JP2018158584A - Resin structure, and vacuum cleaner using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin structure using a fiber-reinforced resin laminated sheet in a housing, which solves problems that a first layer formed of an FRP using a carbon fiber fabric or the like as a reinforcing material, and a second layer formed of a resin are easy to be delaminated, and in particular, are easy to be deformed due to a physical difference (thermal shrinkage) therebetween immediately after molding.SOLUTION: A resin molding 14 is structured of a fiber-reinforced resin laminated sheet 15 formed of a polyolefin resin, and a resin support member 16 formed of a resin having high affinity with the fiber-reinforced resin laminated sheet 15. The resin molding 14 has such a structure that at least one of a glass fiber and talc powder is mixed into the resin support member 16, and the resin support member 16 is fused to the fiber-reinforced resin laminated sheet 15 through an integral molding method including insert molding, and thereby does not cause a shape change due to thermal shrinkage immediately after insert molding, and can prevent deformation such as warpage and shrinkage on a surface which is fused to the fiber-reinforced resin laminated sheet 15.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a resin structure composed of a fiber-reinforced resin laminated sheet and a resin support member, and a vacuum cleaner using the same.

  Conventionally, a housing in which a plurality of reinforcing fiber fabrics such as carbon fibers and aramid fibers are laminated is known (for example, see Patent Document 1).

FIG. 7 shows a conventional housing for electronic / electric equipment described in Patent Document 1. In FIG.
As shown in FIG. 7, a first layer 1a made of carbon fiber woven fabric or FRP (Fiber Reinforced Plastics) formed by press-molding a material in which carbon continuous fibers arranged in a sheet form in one direction are impregnated with resin, and resin or It has a structure in which the second layer 2a formed by injection molding or transfer molding with a resin containing reinforcing short fibers is bonded with an adhesive or an adhesive tape.

JP 9-46082 A

However, in the configuration of Patent Document 1, a first layer 1a made of a carbon fiber woven fabric or FRP using a carbon continuous fiber arranged in a sheet shape in one direction as a reinforcing material and a resin or a resin containing a reinforcing short fiber is used. Between the two layers 2a, there has been a problem that deformation due to a difference in heat shrinkage rate is likely to occur after molding due to delamination and physical properties.
Moreover, since expensive materials such as carbon fiber are used, there is a problem that the cost is high.

  The present invention solves such a conventional problem, and by using a polyolefin-based fiber reinforced resin laminate sheet that can also be integrated by injection molding, at a joint with a polyolefin-based resin support member. Has affinity, especially does not cause deformation due to the difference in thermal shrinkage between the first and second layers, does not delaminate from the outer peripheral edge of the interlayer, is lightweight, has high physical strength against bending, and is inexpensive It is an object of the present invention to provide a vacuum cleaner having a resin structure and a resin structure having the resin structure in a housing of a vacuum cleaner body.

In order to solve the above-mentioned conventional problems, the present invention is a fiber reinforced fiber formed by bonding a fabric layer made of a polyolefin resin to both surfaces of a core layer made of a polyolefin resin through an adhesive layer of a polyolefin film. Layers,
A cover layer formed by combining a transparent layer, a colored layer laminated on the transparent layer, and a transparent protective layer laminated on the colored layer,
A fiber reinforced resin laminate sheet formed by integrating the cover layer on one surface layer of the fiber reinforced layer via an adhesive layer of a polyolefin film;
The fiber reinforced resin laminate sheet and a resin support member made of a resin having high affinity,
At least one of glass fiber and talc powder is mixed in the resin support member, and the resin support member is fused to the fiber reinforced resin laminated sheet by an integral molding method including insert molding.

As a result, the resin structure does not change in shape due to thermal shrinkage immediately after the insert molding of the resin support member due to the action of glass fiber or talc powder mixed in the resin support member. It is possible to prevent deformation such as warpage and sink marks that occur on the fused surface with the laminated sheet.
Furthermore, since the resin support member is formed of a resin having high affinity for the polyolefin-based resin of the fiber-reinforced resin laminated sheet, it has affinity at the joint, no delamination, and is inexpensive and lightweight. The physical strength against bending is also high, and by applying this resin structure to the casing of an electric device, the electric device can be reduced in weight.

