JP2021123095A - Molding structure, and method for producing molding structure - Google Patents

Abstract

To provide a molding structure that resists deformation, and a method for producing such a molding structure.SOLUTION: A pillar garnish 20 has a tabular base material 30 including fiber and thermoplastic resin, and a resin molding 40 containing thermoplastic resin. The resin molding 40 has a first resin molding part 41 joined to a back side 20A of the base material 30, and a second resin molding part 42 joined to a design surface 20B of the base material 30 at a position opposite the first resin molding part 41 across the base material 30.SELECTED DRAWING: Figure 4

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 containing fibers and a thermoplastic resin is known. Patent Document 1 below describes a manufacturing method for molding a resin molded body by injecting a molten resin onto the base material after molding the base material with a pair of molding molds. The molten resin injected onto the base material mixes with the thermoplastic resin constituting the base material. As a result, the resin molded body is bonded to the base material.

Japanese Patent No. 5186883

However, when the molding shrinkage of the base material and the resin molded product is compared, the molding shrinkage of the resin molded product is larger. Therefore, in the cooling process after injection molding, there is a concern that stress is generated on the joint surface due to the difference in the amount of shrinkage between the two, and the molded structure is deformed.

The present invention has been completed based on the above circumstances, and one of the objects of the present invention is to realize a molded structure in which deformation is suppressed. Another further object is to provide a method for manufacturing such a molded structure.

The molded structure disclosed by the present specification includes a plate-shaped base material containing a fiber and a thermoplastic resin, and a resin molded body containing a thermoplastic resin, wherein the resin molded body is one of the base materials. It has a first resin molded portion bonded to the plate surface of the base material and a second resin molded portion bonded to the other plate surface of the base material.

In general, the shrinkage rate of a resin molded product containing a thermoplastic resin is larger than that of a base material containing fibers and a thermoplastic resin. Therefore, assuming that the resin molded body (first resin molded portion) is bonded only to one plate surface of the plate-shaped base material, the bonded surface is in the process of temperature change after molding and aging due to crystallization. Stress is generated in the molded structure and the molded structure is deformed.

Therefore, if the second resin molded portion is bonded to the other plate surface in addition to the first resin molded portion to be bonded to one plate surface, the bonded surfaces are arranged on both sides of the base material. NS. As a result, the stresses generated at the joint surfaces cancel each other out, and the deformation of the molded structure is suppressed. The thermoplastic resin contained in the base material and the thermoplastic resin contained in the resin molded product may be the same material or different materials.

Further, the second resin molded portion may be joined at a position symmetrical with the first resin molded portion with the base material interposed therebetween. In this way, the stress generated at one of the joint surfaces is canceled by the stress generated at the other joint surface arranged at symmetrical positions across the substrate. That is, since the stress is canceled in the region sandwiched between the two joint surfaces, it is difficult for the stress to affect other regions in the molded structure. Thereby, the deformation of the molded structure can be further suppressed.

Further, the other plate surface has a base material recess formed by making the thickness smaller than that of the other portion of the base material, and the second resin molded portion is filled in the base material recess. It can be joined to the base material recess in the form of

By doing so, the size (area when viewed in a plan view and the depth of the base material recess) and the shape of the base material recess can be appropriately changed to increase the amount of the thermoplastic resin constituting the second resin molded portion. The shape can be adjusted. Thereby, the magnitude of the stress generated by the second resin molded portion can be appropriately adjusted to be balanced with the stress caused by the first resin molded portion. As a result, deformation of the molded structure due to temperature changes and the like can be further suppressed.

Further, in such a configuration, the second resin molded portion is joined to the recess of the base material, which is smaller in thickness than the other parts of the base material. Therefore, it is possible to reduce or eliminate the difference in thickness between the portion of the molded structure in which the second resin molded portion is arranged and the other portion. Thereby, the design restriction on the other plate surface due to the presence of the second resin molded portion can be suppressed or eliminated.

