JP2021008040A - Method and apparatus for manufacturing resin molding - Google Patents

Abstract

To provide a resin molding having a high bond strength of a resin member to a base material even when a pressurization force in molding press is low.SOLUTION: A method for manufacturing a resin molding 10 obtained by joining a resin member 15 to a base material 11 containing a fiber and a thermosetting resin includes a plate-like body formation step of forming a plate-like body 12 having a film 14 of a thermosetting resin provided on a mat 13 composed of fibers and a resin molding formation step of joining the resin member 15 to the plate-like body 12, in which the resin molding formation step executes in order a first press step of pressing a junction-containing region in the plate-like body 12 with an upper mold 21 and an inside split mold 35 before the thermosetting resin is cured so that a thickness of the junction-containing region becomes a thickness T2 smaller than a predetermined thickness T3, and a second press step of displacing the inside split mold 35 in a mold-opening direction so as to press the plate-like body 12 with the predetermined thickness T3, and pressing the plate-like body while heating the thermosetting resin until it is cured.SELECTED DRAWING: Figure 5

Description

The present invention relates to a method and an apparatus for manufacturing a resin molded product.

Conventionally, as an example of a method for producing a base material containing a fiber and a resin, a resin is formed into a film by spraying or coating on the surface of the fiber formed in a mat shape, and the fiber is impregnated with the film-like resin. There is a method (Patent Document 1). Further, as a method of joining a resin member to a base material containing fibers and a resin, a method of melting the joint surface of the resin member while press-molding the base material to fix the resin member to the base material. Is known (Patent Document 2).

Japanese Unexamined Patent Publication No. 2003-103551 JP-A-2002-205337

In the above-described configuration, for example, when the base material is an interior material for a vehicle and the resin member is a bracket, the interior material for a vehicle is generally set to have a small basis weight for the purpose of weight reduction. There is a situation that the pressure cannot be increased. Therefore, the pressure at the time of hot pressing is low, the impregnation of the resin with the fibers is insufficient, and the bonding strength of the resin member with respect to the base material tends to decrease.

The present invention has been made in view of the above circumstances, and an object of the present invention is to increase the bonding strength of the resin member to the base material even when the pressure during hot pressing cannot be increased.

The present invention for achieving the above object is a method for producing a resin molded body containing at least fibers and a thermosetting resin and having a base material having a predetermined thickness and a resin member bonded to the base material. The step of forming a plate-like body in which the film of the thermosetting resin is provided on at least one surface of the mat made of the fibers, and the first press when the plate-like body is press-formed. The resin molded body forming step of joining the resin member to the plate-shaped body by inserting the resin member between the first mold and the second mold to form the resin molded body is included. In the resin molded body forming step, before the thermosetting resin is cured, the joint portion-containing region including the region to which the resin member is bonded in the plate-shaped body has a thickness smaller than the predetermined thickness. In addition, the joint-containing region is pressed by the inner split mold and the second mold that form a part of the first mold, and the outer region other than the joint-containing region has the predetermined thickness. The first pressing step of pressing the outer region between the outer split mold provided separately from the inner split mold and the second mold of the first mold, and the mold surface of the inner split mold are the outer side. The inner split mold is displaced in the mold opening direction so as to be flush with the mold surface of the split mold, and the predetermined thickness is heated by the first mold and the second mold until the thermosetting resin is cured. This is a method for producing a resin molded body, in which the second pressing step of pressing is performed in order.

According to the method for producing such a resin molded body, the joint-containing region of the plate-shaped body is pressed by the inner split mold and the second mold of the first mold in the first pressing step with a higher pressing force, so that the outer region is formed. The thermosetting resin is reliably impregnated over the entire thickness direction of the mat. Further, the joint-containing region of the plate-like body is restored to the same thickness as the outer region by the second pressing step in which the pressing force is lower than that in the first pressing step, and the expanded thermosetting resin has a predetermined thickness together with the fibers. It will be cured. As a result, the completed resin molded product has a lightweight base material having a low density of fibers and thermosetting resin, and yet has a high bonding strength between the base material and the resin member. Further, in the joint-containing region, the thermosetting resin is surely distributed throughout the plate-like body, so that the rigidity of the base material is also increased.

In the first pressing step, it is preferable to press the plate-like body so that the thickness is 50 to 90% of a predetermined thickness (thickness of the base material of the resin molded body in the completed form). If it is smaller than 50%, it becomes difficult for the crushed mat to return to a predetermined thickness, or the crushed fibers become dense, and the fluidity of the thermosetting resin that is about to spread decreases. On the other hand, if it is larger than 90%, the diffusion of the thermosetting resin may be insufficient.

The base material is a door trim that constitutes the interior design surface of the vehicle door, and the resin member is joined to the outdoor surface side of the door trim, and a thermosetting resin coating is applied in the plate-like body forming step. It is preferable to provide at least on the indoor surface side of the door trim. According to such a configuration, the thermosetting resin is surely spread over the entire interior surface constituting the interior design surface of the vehicle door, so that the interior design surface can be beautifully formed.

Further, in the first pressing step, the joint portion-containing region may be pressed while the resin member is inserted into the inner split mold surface so as to be exposed. According to such a configuration, the press streaks at the boundary of the split mold, which may be generated by using the split mold, are formed on the surface side of the base material where the resin member is provided, so that the resin member can be formed. The opposite surface of the provided surface, that is, in the case of a door trim, for example, can beautifully form the interior design surface.

