JP2021112827A - Molding structure and method for manufacturing molding structure - Google Patents

Abstract

To provide a molding structure capable of suppressing the generation of warpage and the generation of unevenness in an outer shape, and a method for manufacturing the same.SOLUTION: A pillar garnish 20 comprises: a tabular substrate body part 31 containing a fiber and a thermoplastic resin; and a resin molding 40 containing a thermoplastic resin, arranged in at least a part of the surroundings of the substrate body part 31, and joined with the substrate body part 31. A substrate sub-body part 32 containing a fiber and a thermoplastic resin is embedded inside the resin molding 40.SELECTED DRAWING: Figure 1

Description

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

Conventionally, a molded structure in which a resin molded body is integrally molded with a base material formed by mixing a thermoplastic resin and fibers is known. Patent Document 1 below describes a method for producing a resin molded product, in which a base material is molded by a pair of molding dies and then a molten resin is injected into the molding dies. The molten resin injected onto the base material mixes with the thermoplastic resin constituting the base material. As a result, the resin molded product is bonded to the base material.

Japanese Unexamined Patent Publication No. 2009-11324

By the way, as a molded structure in which a plate-shaped base material and a resin molded body are integrally molded, a configuration in which the resin molded body is bonded to the end face of the base material can be considered. In the manufacturing process of such a resin molded body, stress is generated due to the difference in molding shrinkage between the base material and the resin molded body, and the molded structure is warped or the outer shape is uneven. Is a concern.

The present invention has been completed based on the above circumstances, and provides a molded structure capable of suppressing the occurrence of warpage and the occurrence of irregularities in the outer shape, and a method for manufacturing such a molded structure. The purpose is.

As a means for solving the above problems, the molded structure disclosed by the present specification includes a plate-shaped base material main body portion containing a fiber and a thermoplastic resin, and a base material main body portion containing a thermoplastic resin. A resin molded body disposed in at least a part of the periphery and bonded to the base material main body is provided, and a plate-shaped base material sub-body containing fibers and a thermoplastic resin is inside the resin molded body. The feature is that the part is buried.

Generally, the shrinkage rate of the resin molded product containing the thermoplastic resin is larger than that of the base material main body containing the fiber and the thermoplastic resin. Then, the resin molded body is arranged around the base material main body portion and is joined to the base material main body portion. Therefore, in the process of cooling the molded structure, the base material main body is tightened from the resin molded body arranged around it. As a result, stress is generated inside the molded structure and warpage occurs.

Therefore, when a base material sub-body portion containing fibers and a thermoplastic resin was embedded inside the resin molded body and a part of the resin molded body was replaced with the base material sub-body part, the base material sub-body part was embedded. The shrinkage of the resin molded product is small. As a result, the tightening caused by the difference in shrinkage rate is relaxed and the stress generated is reduced, so that the warpage of the molded structure can be suppressed.

In the above configuration, the base material main body portion has a base material corner portion that projects outward when viewed in a plane, and the resin molded body is located at a position facing the base material corner portion when viewed in a plane and outward. It has a protruding resin corner portion, and the base material subbody portion can be embedded between the base material corner portion and the resin corner portion facing the base material corner portion.

When the base material sub-body portion is not embedded inside the resin molded body, the amount of shrinkage is larger than that of other portions, especially at the resin corner portion, due to the difference in shrinkage rate from the base material main body portion. As a result, unevenness is generated in the outer shape of the resin molded body between the resin corner portion and the other portion. Therefore, with such a configuration, the shrinkage rate of the resin molded body in which the base material sub-body portion is embedded becomes small, and the occurrence of unevenness in the outer shape of the resin molded body, that is, the outer shape of the molded structure is suppressed. can.

In the above configuration, the base material main body portion has a rectangular shape as a whole, and the base material subbody portion is between the adjacent base material corner portions and the respective resin corner portions facing them. It can be buried.

According to such a configuration, shrinkage in the direction along the alignment direction of the base material sub-body portions is particularly suppressed in the adjacent resin corner portions, so that warpage of the molded structure and occurrence of unevenness in the outer shape can be suppressed. ..

In the above configuration, the base material sub-body portion may be formed in succession with the base material main body portion.

