JP2019130776A - Molded structure - Google Patents

Abstract

To increase a joining strength of a resin molded body to a base material.SOLUTION: A molded structure includes a trim board 30 containing a fiber and a thermoplastic resin, a clip seat 40 joined to a plate surface 32 of the trim board 30 and protruding from the plate surface 32, and a resin portion 31 formed integrally with a resin material same as the clip seat 40 and connected to a base end portion of the clip seat 40. The trim board 30 is provided with a through hole 33 penetrating the trim board 30, and the resin portion 31 is disposed inside the through hole 33 and joined to an inner peripheral surface 36 of the through hole 33.SELECTED DRAWING: Figure 1

Description

  The technology disclosed herein relates to a molded structure.

  Conventionally, a molded structure in which a resin molded body is integrally formed on the surface of a substrate containing fibers and a thermoplastic resin is known. Patent Document 1 listed below describes a manufacturing method in which a resin molded body is molded by injecting a molten resin onto a substrate after the substrate is molded with a pair of molds. The molten resin injected onto the base material is mixed with the thermoplastic resin constituting the base material. As a result, the resin molded body is bonded to the base material. Moreover, an anchor effect arises because molten resin permeates between fibers contained in the base material, and the bonding strength of the resin molded body to the base material can be further increased.

JP 2009-113244 A

  The resin molded body described above is bonded to the substrate surface at the base end portion. Depending on the shape of the resin molded body, there is a concern that the contact area of the base end portion with the substrate surface becomes small, and the bonding strength of the resin molded body to the substrate is lowered.

  The technique disclosed in the present specification has been completed based on the above-described circumstances, and aims to further increase the bonding strength of the resin molded body to the base material.

  As a means for solving the above problems, a technique disclosed in the present specification is obtained by joining a plate-like base material including a fiber and a thermoplastic resin, a plate surface of the base material, and from the plate surface. A resin molded body having a protruding shape, and a resin portion integrally formed with the resin molded body with the same resin material as the resin molded body, and connected to a base end portion of the resin molded body, At least one of the through hole formed through the base material and the concave portion formed on the plate surface of the base material is formed on the base material, and the resin portion is formed inside the one side. And is characterized by being joined to the one inner peripheral surface. With such a configuration, the resin molded body is bonded to the plate surface of the base material, and is also bonded to the inner peripheral surface of the through hole (or recess) via the resin portion. As a result, the bonding strength of the resin molded body can be further increased as compared with the configuration in which the resin molded body is bonded only to the plate surface of the base material.

  Further, the resin molded body includes a molded body main body portion that has a shape protruding from the plate surface, and a reinforcing rib that connects a side surface of the molded body main body portion and the plate surface, and the resin portion includes: It can be connected to the reinforcing rib. With such a configuration, when the resin molded body and the resin portion are molded by injection molding, the molding space for molding the molded body main body, the molding space for molding the reinforcing rib, and the molding space for molding the resin portion are in this order. The molten resin can be supplied. For this reason, molten resin can be reliably filled with the molding space which shape | molds a molded object main-body part, and the molding space which shape | molds a reinforcement rib, and a resin molded object can be shape | molded more reliably.

  In addition, a pair of the reinforcing ribs arranged so as to sandwich the molded body main body portion may be provided, and the resin portion may be arranged so as to connect the pair of reinforcing ribs. By making the connection part of the resin part and the resin molded body into at least two places, the strength of the resin molded body can be further increased.

  In addition, a longitudinal rib formed on the plate surface and arranged in such a manner that the resin molded body is sandwiched between the resin portion and the rib is formed at one end in the longitudinal direction with the resin molded body. It can be connected. In the resin molded body, the strength on the side where the resin portion is not disposed can be further increased.

  The resin molded body may be an attachment member for attaching the molded structure to another member. The bonding strength of the resin molded body, which is an attachment member, can be increased, and the molded structure can be more reliably attached to other members.

  According to the technique disclosed in this specification, the bonding strength of the resin molded body to the base material can be further increased.

