JP2020026097A - Manufacturing method of component for vehicle - Google Patents

Abstract

To provide a manufacturing method of a component for vehicle comprising a resin member having a conductive part.SOLUTION: In a manufacturing method of a component for vehicle, an intermediate member comprising a print conformity surface by injection molding is formed, and a conductive part is formed by applying a conductive paste to the print conformity surface by screen printing, and a resin member is formed by bending the intermediate member by thermal bending, and further the conductive part is bent together with the print conformity surface.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a method for manufacturing a vehicle component.

  It is known from Patent Document 1 or the like to form a conductive portion such as a defogger or an antenna by screen-printing a conductive paste on a vehicle window glass.

Japan JP 2018-94949

In recent years, attempts have been made to form vehicle window parts with resin. Since the resin can be formed into various shapes, a highly designable resin member having a curved surface can be formed. However, there is no known method for forming a conductive portion on a resin member having such a curved surface.
Therefore, an object of the present invention is to provide a method for manufacturing a vehicle component provided with a resin member having a conductive portion.

To achieve the above object, according to the present invention,
A method for manufacturing a vehicle component including a resin member having a conductive portion,
Forming an intermediate member with a print compatible surface by injection molding,
Forming the conductive portion by applying a conductive paste to the print compatible surface by screen printing,
A method for manufacturing a vehicle component is provided, in which the intermediate member is bent by thermal bending to form the resin member, and the conductive portion is bent together with the print-compatible surface.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the vehicle component provided with the resin member which has an electroconductive part is provided.

FIG. 2 is a perspective view showing a rear portion of a vehicle including a vehicle back door. It is a schematic diagram which shows the structure of a vehicle back door. It is a figure showing signs that an intermediate member is formed by injection molding. It is a figure showing signs that a defogger is formed in an intermediate member. It is a figure showing the formation method of the defogger concerning a modification. It is a figure showing signs that a thermal bending is performed to an intermediate member.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The dimensions of each member shown in the drawings may be different from the actual dimensions of each member for convenience of explanation.

  Further, in the description of the present embodiment, for convenience of description, “left-right direction”, “front-rear direction”, and “up-down direction” will be appropriately referred to. These directions are relative directions set for the vehicle 1 shown in FIG. Here, the “vertical direction” is a direction including the “upward direction” and the “downward direction”. The “front-rear direction” is a direction including the “front direction” and the “back direction”. "Left-right direction" is a direction including "left direction" and "right direction".

(Vehicle back door and vehicle rear module)
First, a vehicle back door 3 including a vehicle rear module 4 according to the present embodiment will be described with reference to FIGS. 1 and 2. FIG. 1 is a perspective view showing a rear portion of a hatchback type vehicle 1 including a vehicle back door 3. FIG. 2 is a schematic diagram illustrating the configuration of the vehicle back door 3. As shown in FIG. 2, the vehicle back door 3 is attached to the rear of the vehicle 1 so as to open and close an opening 2 provided in the rear of the vehicle 1. The vehicle back door 3 includes a vehicle rear module 4 (an example of a vehicle component) and a back door inner 5 provided inside the vehicle 1 with respect to the vehicle rear module 4.

  The vehicle rear module 4 is formed in a size that can cover the rear opening 2 of the vehicle 1. The vehicle rear module 4 includes a clear member 20 (an example of a resin member) and a coloring member 40. The clear member 20 and the coloring member 40 are made of a resin such as polycarbonate (PC).

  The clear member 20 is a colorless transparent or colored transparent member. The clear member 20 has a lamp portion 22 and a window portion 24 integrally (see FIG. 1). A lamp unit such as a stop lamp, a turn signal lamp, a back lamp, and a high-mount stop lamp is provided on the cabin side of the lamp unit 22. The lamp unit 22 transmits light emitted from the lamp unit. Note that the lamp unit may be attached to the vehicle 1, may be attached to the vehicle rear module 4, or may be attached to the vehicle 1 and the vehicle rear module 4. In this embodiment, as shown in FIG. 2, the vehicle rear module 4 is attached to the vehicle via a hinge 6 so that an opening provided in the vehicle can be opened and closed. The vehicle rear module 4 is provided with a hinge attachment portion 5b to which the hinge 6 is attached.

  The coloring member 40 is attached to the clear member 20. The coloring member 40 is a member having a lower light transmittance than the clear member 20. The coloring member 40 is colored so as to visually shield at least a part of the inside of the vehicle 1 from the outside. The coloring member 40 is made of a material in which a coloring material is kneaded with a resin material such as PC serving as a base. Further, the coloring member 40 may contain an additive such as a filler.