Further, another invention of the present application for achieving the above object is a manufacturing apparatus for manufacturing a resin molded body in which a resin member is bonded to a base material containing at least a fiber and a thermosetting resin, and the plate-shaped body is formed. A first mold and a second mold for pressing are provided, and the first mold is individually divided into an inner split mold and an outer split mold that can be pressed, and the inner split mold is combined with the resin member. Is a resin molded product manufacturing apparatus provided with a resin member holding portion that holds the joint surface with the plate-shaped body so as to be exposed.

According to such a manufacturing apparatus, only the part where the resin member should be joined is pressed relatively large by the inner split type, and then the whole is pressed by the inner split type and the outer split type so as to have a desired thickness. It becomes possible. Further, since the press streaks at the boundary of the split mold, which may be generated by using the split mold, are formed on the surface side of the base material on which the resin member is provided, the opposite surface of the surface on which the resin member is provided. That is, for example, in the case of a door trim, it is possible to beautifully form the interior design surface.

Further, another invention of the present application for achieving the above object is a manufacturing apparatus for manufacturing a resin molded body in which a resin member is bonded to a base material containing at least a fiber and a thermosetting resin, and the plate-shaped body is formed. A first mold and a second mold for pressing are provided, and the first mold is divided into an inner split mold and an outer split mold that can be individually pressed, and the resin member is added to the second mold. Is provided with a resin member holding portion that holds the joint surface with the plate-shaped body so as to be exposed, and the inner split type is a production of a resin molded body provided in a region corresponding to the resin member holding portion. It is a device.

Even with such a manufacturing apparatus, only the part where the resin member should be joined is pressed relatively large by the inner split type, and then the whole is pressed by the inner split type and the outer split type so as to have a desired thickness. It becomes possible. Further, since the resin member holding portion is provided in the second mold having a simple configuration instead of the first mold having a complicated configuration that can be individually pressed, restrictions on the configuration of the mold are reduced, and the manufacturing apparatus as a whole It can be a simpler configuration.

According to the present invention, a resin molded product having high bonding strength of the resin member to the base material can be obtained even when the pressure during hot pressing cannot be increased.

Schematic diagram showing a door trim with bracket according to the first embodiment. Cross-sectional view showing a plate-like body Explanatory drawing showing a process of installing a bracket between a pair of molds. Explanatory drawing which shows the process of installing a plate-like body between a pair of molds which brackets are installed Explanatory drawing which shows the 1st press process Explanatory drawing which shows the 2nd press process Explanatory drawing which shows the process of opening a pair of molds and taking out a resin molded article Explanatory drawing which shows the process of installing a bracket between a pair of molds of Embodiment 2. Explanatory drawing which shows the process of installing a plate-like body between a pair of molds which brackets are installed. Explanatory drawing which shows the 1st press process Explanatory drawing which shows the 2nd press process Explanatory drawing which shows the process of opening a pair of molds and taking out a resin molded article Sectional drawing which shows the plate-like body of another embodiment

<Embodiment 1>
The first embodiment will be described with reference to FIGS. 1 to 7. In the following description, the upper side of FIGS. 1 and 2 is the front side, and the lower side is the back side. Further, the upper side of FIG. 3 is the upper side, and the lower side is the lower side. The resin molded body manufactured by the manufacturing method according to the present embodiment is a door trim 10 with a bracket that constitutes an indoor design surface of a vehicle door, and as shown in FIG. 1, a plate-shaped base material 11 and a base. It has a resin bracket (an example of a resin member) 15 provided on the back surface side of the material 11. The front side of the base material 11 is the indoor design surface (indoor surface 11A), and the back side is the outdoor surface 11B.

The base material 11 is composed of fibers and a thermosetting resin, and has a plate shape having a predetermined thickness T3 with both ends bent like a crank. The base material 11 has a structure in which the thermosetting resin spreads between the entangled fibers in a relatively low density state. Therefore, the base material 11 is a lightweight member while maintaining a predetermined rigidity.

As the above-mentioned fibers, wood fibers obtained by deweaving wood or the like, bast plant fibers such as kenaf, inorganic fibers such as glass fibers and carbon fibers, synthetic resin fibers and the like can be adopted. Examples of the thermosetting resin include one or a combination of two or more of urethane resin, epoxy resin, unsaturated polyester resin and the like. Of these, urethane resin having foamability is preferably used.

The bracket 15 described above is made of, for example, ABS resin, is formed in advance separately from the base material 11, and is joined to the center of the back surface of the base material 11. The bracket 15 is, for example, a clip seat for attaching a clip for locking the door panel.

Next, a manufacturing apparatus 20 for manufacturing the bracketed door trim 10 of the present embodiment will be described. As shown in FIG. 3, the manufacturing apparatus 20 has a pair of molds 21 and 31 for pressing the plate-shaped body 12 described later from the vertical direction to form the bracketed door trim 10 shown in FIG. The pair of molds 21 and 31 are arranged upward, and the upper mold 21 that presses the plate-shaped body 12 from the surface side (upper surface side) that becomes the surface (indoor surface 11A) and the upper mold 21 that presses the plate-like body 12 downward so as to face the upper mold 21 It is composed of a lower mold 31 which is arranged and presses the plate-shaped body 12 from the surface side (lower surface side) which becomes the back surface (outdoor surface 11B).