According to such a configuration, since the relative displacement between the base material main body portion and the base material sub-body portion is suppressed, the relative positioning in the molding space is facilitated, and the occurrence of misalignment is suppressed. Further, since the base material main body and the base material sub-body can be handled as one part instead of a separate part, the number of parts is reduced and the process design becomes easy.

Further, the method for manufacturing a molded structure disclosed in the present specification as a means for solving the above problems is executed after a preboard molding step for molding a preboard and the preboard molding step, and the preboard is molded by a molding die. A press molding step of press molding to form the base material main body portion and the base material subbody portion, and a thermoplastic resin executed after the press molding step and melted in a molding space inside the closed molding die. It includes an injection molding step of injecting and molding the resin molded body so as to surround the base material main body portion, and the base material subbody portion is embedded inside the resin molded body in the injection molding step. It is characterized by being.

When the pre-board molded in the pre-board molding step is placed between the open molding dies and then the molding die is closed, the base material main body and the base material sub-body are molded in the molding space (press molding step). ). Next, when the molten thermoplastic resin is injected into the molding space, the resin molded body is molded, and the molded structure composed of the resin molded body, the base material main body, and the base material subbody is integrally molded. NS. At this time, the resin molded body is molded so as to surround the base material main body portion, and the base material subbody portion is embedded inside the resin molded body portion. As a result, a part of the resin molded body surrounding the main body of the base material is replaced with the sub-body part of the base material to reduce the molding shrinkage rate, and it is possible to suppress the occurrence of warpage of the molded structure and the occurrence of unevenness in the outer shape. Can be done.

In the above configuration, in the pre-board molding step, the portion corresponding to the base material main body portion and the portion corresponding to the base material subbody portion can be molded as one continuous part.

According to the manufacturing method having such a configuration, the relative displacement between the base material main body and the base material subbody is suppressed, so that the relative positioning in the molding space is facilitated and the misalignment is suppressed. Will be done. Further, since the base material main body and the base material sub-body can be handled as one part instead of a separate part, the number of parts is reduced and the process design becomes easy.

According to the present invention, it is possible to realize a molded structure capable of suppressing the occurrence of warpage and the occurrence of unevenness in the outer shape. Further, it is possible to provide a method for manufacturing such a molded structure.

Overall perspective view of the pillar garnish AA cross-sectional view of FIG. Overall perspective view of the base material Top view showing the shape of the first model before cooling Top view showing the shape of the first model after cooling BB sectional view of FIG. Top view showing the shape of the second model before cooling Top view showing the shape of the second model after cooling CC sectional view of FIG. Cross-sectional view showing the pre-board molding process Cross-sectional view showing the mold opening state of the molding apparatus A cross-sectional view showing a cross-sectional view showing a press molding process. Sectional view showing injection molding process A cross-sectional view showing a state in which the slide type is moved from the state shown in FIG. Cross-sectional view showing the state where the pillar garnish is extruded by the extrusion pin. Top view showing the shape of the third model before cooling

<Embodiment>
An embodiment of the present invention will be described with reference to FIGS. 1 to 15. In this embodiment, a pillar garnish 20 for a vehicle is illustrated as a molded structure. The directions of the arrows FR and RR shown in each figure indicate the front (vehicle traveling direction) and the rear, respectively, the directions of the arrows IN and OUT indicate the directions of the inside and the outside of the vehicle, respectively, and the directions of the arrows UP and DW. Indicates above and below, respectively.

The pillar garnish 20 is a vehicle interior material (an example of a vehicle interior material) that is attached from the vehicle interior side to a center pillar (B pillar) arranged on the side wall of the vehicle interior. As shown in FIG. 1, the pillar garnish 20 is a pair of a main wall portion 21 forming a surface facing the occupant and a pair of both end portions (both ends in the vehicle front-rear direction) of the main wall portion 21. The side wall portions 25 and 26 are provided. The pillar garnish 20 illustrated in the present embodiment is arranged on the right side of the passenger compartment, but the same configuration is provided on the left side of the passenger compartment.

