JP2020032586A - Structure and method of manufacturing structure - Google Patents

Abstract

To provide a structure in which a shape is restrained from being constrained by the manufacturing method, and a method for manufacturing the structure in which constraints on the shape of the structure can be restrained.SOLUTION: There is provided a structure that has a base material and a reinforcing member, the base material is made of a foamed resin, the reinforcing member has a plate-like part, the reinforcing member is provided to reinforce the base material, and an edge of the plate-like part is embedded in the base material.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a structure and a method for manufacturing the structure.

  In the method for manufacturing a structure of Patent Document 1, a foamed resin sheet that has been softened by heating is arranged in a cavity of a split mold, and then the foamed resin sheet is secondarily foamed by suctioning the cavity under reduced pressure. A method of expanding a foamed resin sheet has been proposed.

JP 2001-310380 A

  In a method of manufacturing a structure by injection molding, a liquid molten resin is supplied to a cavity of a split mold at a high pressure, so that even if the shape of the cavity is complicated, the molten resin can be easily spread in the cavity. Therefore, in the method of manufacturing a structure by injection molding, it is easy to manufacture a structure having a complicated shape. However, the method of manufacturing a structure disclosed in Patent Document 1 employs a configuration in which one foamed resin sheet is sandwiched between divided molds. Therefore, the method of manufacturing a structure described in Patent Document 1 involves manufacturing a structure by injection molding. In some cases, the shape of the structure that can be formed is more restricted than the method.

  The present invention has been made in view of such circumstances, and has a structure in which the shape is restrained from being constrained due to the manufacturing method, and a structure in which the shape of the structure can be restrained. And a method for producing a body.

  According to the present invention, a base material and a reinforcing member are provided, the base material is made of a foamed resin, the reinforcing member has a plate-like portion, and the reinforcing member A structure is provided that is provided to reinforce and that an edge of the plate-shaped portion is embedded in the base material.

  According to the present invention, a structure includes a base material and a reinforcing member. Here, since the reinforcing member is provided to reinforce the base material, that is, the positional relationship between the reinforcing member and the base material is such that the reinforcing member reinforces the base material. The shape composed of the base material can be easily mixed. However, according to the present invention, the reinforcing member and the base material are integrally formed by embedding the edge of the plate-shaped portion of the reinforcing member in the base material. That is, according to the present invention, since the edge of the plate-shaped portion of the reinforcing member is embedded in the base material when the structure is manufactured, even if the shape of the reinforcing member and the base material is complicated, the foamed resin sheet can be used. The structure can be easily manufactured by the manufacturing method of sandwiching the divided molds. For this reason, according to the present invention, it is suppressed that the shape is restricted by the manufacturing method.

Hereinafter, various embodiments of the present invention will be exemplified. The embodiments described below can be combined with each other.
Preferably, the base has a base wall and a flange wall, the flange wall is connected to the base wall, and the plate-like portion is embedded in the base wall and the flange wall.
Preferably, the reinforcing member has a plurality of the plate-shaped portions and a connection portion, and the connection portion is connected to the plurality of the plate-shaped portions.
Preferably, a hook portion is formed at the edge of the plate portion, and the hook portion is engaged with the base material.
Preferably, the vehicle further includes a fall prevention unit, wherein the fall prevention unit is provided on each of both sides of the plate-shaped portion, and the fall prevention unit supports the plate-shaped portion.

The method for manufacturing a structure according to the embodiment is a method for manufacturing a structure using first and second molds, and includes a sheet forming step, an attaching step, and a forming step. Forming step, mold closing step, and expanding step, the structure includes a base material and a reinforcing member, the reinforcing member has a plate-shaped portion, and in the sheet forming step, The foamed resin was extruded with an extruder to form a foamed resin sheet, and in the attaching step, the reinforcing member was attached to a first mold, and in the shaping step, the foamed resin sheet was provided with the reinforcing member. Forming is performed along the inner surface of the first mold. In the mold closing step, the first and second molds are closed, and the first and second molds are closed in a state where the first and second molds are closed. Between the mold, a foaming space for foaming the foaming resin is formed, and in the expansion step, Serial molding the substrate in the foam space be foamed the foam resin, in a state in which the expansion process is completed, the edges of the plate-like portion is embedded in the base material.
Preferably, the first mold has a slit, and in the attaching step, the reinforcing member is arranged in the first mold such that the plate-shaped portion is inserted into the slit.
Preferably, the plate-shaped portion is configured to engage with the slit.