The mold surface (lower surface) of the upper mold 21 is composed of an upper base portion 22 located at an end portion and extending in the horizontal direction, and a protruding portion 24 protruding downward from the upper base portion 22 in a flat state. The side surface of the projecting portion 24 is an upper inclined portion 23 that is inclined downward and toward the center side from the upper base portion 22. The upper mold 21 is a movable mold that can be moved in the vertical direction by a drive device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) (not shown).

On the other hand, the mold surface (upper surface) of the lower mold 31 has a shape substantially along the mold surface of the upper mold 21 as a whole, and a predetermined distance is provided between the mold surface (upper surface) of the lower mold 31 and the mold surface of the upper mold 21. Is set to. Specifically, the mold surface (upper surface) of the lower mold 31 is a lower base portion 32 that is located at an end and extends in the horizontal direction, and a recessed portion 34 that is flattened downward from the lower base portion 32. It is configured to have and. The inner surface of the recessed portion 34 is a lower inclined portion 33 that is inclined toward the end portion toward the upper side.

In the present embodiment, the lower mold 31 is an inner split type 35 in which the central portion of the recessed portion 34 is divided from the peripheral portion thereof, and the peripheral portion thereof is an outer split type 36. The inner split mold 35 is movable toward the upper mold 21 by a drive device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) (not shown). On the other hand, the outer split type 36 is not provided with a drive device and is a fixed type.

At the center of the inner split mold 35, a bracket holding portion 37 for fitting and holding the above-mentioned bracket 15 inward is formed in a state of being recessed downward from the upper surface thereof. As shown in FIG. 4, the bracket holding portion 37 holds the bracket 15 so that the joint surface 16 with the plate-shaped body 12 (base material 11) described later is exposed in the mold. Further, the bracket holding portion 37 is set to a depth at which the joint surface 16 of the bracket 15 is flush with the mold surface 35A (upper surface) of the inner split mold 35 while the bracket 15 is held.

As described above, the inner split mold 35 includes the bracket holding portion 37, and the inner split mold 35 protrudes from the outer split mold 36 toward the upper mold 21 and is sandwiched between the upper and lower pairs of molds 21 and 31. The joint portion-containing region including the entire portion of the plate-shaped body 12 to which the bracket 15 is joined and the peripheral portion thereof is set so as to be pressed with a higher pressing force than the outer region located on the outside thereof to reduce the plate thickness. ing.

FIG. 3 shows a state in which the upper mold 21 is moved away from the lower mold 31, that is, a state in which the pair of molds 21 and 31 is open. On the other hand, in FIGS. 5 and 6, the upper mold 21 moves in the direction approaching the lower mold 31, and the plate-shaped body 12 is pressed by the pair of molds 21, 31, that is, the pair of molds 21, 31. Indicates a closed state. In the initial state in which the pair of molds 21 and 31 are opened, the inner split mold 35 is in a state of protruding toward the upper mold 21 side from the outer split mold 36. Further, when the pair of molds 21 and 31 are closed, the inner split mold 35 takes two forms as described later. Details will be described later.

Next, a method of manufacturing the door trim 10 with a bracket of the present embodiment will be described. The method for manufacturing the door trim 10 with a bracket is roughly classified as shown in FIG. 2, in which a thermosetting resin coating 14 is formed by applying or spraying a thermosetting resin onto a mat 13 made of entangled fibers. By the plate-shaped body forming step of forming the formed plate-shaped body 12, and as shown in FIGS. 5 and 6, the bracket 15 is inserted into the pair of molds 21 and 31 and the plate-shaped body 12 is pressed. The resin molded body forming step of joining the bracket 15 to the plate-shaped body 12 is provided. In the present embodiment, the mat 13 uses a kenaf mat, and the thermosetting resin constituting the coating film 14 uses a foamable urethane resin.

<Plate-shaped body forming process>
In the plate-like body forming step, as described above, thermosetting property is applied to one surface of the flat mat 13 (the upper surface and the indoor surface 11A in the present embodiment), which is a plate-like member formed by entwining fibers. A film 14 of a thermosetting resin is formed by applying or spraying the resin (see FIG. 2). In the plate-shaped body 12, the thermosetting resin formed in the form of a coating film 14 has not yet solidified, and is in a state of being biased toward the surface of the mat 13. The thickness of the plate-shaped body 12 at this time is T1. The thickness T1 of the plate-shaped body 12 is made larger than the thickness T3 of the base material 11 in the completed form (T1> T3). The weight ratio between the mat 13 and the coating 14 (thermosetting resin) is, for example, about 1: 1.

<Resin molded body forming process>
After forming the plate-shaped body 12 in the plate-shaped body forming step, the plate-shaped body 12 and the bracket 15 are then joined. At this time, in the present embodiment, the following steps are performed.