The main wall portion 21 has a long plate shape in the vertical direction, and an opening 24 for exposing the slide plate to the inside of the vehicle is formed in the central portion thereof. A shoulder belt anchor through which the seat belt is inserted is attached to the slide plate. A pair of mounting pieces 22 for mounting the pillar garnish 20 to the center pillar is provided at the lower end of the main wall portion 21. A clip seat 51 is formed on the back surface (the surface on the outside of the vehicle) of the upper end of the main wall 21 so as to project to the outside of the vehicle. The clip seat 51 can be engaged with a clip provided on the center pillar, whereby the pillar garnish 20 is held by the center pillar.

As shown in FIGS. 1 and 2, which is a cross section taken along the line AA of FIG. 1, the side wall portion 25 is assumed to rise from the front side end of the main wall portion 21 to the outside of the vehicle, and the side wall portion 26 is the main wall portion. It is assumed that the vehicle stands up from the side end on the rear side of 21 to the outside of the vehicle. Further, a plurality of reinforcing ribs 49 arranged in the vertical direction are formed on the back surfaces of the side wall portions 25 and 26. Further, on the back surface of each of the side wall portions 25 and 26, an extension rib 50 extending along each side end portion of the side wall portions 25 and 26 is formed. The extension rib 50 is provided so as to connect a plurality of reinforcing ribs 49 arranged in the vertical direction.

Further, the pillar garnish 20 includes a base material main body portion 31 which is a portion containing fibers and a thermoplastic resin, and a resin molded body 40 made of the thermoplastic resin. In FIG. 1, a portion of the pillar garnish 20 occupied by the resin molded body 40 is shaded. The base material main body 31 is molded by press molding, and the resin molded body 40 is molded by injection molding.

As the fiber used for the base material main body 31, for example, kenaf fiber is used, but the type of fiber is not limited to this, and wood fiber, glass fiber, carbon fiber and the like may be used. Further, in the base material main body 31, the fibers are bound by a thermoplastic resin. The thermoplastic resin used for the base material main body 31 can be exemplified by polypropylene, and the thermoplastic resin used for the resin molded body 40 can be exemplified by polypropylene, but is not limited thereto. The thermoplastic resin used for the base material main body portion 31, the resin molded body 40, and the base material subbody portion 32 described later may be made of the same material or may be made of different materials. Further, the fibers contained in the base material main body portion 31 and the base material subbody portion 32 may be made of the same material or different materials.

The base material main body portion 31 in the present embodiment is continuously and integrally press-molded with the base material subbody portion 32, and both constitute the base material 30 together. An overall view of the base material 30 is shown in FIG. The base material main body 31 is rectangular as a whole, and the portions corresponding to the four vertices are the base material corners 37. Further, the base material main body portion 31 is bent so that the inside of the vehicle is convex, and the base material main wall portion 34 constituting most of the main wall portion 21 (a portion excluding the upper end portion and the lower end portion) and The base material side wall 35 that constitutes most of the side wall 25 (parts other than the upper end, lower end, and side end) and most of the side wall 26 (parts other than the upper end, lower end, and side end). The base material side wall portion 36 constituting the base material is provided.

As shown in FIG. 2, which is a cross section taken along the line AA of FIG. 1, the base material side wall portion 35 is bent with respect to the base material main wall portion 34 and is a front end portion of the base material main wall portion 34 (left side in FIG. 2). , The end of the main wall 21) rises to the outside of the vehicle. Further, the base material side wall portion 36 is bent from the base material main wall portion 34 and rises from the rear end portion of the base material main wall portion 34 to the outside of the vehicle.

The base material sub-body portion 32 is extended in succession to each of the four base material corner portions 37 included in the base material main body portion 31. The base material sub-body portion 32 is a portion forming a substantially rectangular shape smaller than the base material main body portion 31. In the present embodiment, the base material subbody portion 32 is continuous with the base material main body portion 31, and these materials (fibers and thermoplastic resin) are the same, but the base material main body portion 31 and the base material are used. The sub-body portion 32 may not be continuously formed and may be a separate component, or may be made of fibers and thermoplastic resins of different materials.

As shown in FIG. 1, the resin molded body 40 constitutes a plate-shaped resin plate-shaped portion 43, a clip seat 51, a reinforcing rib 49, an extension rib 50, and a mounting piece 22. The resin plate-shaped portion 43 is provided around the pillar garnish 20 so as to surround the base material main body portion 31 and the base material subbody portion 32, and is joined to these. Therefore, the peripheral end portion of the pillar garnish 20 is composed of a resin plate-shaped portion 43 (resin molded body 40).