1A is a front view of the structure 30 according to the embodiment, FIG. 1B is a front perspective view of the structure 30 according to the embodiment, and FIG. 1C is a rear perspective view of the structure 30 according to the embodiment. It is a rear perspective view showing the state where the structure 30 concerning an embodiment was disassembled. FIG. 1B is an AA end view of the structure 30 shown in FIG. 1A. FIG. 4A is an enlarged view of a region A shown in FIG. 3, and FIG. 4B is a BB end view shown in FIG. 1A. 1 shows a foam molding machine 1 and first and second molds 21 and 22 used when manufacturing a structure 30 according to an embodiment. The foamed resin sheet 23 is suspended between the first mold 21 and the second mold 22, and the skin material 32 is arranged between the first mold 21 and the second mold 22, and the first mold 21 is formed. 2 shows a state in which the reinforcing member 50 is arranged. 7A shows a state before the reinforcing member 50 is inserted into the slit sr of the core cr1, and FIG. 7B is a perspective view showing a region B of FIG. 6, in which the reinforcing member 50 is inserted into the slit sr of the core cr1. The state where the reinforcing member 50 is arranged on the core cr1 is shown. 2 shows a state in which the foamed resin sheet 23 is shaped into a shape along the inner surface of the first mold 21. 9A shows a state in which the first and second molds 21 and 22 are closed, FIG. 9B is an enlarged view of a region B shown in FIG. 9A, and FIG. FIG. 10B is a view corresponding to FIG. FIG. 9A shows a state in which the first and second molds 21 and 22 are opened from the state shown in FIG. 9A. 11A is a rear perspective view of a structure 30B according to Modification 1, FIG. 11B is a front perspective view of a reinforcing member 50B shown in FIG. 11A, and FIG. 11C is a rear perspective view of a structure 30C according to Modification 2. 11D is a front perspective view of the reinforcing member 50C shown in FIG. 11C. 12A to 12D are end views at positions corresponding to BB end faces in FIG. 1A, FIG. 12A is an end view of a plate-shaped portion 51D of a reinforcing member 50D according to Modification 3, and FIG. FIG. 12C is an end view of a plate-like portion 51F of a reinforcing member 50F according to a fifth modification, and FIG. 12D is an end view of a plate-like portion 51F of a reinforcing member 50G according to a sixth modification. FIG. 12E is an enlarged view of a region E shown in FIG. 12D. FIG. 13A is a perspective view of a core cr1 and a plate-like portion 51 according to Modification 7, and FIG. 13B is an end view of a reinforcing member 50H according to Modification 7 at a position corresponding to the BB end surface of FIG. 1A. FIG. 13C is an end view of the reinforcing member 50I according to the eighth modification, and is an end view at a position corresponding to the BB end surface in FIG. 1A. 14A is a left side view of a plate portion 51J according to Modification Example 9, FIG. 14B is a front view of the plate portion 51J, FIG. 14C is a rear view of the plate portion 51J, and FIG. 14E is a top view of the portion 51J, FIG. 14E is a left side view of the plate portion 51K according to Modification 10, FIG. 14F is a front view of the plate portion 51K, and FIG. 14G is a rear view of the plate portion 51K. FIG. 14H is a top view of the plate portion 51K. FIG. 15A is a perspective view of a plate-like portion 51L (a reinforcing member 50L) according to Modification 11, FIG. 15B is a perspective view showing a state where the plate-like portion 51L is embedded in a base material 140, and FIG. 15D is a perspective view of a plate-shaped portion 51M (reinforcing member 50M) according to Embodiment 12, FIG. 15D is a perspective view showing a state where the plate-shaped portion 51M is embedded in a base material 140, and FIG. FIG. 15F is a perspective view showing a state where the plate-shaped portion 51N is embedded in the base material 140, FIG. 15G is a perspective view of a reinforcing member 50O according to Modification Example 14, and FIG. It is a perspective view which shows the state which embedded the shape part 51O in the base material 140.

  Hereinafter, embodiments of the present invention will be described. Various features shown in the embodiments described below can be combined with each other. Further, the invention is independently realized for each characteristic matter.