<Installation process>
First, as shown in FIG. 3, the bracket 15 is installed on the bracket holding portion 37 of the inner split mold 35 of the lower mold 31 among the pair of molds 21 and 31 in the open state. In the state where the bracket 15 is installed on the bracket holding portion 37, its upper surface (joining surface 16 with the plate-shaped body 12) is exposed in the mold of the lower mold 31, and the mold surface 35A and the surface of the inner split mold 35. It is said to be one. Further, the bracket 15 is in a state where there is almost no gap between the bracket 15 and the bracket holding portion 37 when the bracket 15 is installed in the bracket holding portion 37. Further, in the initial state in which the bracket 15 is installed on the bracket holding portion 37 in this way, the inner split type 35 is arranged at a position slightly protruding upward from the outer split type 36. By keeping in such a state, the cycle time can be shortened.

After the bracket 15 is installed, the plate-shaped body 12 is arranged at a predetermined position between the upper mold 21 and the lower mold 31 as shown in FIG. In the present embodiment, the plate-shaped body 12 is arranged in the direction in which the surface on which the coating film 14 is formed (the surface to be the indoor surface 11A) is located upward, that is, on the opposite side of the surface to which the bracket 15 is joined.

<First press process>
As shown in FIG. 4, when the bracket 15 and the plate-shaped body 12 are installed at regular positions in the pair of molds 21 and 31 (manufacturing equipment 20), the direction in which the upper mold 21 approaches the lower mold 31 by the driving device. Move to (down). Then, the plate-shaped body 12 is hot-pressed by the pair of molds 21 and 31 (see FIG. 5). At this time, the joint-containing region of the plate-shaped body 12 arranged between the upper mold 21 and the inner split mold 35 is based on the thickness of the target base material 11 (an example of a predetermined thickness, see FIG. 1) T3. On the other hand, the outer region arranged between the upper die 21 and the outer split die 36 is hot-pressed so as to have the thickness of the target base material 11 (an example of a predetermined thickness) T3. .. The temperature of the pair of molds 21 and 31 at this time is about 100 ° C. In the joint-containing region, the thermosetting resin (coating 14) in a state of covering the upper surface (the surface to be the indoor surface 11A) of the mat 13 by pressurizing with a higher pressing force than the outer region is formed. It surely extends to the opposite surface (the lower surface of the mat 13, the surface that becomes the outdoor surface 11B).

The thickness T2 of the joint portion-containing region of the plate-shaped body 12 pressed in this first pressing step is 50 to 90% of the thickness (predetermined thickness) T3 of the base material 11 of the bracketed door trim 10 in the completed form. It is desirable to have a thickness. If the upper die 21 and the inner split die 35 are excessively close to each other and the thickness of the plate-shaped body 12 becomes too small, it becomes difficult for the mat 13 to return to the predetermined thickness T3, or the fibers adhere to each other to form a gap. This is because there is a possibility that the thermosetting resin cannot spread between the fibers. On the other hand, when the upper mold 21 and the inner split mold 35 are not sufficiently close to each other, the gap between the fibers is too large, and the thermosetting resin does not spread sufficiently between the fibers and may remain unevenly distributed near the surface. Because there is sex. In the present embodiment, the thickness of the plate-shaped body 12 pressed in the first pressing step is about 2 to 5 mm, and the thickness of the base material 11 of the door trim 10 with bracket in the completed form is about 2.5 to 6 mm. ..

Further, it is desirable that the time for pressing and holding the thickness of the joint-containing region of the plate-shaped body 12 so as to be T2 is about several seconds. If the holding time is longer than several seconds, the thermosetting resin is cured, and the inner split mold 35 of the lower mold 31 described below is slightly displaced from the upper mold 21 in the mold opening direction (movement). This is because the thickness of the plate-shaped body 12 is not restored in the step), and the base material 11 having the predetermined thickness T3 cannot be formed.

<Movement process>
Next, the inner split mold 35 of the lower mold 31 is moved away from the upper mold 21 so that the thickness of the joint-containing region of the plate-shaped body 12 becomes a predetermined thickness T3 which is the thickness of the base material 11 in the completed form. Move slightly (movement process). That is, the inner split mold 35 is displaced in the mold opening direction so that the mold surface 35A is flush with the mold surface 36A of the outer split mold 36 (see FIG. 6). At this time, the thermosetting resin in the joint-containing region is sufficiently spread in the mat 13 by the first pressing step, but since it has not been cured yet, the fibers of the mat 13 are elastically restored as the inner split mold 35 moves. By doing so, or by foaming the thermosetting resin, the thickness is restored to T3. At this time, the thermosetting resin in the mat 13 in the joint-containing region spreads in a uniform state in the thickness direction. Hereinafter, the base material 11 is a state in which the thermosetting resin is spread in the mat 13.

<Second press process>
Further, the pair of molds 21 and 31 is held for a predetermined time in this state (the thickness of the base material 11 is set to the predetermined thickness T3) (see FIG. 6). During this time, the thermosetting resin spread in the base material 11 is cured by the heat in the second pressing step. By curing the thermosetting resin, the bracket 15 and the base material 11 are integrally joined. At this time, since the fibers and the thermosetting resin are in good contact with the joint surface 16 of the bracket 15, high joint strength can be obtained.

<Withdrawal process>
After a predetermined time (time for the resin to cure) has elapsed in the second pressing step, the base material 11 is separated from the pair of molds 21 and 31 (see FIG. 7). In this way, a door trim 10 with a bracket is obtained in which the bracket 15 is joined to the base material 11 having a predetermined thickness T3.