  The resin structure of the present invention does not cause a shape change due to heat shrinkage immediately after the insert molding of the resin support member, can prevent deformation such as warpage and sinking on the fusion surface with the fiber reinforced resin laminated sheet, Since the resin support member is made of a resin having a high affinity for the polyolefin resin of the fiber reinforced resin laminated sheet, it has an affinity at the joint, there is no delamination, it is inexpensive and lightweight, and it is resistant to bending. The physical strength is also high, and by applying this resin structure to a housing of an electrical device, the weight of the electrical device can be reduced.

The external appearance perspective view of the vacuum cleaner in embodiment of this invention External perspective view of the vacuum cleaner body from above Central cross-sectional view of the main body of the vacuum cleaner External perspective view of the vacuum cleaner dust lid from the back side AA sectional view of FIG. 4 showing the dust cover of the vacuum cleaner Sectional drawing which showed the laminated structure of the fiber reinforced resin laminated sheet used for the dust cover of the vacuum cleaner 5 is a partially enlarged plan view of FIG. 5 showing the dust cover of the electric vacuum cleaner as viewed from the B direction. (A) Enlarged view of C part (outer peripheral end surface of fiber reinforced resin laminate sheet) shown in FIG. 5, (b) Enlarged view showing another form of the C part, (c) Shown another form of the C part Enlarged view Enlarged view of part D shown in FIG. 5 (resin support member deformed by heat shrinkage after molding) External perspective view showing conventional housing parts

A first invention is a fiber reinforced layer formed by bonding a fabric layer made of a polyolefin resin to both surfaces of a core layer made of a polyolefin resin via an adhesive layer of a polyolefin film;
A cover layer formed by combining a transparent layer, a colored layer laminated on the transparent layer, and a transparent protective layer laminated on the colored layer,
A fiber reinforced resin laminate sheet formed by integrating the cover layer on one surface layer of the fiber reinforced layer via an adhesive layer of a polyolefin film;
The fiber reinforced resin laminate sheet and a resin support member made of a resin having high affinity,
By mixing at least one of glass fiber and talc powder into the resin support member, and making the resin support member fused to the fiber reinforced resin laminate sheet by an integral molding method including insert molding, The resin structure does not change in shape due to thermal shrinkage immediately after insert molding of the resin support member due to the action of glass fiber or talc powder mixed in the resin support member, and the resin support member and the fiber reinforced resin laminated sheet Deformation such as warpage and sinking that occurs on the fused surface can be prevented.
Furthermore, since the resin support member is formed of a resin having high affinity for the polyolefin-based resin of the fiber-reinforced resin laminated sheet, it has affinity at the joint, no delamination, and is inexpensive and lightweight. The physical strength against bending is also high, and by applying this resin structure to the casing of an electric device, the electric device can be reduced in weight.

  In the second invention, in particular, in the first invention, by mixing a foaming agent into the resin support member, the total weight of the resin structure can be reduced, and by adjusting the amount of the foaming agent, Weight reduction can be achieved without impairing strength and rigidity.

  In the third invention, particularly in the first or second invention, since the resin support member is formed of a polyolefin resin, both the fiber reinforced resin laminated sheet and the resin support member are a polyolefin resin. It is compatible, free of delamination, inexpensive and lightweight, has high physical strength against bending, and by applying this resin structure to the housing of electrical equipment, it is possible to reduce the weight of electrical equipment. it can.

The fourth invention is a vacuum cleaner body that is inexpensive and lightweight by using the resin structure of any one of the first to third inventions as a vacuum cleaner that is used for the whole or a part of the cleaner body. Can be realized.
Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments.

(Embodiment 1)
FIG. 1 is an external perspective view of the electric vacuum cleaner according to the first embodiment of the present invention. As shown in FIG. 1, the vacuum cleaner of the present invention includes a vacuum cleaner body 1 and a suction tool 2 that sucks dust on the surface to be cleaned, an extension pipe 3 having one end connected to the suction tool 2, and one end extended. The hose 4 is connected to the pipe 3 and the other end is connected to the cleaner body 1.