1. Structure 30
The structure 30 according to the embodiment is an interior part of an automobile. The surface 30a is formed on the structure 30, and an occupant of the automobile can place an article such as a drink container on the surface 30a. As described above, since the surface portion 30a is a portion to which a load of an article is applied, the structure 30 includes a configuration (a reinforcing member 50 described later) that reinforces a region of the structure 30 where the surface 30a is formed.

  As shown in FIGS. 1A and 2, the structure 30 includes a base material 40, a skin material 32, and a reinforcing member 50. Since the front surface of the base material 40 is covered by the skin material 32, the base material 40 is hidden by the skin material 32 and cannot be seen in FIGS. 1A and 1B. Here, since the skin material 32 is provided along the front surface of the base material 40, the shape of the skin material 32 and the shape of the base material 40 are the same. For this reason, in FIGS. 1A and 1B, it is assumed that the lead line of the code indicating the configuration of the base material 40 indicates the configuration of the base material 40 instead of the skin material 32.

  As shown in FIG. 3, the structure 30 has a two-layer structure. That is, in the structure 30, the base material 40 is the first layer, and the skin material 32 is the second layer. The base material 40 is a molded body formed of a foamed resin. The expansion ratio of the substrate 40 is not particularly limited, but is, for example, 1.5 to 6 times. In the embodiment, the case where the structure 30 includes the skin material 32 will be described as an example, but the structure body 30 may not include the skin material 32. Further, the projecting portion 35 is formed on the structure 30. The protrusion 35 divides the concave space of the structure 30 into a first region R1 and a second region R2.

1-1. Substrate 40
As shown in FIGS. 1A and 2, the base material 40 includes a base material body 41 and a flange wall 42. The base body 41 is formed in a concave shape, and a flange wall 42 is connected to an edge of the base body 41. The base material body 41 has a base wall 43 and an upright wall 44. The base wall 43 is a plate-like member, and in the embodiment, the base wall 43 is a flat plate. Note that the base wall 43 may be curved. The base wall 43 is supported by the reinforcing member 50, and when a load is applied to the base wall 43, deformation of the base wall 43 is suppressed. The base wall 43 has a first edge 43A, a second edge 43a, a covering surface 43B, and an embedding surface 43C. The flange wall 42 is connected to the first edge 43A. The covering surface 43B is formed on the opposite side of the embedding surface 43C, and the covering surface 43B is covered with the skin material 32. The covering surface 43B is formed in a range where the above-described surface portion 30a is provided. A part of the reinforcing member 50 is embedded in the embedding surface 43C. The embedding surface 43C is a surface supported by the reinforcing member 50. The standing wall 44 is a plate-like member, and the standing wall 44 extends so as to rise from the base wall 43. In the embodiment, the standing wall 44 is connected to the second edge 43a. The flange wall 42 is connected to the edge of the standing wall 44.

  The flange wall 42 is a plate-like member. The flange wall 42 has a first wall 42A, a second wall 42B, and a third wall 42C. The first wall 42A has an annular portion 42A1 and a leg 42A2. The annular portion 42A1 is formed in an annular shape, the inner edge of the annular portion 42A1 is connected to the first edge 43A, and the outer edge of the annular portion 42A1 is connected to the leg 42A2. An opening 42a is formed in the annular portion 42A1, and a fixing member (for example, a bolt) for fixing the structure 30 to a vehicle interior part is inserted into the opening 42a. The second wall 42B is provided so as to face the embedding surface 43C of the base wall 43. One end of the second wall 42B is connected to the first wall 42A, and the other end of the second wall 42B is connected to the third wall 42C. The distance between the second wall 42B and the embedding surface 43C increases from the first wall 42A to the third wall 42C. An opening 42C1 is formed in the third wall 42C, and a fixing member (for example, a bolt) for fixing the structure 30 to a vehicle interior part is inserted into the opening 42C1.