Further, the method for manufacturing a molded structure disclosed in the present specification as a means for solving the above problems includes a preboard molding step of molding a plate-shaped preboard containing fibers and a thermoplastic resin by a pair of press molds. A base material molding step executed after the pre-board molding step to mold the base material by press-molding the pre-board with a molding die, and a molding inside the closed molding die executed after the base material molding step. An injection molding step of injecting molten resin into a space to mold the resin molded body is provided. In the injection molding step, the first resin molding portion and the second resin molding portion sandwich the base material, respectively. It is characterized in that it is molded at a position and bonded to the base material.

In this way, the first resin molding portion and the second resin molding portion molded in the injection molding step are joined to each other at positions sandwiching the base material. Then, in the cooling process after the injection molding process, the stresses generated at the respective joint surfaces are opposite to each other and cancel each other out, so that the deformation of the molded structure is suppressed.

Further, the method for manufacturing a molded structure disclosed in the present specification as a means for solving the above problems includes a preboard molding step of molding a plate-shaped preboard containing fibers and a thermoplastic resin by a pair of press molds. A base material molding step executed after the pre-board molding step to mold the base material by press-molding the pre-board with a molding die, and a molding inside the closed molding die executed after the base material molding step. A press having an injection molding step of injecting a molten resin into a space to form the resin molded body, and the pair of press molds having a convex direction toward at least one press surface and the other press surface. It has at least one surface convex portion, and in the preboard molding step, the press surface convex portion is pressed against the preboard to form a preboard concave portion in a part of the preboard, and in the base material molding step, the preboard concave portion is formed. The pre-board recess becomes the base material recess in the base material press-molded by the molding mold, and in the injection molding step, the first resin molding part and the second resin molding part sandwich the base material, respectively. It is characterized in that it is molded at a position and joined to the base material.

In this way, in the pre-board forming process, the pre-board recess is formed in the portion where the convex portion of the press surface is pressed, and the thickness of the pre-board recess is smaller than that of the other portion of the pre-board. Then, in the subsequent base material molding step, the base material is molded from the pre-board, and at this time, the pre-board recess becomes the base material recess in the base material. That is, by forming the convex portion of the press surface in the press mold in advance, the step of separately forming the concave portion of the base material becomes unnecessary. As a result, deformation can be further suppressed without increasing the number of steps in the production of the molded structure.

According to the present invention, deformation of the molded structure can be suppressed.

Overall perspective view of pillar garnish 20 (design side) Overall perspective view of the pillar garnish 20 (back side) Overall perspective view of the base material 30 AA cross-sectional view of FIG. Cross-sectional view corresponding to FIG. 4 when the second resin molding portion 42 is not provided. Sectional drawing which shows the preboard forming process S10 Cross-sectional view showing the mold opening state of the molding apparatus 70 Cross-sectional view showing the base material molding step S20 Sectional drawing which represents injection molding process S30 Cross-sectional view showing a state in which the slide type is moved from the state shown in FIG. Cross-sectional view showing a state in which the pillar garnish is extruded by the extrusion pin 77.

<Embodiment>
An embodiment of the present invention will be described with reference to FIGS. 1 to 11. 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 inside of the vehicle to a center pillar (B pillar) arranged on the side wall of the vehicle interior. As shown in FIG. 4 which is a perspective view of FIGS. 1 and 2 and a cross-sectional view taken along the line AA of FIG. It includes a pair of side wall portions 25 and 26 provided at both end portions (both ends in the front-rear direction of the vehicle), respectively. The surface of the pillar garnish 20 facing the outside of the vehicle is the back surface (one plate surface) 20A, and the surface facing the inside of the vehicle is the design surface (the other plate surface, the front surface) 20B. Although the pillar garnish 20 illustrated in the present embodiment is arranged on the right side of the vehicle interior, it is assumed that the same configuration is provided on the left side of the vehicle interior.

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 for inserting and fixing the seat belt 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 (outside surface of the vehicle) of the upper end portion of the main wall portion 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, 2, and 4, 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 located on the rear side of the main wall portion 21. It is supposed to stand up from the side end to the outside of the car. 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 30 containing fibers and a thermoplastic resin, and a resin molded body 40 containing the thermoplastic resin. In FIGS. 1 and 2, the portion of the pillar garnish 20 occupied by the resin molded body 40 is shaded. The base material 30 is molded by press molding described later, and the resin molded body 40 is molded by injection molding described later.