FIG. 2 is an external perspective view of the cleaner body 1, and FIG. 3 is a central sectional view of the cleaner body 1.
The vacuum cleaner main body 1 includes a lower body body 5 that forms an outer lower surface, a front wheel 6 that is rotatably fitted to the lower body body 5, and a pair of left and right rear wheels 7 that are also fitted so as to be able to rotate back and forth. A front cover 8 that is locked to the lower body body 5 and holds one end of the hose 4, a handle 9 that is locked to the front cover 8 and carried by the user, and a body body that forms the outer and rear surfaces 10, a body attainer 11 for covering and decorating a part of the upper body body 10, and a dust lid 13 for preventing air leakage of the dust collecting portion 12. The dust lid 13 is rotatably fitted on the main body body 10.

  The resin structure according to the present invention is employed in the body attenuator 11 and the dust lid 13, but the dust lid 13 will be described as an example for the same configuration.

  4 is an external perspective view of the dust cover 13 of the vacuum cleaner as viewed from the back side, and FIG. 5 is a cross-sectional view taken along line AA of the dust cover 13 shown in FIG.

  The dust lid 13 is a resin structure 14 formed by integrally molding a fiber reinforced resin laminated sheet 15 made of a polyolefin resin as a basic material and a polyolefin resin support member 16 called a rib or a boss. And forms a housing of the vacuum cleaner main body 1. The polyolefin resin support member 16 in the present embodiment is a polypropylene resin.

  FIG. 6 is a cross-sectional view showing a laminated configuration of the fiber reinforced resin laminated sheet 15 used in the dust lid 13 shown in FIGS. 4 and 5.

The laminated structure of the fiber reinforced resin laminated sheet 15 includes a core layer 17, fabric layers 18 a and 18 b, adhesive layers 19 a, 19 b and 19 c, a transparent layer 20, a colored layer 21, and a transparent protective layer 22. Here, the core layer 17, the fabric layers 18a and 18b, and the adhesive layers 19a, 19b, and 19c are collectively referred to as a fiber reinforced layer 23, and the transparent layer 20, the colored layer 21, and the transparent protective layer 22 are collectively referred to as a cover layer 24. Call.

  The fiber reinforced resin laminated sheet 15 includes a fiber reinforced layer in which the fabric layers 18a and 18b are bonded to both surfaces of the core layer 17 via the adhesive layers 19a and 19b.

  The core layer 17 is a resin mainly composed of polypropylene. The core layer 17 is laminated in the form of a sheet or film. The core layer 17 is preferably made of a non-foamed polypropylene sheet. Non-foamed polypropylene-based sheets are not crushed by press molding, and can be easily formed by vacuum molding, bending molding utilizing thermal deformation, or the like.

  The woven fabric layers 18a and 18b are composed of a core-sheath composite fiber yarn in which the core component is a polypropylene resin and the sheath component is a polyolefin resin having a lower melting point than the core component. By making the sheath component a low-melting-point polyolefin-based component, it becomes easy to heat-bond. The woven fabric may be a woven fabric of any structure such as plain weave, twill weave (oblique fabric), satin weave, and other changed weaves.

  The adhesive layers 19a, 19b, and 19c are transparent heat-fused polyolefin films. By using this material, the core layer 17 and the fabric layers 18a and 18b can be heated and pressurized to be laminated and integrated easily.

The fiber reinforced resin laminated sheet 15 is obtained by integrating a cover layer 24 on one surface layer of the fiber reinforced layer 23 via an adhesive layer 19c.
The cover layer 24 is preferably a transparent polyolefin-based resin sheet and is transparent so that the fabric layer 18a can be seen from the outside. When the fabric layer 18a is seen from the outside, it looks high in strength and can maintain a beautiful appearance.

The cover layer 24 includes a transparent layer 20 made of a polypropylene resin sheet, a colored layer 21, and a protective layer 22 made of a polypropylene resin sheet.
By putting the thin colored layer 21 between the protective layer 22 and the transparent layer 20, it is possible to make the white fabric layer 18a look like dyed.