1-2. Reinforcing member 50
As shown in FIG. 2, the reinforcing member 50 includes a plate portion 51. In the embodiment, the reinforcing member 50 is configured by the plate-shaped portion 51, but the embodiment is not limited thereto, and the reinforcing member 50 may have a configuration other than the plate-shaped portion 51. The plate portion 51 is a flat plate, and the plate portion 51 is provided to stand on the base wall 43 and the flange wall 42. As shown in FIG. 3 to FIG. 4B, the plate portion 51 has an edge portion 51a. The edge 51 a is a part of the plate-shaped portion 51, and the edge 51 a is provided on the periphery of the plate-shaped portion 51. The edge 51a is embedded in the base material 40. As shown in FIGS. 4A and 4B, in the embodiment, the edge 51 a is embedded in the base wall 43 and the flange wall 42. Specifically, the edge 51a is embedded in the base wall 43, the first wall 42A, the second wall 42B, and the third wall 42C. By embedding the edge portion 51a in the base wall 43 and the flange wall 42 in this manner, the reinforcing member 50 is firmly fixed to the base material 40. As a result, the surface portion 30a (the base wall 43) is It is strongly reinforced to 50. The edge portion 51a does not need to be embedded in all of the base wall 43, the first wall 42A, the second wall 42B, and the third wall 42C, that is, all of the four configurations listed here. What is necessary is just to be embedded in at least one of the four listed configurations.

1.3. Skin material 32
As shown in FIG. 3, the skin material 32 is provided on the entire front surface of the base material 40. The skin material 32 is made of, for example, a nonwoven fabric having air permeability, and specific examples thereof include nylon fibers, cellulose fibers, and aramid fibers, but are not limited thereto.

2. Configuration of Foam Molding Machine 1 As shown in FIG. 5, the foam molding machine 1 includes a resin supply device 2, a T die 18, a first mold 21, and a second mold 22. The resin supply device 2 includes a hopper 12, an extruder 13, an injector 16, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27.

2-1. Hopper 12 and extruder 13
The hopper 12 is used for charging the raw material resin 11 into the cylinder 13 a of the extruder 13. The form of the raw material resin 11 is not particularly limited, but is usually in a pellet form. The raw material resin is, for example, a thermoplastic resin such as a polyolefin. Examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer, and a mixture thereof. After the raw material resin 11 is put into the cylinder 13a from the hopper 12, it is melted by being heated in the cylinder 13a to become a molten resin. Further, it is conveyed toward the tip of the cylinder 13a by the rotation of a screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and conveys the molten resin while kneading it by its rotation. A gear device is provided at the proximal end of the screw, and the screw is driven to rotate by the gear device.

2-2. Injector 16
The cylinder 13a is provided with an injector 16 for injecting a blowing agent into the cylinder 13a. The foaming agent injected from the injector 16 includes a physical foaming agent, a chemical foaming agent, and a mixture thereof, and is preferably a physical foaming agent. As the physical foaming agent, use is made of an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, and water, and an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, and dichloroethane, and further, a supercritical fluid thereof. be able to. As the supercritical fluid, it is preferable to use carbon dioxide, nitrogen, or the like. For nitrogen, the critical temperature is 149.1 ° C. and the critical pressure is 3.4 MPa or more. It can be obtained by setting it to 7.4 MPa or more. Examples of the chemical blowing agent include those which generate carbon dioxide gas by a chemical reaction between an acid (eg, citric acid or a salt thereof) and a base (eg, baking soda). The chemical blowing agent may be supplied from the hopper 12 instead of being injected from the injector 16.

2-3. Accumulator 17 and T die 18
The foamed resin obtained by melting and kneading the raw material resin and the foaming agent is extruded from the resin extrusion port of the cylinder 13 a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b that can slide inside the cylinder 17a, and the foamed resin can be stored in the cylinder 17a. Then, by moving the piston 17b after the foamed resin is stored in the cylinder 17a in a predetermined amount, the foamed resin is pushed out from the slit provided in the T-die 18 through the connecting pipe 27 and hangs down, thereby forming the foamed resin sheet 23. Form.