Examples of the fiber contained in the base material 30 include kenaf fiber, 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 30, the fibers are bound by a thermoplastic resin. The thermoplastic resin contained in the base material 30 can be exemplified by polypropylene, and the thermoplastic resin contained in the resin molded product 40 can be exemplified by polypropylene, but is not limited thereto. The thermoplastic resin used for the base material 30 and the resin molded body 40 may be made of the same material or different materials.

An overall view of the base material 30 according to this embodiment is shown in FIG. The base material 30 is a plate-shaped member having a rectangular shape as a whole. Further, the base material 30 is bent so that the inside of the vehicle is convex, and the base material main wall portion 34 and the side wall portion forming most of the main wall portion 21 (the portion excluding the upper end portion and the lower end portion). The base material side wall 35 that constitutes most of 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) are configured. The base material side wall portion 36 is provided.

As shown in FIG. 4, the base material side wall portion 35 is bent with respect to the base material main wall portion 34 at the front end portion of the base material main wall portion 34 (left side in FIG. 4, the end portion of the main wall portion 21). It is in the form of standing up from the outside of the car. 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.

As shown in FIGS. 3 and 4, a part of the side wall portion 35 of the base material is a base material recess 35A having a thickness smaller than that of the other part of the base material 30. The base material recess 35A is arranged along the vertical direction with a certain width at the end portion of the base material side wall portion 35 on the outer side of the vehicle. The base material recess 35A has a shape in which the surface on the side to be the design surface 20B is recessed, and the thickness is reduced. In the base material side wall portion 36, a base material recess 36A having the same structure as the base material recess 35A is formed.

The resin molded body 40 includes a first resin molding portion 41 joined to the back surface 20A, a second resin molding portion 42 joined to the design surface 20B, and a resin upper end portion 44A forming the upper end portion of the pillar garnish 20. A resin lower end portion 44B forming the lower end portion of the pillar garnish 20 and resin extending portions 47 and 48 forming both end portions on the outer side of the pillar garnish 20 are provided. These are integrally molded by injection molding described later. The reinforcing rib 49 and the extended rib 50 joined to the back surface 20A of the pillar garnish 20 are collectively referred to as the first resin molding portion 41.

The first resin molding portion 41 is made of a thermoplastic resin such as polypropylene. The second resin molding portion 42 is made of the same thermoplastic resin as the first resin molding portion 41, and is a plate-shaped member joined so as to cover the base material recesses 35A and 36A from the design surface side. Further, the second resin molding portion 42 is connected (continuously connected) to the resin extending portions 47 and 48 at the end portion on the outer side of the vehicle.

Assuming that the thickness of the side wall portions 35 and 36 of the base material is D1, the thickness of the recesses 35A and 36A of the base material is D2, and the thickness of the second resin molding portion 42 is D3, D1 = D2 + D3. That is, on the design surface 20B of the pillar garnish 20, there is no difference in thickness between the portion where the second resin molded portion 42 appears on the surface and the portion where the base material side wall portions 35 and 36 appear on the surface, and the design surface. There is no unevenness in 20B.

Next, a molding apparatus 70 for molding the pillar garnish 20 according to the present embodiment will be described. As shown in FIG. 7, the molding apparatus 70 includes a molding die 71 and an injection apparatus 78. The molding mold 71 includes a core mold 72, a cavity mold 73, and a slide mold 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 space S2.

In the mold closed state shown in FIG. 8, a molding space S1 for molding the base material 30 and a molding space S2 for molding the resin molded body 40 are formed by the core mold 72, the cavity mold 73, and the slide mold 74. NS. The molten resin supplied from the injection device 78 (see FIG. 7) 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. 8 to 11.