Specifically, the resin plate-shaped portion 43 includes a main wall upper end portion 44A forming the upper end portion of the main wall portion 21, a main wall lower end portion 44B forming the lower end portion of the main wall portion 21, and a side wall portion 25. The upper end portion 45A of the side wall forming the upper end portion, the lower end portion 45B of the side wall forming the lower end portion of the side wall portion 25, the upper end portion 46A of the side wall forming the upper end portion of the side wall portion 26, and the lower end portion of the side wall portion 26 are formed. The lower end portion 46B of the side wall, the front end portion 55 of the side wall forming most of the outer end of the side wall 25, and the rear end 56 of the side wall forming most of the outer end of the side wall 26. Be prepared. The lower end portion 44B of the main wall, the lower end portion 45B of the side wall, and the lower end portion 46B of the side wall have a stepped shape in which the lower portion is displaced to the outside of the vehicle with respect to the upper portion.

Therefore, each base material subbody portion 32 extending from each base material corner portion 37 is embedded in each of the side wall upper end portion 45A, the side wall lower end portion 45B, the side wall upper end portion 46A, and the side wall lower end portion 46B. It will be.

As shown in FIGS. 1 and 2, the side wall rear end portion 56 extends in the vertical direction and connects the side wall upper end portion 46A and the side wall lower end portion 46B. The rear end surface portion 56 of the side wall extends along the end surface 36A on the outer side of the vehicle on the side wall portion 36 of the base material and is joined to the end surface 36A. That is, the side wall portion 26 includes a side wall upper end portion 46A, a side wall lower end portion 46B, and a side wall rear end portion 56. The side wall portion 25 has the same configuration as the side wall portion 26, and includes a side wall upper end portion 45A, a side wall lower end portion 45B, and a side wall front end portion 55.

Next, a molding apparatus 70 for molding the pillar garnish 20 according to the present embodiment will be described. As shown in FIG. 11, the molding apparatus 70 includes a molding die 71 and an injection apparatus 78. The molding die 71 includes a core die 72, a cavity die 73, and a slide die 74. The core type 72 and the cavity type 73 are arranged to face each other, and can be approached or separated by a driving device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.). As a result, the core mold 72 and the cabinet mold 73 can be closed and opened. The injection device 78 is a device for pumping the molten resin to the gates 76A, 76B, 76C (see FIG. 1 for the gate 76A) provided in the molding die 71 and injecting the molten resin into the molding spaces S1 and S2.

In the mold closed state shown in FIG. 12, the core mold 72, the cavity mold 73, and the slide mold 74 form a molding space S1 for molding the base material 30 and a molding space S2 for molding the resin molded body 40. NS. The molten resin supplied from the injection device 78 (see FIG. 11) is injected into the molding space S2 via the gates 76A, 76B, and 76C. Note that the injection device 78 is not shown in FIGS. 11 to 15.

Next, a method for manufacturing the pillar garnish 20 according to the present embodiment will be described. The method for producing the pillar garnish 20 according to the present embodiment includes a pre-board molding step S10 for molding the pre-board P1 which is a base material 30 before molding, and a base material 30 which is press-molded by the core mold 72 and the cavity mold 73 for the pre-board P1. The press molding step S20 and the injection molding step S30 for molding the resin molded body 40 in a form of being joined to the base material 30 by injecting the molten resin into the molding space S2 are provided.

As shown in FIG. 10, in the pre-board forming step S10, the fiber mat 80 made of fibers and a thermoplastic resin is heat-pressed by a pair of press dies 81. As a result, the fiber mat 80 is compressed. After that, the thermoplastic resin contained in the fiber mat 80 is cooled and solidified to form the pre-board P1.

In the press forming step S20 executed after the preboard forming step S10, first, the heated and softened preboard P1 is arranged between the core mold 72, the slide mold 74, and the cavity mold 73, as shown in FIG. Subsequently, as shown in FIG. 12, by closing the core mold 72 and the cavity mold 73, the pre-board P1 is press-molded by the molding surfaces of the core mold 72, the slide mold 74, and the cavity mold 73. As a result, the pre-board P1 press-molded by the molding die 71 has a shape that follows the shape of the molding space S1 and becomes the base material 30. In the base material 30 according to the present embodiment, as shown in FIG. 3, the base material main body portion 31 and the base material subbody portion 32 are continuously formed.