2-4. First and second molds 21 and 22
The foamed resin sheet 23 is guided between the first and second molds 21 and 22. The first mold 21 has a concave cavity cv1 and a convex core cr1. As shown in FIG. 7A, a slit sr is formed in the core cr1, and the slit sr is configured so that the plate-shaped portion 51 of the reinforcing member 50 can be inserted. As shown in FIG. 7B, when the plate-shaped portion 51 is inserted into the slit sr, the plate-shaped portion 51 is sandwiched by the core cr1, and the plate-shaped portion 51 is fixed to the core cr1. The second mold 22 has a convex core cr2 and a concave cavity cv2. In the moving direction of the first and second molds 21 and 22, the core cr2 and the cavity cv1 face each other, and the cavity cv2 and the core cr1 face each other. The first and second molds 21 and 22 are provided with a number of reduced pressure suction holes (not shown). The first and second molds 21 and 22 are formed with convex pinch-off portions 21c and 22c.

3. Method of Manufacturing Structure 30 The method of manufacturing the structure 30 according to the present embodiment includes a sheet forming step, an attaching step, a forming step, and a cutting step.

3-1. Sheet Forming Step As shown in FIG. 5, in the sheet forming step, the molten foamed resin is extruded from the slit of the T-die 18 to form the foamed resin sheet 23. When extruded from the slit of the T-die 18, the foamed resin sheet 23 hangs down in a space between the first mold 21 and the second mold 22.

3-2. Attachment Step As shown in FIG. 6, in the attachment step, the foamed resin sheet 23 and the skin material 32 are arranged between the first mold 21 and the second mold 22. 7A and 7B, the reinforcing member 50 is attached to the first mold 21 in the attaching step. Specifically, the plate-shaped portion 51 is inserted into the slit sr of the core cr1 of the first mold 21, the plate-shaped portion 51 is sandwiched between the cores cr1, and the plate-shaped portion 51 is fixed to the core cr1. Further, as shown in FIG. 7B, in a state where the reinforcing member 50 is arranged on the first mold 21, the edge 51 a of the plate-shaped portion 51 protrudes from the core cr <b> 1.

3-2. Forming Step In the forming step, the structure 30 having the base material 40, the skin material 32, and the reinforcing member 50 is formed. The molding step includes a shaping step, a mold closing step, and an expansion step. As shown in FIG. 8, in the shaping step, the foamed resin sheet 23 and the skin material 32 are sucked from the reduced-pressure suction holes of the second mold 22. Thereby, the foamed resin sheet 23 and the skin material 32 are formed into a shape along the inner surface of the second mold 22.

  As shown in FIG. 9A, in the mold closing step, the first mold 21 and the second mold 22 are brought close to each other, and the first and second molds 21 and 22 are closed. In the state where the mold closing step is completed, the portion of the plate-shaped portion 51 protruding from the core cr1, that is, the edge portion 51a of the plate-shaped portion 51 may or may not enter the foamed resin sheet 23. Is also good. 9A and 9B, when the mold closing step is completed, the pinch-off portion 21c and the pinch-off portion 22c come into contact with each other, so that the first mold 21 and the second mold 22 have a closed space S. It is formed. The closed space S is a foaming space for foaming the foamed resin. A portion of the foamed resin sheet 23 and the skin material 32 outside the closed space S becomes a burr br. As shown in FIG. 9C, in the expansion step, the pressure in the closed space S is reduced through the reduced-pressure suction holes of the first and second molds 21 and 22. When the pressure in the closed space S is reduced, the foaming of the foamed resin sheet 23 is promoted, the foamed resin sheet 23 expands, and the base material 40 is formed. In a state where the expansion step is completed, the edge 51 a of the plate-shaped portion 51 is embedded in the base material 40.

3-3. Cutting Step As shown in FIG. 10, the first and second molds 21 and 22 are opened, and the structure 30 is removed from the first and second molds 21 and 22. In the cutting step, the burr br formed on the structure 30 is cut.