  The back door inner 5 is made of a material obtained by kneading glass fiber or the like into a resin such as polypropylene. However, the material forming the back door inner 5 is not limited to a specific resin, but may be a metal, for example. The back door inner 5 is formed so as to cover the entire outer peripheral portion of the vehicle rear module 4, and has an opening 5 a corresponding to the ramp 22 and the window 24.

  The vehicle back door 3 is formed by bonding the back door inner 5 to the vehicle rear module 4 via an adhesive. The vehicle back door 3 is attached to a rear portion of the vehicle via a hinge 6 provided on the back door inner 5.

  As shown in FIG. 1, the clear member 20 is provided with a defogger 10 (an example of a conductive portion). The defogger 10 generates heat by electric power supplied from a power supply unit (not shown). Thereby, the defogger 10 removes the fogging generated on the clear member 20.

Next, a method for manufacturing the vehicle rear module 4 will be described with reference to FIGS.
First, as shown in FIG. 3, an intermediate member 30 serving as the clear member 20 is formed by injection molding. FIG. 3 shows the intermediate member 30 in a plan view. Examples of resins that can be used for injection molding include thermoplastic resin materials such as polycarbonate (PC), acrylic resin (PMMA), cycloolefin resin, and polystyrene resin. As is clear from comparison between FIG. 1 and FIG. 3, the shape of the intermediate member 30 formed by injection molding is different from the shape of the clear member 20. The shape of the intermediate member 30 is flatter than the shape of the clear member 20. The intermediate member 30 has a print compatible surface 31. The shape of the intermediate member 30 and the print compatible surface 31 will be described later.

  After forming the intermediate member 30, a silicone resin may be applied to the surface of the intermediate member 30 to form the hard coat layer 7 (see FIG. 4). The hard coat layer 7 can enhance the abrasion resistance of the clear member 20. The hard coat layer 7 can be formed by applying the liquid silicone resin forming the hard coat layer 7 to the surface of the intermediate member 30 by a technique such as dip coating, flow coating, or spray coating. By using such a method, the hard coat layer 7 can be reliably formed on the surface of the three-dimensional intermediate member 30.

  Further, a protective layer 8 (protection layer) (see FIG. 4) may be further provided on the hard coat layer 7. The protective layer 8 can further enhance the abrasion resistance of the clear member 20. The protective layer 8 can be provided particularly on the window 24 where abrasion resistance is required. The protective layer 8 can be formed by irradiating the hard coat layer 7 made of a silicone resin with ultraviolet rays so that the upper portion of the hard coat layer 7 is vitrified. Alternatively, it can be formed by depositing silica on the surface of the hard coat layer 7 by plasma CVD. Note that the protective layer 8 may not be provided.

  Next, as shown in FIG. 4, the defogger 10 is formed on the print compatible surface 31 of the intermediate member 30 by screen printing. FIG. 4 shows a cross section taken along line AA in FIG. 3 during screen printing. As shown in FIG. 4, a screen 51 is attached to the print compatible surface 31. The screen 51 has a hole 52 corresponding to the defogger 10. The conductive paste 54 is applied on the screen 51, and the squeegee 53 pushes the conductive paste 54 into the holes 52 of the screen 51. Then, the conductive paste 54 is applied to the surface of the print compatible surface 31 in the shape of the defogger 10, and the defogger 10 is formed. When the defogger 10 is formed, the screen 51 is removed.

  When forming the defogger 10 by screen printing, it is convenient that the surface on which the defogger 10 is formed is formed in a shape that the screen 51 can easily follow. In the present embodiment, a surface that is convenient for forming the defogger 10 is called a print compatible surface 31. More specifically, the print compatible surface 31 is a surface that is bent or curved in two or more directions, and a surface other than a surface that is bent or curved in one direction and the bent portion or the curved portion forms an acute angle. is there. Here, the acute angle means that the angle formed by the surface on which the defogger 10 is formed on the side to which the conductive paste 54 is applied is an acute angle. If the surface on which the conductive paste 54 is applied is at an acute angle and the opposite surface is at an obtuse angle, the bent portion is said to form an acute angle.

The screen 51 cannot follow a surface curved in two directions. For example, the screen 51 cannot follow a surface bent in two or more directions like the ramp portion 22 shown in FIG. 1 and is not suitable for screen printing.
Even if the surface is bent in one direction, the screen 51 cannot follow the bent portion / bent portion bent at an acute angle. Further, it is difficult to insert the squeegee 53 into the inside of the bent portion / bent portion bent at an acute angle. For this reason, although it is bent in one direction, a surface having a sharp bend is also unsuitable for screen printing.
The screen 51 can follow a curved portion that is curved in one direction and forms an obtuse angle. Such a surface is included in the print compatible surface 31. The print compatible surface 31 includes a flat surface, an outer peripheral surface of a cylinder, and the like. The printing compatible surface 31 is preferably a curved surface having a radius of curvature of 0.1 m or more and curved in one direction.
When the intermediate member 30 is injection molded, the intermediate member 30 is formed into a shape including such a print compatible surface 31.