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 pre-board P1 press-molded by a core mold 72 and a cavity mold 73 to form the base material 30. The base material 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. 6, in the pre-board forming step S10, a rectangular fiber mat 80 made of a fiber and a thermoplastic resin is heat-pressed by a pair of pressing dies 81 and 82 facing each other. As a result, the fiber mat 80 is heated and compressed, and then the thermoplastic resin contained in the fiber mat 80 is cooled and solidified to form the preboard P1. The press mold 81 has a flat press surface 81A, but the press mold 82 has a press surface concave portion 82B and a press surface convex portion 82C which is higher than the press surface concave portion 82B by D4. Has. The press surface 82A, the press surface concave portion 82B, and the press surface convex portion 82C are surfaces parallel to each other.

The press surface recess 82B is a strip-shaped flat portion that crosses the press surface 82A when viewed in a plane. Further, the press surface convex portion 82C is a portion of the press surface 82A other than the press surface concave portion 82B, and is arranged so as to sandwich the press surface concave portion 82B from both sides. In the pre-board P1 formed by such a pair of press dies 81 and 82, the plate surface on the side where the press surface 81A is in contact becomes flat. However, the plate surface on the side where the press surface 82A is in contact has a step between the portion where the press surface concave portion 82B is in contact and the portion where the press surface convex portion 82C is in contact. The height is D4. In the rectangular pre-board P1, a pre-board convex portion P1B which is a thick portion extending in a strip shape along the longitudinal direction and a pre-board concave portion P1A arranged so as to sandwich the pre-board convex portion P1B from both sides are formed.

In the base material molding step S20 executed after the preboard molding step S10, as shown in FIG. 7, the preboard P1 that has been first heated and softened is placed between the core mold 72, the slide mold 74, and the cavity mold 73. Subsequently, as shown in FIG. 8, 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 injection molding step S30 executed after the base material molding step S20, as shown in FIG. 9, the base material 30 and the molding are performed in a state where the base material 30 is sandwiched between the core mold 72, the slide mold 74 and the cavity mold 73. A molten resin (for example, polypropylene) is injected into the molding space S2 formed by both molds 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 mold 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.
The gate 76A mainly supplies the molten resin to the molding space S2 for molding the resin upper end portion 44A. Further, the gates 76B and 76C mainly form the first resin molding portion 41, the second resin molding portion 42, the resin lower end portion 44B, and the resin extension portions 47 and 48 in the molding space S2. Supply molten resin to.

After that, when the temperature of the molten resin drops, the molten resin filled in the molding space S2 solidifies to become a resin molded body 40 bonded to the base material 30. For example, the second resin molding portion 42 is molded in a state of being joined to the base material recesses 35A and 36A.

Then, as shown in FIG. 10, 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 the configuration according to the present embodiment will be described. The pillar garnish 20 according to the present embodiment includes a plate-shaped base material 30 containing fibers and a thermoplastic resin, and a resin molded body 40 containing a thermoplastic resin, and the resin molded body 40 is a back surface of the base material 30. It has a first resin molding portion 41 bonded to 20A and a second resin molding portion 42 bonded to the design surface 20B of the base material 30.

Generally, the shrinkage rate of the resin molded body 40 containing the thermoplastic resin is larger than that of the base material 30 containing the fibers and the thermoplastic resin. Therefore, as shown in FIG. 5, when the first resin molding portion 41 (reinforcing rib 49, extending rib 50) is joined only to the back surface 120A side of the plate-shaped base material 130, molding is performed. Stress is generated on the joint surface in the process of the subsequent temperature change and the time-dependent change accompanying the crystallization of the thermoplastic resin, and the pillar garnish 120 is deformed. For example, it is conceivable that the side wall portions 135 and 136 of the base material are curved so as to bulge inward of the vehicle when viewed from the vertical direction. Further, since the outer portions of the side wall portions 125 and 126 have long joint surfaces continuous along the vertical direction of the pillar garnish 120, they are easily deformed due to the generation of stress due to temperature changes and the like. Specifically, it is conceivable that the side wall portion 125 is deformed to the front and the side wall portion 126 is deformed to the rear when viewed from the inside of the vehicle.