4. Effects of Embodiment The structure 30 according to the embodiment includes a base material 40 and a reinforcing member 50. Here, since the reinforcing member 50 is provided so as to reinforce the base member 40, the positional relationship between the reinforcing member 50 and the base member 40 is such that the reinforcing member 50 is arranged on the back side (back side) of the base member 40. And the shape of the reinforcing member 50 and the base material 40 is complicated. The structure having such a configuration can be manufactured relatively easily by a manufacturing method using injection molding. On the other hand, in the manufacturing method in which one foamed resin sheet 23 is sandwiched between the first and second molds 21 and 22 as in the manufacturing method of the structure 30 according to the embodiment, the structure like the structure 30 is used. It is difficult to form a structure having the above technically. In the structure 30 according to the embodiment, the reinforcing member 50 and the base material 40 are integrally formed by embedding the edge 51a of the plate-shaped portion 51 of the reinforcing member 50 in the base material. That is, since the edge portion 51a of the plate-shaped portion 51 of the reinforcing member 50 is embedded in the base material 40 when the structure 30 is manufactured, even if the shape of the reinforcing member 50 and the base material 40 is complicated, the foamed resin sheet The structure 30 can be easily manufactured by a manufacturing method in which 23 is sandwiched between the first and second molds 21 and 22. Therefore, the structure 30 according to the embodiment has a configuration in which the shape is not restricted by the manufacturing method. Further, the manufacturing method according to the embodiment is a method capable of suppressing the restriction on the shape of the structure. In particular, the manufacturing method according to the first embodiment is effective when a reinforcing structure is provided on the back side (back side) of a structure having a deep drawing shape like the structure 30.

  Since the edge portion 51a of the plate portion 51 of the structure 30 according to the embodiment is embedded in the base material 40, the plate portion 51 is firmly fixed to the base material 40, and as a result, the base wall 43 (FIG. (See FIG. 2) is strongly reinforced by the plate portion 51. In particular, as shown in FIG. 3, the rigidity of the structure 30 with respect to the load in the direction of the arrow Ar1 is improved. In the embodiment, since the plate portion 51 is in contact with the first wall 42A and the second wall 42B, the load applied to the base wall 43 is received by the first wall 42A and the second wall 42B. That is, the load applied to the base wall 43 is distributed to the first wall 42A and the second wall 42B. Therefore, when a load is applied to the base wall 43, the deformation of the structure 30 is suppressed.

5. Modifications 1 and 2 of Embodiment: Plural Plates and Connections As shown in FIGS. 11A and 11C, reinforcing members 50B and 50C of structures 30B and 30C according to Modifications 1 and 2 include a plurality of plates. It has the shape parts 51B and 51C. In addition, in the modified examples 1 and 2, the number of the plate portions 51B and 51C may be two or more. Since the reinforcing members 50B and 50C have the plurality of plate portions 51B and 51C, the base member 40 is more strongly reinforced by the reinforcing members 50B and 50C.

  As shown in FIGS. 11A and 11B, the reinforcing member 50B according to the first modification includes a plurality of plate-shaped portions 51B and a connecting portion 52B. A notch or a through hole is formed in the plate portion 51B, and the connecting portion 52B is inserted into the notch or the through hole. In the first modification, a notch is formed in the plate portion 51B. The connecting portion 52B is a flat member. The connecting portion 52B is connected to each plate-shaped portion 51B. Since the reinforcing member 50B has the connecting portion 52B, the reinforcing member 50B is unitized, so that the work load for attaching the reinforcing member 50B to the first mold 21 is suppressed. Further, since the reinforcing member 50B has the connecting portion 52B, the structure 30B has not only rigidity against a load in the direction of the arrow Ar1 (direction from the upper side to the lower side) but also the direction of the arrow Ar2 (direction from the front side to the rear side). Stiffness against the load of the tire is improved.

  As shown in FIGS. 11C and 11D, a reinforcing member 50C according to Modification 2 has a plurality of plate-shaped portions 51C and a connecting portion 52C. A notch or a through-hole is formed in the plate-shaped portion 51C, and the connecting portion 52C is inserted into the notch or the through-hole. In Modification 2, a notch is formed in the plate-shaped portion 51C. The connecting portion 52C is connected to each plate-shaped portion 51C. The connecting portion 52C is a rod-shaped member. The width in the short direction of the connecting portion 52C according to the second modification is wider than the width in the short direction of the connecting portion 52B according to the first modification. The reinforcing member 50C according to Modification 2 has the same effect as the reinforcing member 50B according to Modification 1.

6. Modifications 3 to 6 of Embodiment: Hook Portion Since the plate portions 51D to 51G of the modification examples 3 to 6 have the hook portions 53D to 53G that engage with the base material 40, the plate portions 51D to 51G are attached to the base material 40. To connect more firmly.