The thickness T3 of the base material 11 at this time is about half the thickness T1 of the plate-shaped body 12 before pressing. Therefore, the relationship between the thicknesses of the plate-shaped body 12 and the base material 11 in each step is T1> T3> T2.

Next, the action and effect will be described. The present embodiment is a method for manufacturing a door trim 10 with a bracket including a base material 11 containing fibers and a thermosetting resin and a bracket 15 bonded to the base material 11, and is formed on the surface of a mat 13 made of fibers. A bracket 15 is placed between the upper mold 21 and the lower mold 31 to be pressed when the plate-shaped body 12 is press-molded and the plate-shaped body forming step of forming the plate-shaped body 12 provided with the thermosetting resin coating 14. In the resin molded body forming step, which includes a resin molded body forming step of joining the bracket 15 to the plate-shaped body 12 to form the door trim 10 with the bracket by inserting, before the thermosetting resin is thermoset. In addition, the inner split mold 35 forming a part of the lower mold 31 so that the joint portion-containing region including the region to which the bracket 15 is joined in the plate-shaped body 12 has a thickness T2 smaller than the predetermined thickness T3. The outer division of the lower mold 31 is divided from the inner division mold 35 so that the joint-containing region is pressed with the upper mold 21 and the outer region other than the joint-containing region has a predetermined thickness T3. In the first pressing step of pressing the outer region with the mold 36 and the upper mold 21, the inner split mold 35 is opened so that the mold surface 35A of the inner split mold 35 is flush with the mold surface 36A of the outer split mold 36. The second pressing step of shifting in the direction and pressing with a predetermined thickness T3 while heating with the upper mold 21 and the lower mold 31 until the thermosetting resin is thermally cured is executed in order.

According to the method for manufacturing the door trim 10 with a bracket, the joint-containing region of the plate-shaped body 12 is subjected to a higher pressing force than the outer region by the inner split mold 35 and the upper mold 21 of the lower mold 31 in the first pressing step. Since it is pressed, the thermosetting resin is surely impregnated over the entire thickness direction of the mat 13 as compared with the outer region. Further, the joint-containing region of the plate-shaped body 12 is restored to the same thickness as the outer region by the second pressing step in which the pressing force is lower than that in the first pressing step, and the expanded thermosetting resin has a predetermined thickness together with the fibers. It will be cured at T3. As a result, the completed door trim 10 with a bracket is provided with a lightweight base material 11 having a low density of fibers and thermosetting resin, and yet has a high bonding strength between the base material 11 and the bracket 15. Further, in the joint-containing region, the thermosetting resin is surely distributed throughout the plate-like body 12, so that the rigidity of the base material 11 is also high.

In the first pressing step, it is preferable to press the plate-shaped body 12 so that the thickness T2 is 50 to 90% of the predetermined thickness T3 (the thickness of the base material 11 of the bracketed door trim 10 in the completed form). If it is smaller than 50%, it becomes difficult for the crushed mat 13 to return to a predetermined thickness T3, or the crushed fibers become dense, and the fluidity of the thermosetting resin that is about to spread decreases. On the other hand, if it is larger than 90%, the diffusion of the thermosetting resin may be insufficient.

The base material 11 is a door trim constituting the indoor design surface (indoor surface 11A) of the vehicle door, and the bracket 15 is joined to the outdoor surface 11B side of the door trim, and heat is generated in the plate-like body forming step. A curable resin coating 14 is provided on the indoor surface 11A side of the door trim. According to such a configuration, the thermosetting resin is surely spread over the entire interior surface 11A constituting the interior design surface of the vehicle door, so that the interior design surface can be beautifully formed.

Further, in the first pressing step, the joint portion-containing region may be pressed in a state where the joint surface 16 of the bracket 15 is exposed in the mold surface 35A of the inner split mold 35. According to such a configuration, the press streaks at the boundary of the split mold, which may be generated by using the split mold, are formed on the surface on the bracket 15 side (outdoor surface 11B), so that the bracket 15 is provided. It is possible to beautifully form the opposite surface, that is, the indoor design surface.

Further, the manufacturing apparatus 20 of the present embodiment manufactures a door trim 10 with a bracket in which a bracket 15 is bonded to a base material 11 containing fibers and a thermosetting resin, and is used for pressing the plate-shaped body 12. The upper die 21 and the lower die 31 are provided, and the lower die 31 is divided into an inner split die 35 and an outer split die 36 which are movable relative to each other and can individually press the plate-shaped body 12. The inner split mold 35 is provided with a bracket holding portion 37 that holds the bracket 15 so that the joint surface 16 with the plate-shaped body 12 is exposed.

According to such a manufacturing apparatus 20, only the portion to which the bracket 15 should be joined is pressed relatively large by the inner split mold 35, and then the entire portion is made of the desired thickness T3 by the inner split mold 35 and the outer split mold 36. It becomes possible to press so as to become. Further, since the press streaks at the boundary of the split mold, which may be generated by using the split mold, are formed on the surface (outdoor surface 11B) side of the base material 11 to which the bracket 15 is joined, the interior design. It is possible to beautifully form the surface (indoor surface 11A).

