JP2013075555A - Resin molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin molded article where the side surface and back surface of a substrate can be covered with a skin material by simpler work.SOLUTION: The resin molded article 20 includes: a substrate 21 produced from a synthetic resin; the skin material 22 provided on the surface side of the substrate 21; a hinge 25 molded integrally with the side surface 23 of the substrate 21; a plate-shaped fold-back piece 26 molded integrally with the hinge 25 and folded back onto the back surface 33 of the substrate 21; a skin piece 27 formed from the skin material 22 and pressure-bonded to the surfaces of the hinge 25 and the fold-back piece 26; and a recess 28 provided in the substrate 21 to accommodate the fold-back piece 26.

Description

  The present invention relates to a resin molded body, and particularly to a plate-shaped resin molded body having a synthetic resin base material and a skin material provided on the surface of the base material.

  Conventionally, a plate-like resin molded body having a synthetic resin base material and a skin material provided on the surface of the base material has been widely used. As a method of molding a plate-shaped resin molded body, a molding material for a base material such as blow molding and sheet blow molding and a molding material for a skin material are sandwiched between a pair of molds and molded along a cavity. A molding method in which a skin material is integrated with a base material is known.

  In this type of molding method, the skin material is placed in one mold for molding the surface side of the substrate. Further, the dividing position (parting line) of the pair of molds is generally set on the side surface of the base material. Therefore, the skin material is molded so as to cover the side surface from the surface of the base material to the parting line. That is, at least the lower part and the back surface of the side surface of the base material are not covered with the skin material.

  Such a resin molded body is used, for example, for a deck board placed in a luggage compartment of a vehicle. When used in a deck board, if the parting line is set on the side surface of the base material, the end part when the burr is cut in the parting line may protrude and damage the contact surface of the cargo room. Further, when the side surface of the deck board is exposed, the side surface of the base material can be seen from the outside, so that the appearance of the luggage compartment is impaired. Further, when the back surface of the base material is directly placed on the floor support, hard parts come into contact with each other, so that there is a possibility that abnormal noise is generated or the contact surface is worn during traveling. As a countermeasure, a non-woven fabric is partially pasted on the back surface of the base material. However, if a non-woven fabric is separately pasted on the back surface of the base material as a cushioning material, the productivity of the deck board is reduced accordingly.

  Therefore, Patent Document 1 proposes a technique for covering the side surface and the back surface of a base material with a skin material. FIG. 9 is a diagram illustrating a method for molding a resin molded body described in Patent Document 1. In this molding method, first, a molding material for a base material (so-called parison) and a molding material for a skin material are sandwiched between a pair of molds 101, 102, and pressure air is blown into the parison to inflate it. Thereby, the resin molding 100 in which the skin material 105 is integrated with the hollow base material 104 is obtained.

  End portions (so-called burrs) 104 a and 105 b of the molding material that protrude from the cavity 103 are crushed by the pinch-off portions 106 outside the cavity 103. In the technique of Patent Document 1, the space between the pinch-off portions 106 is secured wide to prevent the end portions 104a and 105b from being bonded.

  Next, after the resin molded body 100 is taken out from the molds 101 and 102, the end 104a of the parison is removed. Then, as shown in FIGS. 10A and 10B, the end portion 105 a is bonded to the base material 104 so as to cover the side surface 108 and the back surface 109 of the base material 104. As a result, the appearance of the resin molded body 100 is improved. Moreover, since the cushioning property of the back surface of the resin molded body 100 is enhanced by the end portion 105a, it is not necessary to separately paste a non-woven fabric as a buffer material on the back surface.

JP 2011-115980 A

  However, in the technique of Patent Document 1, it is necessary to separate only the end portion 104a of the parison from the resin molded body 100 while leaving the end portion 105a of the skin material molding material on the resin molded body 100. For this reason, it takes time to cut the end 104a. While the productivity improvement of a resin molding is calculated | required, the technique which covers the side surface and back surface of a base material with a skin material by simpler operation | work is desired.

  Then, this invention is made | formed in view of such a situation, The objective is providing the resin molding which can cover the side surface and back surface of a base material with a skin material by simpler operation | work. It is in.