In the injection molding step S30 executed after the press molding step S20, as shown in FIG. 13, the base material 30 and the molding mold 30 are sandwiched between the core mold 72, the slide mold 74 and the mold 73. A molten resin (for example, polypropylene or the like) is injected into the molding space S2 formed by both of the 71. In the process of filling the molding space S2 with the molten resin, the molten resin permeates into the fibers of the base material 30 at the contact points with the base material 30. At the same time, the molten resin that has permeated the inside of the fiber mixes with the softened thermoplastic resin inside the base material 30 and becomes completely integrated (mixed).

Specifically, in the injection molding step S30, the molten resin supplied from the injection device 78 is injected into the molding space S2 from the three gates 76A, 76B, 76C provided in the molding die 71. In FIG. 1, the positional relationship between the resin molded body 40 and the gates 76A, 76B, 76C is illustrated by showing the gates 76A, 76B, and 76C as dots. As shown in FIG. 1, the gate 76A injects the molten resin mainly into the molding space S2 for molding the main wall upper end portions 44A and the side wall upper end portions 45A and 46A in the molding space S2. Further, the gates 76B and 76C are mainly used for molding the side wall front end portion 55, the side wall rear end portion 56, the main wall lower end portion 44B, the side wall lower end portion 45B, and the side wall lower end portion 46B in the molding space S2. The molten resin is supplied to S2.

After that, when the molten resin is cooled, the molten resin filled in the molding space S2 becomes a resin molded body 40 bonded to the base material 30. For example, the side wall front end portion 55 and the side wall rear end portion 56 are formed in a state of being joined to the end faces 35A and 36A of the base material side wall portions 35 and 36, respectively.

Then, as shown in FIG. 14, the slide mold 74 is moved so that the undercut portion (for example, the extension rib 50) in the pillar garnish 20 can be die-cut, and is provided on the core mold 72 as shown in FIG. The pillar garnish 20 can be die-cut by extruding the pillar garnish 20 with the extruded pin 77. In the subsequent step, processing such as providing the opening 24 is performed to complete the pillar garnish 20.

Next, the operation and effect of this embodiment will be described. The pillar garnish 20 according to the present embodiment is arranged so as to surround a plate-shaped base material main body 31 containing fibers and a thermoplastic resin and a base material main body 31 containing a thermoplastic resin, and is a base material. A resin molded body 40 to be joined to the main body 31 is provided, and a plate-shaped base material subbody portion 32 containing fibers and a thermoplastic resin is embedded inside the resin molded body 40.

Generally, the molding shrinkage rate of the resin molded body 40 containing the thermoplastic resin is larger than that of the base material main body 31 containing the fibers and the thermoplastic resin. Then, the resin molded body 40 according to the present embodiment is provided around the base material main body 31 so as to surround the base body main body 31 and is joined to the base material main body 31. In such a configuration, in the process of cooling the thermoplastic resin, there is a concern that warpage may occur due to the difference in molding shrinkage rate and unevenness may occur in the outer shape.

Here, in order to explain the occurrence of warpage and unevenness in the outer shape, the models M10 and M20 in which the structure of the pillar garnish 20 is a simple rectangular plate shape will be examined with reference to FIGS. 4 to 9. The first model M10 (FIG. 4) is a model composed of a rectangular plate-shaped base material main body M11 and a similarly rectangular plate-shaped resin molded body M12 circulated so as to surround the periphery thereof, and is the same as the first model M10. The second model M20 (FIG. 7) is a model having the base material main body portion M21 of the above, but in which a part of the resin molded body M22 is replaced with the rectangular plate-shaped base material subbody portion M23.

The base material main body portions M11 and M21 and the base material subbody portion M23 are made of a material containing fibers and a thermoplastic resin like the base material main body portion 31 of the pillar garnish 20 described above. Further, the resin molded bodies M12 and M22 are also made of a material containing a thermoplastic resin like the resin molded body 40.

The first model M10 and the second model M20 are molded by press molding and injection molding, and at the time point before cooling immediately after the molten resin is injected, the base material main body M11 and the resin molding are as shown in FIGS. 4 and 7. Both bodies M12 are square when viewed in a plane, and there is no warpage or unevenness in the outer shape.