<Embodiment 2>
Next, the second embodiment will be described with reference to FIGS. 8 to 12. In the following, the same components as those in the above embodiment will be designated by the same reference numerals, and redundant description will be omitted. Further, for the upper mold and the lower mold, for the same configuration as that of the first embodiment, the code of the number obtained by adding 20 to the number of the code attached to each configuration of the above embodiment shall be used.

FIG. 8 shows a manufacturing apparatus 40 for the bracketed door trim 10 of the present embodiment. In the first embodiment, the lower mold 31 is divided into an inner split type 35 and an outer split type 36, but in the present embodiment, the upper mold 41 is divided into an inner split type 45 and an outer split type 45 instead of the lower mold. It differs from the mold 46 in that it is divided into two parts.

Specifically, in the present embodiment, the upper mold 41 is an inner split type 45 in which the central portion of the protruding portion 44 is divided from the peripheral portion thereof, and the peripheral portion thereof is an outer split type 46. The upper die 41 can be moved up and down as a whole by a drive device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) provided in the outer split die 46, and the inner split die 45 is the inner split die 45. A drive device (not shown) separately provided in the above allows the outer split type 46 to move up and down separately from the outer split type 46. In the inner split type 45, the lower surface of the outer split type 46 is flush with the mold surface 46A of the outer split type 46, and the mold surface 45A is the mold surface 46A of the outer split type 46. It is possible to displace from the position protruding downward from.

At the center of the recessed portion 54 of the lower mold 51, a bracket holding portion 57 for fitting and holding the bracket 15 inward is formed in a state of being recessed downward from the upper surface thereof. As shown in FIG. 9, the bracket holding portion 57 holds the bracket 15 so that the joint surface 16 with the plate-shaped body 12 is exposed in the mold. Further, the bracket holding portion 57 is set to a depth at which the joint surface 16 of the bracket 15 is flush with the upper surface of the recessed portion 54 of the lower mold 51 while the bracket 15 is held.

The inner split mold 45 of the upper mold 41 described above has a size including a region facing the bracket holding portion 57 of the lower mold 51. Alternatively, the inner split mold 45 projects from the outer split mold 46 toward the lower mold 51, so that the portion of the plate-shaped body 12 sandwiched between the pair of upper and lower molds 41 and 51 to which the bracket 15 is joined and its periphery thereof. The joint-containing region of the plate-shaped body 12 including the portion is pressed with a higher pressing force than the outer region located outside the portion, and the plate thickness is set to be thin.

FIG. 8 shows a state in which the upper mold 41 is moved away from the lower mold 51, that is, a state in which the pair of molds 41 and 51 are open. On the other hand, in FIGS. 10 and 11, the upper mold 41 moves in the direction approaching the lower mold 51, and the plate-shaped body 12 is pressed by the pair of molds 41, 51, that is, the pair of molds 41, 51 Indicates a closed state. When the pair of molds 41 and 51 are closed, the inner split mold 45 takes two forms, as will be described later. Details will be described later.

Next, a method of manufacturing the door trim 10 with a bracket of the present embodiment will be described.

<Plate-shaped body forming process>
In the plate-like body forming step, as in the first embodiment described above, thermosetting property is applied to one surface (upper surface, surface to be the indoor surface 11A) of the flat mat 13 which is a plate-like member formed by entwining fibers. A film 14 of a thermosetting resin is formed by applying or spraying the resin. The thickness of the plate-shaped body 12 at this time is T1.

<Resin molded body forming process>
Next, the above-mentioned plate-shaped body 12 and the bracket 15 are joined. In this embodiment, the following steps are performed.

<Installation process>
As shown in FIG. 8, the bracket 15 is installed on the bracket holding portion 57 of the lower mold 51 of the pair of molds 41 and 51 in the open state. When the bracket 15 is installed on the bracket holding portion 57, its upper surface (joining surface 16 with the plate-shaped body 12) is exposed in the pair of molds 41 and 51, and the mold surface (recessed portion) of the lower mold 51 is exposed. It is flush with the upper surface of 54). Further, the bracket 15 is in a state where there is almost no gap between the bracket 15 and the bracket holding portion 57 (see FIG. 9).

After the bracket 15 is installed in this way, as shown in FIG. 9, the plate-shaped body 12 is arranged at a predetermined position between the upper die 41 and the lower die 51. Also in the present embodiment, the plate-shaped body 12 is arranged in the direction in which the surface on which the coating film 14 is formed (the surface to be the indoor surface 11A) is located upward, that is, on the side opposite to the surface to which the bracket 15 is joined. To.

<First press process>
As shown in FIG. 9, when the bracket 15 and the plate-shaped body 12 are installed at regular positions in the pair of molds 41, 51 (manufacturing equipment 40), the entire upper mold 41 is brought closer to the lower mold 51 by the driving device. Move in the direction (downward). At the same time, the inner split die 45 of the upper die 41 is moved by the driving device in the direction of protruding downward from the outer split die 46. Then, the plate-shaped body 12 is hot-pressed by the pair of molds 41 and 51 (see FIG. 10). At this time, the joint-containing region of the plate-like body 12 arranged between the inner split mold 45 of the upper mold 41 and the lower mold 51 is from the thickness of the target base material 11 (an example of a predetermined thickness) T3. On the other hand, the outer region arranged between the outer split mold 46 and the lower mold 51 of the upper mold 41 has a thickness T3 of the target base material 11 (an example of a predetermined thickness). Heat press to. In the joint-containing region, the thermosetting resin in a state of covering the upper surface (the surface to be the indoor surface 11A) of the mat 13 by pressurizing with a higher pressing force than the outer region is formed on the opposite surface (mat). It surely extends to the lower surface of 13 and the surface serving as the outdoor surface 11B).