The perspective view which shows the door trim which concerns on Embodiment 1. FIG. 1 is a view of the door trim of FIG. 1 viewed from the outside of the passenger compartment. Sectional drawing showing a molding device (a pair of molds are in an open state) Sectional view showing press forming process Sectional drawing which shows an injection molding process (corresponding to the figure which cut | disconnected the clip seat by the VV line of FIG. 2) Sectional drawing which shows the door trim and injection molding process which concern on Embodiment 2.

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. In this embodiment, the door trim 20 for vehicles is illustrated as a shaping | molding structure. As shown in FIG. 1, the door trim 20 includes a trim board 30 (base material), a clip seat 40 (resin molded body) formed on a plate surface 32 (for example, a surface outside the passenger compartment) of the trim board 30, and a clip. And a resin portion 31 that connects the seat 40 and the trim board 30. The trim board 30 has a plate shape and includes fibers and a thermoplastic resin. In addition, as a fiber used for the trim board 30, bast plant fibers, such as a wood fiber and kenaf, are used, for example, However, The kind of fiber is not limited to this. For example, glass fiber or carbon fiber may be used as the fiber. In the trim board 30, the fibers are bound by a thermoplastic resin. The thermoplastic resin used for the trim board 30 can be exemplified by polypropylene, but is not limited thereto.

  The clip seat 40 (retainer bracket) is formed on the clip seat main body portion 41 (molded body main body portion) that protrudes from the plate surface 32 of the trim board 30 toward the door panel 10 and on the side surface of the clip seat main body portion 41. A pair of reinforcing ribs 42, 42. The clip seat body 41 as a whole has a box shape (Yakura shape) opened in a direction along the plate surface 32. The clip seat main body 41 is formed on the seat surface portion 45 to which the clip 43 (retainer) is attached, the connection wall portion 46 that connects the peripheral end portion of the seat surface portion 45 and the plate surface 32, and the inner surface of the connection wall portion 46. Ribs 47 and 48. An attachment hole 49 to which the clip 43 is attached is formed through the seat surface portion 45. In addition, an entrance hole 50 is formed in the seat surface portion 45 by cutting out a part of the peripheral edge portion of the mounting hole 49.

  When attaching the clip 43 to the seat surface portion 45, the shaft portion of the clip 43 is caused to enter the attachment hole 49 through the entry hole 50. The tip of the clip 43 is elastically deformable. It is configured to be insertable while being reduced in diameter with respect to an attachment hole (not shown) formed in the door panel 10 constituting the vehicle door. Thereby, the door trim 20 is attached to the door panel 10 via the clip 43. That is, the clip seat 40 is an attachment member for attaching the door trim 20 to the door panel 10 (other member).

  The reinforcing rib 42 has a triangular shape in a front view, and is provided so as to connect the proximal end portion of the clip seat main body portion 41 and the plate surface 32 of the trim board 30. As shown in FIG. 2, the pair of reinforcing ribs 42 are arranged so as to sandwich the clip seat main body 41. The trim board 30 is formed with a U-shaped through hole 33. The through hole 33 is arranged on the trim board 30 so as to be adjacent to the opening side of the clip seat main body 41. The resin part 31 is filled in the through hole 33. That is, the resin portion 31 is surrounded by the trim board 30 in a plan view of the clip seat 40 shown in FIG.

  The resin portion 31 is U-shaped like the through-hole 33 and is arranged so as to connect a pair of reinforcing ribs 42 and 42. The resin portion 31 is formed integrally with the clip seat 40 using the same resin material as that of the clip seat 40, and is connected to a pair of reinforcing ribs 42 and 42 (base end portions of the clip seat 40). Specifically, the resin portion 31 includes a pair of extending portions 35 and 35 connected to the pair of reinforcing ribs 42 and 42, and a long connecting portion 34 connecting the pair of extending portions 35 and 35, respectively. It is equipped with. The extending portion 35 extends from the reinforcing rib 42 in, for example, the opening direction of the clip seat main body portion 41 (lower side in FIG. 2). One end of the extending portion 35 is connected to the bottom surface of the reinforcing rib 42, and the other end is connected to the connecting portion 34.