  As shown in FIG. 12A, a hook 53 </ b> D is formed at the edge of the plate-shaped portion 51 </ b> D of the reinforcing member 50 </ b> D according to the third modification. The hook portion 53D is formed so as to protrude from the surface of the plate portion 51D, and the hook portion 53D is embedded inside the base material 40. As shown in FIG. 12B, a hook 53 </ b> E is formed at an edge of the plate-shaped portion 51 </ b> E of the reinforcing member 50 </ b> E according to the fourth modification. The hook portion 53E is formed so as to protrude from the surface of the plate portion 51E. The hook portion 53E is formed so as to increase in width toward the tip, and the cross-sectional shape of the hook portion 53E is tapered. The hook 53 </ b> E is embedded inside the base material 40.

  As shown in FIG. 12C, a hook 53F is formed at the edge of the plate-like portion 51F of the reinforcing member 50F according to the fifth modification. The hook portion 53F is formed so as to protrude from the surface of the plate portion 51F, and the cross-sectional shape of the hook portion 53F is arc-shaped. The hook 53F is embedded inside the base material 40. As shown in FIGS. 12D and 12E, a hook 53G is formed at the edge of the plate-like portion 51G of the reinforcing member 50G according to the sixth modification. The hook 53G has a narrow portion 53G1 whose width decreases toward the tip, and the narrow portion 53G1 has a claw structure.

7. Modifications 7 and 8 of Embodiment: Overturn Prevention Unit The configurations of the modifications 7 and 8 include overturn prevention units 54H and 54I for preventing the plate-shaped portion 51 from overturning. As shown in FIG. 13A, a fall prevention unit 54 </ b> H according to Modification 7 is formed on a base material 40. The overturn prevention portions 54H are provided on both sides of the plate portion 51, respectively, and the overturn prevention portions 54H support the plate portion 51. The overturn prevention portion 54H is formed by swelling a portion of the base material 40 in which the edge portion 51a is embedded. Here, as shown in FIG. 13B, the core cr1 of the first mold 21 is formed with a tapered surface tp. When the foamed resin sheet enters between the surface of the plate-shaped portion 51 and the tapered surface tp, the fall prevention portion 54H is formed in the portion of the base material 40 where the edge portion 51a is embedded.

  As shown in FIG. 13C, the fall prevention portions 54I according to Modification 8 are provided on both sides of the plate portion 51, respectively, and the fall prevention portions 54I support the plate portion 51. The plan view shape of the fall prevention portion 54I is a triangular shape, and the fall prevention portion 54I is a plate-shaped member. The overturn preventing portion 54I is provided so as to contact the surface of the plate portion 51 and the surface of the base material 40.

8. Modifications 9 and 10 of Embodiment: Engaging Structure Protrusions 55J and 55K are formed on the plate-like portions 51J and 51K of the modifications 9 and 10, respectively. As shown in FIGS. 14A to 14D, the surface of the protrusion 55J according to the modification 9 is formed in a curved surface, and as shown in FIGS. 14E to 14H, the protrusion 55K according to the modification 10 is formed in a triangular prism shape. Have been. Since the protruding portions 55J and 55K are formed on the plate-shaped portions 51J and 51K, the plate-shaped portions 51J and 51K engage with the core cr1 of the first mold 21, and the displacement of the plate-shaped portions 51J and 51K is reduced. Is suppressed.

9. Modifications 11 to 14 of Embodiment
In the embodiment and Modifications 1 to 10, the reinforcing member is applied to the substrate having the deep drawing shape, but is not limited thereto. The reinforcing member can be applied to a flat base material.

  As shown in FIG. 15A and FIG. 15B, the edge of the plate-like portion 51L of the reinforcing member 50L according to Modification 11 is embedded in a flat base material 140. As shown in FIGS. 15C and 15D, the reinforcing member 50M according to Modification 12 has a plurality of plate-shaped portions 51M. Otherwise, Modification 12 is the same as Modification 11.

Modification 13 is a form having the same function as Modifications 1 and 2. As shown in FIGS. 15E and 15F, the reinforcing member 50N according to Modification 13 has a plurality of plate-shaped portions 51N and a plurality of connecting portions 52N. Each connecting portion 52N is connected to a plurality of plate-shaped portions 51N.
Modification 14 is a form having the same function as Modification 8. As shown in FIGS. 15G and 15H, a reinforcing member 50O according to Modification 14 has a plate-like portion 51O and a fall prevention portion 54O. Note that the broken line shown in FIG. 15H indicates a portion of the fall prevention portion 540 embedded in the base material 140. The fall prevention portions 54O are provided on both sides of the plate portion 51O, respectively, and the fall prevention portions 54O support the plate portion 51O.