<Movement process>
Next, the inner split die 45 of the upper die 41 is moved away from the lower die 51 so that the thickness of the joint-containing region of the plate-shaped body 12 becomes a predetermined thickness T3 which is the thickness of the base material 11 in the completed form. Move slightly (movement process). That is, the inner split mold 45 is displaced in the mold opening direction so that the mold surface 45A is flush with the mold surface 46A of the outer split mold 46 (see FIG. 11).

<Second press process>
Further, in this state (a state in which the thickness z of the entire base material 11 is set to a predetermined thickness T3), the pair of molds 41 and 51 are held for a predetermined time to cure the thermosetting resin spread in the base material 11. By curing the thermosetting resin, the bracket 15 and the base material 11 are integrally joined.

<Withdrawal process>
After a predetermined time (time for the thermosetting resin to cure) has elapsed in the second pressing step, the base material 11 is cooled and separated from the pair of molds 41 and 51 (see FIG. 12). In this way, a door trim 10 with a bracket is obtained in which the bracket 15 is joined to the base material 11 having a predetermined thickness T3.

Next, the action and effect will be described. The present embodiment is a method for manufacturing a door trim 10 with a bracket including a base material 11 containing fibers and a thermosetting resin and a bracket 15 bonded to the base material 11, and is formed on the surface of a mat 13 made of fibers. A bracket 15 is placed between the upper mold 41 and the lower mold 51 to be pressed when the plate-shaped body 12 is press-molded and the plate-shaped body forming step of forming the plate-shaped body 12 provided with the thermosetting resin coating 14. By inserting, the bracket 15 is joined to the plate-shaped body 12, and a resin molded body forming step of forming the door trim 10 with the bracket is included. In the resin molded body forming step, before the thermosetting resin is cured. The inner split mold 45 and the lower mold forming a part of the upper mold 41 so that the joint portion-containing region including the region to which the bracket 15 is joined in the plate-shaped body 12 has a thickness T2 smaller than the predetermined thickness T3. The outer split mold 46 is provided separately from the inner split mold 45 of the upper mold 41 so that the joint-containing region is pressed by 51 and the outer region other than the joint-containing region has a predetermined thickness T3. In the first pressing step of pressing the outer region with the lower mold 51 and the inner split mold 45 in the mold opening direction so that the mold surface 45A of the inner split mold 45 is flush with the mold surface 46A of the outer split mold 46. The second pressing step of displacement and pressing with a predetermined thickness T3 while heating with the upper mold 41 and the lower mold 51 until the thermosetting resin is cured is executed in order.

Even in such a method of manufacturing the door trim 10 with a bracket, the joint-containing region of the plate-shaped body 12 is pressed with a higher pressing force than the outer region by the first pressing step, so that heat is compared with the outer region. The curable resin is surely impregnated over the entire thickness direction of the mat 13. In addition, the base material 11 (mat 13 and thermosetting resin) is cured in a state where the thickness is T3, which is equivalent to that of the outer region, by the second pressing step. As a result, the completed door trim 10 with a bracket is provided with a lightweight base material 11 having a low density of fibers and thermosetting resin, and yet has a high bonding strength between the base material 11 and the bracket 15. Further, in the joint-containing region, the thermosetting resin is surely distributed throughout the plate-like body 12, so that the rigidity of the base material 11 is also improved.

Further, as in the above embodiment, the bracket 15 is joined to the outdoor surface 11B side of the door trim, and in the plate-like body forming step, the thermosetting resin coating 14 is applied to the indoor surface 11A side of the door trim. Since it is provided, the thermosetting resin can be reliably spread over the entire interior surface 11A constituting the interior design surface of the vehicle door, and the interior design surface can be beautifully formed.

Further, the manufacturing apparatus 40 of the present embodiment manufactures a door trim 10 with a bracket in which a bracket 15 is bonded to a base material 11 containing fibers and a thermosetting resin, and is used for pressing the plate-shaped body 12. The upper die 41 and the lower die 51 are provided, and the upper die 41 is divided into an inner split die 45 and an outer split die 46 which are movable relative to each other and can individually press the plate-shaped body 12. The lower mold 51 is provided with a bracket holding portion 57 that holds the bracket 15 so that the joint surface 16 with the plate-shaped body 12 is exposed, and the inner split mold 45 is provided in the area corresponding to the bracket holding portion 57. ing.

According to such a manufacturing apparatus 40, only the portion to which the bracket 15 should be joined is pressed relatively large by the inner split mold 35, and then the entire portion is made of the desired thickness T3 by the inner split mold 35 and the outer split mold 36. It becomes possible to press so as to become. Further, since the press streaks at the boundary of the split mold, which may be generated by using the split mold, are formed on the surface (outdoor surface 11B) side of the base material 11 to which the bracket 15 is joined, the interior design. It is possible to beautifully form the surface (indoor surface 11A).