However, in the case of the first model M10, in the process of cooling after the injection of the molten resin, due to the difference in the molding shrinkage between the base material main body M11 and the resin molded body M12, the surroundings thereof are surrounded more than the base material main body M11. The resin molded product M12 shrinks more. As a result, the base material main body M11 is tightened by the resin molded body M12 surrounding the periphery, stress is generated inside the first model M10, and a large warp occurs in the Z direction as shown in FIG.

On the other hand, in the case of the second model M20 as well, in the cooling process, the resin molded body M22 surrounding the base material body M21 contracts more than the base material main body M21, so that stress is applied to the inside of the second model M20. appear. However, as compared with the resin molded body M12 of the first model M10, since a part of the resin molded body M22 is replaced with the base material subbody portion M23, the amount of shrinkage is smaller than that of the first model M10, and the generation occurs. The stress to be applied becomes smaller. Therefore, as shown in FIG. 9, the occurrence of warpage is suppressed as compared with the first model M10.

Therefore, also in the pillar garnish 20 according to the present embodiment, the base material sub-body portion 32 is embedded in the resin molded body 40 that is provided around the base material main body portion 31 so as to surround the base material sub-body portion 31. Since the stress generated inside the pillar garnish 20 is reduced as compared with the case where the body portion 32 is not provided, the occurrence of warpage due to the difference in molding shrinkage is suppressed.

Further, in the pillar garnish 20 according to the present embodiment, the base material main body 31 has a base material corner portion 37 that projects outward when viewed in a plane, and the resin molded body 40 is at a position facing the base material corner portion 37. In addition, it has a resin corner portion 41 that projects outward when viewed in a plane, and the base material subbody portion 32 is embedded between the base material corner portion 37 and the resin corner portion 41 facing the base material corner portion 37.

Here, the change in the outer shape of the pillar garnish 20 will be described again by taking as an example again the models (first model M10 and second model M20) obtained by simplifying the pillar garnish 20 described above. As shown in FIG. 5, the first model M10 shrinks after cooling (solid line) as compared with that before cooling (two-dot chain line) and has a smaller outer shape. In particular, since the resin corner portion M15 has a large shrinkage amount, the outer shape that was square before cooling has irregularities. This is because the resin corner portion M15 is arranged in the contraction direction (X direction and Y direction in FIG. 5) of the resin molded body M12 rather than the portion other than the resin corner portion M15 of the resin molded body M12. This is because there are many regions, so the amount of shrinkage is also large.

On the other hand, also in the second model M20 having the base material sub-body portion M23, as shown in FIG. 8, after cooling (solid line), the outer shape shrinks more than before cooling (two-dot chain line). In particular, the resin corner portion M25 has a large amount of shrinkage, and the outer shape has irregularities. However, in the second model M20, since the base material subbody portion M23 is arranged between the four base material corner portions M24 and the four resin corner portions M25, respectively, the shrinkage direction (X) from the resin corner portion M25. When looking at the direction (direction and Y direction), the area of the resin molded body M22 arranged is reduced. Therefore, although it shrinks, the amount of shrinkage is smaller than that of the resin corner portion M15, and the occurrence of unevenness is suppressed.

In the pillar garnish 20 according to the present embodiment, the upper end portions 45A and 46A of the side walls have a larger amount of contraction in the vertical direction than the upper end portions 44A of the main wall. Therefore, the upper end portion 44A of the main wall is convex, and the upper end portions 45A and 46A of the side wall are concave. However, as compared with the case where the base material sub-body portion 32 is not provided, the amount of shrinkage thereof is reduced due to the presence of the base material sub-body portion 32, so that the occurrence of unevenness is suppressed. The upper end of the pillar garnish 20 and the ceiling material arranged so as to be adjacent to the upper end of the pillar garnish 20 are in contact with each other, and if the unevenness is large, a gap is formed between the two and the appearance of the interior is deteriorated. With the configuration according to the present embodiment, it is possible to suppress the occurrence of gaps and prevent the appearance of the interior from being deteriorated.

Further, in the pillar garnish 20 according to the present embodiment, the base material main body portion 31 has a rectangular shape as a whole, and the base material subbody portion 32 is the adjacent base material corner portions 37 and their respective resins facing each other. It can be buried between the corner portion 41 and the corner portion 41.