  The fiber reinforced resin laminated sheet 15 is integrally formed by bonding the fabric layers 18a and 18b to both surfaces of the core layer 17 via the adhesive layers 19a and 19b. A transparent layer 20 made of polypropylene resin, a colored layer 21, and a protective layer 22 made of polypropylene resin are laminated and integrated on the surface of the fabric layer 18a through an adhesive layer 19c. Here, the transparent layer 20, the colored layer 21, and the protective layer 22 may be laminated and integrated in advance as the cover layer 24.

  The fiber reinforced resin laminated sheet 15 laminated and integrated in this way is punched in the first step and cuts unnecessary portions, and then in the second step, a heat press machine according to the three-dimensional shape of the product outline. And pressure bending.

  In the next third step, the fiber reinforced resin laminated sheet 15 and a polyolefin resin support member 16 called ribs or bosses necessary for performing the function as the dust lid 13 are integrally molded to form a resin structure. By forming the body 14, it is possible to obtain a resin structure 14 in which polyolefin-based resins that are difficult to bond with an adhesive are firmly bonded.

Since the fiber reinforced resin laminated sheet 15 has a high resistance to bending, stretching, impact, etc., it is possible to maintain the same or better performance with a thin material compared to the conventional ABS resin (Acrylonitrile Butadiene Styrene). It becomes. In general, polyolefin resin is light in specific gravity, so it is more suitable for weight reduction than carbon fiber and glass fiber, and it is inexpensive and suitable for mass production.

  In addition, by providing the transparent cover layer 24, the surface can be given a glossy appearance and can be prevented from being scratched. Furthermore, by providing the colored layer 21 between the protective layer 22 and the transparent layer 20, the white fabric layer 18a can appear as if it is dyed, and color development becomes easy.

  Further, in the present embodiment, there is a resin structure 14 in which a polyolefin-based fiber reinforced resin laminate sheet 15 and a polyolefin-based resin support member 16 made of polypropylene resin are integrally formed by insert injection molding. 14 is a resin made of the same type of polyolefin-based material in which both the fiber reinforced resin laminated sheet 15 and the resin support member 16 are made of resin, so that there is affinity at the joint and there is no delamination, and adhesion of each layer is also polyolefin-based Since it is a resin, it has affinity, does not delaminate, is inexpensive and lightweight, and can increase the physical strength against bending. Furthermore, by applying this resin structure 14 to a casing of an electric device, the weight of the electric device can be reduced.

  FIG. 7 is a partially enlarged plan view of the dust lid 13 which is the resin structure 14 shown in FIG. 5 when viewed from the B direction. As shown in FIGS. 6 and 7, in the present embodiment, as a laminated configuration of the fiber reinforced resin laminated sheet 15, a polyolefin-based material called a rib or a boss is formed by setting the fabric layer 18 b as the lowest layer. In the integral molding with the resin support member 16, the resin of the polyolefin-based resin support member 16 enters the fiber braided portion 25 on the surface of the fabric layer 18 b and is difficult to peel off (this phenomenon is hereinafter referred to as an anchor effect).

  In addition, the anchor effect can be further enhanced by providing many fine uneven portions 26 by intentionally roughening the surface layer of the lowermost fabric layer 18b.

  Further, by providing, for example, a T-shaped extended portion 27 at the base of the polyolefin-based resin support member 16, the contact area between the fiber-reinforced resin laminate sheet 15 and the polyolefin-based resin support member 16 can be increased. Strength can be increased.

  Furthermore, in the present embodiment, as shown in FIG. 8A in which the portion C in FIG. 5 is enlarged, the outer peripheral end surface of the fiber reinforced resin laminated sheet 15 is covered with the outer peripheral holding portion 28 provided on the resin support member 16. By using the resin structure 14, it is possible to prevent the outer peripheral portion of the fiber reinforced resin laminated sheet 15 that is most easily peeled off by an external force from being peeled from the resin support member 16.

  Further, as shown in FIG. 8B, a thin portion 29 having a small thickness is provided on the outer periphery of the fiber reinforced resin laminated sheet 15 with a constant width from the outer periphery, and the resin thickness of the outer peripheral holding portion 28 in the thin portion 29 is increased. By providing the thick portion 30, the strength of the outer peripheral holding portion 28 and the rigidity against the bending force / twist of the end surface are increased, and it is possible to prevent peeling from the outer peripheral end surface.