Even with such a manufacturing apparatus 40, only the portion of the base material 11 to which the bracket 15 should be joined is pressed relatively large by the inner split mold 45, and then the whole is pressed by the inner split mold 45 and the outer split mold 46. It is possible to press to obtain a desired thickness. Further, since the bracket holding portion 57 is provided on the lower die 51 having a simple structure instead of the upper die 41 having a complicated structure having the inner split die 45 and the outer split die 46 that can be individually pressed, the mold is formed. The restrictions on the configuration are reduced, and the manufacturing apparatus 40 as a whole can have a simpler configuration.

<Other embodiments>
The present invention is not limited to the embodiments described by the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, within the scope not deviating from the gist other than the following. It can be implemented with various changes.

(1) In the above embodiment, the plate-like body 12 having the structure in which the film 14 of the thermosetting resin is provided on the front surface of the mat 13 is shown, but the film 14 may be provided on the back surface side. Further, as the plate-shaped body 112, a mat 13 having a thermosetting resin coating 14 formed on both sides thereof may be used (see FIG. 13). With such a configuration, it is possible to realize a high-quality base material 11 in which the thermosetting resin spreads more reliably in the fibers. On the other hand, the configuration in which the coating film 14 is provided on one side is excellent in cycle time.

(2) In addition to the above embodiment, the shape of the base material 11 can be changed as appropriate. In the above embodiment, the base material 11 has a structure in which a flat plate-shaped member is bent, but the present invention is not limited to this. For example, the base material 11 may be a curved bent plate-like member.

(3) Further, the bracket 15 may be another resin member, and the position and number of the bracket 15 to be joined to the base material 11 are not limited to the above embodiment.

(4) The resin molded body is not limited to the door trim 10 with a bracket that constitutes the interior design surface of the vehicle door, and the technique of the present invention can be applied to various molded bodies.

10: Door trim with bracket (resin molded body), 11: base material, 11A: indoor surface, 11B: outdoor surface, 12,112: plate-like body, 13: mat (fiber), 14: coating (thermosetting resin) , 15: Bracket (resin member), 16: Joint surface, 20, 40: Manufacturing equipment, 21: Upper mold (2nd mold), 31: Lower mold (1st mold), 35, 45: Inner split mold, 36 , 46: outer split type, 37, 57: bracket holding part, 41: upper mold (first type), 51: lower mold (second type), T2: thickness smaller than a predetermined thickness, T3: predetermined thickness

Claims (6)

A method for producing a resin molded product, which comprises a base material containing at least fibers and a thermosetting resin and having a predetermined thickness, and a resin member bonded to the base material.
A plate-like body forming step of forming a plate-like body in which a coating of the thermosetting resin is provided on at least one surface of the mat made of the fibers.
When the plate-shaped body is press-molded, the resin member is inserted between the first mold and the second mold to be pressed to join the resin member to the plate-shaped body to form the resin molded body. Including a resin molded body forming step to be formed,
In the resin molded body forming step, before the thermosetting resin is cured, the joint portion-containing region including the region to which the resin member is bonded in the plate-shaped body has a thickness smaller than the predetermined thickness. As described above, the joint-containing region is pressed by the inner split mold and the second mold that form a part of the first mold, and the outer region other than the joint-containing region has the predetermined thickness. In addition, among the first molds, the inner split mold is divided into an outer split mold, and the second mold presses the outer region.
The inner split mold is displaced in the mold opening direction so that the mold surface of the inner split mold is flush with the mold surface of the outer split mold, and the first mold and the first mold are cured until the thermosetting resin is cured. A method for producing a resin molded product, which sequentially executes a second pressing step of pressing with a predetermined thickness while heating with a mold 2. The method for producing a resin molded product according to claim 1, wherein in the first pressing step, the joint-containing region is pressed so that the thickness thereof is 50 to 90% of the predetermined thickness. The base material is a door trim constituting the interior design surface of the vehicle door, and the resin member is joined to the outdoor surface side of the door trim.
The method for producing a resin molded product according to claim 1 or 2, wherein in the plate-shaped body forming step, a coating film of the thermosetting resin is provided at least on the indoor surface side of the door trim. The method according to any one of claims 1 to 3, wherein in the first pressing step, the joint portion-containing region is pressed while the resin member is inserted into the inner split mold surface so as to be exposed. Method for manufacturing a resin molded product. A manufacturing apparatus for manufacturing a resin molded product in which a resin member is bonded to a base material containing at least fibers and a thermosetting resin.
Equipped with a first mold and a second mold for pressing a plate-shaped body,
The first mold is divided into an inner split type and an outer split type that can be individually pressed.
An apparatus for manufacturing a resin molded product, wherein the inner split mold is provided with a resin member holding portion that holds the resin member so that a joint surface with the plate-shaped body is exposed. A manufacturing apparatus for manufacturing a resin molded product in which a resin member is bonded to a base material containing at least fibers and a thermosetting resin.
Equipped with a first mold and a second mold for pressing a plate-shaped body,
The first mold is divided into an inner split type and an outer split type that can be individually pressed.
The second mold is provided with a resin member holding portion that holds the resin member so that the joint surface with the plate-shaped body is exposed.
The inner split type is a resin molded product manufacturing apparatus provided in a region corresponding to the resin member holding portion.

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