  In the present embodiment, the bottom surface of the clip seat body 41 and the bottom surface of the reinforcing rib 42 are joined to the plate surface 32 of the trim board 30. The resin portion 31 is filled in the through hole 33 and joined to the inner peripheral surface 36 (one inner peripheral surface) of the through hole 33. Further, as shown in FIG. 1, longitudinal ribs 37 are formed on the plate surface 32. As shown in FIG. 2, the rib 37 is disposed on the opposite side of the resin portion 31 with respect to the clip seat 40. The rib 37 is connected to the clip seat 40 (the lower end portion of the connecting wall portion 46) at one end portion in the longitudinal direction.

  Next, a forming apparatus 60 for forming the trim board 30 and the clip seat 40 will be described. As shown in FIG. 3, the molding device 60 includes a pair of molding dies 61 and 62, a slide die 63, an injection device 64, and a drive device 74. The injection device 64 is, for example, a screw type, and is provided in the molding die 62 in this embodiment. The molding die 61 is connected to a drive device 74 (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) via a shaft, and can approach or separate from the molding die 62. Accordingly, the pair of molds 61 and 62 can be closed and opened. In this embodiment, the configuration in which the opening / closing direction of the pair of molding dies 61, 62 is the vertical direction is illustrated, but the present invention is not limited to this. For example, the opening / closing direction of the pair of molding dies 61, 62 is horizontal. It may be a direction.

  The molding die 61 is a mold and has a molding surface 65 shaped to follow the design surface of the trim board 30. The molding die 62 is a core die, and has a first molding surface 66 shaped to follow the back surface (plate surface 32) of the trim board 30. The slide mold 63 is provided for molding the clip seat 40 having an undercut portion (seat surface portion 45, rib 47), a tip portion 67 having a shape following the internal space of the clip seat body portion 41, and a rod. And a base end portion 69 attached to 68. The slide mold 63 is accommodated in a recess 70 formed in the mold 62. The surface of the slide mold 63 that faces the molding surface 65 is flush with the first molding surface 66 and is a second molding surface 71 that follows a part of the plate surface 32 of the trim board 30.

  In the mold closed state shown in FIG. 4, a board forming space S <b> 1 for forming a trim board is formed between the first forming surface 66 and the forming surface 65 and between the second forming surface 71 and the forming surface 65. A clip seat molding space S <b> 2 for molding the clip seat 40 is formed between the outer peripheral surface of the tip portion 67 of the slide die 63 and the inner surface of the recess 70 in the molding die 62. The clip seat forming space S2 is opened on the board forming space S1 side, and is connected to the board forming space S1.

  In addition, the molding die 62 is formed with a runner 72 that is a groove opened on the board molding space S1 side. The runner 72 is formed so as to connect the injection device 64 and the clip seat molding space S2. Thereby, the molten resin injected from the injection device 64 is supplied to the clip seat molding space S <b> 2 via the runner 72.

  Next, the manufacturing method of the door trim 20 of this embodiment is demonstrated. The manufacturing method of the door trim 20 according to the present embodiment includes a through-hole forming step of forming the through-hole 33 in the plate-like member 73 before being formed on the trim board 30, and the plate-like member 73 with a pair of forming dies 61 and 62. A press molding step of press molding to form the trim board 30; and an injection molding step of molding the clip seat 40 and the resin portion 31 in a form to be joined to the trim board 30.

(Through hole forming process)
In the through-hole forming step, a part of the plate-like member 73 (see FIG. 3) is cut with a cutting tool (not shown) such as an ultrasonic cutter to form the through-hole 33. The plate member 73 may be called a preboard.

(Press molding process)
In the press molding process performed after the through hole forming process, the plate-like member 73 that has been softened by heating in advance is placed between the plate-like member 73 and the pair of molds 61 and 62 as shown in FIG. Deploy. Subsequently, as shown in FIG. 4, by closing the pair of molding dies 61, 62, the plate-shaped member 73 is press-molded by the pair of molding dies 61, 62, and the peripheral end portion of the plate-shaped member 73. 75 (peripheral unnecessary portion) is excised by shearing the pair of molds 61 and 62. Accordingly, the plate-like member 73 has a shape that follows the shape of the board forming space S <b> 1, and the trim board 30 is obtained. In addition, the through-hole 33 is arrange | positioned in the form connected to the shaping | molding space (not shown) for shape | molding a pair of reinforcement ribs 42 and 42 among clip seat shaping | molding space S2.

