expansion coefficient of the substrate is 6 × 10 ⁻⁵ / ° C. or less,
A large-sized exterior part for a vehicle, wherein the covering material is molded.   The large-sized exterior part for vehicles according to claim 1 whose thickness of said covering material is 1.5 mm or more.   The large-sized exterior part for vehicles according to claim 1 or 2 whose average fiber diameter of said textiles is 6 micrometers-15 micrometers.   The large-sized exterior part for vehicles according to any one of claims 1 to 3, wherein an average fiber length of the fiber material is 0.2 mm to 10 mm. The covering material side surface of the base material has a concavo-convex shape having a peeling suppressing portion that protrudes in the direction of the covering material and extends in a direction intersecting with a longitudinal direction of the large vehicle exterior component.
The large-sized exterior part for vehicles according to any one of claims 1 to 4, wherein the base material side surface of the covering material has an uneven shape complementary to the covering material side surface of the base material.

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