In such a configuration, the two base material sub-body portions 32 are always arranged between the two adjacent resin corner portions 41. Therefore, shrinkage in the direction along the alignment direction of the two base material sub-body portions 32, that is, in the direction along the alignment direction of the two adjacent resin corner portions 41 is particularly suppressed. As a result, it is possible to further suppress the warpage of the pillar garnish 20 and the occurrence of unevenness in the outer shape.

Further, in the pillar garnish 20 according to the present embodiment, the base material subbody portion 32 can be formed in succession with the base material main body portion 31.

In such a configuration, in the pre-board molding step S10, the portion corresponding to the base material main body portion 31 and the portion corresponding to the base material sub-body portion 32 are molded as a continuous pre-board P1. When it is cooled and solidified, the relative displacement between the two is suppressed. As a result, in the subsequent press molding step S20, positioning when the preboard P1 is arranged between the open molding dies 71 can be facilitated. Further, when the molding die 71 is subsequently closed, it is possible to suppress the occurrence of misalignment in the molding space S1. Further, since the base material main body portion 31 and the base material sub-body portion 32 can be handled as one base material 30 instead of as individual parts, the number of parts can be reduced and the process can be easily designed. ..

Next, a method for manufacturing the pillar garnish 20 according to the present embodiment will be described. The method for producing the pillar garnish 20 according to the present embodiment is executed after the pre-board molding step S10 for molding the pre-board P1 which is the base of the base material main body 31 and the base material sub-body 32, and the pre-board molding step S10. The press molding step S20 in which P1 is press-molded by the molding die 71 to form the base material main body portion 31 and the base material subbody portion 32, and the molding space inside the closed molding die 71 executed after the press molding step S20. An injection molding step S30 is provided in which a molten thermoplastic resin is injected into S2 to form a resin molded body 40 so as to surround the base material main body 31, and the base material subbody portion 32 is in the injection molding step S30. It is characterized in that it is embedded inside the resin molded body 40.

First, the plate-shaped preboard P1 is molded in the preboard forming step S10. Next, in the press forming step S20, the preboard P1 is arranged between the open forming dies 71 (core die 72, slide die 74, and cavity die 73), and then the forming die 71 is closed, and the base material main body portion is formed in the forming space S1. 31 and the base material sub-body portion 32 are molded. After that, in the injection molding step S30, when the molten thermoplastic resin is injected into the molding space S2 which is a space surrounded by the molding die 71, the base material main body 31 and the base material subbody 32, the resin molded body 40 is formed. The pillar garnish 20 is integrally molded in a state of being joined to the base material main body portion 31 and the base material subbody portion 32.

According to the manufacturing method having such a configuration, the resin molded body 40 is molded so as to surround the base material main body portion 31, and the base material subbody portion 32 is embedded inside the resin molded body 40. As a result, a part of the resin molded body 40 surrounding the periphery of the base material main body 31 is replaced with the base material subbody portion 32 to reduce the molding shrinkage rate, and the pillar garnish 20 is warped and outer shape after cooling. It is possible to suppress the occurrence of unevenness in the shape.

Further, in the pre-board molding step S10, the portion corresponding to the base material main body portion 31 and the portion corresponding to the base material subbody portion 32 can be molded as one continuous part.

According to the manufacturing method having such a configuration, the base material main body portion 31 and the base material subbody portion 32 can be treated as a continuous base material 30. As a result, the relative displacement between the base material main body portion 31 and the base material subbody portion 32 is suppressed, so that the relative positioning in the molding space S1 is facilitated, and the occurrence of misalignment is suppressed. Further, since the base material main body portion 31 and the base material subbody portion 32 can be handled as one part instead of a separate part, the number of parts is reduced and the process design becomes easy.

<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 base material main body portion and the base material separate body portion are both rectangular, and are formed in succession so that the periphery of each apex overlaps, but the connection state between the two is this. Not limited to. It suffices that the base material main body portion and the base material separate body portion can be collectively handled as one component, and the relative displacement between the two is regulated. For example, the base material main body portion and the base material separate body portion may be connected via an elongated plate-shaped connecting portion.