  Further, as shown in FIG. 8C, a thin portion 29 having a small thickness is provided on the outer periphery of the fiber reinforced resin laminated sheet 15 with a constant width from the outer periphery, and the resin of the outer peripheral holding portion 28 covers the front and back surfaces of the thin portion 29. By being configured to cover both, the strength of the outer periphery holding portion 28 and the rigidity against peeling are increased, and separation from the outer peripheral end surface can be prevented.

  FIG. 9 is an enlarged view of a portion D shown in FIG. 6 and shows a state in which the resin support member 16 is deformed by heat shrinkage after molding. In the present embodiment, glass fiber or talc powder, which is an additive, is mixed into the resin support member 16 to change the physical properties, thereby making it difficult to cause heat shrinkage after molding, and deformation as shown in FIG. I try not to get up.

  Thereby, the resin structure 14 does not generate a shape change due to thermal contraction immediately after the insert molding of the resin support member 16, and the warp generated on the fusion surface between the resin support member 16 and the fiber reinforced resin laminated sheet 15. Deformation such as sink marks can be prevented.

  Further, in the present embodiment, since a foaming agent is mixed in the resin support member 16, bubbles are generated inside the resin, and the weight is reduced accordingly. Therefore, the total weight of the resin structure 14 can be reduced. it can. Further, by adjusting the amount of the foaming agent, the weight of the housing can be reduced without impairing the strength and rigidity.

  In the present embodiment, the case where the same type of polyolefin resin as the resin having affinity with the fiber reinforced resin laminated sheet 15 made of polyolefin resin is used for the resin support member 16 has been described. However, the present invention is limited to this case. Even if the resin is not the same system as the polyolefin resin, the same effect can be obtained as long as the resin has an affinity with the polyolefin resin.

  Further, in the present embodiment, the resin structure 14 has been described in the case where the fiber reinforced resin laminated sheet 15 and the polyolefin resin support member 16 are integrally formed, but there are several ways of joining. The same effect can be obtained by bonding individually molded products with an adhesive.

  As described above, in the present invention, a polyolefin fiber reinforced resin laminated sheet is used for a product casing, so that an inexpensive and impact-resistant product can be made without using expensive materials such as carbon fiber and aramid fiber. It can be used effectively to reduce the thickness and weight of the housing of the electric vacuum cleaner.

DESCRIPTION OF SYMBOLS 1 Vacuum cleaner main body 2 Suction tool 3 Extension pipe 4 Hose 5 Lower body body 6 Front wheel 7 Rear wheel 8 Front cover 9 Handle 10 Upper body body 11 Body atator 12 Dust collecting part 13 Dust cover 14 Resin structure 15 Fiber reinforced resin laminated sheet 16 Resin support member 17 Core layer 18a, 18b Textile layer 19a, 19b, 19c Adhesive layer 20 Transparent layer 21 Colored layer 22 Protective layer 23 Fiber reinforcing layer 24 Cover layer 25 Fiber braided portion 26 Uneven portion 27 Extended portion 28 Outer peripheral holding portion 29 Thin wall Part 30 Thick part

Claims (4)

A fiber reinforced layer formed by laminating a fabric layer made of polyolefin resin on both surfaces of a core layer made of polyolefin resin via an adhesive layer of a polyolefin film;
A cover layer formed by combining a transparent layer, a colored layer laminated on the transparent layer, and a transparent protective layer laminated on the colored layer,
A fiber reinforced resin laminate sheet formed by integrating the cover layer on one surface layer of the fiber reinforced layer via an adhesive layer of a polyolefin film;
The fiber reinforced resin laminate sheet and a resin support member made of a resin having high affinity,
A resin structure having a structure in which at least one of glass fiber and talc powder is mixed into the resin support member, and the resin support member is fused to the fiber reinforced resin laminated sheet by an integral molding method including insert molding. The resin structure according to claim 1, wherein a foaming agent is mixed in the resin support member. The resin structure according to claim 1 or 2, wherein the resin support member is formed of a polyolefin-based resin. The electric vacuum cleaner characterized by using the resin structure of any one of the said Claims 1-3 for the whole or a part of vacuum cleaner main body.