Therefore, in the pillar garnish 20 according to the present embodiment, as shown in FIG. 4, in addition to the first resin molding portion 41 being joined to the back surface 20A, the second resin molding portion 42 is joined to the design surface 20B. Joint surfaces are arranged on both sides of the base material 30. As a result, the stresses generated at the joint surfaces cancel each other out, and the deformation of the pillar garnish 20 is suppressed. The thermoplastic resin contained in the base material 30 and the thermoplastic resin contained in the resin molded product 40 may be the same material or different materials.

Further, the second resin molding portion 42 may be joined to the first resin molding portion 41 at a position symmetrical with respect to the base material 30.

In this way, the stress generated at either the joint surface on the design surface 20B side or the back surface 20A side is canceled by the stress generated on the other joint surface arranged at symmetrical positions across the base material 30. Is done. That is, since the stress is canceled in the region sandwiched between the two joint surfaces, it becomes difficult for the stress to affect other regions in the pillar garnish 20. Thereby, the deformation of the pillar garnish 20 can be further suppressed.

The design surface 20B has base material recesses 35A and 36A formed by reducing the thickness of the base material 30 as compared with other parts, and the second resin molding portion 42 fills the base material recesses 35A and 36A. It can be joined to the base material recesses 35A and 36A in the form of the above.

By doing so, the second resin molding portion 42 is configured by appropriately changing the size (area when viewed in a plan view and the depth of the base material recesses 35A and 36A) and the shape of the base material recesses 35A and 36A. The amount and shape of the thermoplastic resin can be adjusted. As a result, the magnitude of the stress generated by the second resin molding portion 42 can be appropriately adjusted, and can be balanced with the stress caused by the first resin molding portion 41. As a result, deformation of the pillar garnish 20 due to temperature changes and the like can be further suppressed.

Further, in such a configuration, the second resin molding portion 42 is joined to the base material recesses 35A and 36A, which are smaller in thickness than the other parts of the base material 30. Therefore, it is possible to reduce or eliminate the difference in thickness between the portion where the second resin molding portion 42 of the pillar garnish 20 is arranged and the portion other than that. Thereby, the design restriction on the design surface 20B due to the presence of the second resin molding portion 42 can be suppressed or eliminated.

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 plate-shaped pre-board P1 containing the fiber and the thermoplastic resin by the pair of press dies 81 and 82, and the pre-board molding step S10. , The base material molding step S20 in which the pre-board P1 is press-molded by the molding die 71 to form the base material 30, and the molten resin is executed in the molding space S2 inside the closed molding die 71, which is executed after the base material molding step S20. An injection molding step S30 for injecting and molding a resin molded body 40 is provided. In the injection molding step S30, the first resin molding section 41 and the second resin molding section 42 are molded at positions sandwiching the base material 30, respectively. It is characterized in that it is bonded to the base material 30.

In the method for manufacturing the pillar garnish 20 having such a configuration, the first resin molding portion 41 and the second resin molding portion 42 molded in the injection molding step S30 are joined to each other at positions sandwiching the base material 30. In this way, in the cooling process after the injection molding step S30, the stresses generated at the respective joint surfaces are opposite to each other and cancel each other out, so that the deformation of the pillar garnish 20 is suppressed.

Further, in the pre-board forming step S10, the pair of press dies 81 and 82 have at least one press surface convex portion 82C on at least one press surface 81A or 82A in a direction that is convex toward the other press surface. The pre-board recess P1A is formed in a part of the pre-board P1 by pressing the press surface convex portion 82C against the pre-board P1, and in the base material molding step S20, the pre-board recess P1A is press-molded by the molding die 71. The base material recesses 35A and 36A in the base material 30 can be used.

By doing so, in the pre-board forming step S10, the pre-board concave portion P1A is formed in the portion where the press surface convex portion 82C is pressed, and the pre-board concave portion P1A is compared with the other portion (pre-board convex portion P1B) of the pre-board P1. The thickness becomes smaller. Then, in the subsequent base material forming step S20, the base material 30 is formed based on the pre-board P1, and the pre-board recesses P1A become the base material recesses 35A and 36A in the base material 30.