(2) In the above embodiment, the pillar garnish is exemplified as the molded structure, but the technical scope of the present invention is not limited to this. The molded structure may be a vehicle interior material such as a board member (upper board or the like) constituting the door trim, an instrument panel, a luggage trim, or a package tray. Further, the molded structure may be an interior material (interior material for vehicles) mounted on a vehicle other than the vehicle, or may be a member other than the interior material. The vehicle panel to which the vehicle interior material is fixed is not limited to the center pillar, and can be appropriately changed depending on the type of the vehicle interior material.

(3) The arrangement locations of the gates 76A, 76B, and 76C and the total number of gates are not limited to those illustrated in the above embodiment and can be changed as appropriate.

(4) In the above embodiment, it is exemplified that the outer peripheral end portion of the molded structure (pillar garnish) is composed of the resin molded body, but the present invention is not limited to this. For example, a part of the outer peripheral end of the molded structure may be composed of a base material.

(5) The pillar garnish may include a skin material that covers the base material and the resin molded body from the inside of the vehicle.

(6) In the above embodiment, the configuration in which one pillar garnish includes four base material sub-body parts has been described, but the number of base material sub-body parts is not limited to this, and may be three or less, or five. It may be the above. Further, not only when the base material sub-body portion is arranged between the base material corner portion and the resin corner portion facing the base material corner portion, but also when the base material sub-body portion is embedded between two adjacent resin corner portions. It doesn't matter.

(7) In the above embodiment, as shown in FIG. 1, the resin molded body 40 is arranged so as to surround the outer periphery of the base material main body 31 without a gap. However, the mode of the resin molded body 40 is not limited to this, and the resin molded body M32 may surround at least a part of the periphery of the base material main body portion M31 as in the third model M30 shown in FIG. .. Therefore, there may be a portion M36 that is not surrounded by the resin molded body M32.

20 ... Pillar garnish (molded structure), 21 ... Main wall part, 22 ... Mounting piece, 24 ... Opening, 25, 26 ... Side wall part, 31 ... Base material body part, 32 ... Base material subbody part, 37 ... Base material corners, 40 ... resin molded body, 41 ... resin corners, 43 ... resin plate-like parts, 44A ... main wall upper end, 44B ... main wall lower end, 45A ... side wall upper end, 45B ... side wall lower end, 46A ... Upper end of side wall, 46B ... Lower end of side wall, 49 ... Reinforcing rib, 50 ... Extended rib, 51 ... Clip seat, 55 ... Front end of side wall, 56 ... Rear end of side wall

Claims (6)

A plate-shaped base material body containing fibers and thermoplastic resin,
A resin molded product containing a thermoplastic resin, which is disposed around at least a part of the base material main body portion and is bonded to the base material main body portion, is provided.
A molded structure in which a plate-shaped base material sub-body portion containing fibers and a thermoplastic resin is embedded inside the resin molded body. The base material main body portion has a base material corner portion that projects outward when viewed in a plane.
The resin molded body has a resin corner portion that protrudes outward when viewed in a plane at a position facing the corner portion of the base material.
The molded structure according to claim 1, wherein the base material subbody portion is embedded between the base material corner portion and the resin corner portion facing the base material corner portion. The base material main body has a rectangular shape as a whole.
The molded structure according to claim 2, wherein the base material sub-body portion is embedded between the adjacent base material corner portions and the respective resin corner portions facing the base material corner portions. The molded structure according to any one of claims 1 to 3, wherein the base material sub-body portion is formed in succession with the base material main body portion. The method for manufacturing a molded structure according to any one of claims 1 to 4.
Pre-board molding process to mold pre-board and
A press molding step executed after the pre-board molding step, in which the pre-board is press-molded by a molding die to form the base material main body portion and the base material sub-body portion.
An injection molding step executed after the press molding step, in which a molten thermoplastic resin is injected into a molding space inside the closed molding mold, and the resin molded body is molded so as to surround the base material main body portion. , Equipped with
A method for manufacturing a molded structure, wherein the base material subbody portion is embedded inside the resin molded body in the injection molding step. The fifth aspect of the present invention, wherein in the pre-board molding step, a portion corresponding to the base material main body portion and a portion corresponding to the base material subbody portion are molded as one continuous part. A method for manufacturing a molded structure.

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