  The present invention relates to a plate-like resin molded body having a synthetic resin base material and a skin material provided on the surface side of the base material, a hinge integrally formed on the side surface of the base material, and the hinge A folded piece that is integrally molded and folded back on the back surface of the base material, a skin piece that is made of the skin material and is crimped to the surface of the hinge and the folded piece, and a folded piece provided on the base material. It has the dent which escapes, It is characterized by the above-mentioned.

The said invention is comprised so that the said skin piece may protrude rather than the back surface of the said base material.
The said invention is a substantially rectangular resin molding, The said folding piece is provided in two opposing side parts, It is characterized by the above-mentioned.
In the above invention, the folded piece includes a side plate extending along the side surface of the base material and a bottom plate connected to the side plate and extending along the back surface of the base material, and is formed in a substantially L shape. .

  According to the present invention, the side surface and the back surface of the base material can be covered with the skin material by a simple operation of folding the folded piece back to the back surface of the base material.

It is a figure explaining the usage example of the resin molding of 1st Embodiment concerning this invention. It is the sectional view on the AA line of FIG. It is a figure explaining the shaping | molding method of the resin molding of 1st Embodiment, (a) is a figure which shows the state which opened the shaping | molding die, (b) is a figure which shows the state which closed the shaping | molding die. is there. It is a perspective view of the resin molding of 1st Embodiment. It is the BB sectional view taken on the line of FIG. It is sectional drawing of the resin molding of 2nd Embodiment, and is a figure equivalent to FIG. 2 in 1st Embodiment. It is a figure explaining the shaping | molding method of the resin molding of 2nd Embodiment, (a) is a figure which shows the state which opened the mold, (b) is a figure which shows the state which closed the mold is there. It is sectional drawing of the resin molding of 2nd Embodiment, and is a figure corresponded in FIG. 5 in 1st Embodiment. It is a figure explaining the shaping | molding method of the conventional resin molding. It is a figure explaining the basic composition of the conventional resin molding, (a) is a figure which shows the form which cut off the edge part of a parison, (b) is a figure which shows the form which turned up the edge part of the molding material for skin materials It is.

(First embodiment)
Hereinafter, a first embodiment for carrying out the present invention will be described in detail with reference to the accompanying drawings. Note that the same number is assigned to the same element throughout the description of the embodiment.

  1st Embodiment is an example which used the resin molding of this invention for the vehicle deck board. As shown in FIG. 1, the vehicle 10 has a luggage compartment 12 behind the rear seat 11. A storage box 14 for storing articles is provided on the floor 13 of the luggage compartment 12. Support portions 15 extending in the vehicle width direction are provided at both ends of the storage box 14 in the vehicle front-rear direction. The resin molded body 20 is a substantially rectangular deck board that closes the opening of the storage box 14, and opposed side portions (here, front and rear long side portions) are supported by the support portion 15.

  As shown in FIG. 2, the resin molded body 20 includes a base material 21 and a skin material (so-called carpet) 22 provided on the surface side of the base material 21. Further, the resin molded body 20 includes a first hinge 25 integrally formed on the side surface 23 of the base material 21, a plate-like folded piece 26 integrally formed on the first hinge 25, and a surface of the folded piece 26. It has the skin piece 27 provided and the dent 28 which is provided in the base material 21 and escapes the folding piece 26.

Hereinafter, the configuration of each unit will be described in detail.
The base material 21 is a hollow molded body made of a synthetic resin such as polyethylene or polypropylene. In addition, the base material 21 which has high rigidity and high heat insulation can be obtained by filling the hollow part 29 with a foaming material.

  The skin material 22 includes a skin body 31 that covers at least the surface of the base material 21 (here, the top surface and the upper end of the side surface 23), and a skin piece 27 that is crimped to the folded piece 26. The skin body 31 and the skin piece 27 are made of one sheet material. The material of the skin material 22 is appropriately selected from, for example, a non-woven fabric, a woven fabric, a knitted fabric, or a fabric having these raised.

  The first hinge 25 is provided on the parting line PL on the side surface 23 and is formed thinner than the main body portion of the base material 21. Further, the first hinge 25 is formed so as to avoid left and right ends (left and right corners) of the side surface 23.

  The folded piece 26 includes a side plate 32 along the side surface 23, and a bottom plate 34 connected to the side plate 32 and along the back surface 33 of the base material 21. The side plate 32 and the bottom plate 34 are integrally formed via a thin second hinge 35. The folded piece 26 is aligned with the side surface 23 and the back surface 33 of the base material 21 by bending the first hinge 25 and the second hinge 35.