That is, by forming the press surface convex portions 82C in the press molds 81 and 82 in advance, the step of separately forming the base material recesses 35A and 36A becomes unnecessary. As a result, deformation can be further suppressed without increasing the number of steps in the production of the pillar garnish 20.

<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 recesses 35A and 36A are arranged at the outer end of the base material 30 on the vehicle side, but the positions of the base material recesses 35A and 36A are not limited to this. For example, the base material recesses 35A and 36A may be arranged at arbitrary positions on the base material side wall portions 35 and 36 and at arbitrary positions on the base material main wall portion 34.

(2) In the above embodiment, the press surface 82A, the press surface concave portion 82B, and the press surface convex portion 82C are each flat, but even if these are not flat, they are included in the technical scope of the present invention. For example, each press surface may have a wavy shape or may have fine grooves.

(3) In the above embodiment, the press surface 81A, the press surface concave portion 82B, and the press surface convex portion 82C are parallel to each other, but each of these surfaces may be inclined to each other instead of being parallel. ..

(4) In the above embodiment, a step is formed between the press surface concave portion 82B and the press surface convex portion 82C, but the step may not exist. For example, the press surfaces 82B and 82C having different heights may be connected by a gentle curved surface.

20 ... Pillar garnish (molded structure), 20A, 120A ... Back surface (one plate surface), 20B, 120B ... Design surface (other plate surface, front surface), 21 ... Main wall, 25, 125, 26, 126 ... Side wall portion, 30, 130 ... Base material, 35, 135, 36, 136 ... Base material side wall portion 35A, 36A ... Base material recess, 40 ... Resin molded body, 41 ... First resin molded part, 42 ... Second resin Molded part, 47, 48 ... Resin extension part, 49 ... Reinforcing rib, 50 ... Extension rib, D1 ... Thickness of base material side wall parts 35, 36, D2 ... Thickness of base material recesses 35A, 36A, D3 ... Second Thickness of resin molding part 42

Claims (5)

With a plate-shaped base material containing fibers and thermoplastic resin,
With a resin molded body containing a thermoplastic resin,
The resin molded body is
A first resin molded portion bonded to one plate surface of the base material and
A molded structure having a second resin molded portion bonded to the other plate surface of the base material. The molding structure according to claim 1, wherein the second resin molding portion is joined at a position symmetrical with respect to the first resin molding portion with the base material interposed therebetween. The other plate surface has a base material recess formed by reducing the thickness as compared with other parts of the base material.
The molded structure according to claim 1 or 2, wherein the second resin molding portion is joined to the base material recess in a form of being filled in the base material recess. The method for manufacturing a molded structure according to claim 1 or 2.
A pre-board molding process that molds a plate-shaped pre-board containing fibers and thermoplastic resin using a pair of press molds,
A base material molding step, which is executed after the pre-board molding step and press-molds the pre-board with a molding die to form the base material,
An injection molding step, which is executed after the base material molding step and injects molten resin into a molding space inside the closed molding mold to mold the resin molded body, is provided.
In the injection molding step, a method for manufacturing a molded structure in which the first resin molding portion and the second resin molding portion are molded at positions sandwiching the base material and joined to the base material. The method for manufacturing a molded structure according to claim 3.
A pre-board molding process that molds a plate-shaped pre-board containing fibers and thermoplastic resin using a pair of press molds,
A base material molding step, which is executed after the pre-board molding step and press-molds the pre-board with a molding die to form the base material,
An injection molding step, which is executed after the base material molding step and injects molten resin into a molding space inside the closed molding mold to mold the resin molded body, is provided.
The pair of press dies have at least one press surface convex portion on at least one press surface in a direction that is convex toward the other press surface.
In the pre-board molding step, the press surface convex portion is pressed against the pre-board to form a pre-board concave portion in a part of the pre-board.
In the base material molding step, the pre-board recess becomes the base material recess in the base material press-molded by the molding mold.
In the injection molding step, a method for producing a molded structure in which the first resin molding portion and the second resin molding portion are molded at positions sandwiching the base material and joined to the base material.

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