(Injection molding process)
In the injection molding process performed after the press molding process, molten resin (for example, polypropylene or the like) is injected from the injection device 64 to the runner 72 while the trim board 30 is sandwiched between the pair of molds 61 and 62. As shown in FIG. 5, the molten resin injected into the runner 72 flows into the clip seat molding space S <b> 2 through the runner 72. Then, the molten resin flows through the clip seat molding space S2 to the through hole 33 communicating with the clip seat molding space S2. As a result, the molten resin is filled into the clip seat molding space S2 and the through hole 33. In the process of filling the clip seat molding space S <b> 2 and the through hole 33 with the molten resin, the molten resin penetrates into the fibers of the trim board 30. At the same time, the molten resin that has penetrated into the fiber mixes with the softened thermoplastic resin inside the trim board 30 and becomes a unitary (mixed).

  Thereafter, the molten resin is cooled and solidified, so that the molten resin filled in the clip seat forming space S2 becomes the clip seat 40 joined to the plate surface 32 of the trim board 30, as shown in FIG. The molten resin filled in 33 becomes the resin portion 31 joined to the inner peripheral surface 36 of the through hole 33. Further, the molten resin filled in the runner 72 becomes the rib 37 by being cooled and solidified. Thereafter, the pair of molds 61 and 62 are opened and the slide mold 63 is driven, so that the door trim 20 in a state where the clip seat 40 and the resin portion 31 are integrally joined to the trim board 30 is removed.

  Next, the effect of this embodiment will be described. In this embodiment, the clip seat 40 is joined to the plate surface 32 of the trim board 30 and is joined to the inner peripheral surface 36 of the through hole 33 via the resin portion 31. As a result, compared to the configuration in which the clip seat 40 is joined only to the plate surface 32 of the trim board 30, the joining strength of the clip seat 40 to the trim board 30 can be further increased. In addition, according to the test conducted by the inventors of the present application, it is confirmed that the tensile strength of the clip seat 40 is about 1.75 times greater in the configuration including the resin portion 31 than in the configuration not including the resin portion 31. Has been.

  Further, the clip seat 40 includes a clip seat main body portion 41 that protrudes from the plate surface 32, and a reinforcing rib 42 that connects the side surface of the clip seat main body portion 41 and the plate surface 32. The reinforcement rib 42 is connected. With such a configuration, when the clip seat 40 and the resin portion 31 are molded by injection molding, a molding space for molding the clip seat main body portion 41, a molding space for molding the reinforcing rib 42, and the resin portion 31 are molded. Molten resin can be supplied in the order of the molding space. For this reason, molten resin can be reliably filled with the shaping | molding space which shape | molds the clip seat main-body part 41, and the shaping | molding space which shape | molds the reinforcement rib 42, and the clip seat 40 can be shape | molded more reliably.

  In addition, a pair of reinforcing ribs 42 and 42 are disposed so as to sandwich the clip seat main body 41, and the resin portion 31 is disposed so as to connect the pair of reinforcing ribs 42 and 42. By making the connection part of the resin part 31 and the clip seat 40 into at least two places, the strength of the clip seat 40 can be further increased.

  In addition, the rib 37 is formed on the plate surface 32 and disposed on the opposite side of the resin seat 31 with respect to the clip seat 40, and the rib 37 is connected to the clip seat 40 at one end in the longitudinal direction. Has been. If it does in this way, the intensity | strength of the side by which the resin part 31 is not distribute | arranged in the clip seat 40 can be made higher.

  The resin molded body is a clip seat 40 (attachment member) for attaching the door trim 20 to the door panel 10. The joining strength of the clip seat 40 which is an attachment member can be increased, and the door trim 20 can be more reliably attached to the door panel 10.

  Moreover, in this embodiment, the resin part 31 can be shape | molded by forming the through-hole 33 in the plate-shaped member 73, and filling the through-hole 33 with molten resin at an injection molding process. For this reason, the resin part 31 can be shape | molded by the simple method of forming the through-hole 33. FIG.