  The skin piece 27 is provided so as to cover the entire surface of the folded piece 26. That is, the skin piece 27 is formed so as to cover the first hinge 25, the side plate 32, the second hinge 35, and the bottom plate 34.

  The recess 28 has a recess 36 into which the side plate 32 fits and a recess 37 into which the bottom plate 34 fits. The recess 36 and the recess 37 are provided at the end portions of the side surface 23 and the back surface 33 of the base material 21, respectively. Since the side plate 32 fits into the recess 36, the skin piece 27 and the skin body 31 are located on substantially the same plane, and thus are smoothly connected. Further, when the bottom plate 34 is fitted into the recess 37, the step between the skin piece 27 and the back surface 33 is also reduced. However, here, the depth of the dent 37 is set so that the skin piece 27 protrudes from the back surface 33. Thereby, since the skin piece 27 comes to be supported by the support part 15, the back surface 33 does not contact the support part 15, and the indicator part 5 is not damaged by the parting line.

Then, the manufacturing method of the resin molding 20 is demonstrated based on FIGS.
In this manufacturing method, a molding die 40 is used as shown in FIG. In addition, since the resin molding 20 and the molding surface of the molding die 40 have substantially the same surface shape, in the following description, each part of the resin molding 20 and each part of the molding die 40 are connected to each molding surface of the molding die 40. Use a common designation. However, in the molding die 40, “part” is added for distinction. For example, “first hinge 25” and “dent 36” are used in the resin molded body 20, but “hinge portion 25A” and “dent 36A” are used on the molding surface of the molding die 40.

  As shown in FIGS. 3A and 3B, the molding die 40 includes a first die 41 that molds the front surface side of the resin molded body 20 and a second mold that molds the back surface side of the resin molded body 20. And a metal mold 42. The first mold 41 has a molding surface composed of a skin main body portion 31A and a skin piece portion 27A. On the other hand, the second mold 42 has a molding surface composed of a back surface portion 33A, recess portions 36A and 37A, a first hinge portion 25A, a side plate portion 32A, a second hinge portion 35A, and a bottom plate portion 34A. A cavity 43 is formed in the molding die 40 by these molding surfaces. The inner surface shape of the cavity 43 is processed into substantially the same shape as the outer surface shape of the resin molded body 20. In addition, a pinch-off portion 44 is provided outside the cavity 43 to crush between a portion formed by the cavity 43 and an extra portion.

Next, a molding method using this molding die 40 will be described.
A sheet 45, which is a molding material for the skin material, is placed in the mold 41. Further, a molten cylindrical parison 46 which is a molding material for the base material is extruded between the dies 41 and 42. Next, the molds 41 and 42 are combined and closed, and the sheet 45 and the parison 46 are sandwiched between the molds 41 and 42. In this state, gas is blown into the parison 46, and the parison 46 swells toward the skin main body 31A, the back surface 33A, and the recesses 36A and 37A. Thereby, the main-body part of the resin molding 20 is shape | molded.

  On the other hand, in the skin piece portion 27A, the first hinge portion 25A, the side plate portion 32A, the second hinge portion 35A, and the bottom plate portion 34A, the sheet 45 and the parison 46 are crushed and compression-molded. Thereby, the folded piece 26 in which the first hinge 25, the side plate 32, the second hinge 35, and the bottom plate 34 are integrally formed is formed. At the same time, the skin piece 27 is crimped to the folded piece 26. On the outside of the cavity 43, a cut line 47 is formed in the sheet 45 and the parison 46 by the pinch-off portion 44.

  After cooling, the molds 41 and 42 are opened, the resin molded body 20 is taken out, the cut line 47 is cut, and the burr 48 is cut off. Then, as shown in FIG. 4, a resin molded body 20 having a substantially flat folded piece 26 is obtained.

  Then, as shown in FIG. 5, the first hinge 25 and the second hinge 35 are bent, the folded piece 26 is fitted into the recess 28, and fixed with a double-sided tape (reference numeral 49 in FIG. 2). As a result, the resin molded body 20 in which the end portions of the side surface 23 and the back surface 33 of the base material 21 are covered with the skin pieces 27 is obtained. The fixing of the folded piece 26 and the base material 21 is not limited to the fixing by the double-sided tape 49, but may be fixing by a fastening means such as a screw or a bolt, and the means is arbitrary.