1: foam molding machine 2: resin supply device 11: raw material resin 12: hopper 13: extruder 13a: cylinder 16: injector 17: accumulator 17a: cylinder 17b: piston 18: T die 21: first mold 21c: pinch-off portion 22: second mold 22c: pinch-off portion 23: foam resin sheet 25: connecting tube 27: connecting tube 30: structure 30a: surface portion 32: skin material 35: projecting portion 40: base material 41: base material body 42: flange Wall 42a: Opening 42A: First wall 42A1: Annular portion 42A2: Leg 42B: Second wall 42C: Third wall 42C1: Opening 43: Base wall 43A: First edge 43B: Covering surface 43C: Embedded Surface 43a: second edge portion 44: standing wall 50: reinforcing member 51: plate portion 51a: edge portion R1: first region R2: second region S: closed space r: Burr cr1: Core cr2: Core cv1: Cavity cv2: Cavity sr: Slit 30B: Structure 50B: Reinforcement member 51B: Plate portion 52B: Connection portion 30C: Structure 50C: Reinforcement member 51C: Plate portion 52C: Connecting portion 50D: reinforcing member 51D: plate portion 53D: hook portion 50E: reinforcing member 51E: plate portion 53E: hook portion 50F: reinforcing member 51F: plate portion 53F: hook portion 50G: reinforcing member 51G: plate portion. 53G: hooking portion 53G1: narrow portion 50H: reinforcing member 54H: tipping prevention portion tp: tapered surface 50I: reinforcing member 54I: tipping prevention portion 51J: plate portion 55J: projecting portion 51K: plate portion 55K: projecting portion 140 : Base material 50L: Reinforcing member 51L: Plate 50M: Reinforcing member 51M: Plate 50N: Reinforcing member 51N: Plate 52 : Connecting portion 50O: reinforcing member 51O: plate-shaped portion 54O: overturn preventing portion

Claims (8)

Comprising a base material and a reinforcing member,
The base material is made of a foamed resin,
The reinforcing member has a plate-like portion, and the reinforcing member is provided to reinforce the base material,
A structure in which an edge of the plate-like portion is embedded in the base material. The structure according to claim 1, wherein:
The base material has a base wall and a flange wall,
The flange wall is connected to the base wall,
The structure, wherein the plate-like portion is embedded in the base wall and the flange wall. The structure according to claim 1 or 2, wherein
The reinforcing member has a plurality of the plate-shaped portions and a connecting portion,
The said connection part is a structure connected with the some said plate-shaped part. It is a structure according to any one of claims 1 to 3,
A hook portion is formed on the edge of the plate portion,
The structure, wherein the hook portion is engaged with the base material. It is a structure according to any one of claims 1 to 4,
Further equipped with a fall prevention part,
The structure in which the overturn prevention portions are provided on both sides of the plate-shaped portion, respectively, and the overturn prevention portion supports the plate-shaped portion. A method for manufacturing a structure using first and second molds,
A sheet forming step, an attaching step, and a forming step,
The molding step includes a shaping step, a mold closing step, and an expansion step,
The structure includes a substrate and a reinforcing member, the reinforcing member has a plate-shaped portion,
In the sheet forming step, the molten foamed resin is extruded by an extruder to form a foamed resin sheet,
In the attaching step, attaching the reinforcing member to a first mold,
In the shaping step, the foamed resin sheet is shaped along an inner surface of a first mold in which the reinforcing member is arranged,
In the mold closing step, the first and second molds are closed, and the foamed resin is foamed between the first mold and the second mold in a state where the first and second molds are closed. Foaming space is formed,
In the expansion step, the base material is formed by foaming the foamed resin in the foaming space, and in a state where the expansion step is completed, an edge of the plate-shaped portion is embedded in the base material. Is the way. The method of claim 6, wherein
The first mold has a slit,
In the attaching step, the reinforcing member is arranged in a first mold so that the plate-shaped portion is inserted into the slit. The method according to claim 7, wherein
The method, wherein the plate is configured to engage the slit.