  Note that the defogger 10 may be formed by any of the methods shown in FIGS. 5A, 5B, and 5C. FIG. 5 is a diagram showing a method for forming the defogger 10 according to the modification. As shown in FIGS. 5A to 5C, a groove 55 may be formed in the print compatible surface 31 during injection molding, and the conductive paste 54 may be embedded in the groove 55 during screen printing. Good. The cross-sectional shape of the groove 55 can be a rectangular shape shown in FIG. 5A, a circular shape shown in FIG. 5B, a triangular shape shown in FIG. When the grooves 55 are formed on the print-compatible surface 31 in this manner, the conductive paste 54 may be embedded with the squeegee 53 without using the screen 51. When the defogger 10 is formed by using the groove 55 provided on the printing compatible surface 31 as described above, the defogger 10 does not protrude from the surface of the clear member 20, and the defogger 10 is easily protected.

  Next, as shown in FIG. 6, the intermediate member 30 is subjected to thermal bending. The clear member 20 is formed by bending the defogger 10 together with the print compatible surface 31 by thermal bending. FIG. 6 shows a cross section taken along the line AA in FIG. 3 during the thermal bending. In the illustrated example, the heated intermediate member 30 is deformed by using a mold 60 including an upper mold 61 and a lower mold 62.

  The intermediate member 30 is heated to such an extent that the resin constituting the intermediate member 30 exhibits plasticity, and is deformed into the shape of the clear member 20 using the mold 60. At this time, the print compatible surface 31 is also deformed together with the defogger 10. Thus, the defogger 10 can be formed even at a portion bent to nearly 90 degrees as shown in FIG.

  At the time of the thermal bending, a portion of the intermediate member 30 other than the print compatible surface 31 may be deformed. In the present embodiment, the ramp portion 22 having the bent portion 23 is not provided on the intermediate member 30, and the intermediate member 30 is deformed by thermal bending to form the ramp portion 22 having the bent portion 23.

  Through the above steps, the clear member 20 including the defogger 10 is formed. The coloring member 40 is attached to the thus formed clear member 20 by using a mechanical coupling means or an adhesive means such as an adhesive. Thus, the vehicle rear module 4 is manufactured.

According to the method of manufacturing the vehicle rear module 4 including the clear member 20 having the defogger 10 according to the present embodiment, the clear member 20 having the defogger 10 formed on a curved surface can be efficiently formed.
The inventor has studied forming the defogger 10 efficiently on the clear member 20 having a curved surface. However, when screen printing is performed on a curved surface, it is difficult to make the screen 51 follow the shape of the clear member 20. Therefore, unlike the present invention, it is conceivable to apply the conductive paste 54 to the curved surface with a single stroke by using a dispenser instead of screen printing, but this results in poor production efficiency.
Therefore, according to the method for manufacturing the vehicle rear module 4 according to the present embodiment, the defogger 10 can be formed by screen printing. Since the defogger 10 can be formed collectively, the production efficiency is high. Further, since the defogger 10 is bent after the screen printing, the defogger 10 having a curved surface or a bent shape can be easily formed. Thus, according to the method for manufacturing the vehicle rear module 4 according to the present embodiment, the vehicle rear module 4 having the defogger 10 can be manufactured simply and efficiently.

  As described above, in the method for manufacturing the vehicle rear module 4 according to the present embodiment, the intermediate member 30 is formed by injection molding so as to form the defogger 10 so as to have a shape suitable for screen printing. For this reason, the intermediate member 30 cannot have the same shape as the clear member 20. Therefore, in the present embodiment, the clear member 20 is formed by deforming the intermediate member 30 by applying heat bending after forming the defogger 10 on the intermediate member 30. For this reason, the intermediate member 30 has a flatter shape than the clear member 20. In addition, it can be said that the print-compatible surface 31 is a surface having a smaller degree of bending and a smaller radius of curvature than after thermal bending.