  As described above, according to the resin molded body 20 of the first embodiment described above, the side surface 23 and the back surface 33 of the base material 21 can be covered with the skin material 22 by a simple operation of folding back the folded piece 26. Moreover, since it comprised so that the skin piece 27 might protrude from the back surface 33 of the base material 21, the skin piece 27 with high cushioning properties can be supported by the support part 15. FIG. At the same time, contact between the base material 21 and the support portion 15 can be prevented, and wear of the base material 21 and the support portion 15 can be prevented. In addition, since the folded pieces 26 are provided on the two side portions of the base material 21, the resin molded body 20 can be stably supported by the two support portions 15.

(Second Embodiment)
Next, the resin molded body of 2nd Embodiment is demonstrated based on FIGS. In addition, the same code | symbol is attached | subjected to the site | part which is common in the resin molding concerning 1st Embodiment mentioned above, and the overlapping description is abbreviate | omitted.

  In the first embodiment, the folded piece is formed in a substantially flat plate shape, but the folded piece may be formed in a substantially L shape. That is, as shown in FIG. 6, in the resin molded body 50 of the second embodiment, the second hinge is not provided between the side plate 32 and the bottom plate 34, and the side plate 32 and the bottom plate 34 are connected directly and substantially at a right angle. The folded piece 38 is integrally formed.

  A forming method for forming such a substantially L-shaped folded piece 38 will be described. As shown in FIGS. 7A and 7B, each of the first mold 41 and the second mold 42 is provided with a concave skin piece portion 27A and a convex folded piece portion 38A. The skin piece portion 27A and the folded piece portion 38A form a substantially L-shaped gap (a part of the cavity 43) during mold clamping. Molding is performed in the same manner as in the first embodiment using the molding die 40 having the skin piece portion 27A and the folded piece portion 38A.

  Then, as shown in FIG. 8, a resin molded body 50 having a substantially L-shaped folded piece 38 is obtained. Then, the first hinge 25 is bent, the folded piece 38 is fitted into the recess 28, and fixed with a double-sided tape 49 (see FIG. 6). As a result, a resin molded body 50 in which the end portions of the side surface 23 and the back surface 33 of the base material 21 are covered with the skin pieces 27 is obtained. The means for fixing the folded piece 38 to the base material 21 can be selected from any means as in the first embodiment.

  According to the resin molded body 50 of 2nd Embodiment, the effect similar to the resin molded body 10 of 1st Embodiment mentioned above can be acquired. Furthermore, since the folded piece 38 is formed in a substantially L shape, the labor of bending the bottom plate with respect to the side plate can be saved. For this reason, the work of folding back the folded piece 38 is further simplified.

  As mentioned above, although this invention was demonstrated using embodiment, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiments. Further, it is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

  For example, in the embodiment, the base material is molded by a blow molding method using a cylindrical parison, but the molding method is not particularly limited to the blow molding method and is arbitrary. For example, instead of a cylindrical parison, two molten sheets are arranged between a plurality of divided molds, and a closed space between the sheets and the divided molds is sucked to form a hollow base material. You may shape | mold. Such a molding method is suitable for producing a resin molded body having higher rigidity because it is easy to put a foam material or the like as a core material between two sheets.

DESCRIPTION OF SYMBOLS 15 Support part 20 Resin molding 21 Base material 22 Skin material 23 Side surface of base material 25 1st hinge (hinge)
26 Folded piece 27 Skin piece 28 Recess 32 Side plate 33 Back surface of base material 34 Bottom plate 38 Folded piece 50 Resin molded body

Claims (4)

In a plate-shaped resin molded body having a synthetic resin base material and a skin material provided on the surface side of the base material,
A hinge integrally formed on a side surface of the substrate;
A folded piece integrally formed with the hinge and folded back on the back surface of the substrate;
An outer skin piece composed of the outer skin material and crimped to the surface of the hinge and the folded piece;
A resin molded body having a recess provided on the base material and allowing the folded piece to escape.   The resin molded body according to claim 1, wherein the skin piece is configured to protrude from a back surface of the base material. A substantially rectangular resin molded body,
The resin molded body according to claim 1, wherein the folded piece is provided on two opposing side portions.   The said folded piece has a side plate along the side surface of the base material and a bottom plate connected to the side plate and along the back surface of the base material, and is formed in a substantially L shape. 4. The resin molded product according to any one of 3.

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