<Embodiment 2>
Next, Embodiment 2 of the present invention will be described with reference to FIG. The same parts as those in the above embodiment are denoted by the same reference numerals, and redundant description is omitted. In the door trim 220 of the present embodiment, as shown in FIG. 6, a recess 233 is formed in the trim board 30 instead of the through hole 33. The recess 233 is recessed in the plate surface 32 of the trim board 30. Such a recess 233 can be formed, for example, by partially cutting the plate surface 32 of the trim board 30. Although not shown, the recess 233 communicates with the clip seat forming space S2 in the same manner as the through hole 33 of the first embodiment. For this reason, in the injection molding process, the molten resin flows from the clip seat molding space S2 into the concave portion 233, and the molten resin filled in the concave portion 233 is solidified to be joined to the inner peripheral surface 236 of the concave portion 233. The resin portion 231 is molded in such a manner. Although not shown in FIG. 6, the resin portion 231 is connected to the pair of reinforcing ribs 42, 42 of the clip seat 40, similarly to the resin portion 31 of the first embodiment.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.
(1) In the above embodiment, the door trim is illustrated as the molded structure and the trim board is illustrated as the base material. However, the present invention is not limited to this. The molded structure may be a vehicle interior material other than a door trim, such as an instrument panel, a luggage trim, a package tray, or the like, and the substrate may be a plate-like member that constitutes the vehicle interior material. Further, the molded structure is not limited to the vehicle interior material.
(2) In the said embodiment, although the clip seat 40 was illustrated as a resin molding, it is not limited to this. The resin molded body may be an attachment member other than the clip seat, such as an attachment boss or a locking claw. Further, the resin molded body is not limited to an attachment member for attaching the molded structure to another member. For example, the resin molded body may include a contact boss that regulates displacement of the trim board toward the door panel by contacting the door panel.
(3) In the said embodiment, although the resin parts 31 and 231 illustrated what makes a U shape, the shape of a resin part is not limited to this. For example, the resin part 31 may not include the connecting part 34 but may include only the extending part 35 connected to the reinforcing rib 42.
(4) In the above embodiment, both the through hole 33 and the recess 233 may be formed in the trim board 30.

DESCRIPTION OF SYMBOLS 10 ... Door panel (other member), 20 ... Door trim (molded structure), 30 ... Trim board (base material), 31, 231 ... Resin part, 32 ... Plate surface (plate surface of base material), 33 ... Through-hole, 36 ... Inner peripheral surface (inner peripheral surface of through-hole, one inner peripheral surface), 37 ... rib, 40 ... clip seat (resin molded body), 41 ... clip seat main body (molded body main body), 42 ... reinforcement Ribs, 233... Recesses, 236 .. inner peripheral surface (inner peripheral surface of the recess, one inner peripheral surface)

Claims (5)

A plate-like substrate containing fibers and thermoplastic resin;
A resin molded body that is bonded to the plate surface of the base material and has a shape protruding from the plate surface;
A resin portion formed integrally with the resin molded body with the same resin material as the resin molded body and connected to a base end portion of the resin molded body,
The base material is formed with at least one of a through hole formed through the base material and a recess formed in the plate surface of the base material,
The said resin part is a molded structure body which is distribute | arranged to said one inside and is joined to said one internal peripheral surface. The resin molding is
A molded body main body having a shape protruding from the plate surface;
A reinforcing rib connecting the side surface of the molded body main body and the plate surface;
The molded structure according to claim 1, wherein the resin portion is connected to the reinforcing rib. A pair of reinforcing ribs arranged in a manner sandwiching the molded body body,
The molded structure according to claim 2, wherein the resin portion is arranged in such a manner as to connect the pair of reinforcing ribs. Formed on the plate surface, and provided with a longitudinal rib disposed on the side opposite to the resin portion with respect to the resin molded body,
The molded structure according to any one of claims 1 to 3, wherein the rib is connected to the resin molded body at one end portion in a longitudinal direction.   The molded structure according to any one of claims 1 to 4, wherein the resin molded body is an attachment member for attaching the molded structure to another member.

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