In the above-described embodiment, an example in which the hard coat layer 7 and the protective layer 8 are formed after resin molding and before screen printing is described. As described above, if the hard coat layer 7 and the protective layer 8 are formed immediately after molding, it is possible to prevent the product (the intermediate member 30) from being damaged when the product (intermediate member 30) is transported in the operation of the next step. In addition, when the print-compatible surface 31 is coated with the hard coat layer 7 without any irregularities, uneven coating is less likely to occur. However, the present invention is not limited to this. The hard coat layer 7 and the protective layer 8 may be formed after screen printing and before heat bending. The conductive paste 54 (defogger 10) can be protected by the hard coat layer 7 and the protective layer 8.
Alternatively, the hard coat layer 7 and the protective layer 8 may be formed after hot bending. When the hard coat layer 7 and the protective layer 8 are formed after the heat bending, the hard coat layer 7 and the protective layer 8 can be reliably formed at the bent portion formed by the heat bending. When the hard coat layer 7 and the protective layer 8 are formed on the defogger 10, the defogger 10 can be protected by the hard coat layer 7 and the protective layer 8. When the hard coat layer 7 and the protective layer 8 are formed after the thermal bending, it is easy to prevent the hard coat layer 7 and the protective layer 8 from being cracked.

  In the embodiment described above, the example in which the defogger 10 is formed on the concave curved surface of the curved clear member 20 has been described, but the present invention is not limited to this. The defogger 10 may be formed on a convex curved surface of the curved clear member 20. Further, the defogger 10 may be formed on the inner surface of the clear member 20 or on the outer surface of the clear member 20. The hard coat layer 7 and the protective layer 8 are formed on the outer surface of the vehicle.

  In the above-described embodiment, an example in which the defogger 10 is formed as the conductive portion has been described, but the present invention is not limited to this. By using the above-described manufacturing method, a resin member having a curved surface including an antenna, an electrode of a display formed on a rear module, an electrode of a surface-emitting lamp such as an organic EL, an electrode of a light control portion formed of a photochromic material, and the like. Can be formed.

  Further, in the above-described embodiment, the example in which the vehicle rear module 4 is formed as the resin member has been described, but the present invention is not limited to this. A resin front window for a vehicle may be formed using the above-described manufacturing method. A defogger having a relatively large area is provided on the rear window and the front window. Unlike the present invention, it takes time to form such a large defogger with a single stroke using a dispenser. When the defogger is formed by screen printing as in the present invention, the production efficiency can be increased.

  Further, in the above-described embodiment, the example in which the vehicle rear module 4 is formed as the resin member has been described, but the present invention is not limited to this. When the above-described manufacturing method is used, it can be applied to a vehicle lamp. In some vehicle lamps, a defogger for the purpose of anti-fog and snow melting functions is provided on the curved surface of the outer cover. According to the present invention, it is possible to manufacture a vehicle lamp including an outer cover provided with such a defogger.

  Note that the present invention is not limited to the above-described embodiment, and may be freely modified and improved. In addition, the materials, shapes, dimensions, numerical values, forms, numbers, arrangement locations, and the like of the components in the above-described embodiments are arbitrary and are not limited as long as the present invention can be achieved.

Reference Signs List 1 vehicle, 2 opening, 3 vehicle back door, 4 vehicle rear module, 5 back door inner, 5a opening, 5b hinge mounting portion, 6 hinge, 7 hard coat layer, 8 protective layer, 10 defogger, 20 clear member 22 lamp part, 23 bent part, 24 window part, 30 intermediate member, 31 printing compatible surface, 40 coloring member, 51 screen, 52 hole, 53 squeegee, 54 conductive paste, 60 mold, 61 upper mold, 62 Lower mold

Claims (6)

A method for manufacturing a vehicle component including a resin member having a conductive portion,
Forming an intermediate member with a print compatible surface by injection molding,
Forming the conductive portion by applying a conductive paste to the print compatible surface by screen printing,
A method for manufacturing a vehicle component, wherein the intermediate member is bent by thermal bending to form the resin member, and the conductive portion is bent together with the print-compatible surface.   The print-compatible surface is a surface other than a surface that is bent or curved in two or more directions and a surface that is bent or curved in one direction and a bent portion or a curved portion forms an acute angle. 4. The method for manufacturing a vehicle component according to claim 1.   The method for manufacturing a vehicle component according to claim 1, wherein a hard coat layer is formed on the intermediate member before hot bending.   The method for manufacturing a vehicle component according to claim 1, wherein a hard coat layer is formed on the resin member after the heat bending. The resin member is attached to the vehicle so that an opening provided in the vehicle can be opened and closed via a hinge,
The method for manufacturing a vehicle component according to claim 1, wherein the resin member is provided with a hinge attachment portion to which the hinge is attached. By the injection molding, a groove is formed on the print compatible surface,
The method for manufacturing a vehicle component according to claim 1, wherein the conductive paste is embedded in the groove by the screen printing.

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