JP4690773B2 - Manufacturing method of mounting bracket - Google Patents

Description

The present invention relates to a method for manufacturing a mounting bracket for fixing a mounting member on a substrate.

  As a conventional technique for fixing a pair of base materials to each other, both base materials are overlapped, and a synthetic resin material is supplied to a through hole formed in one base material to form a clip that joins the base materials together (For example, refer to Patent Document 1). This is because the resin material forming the clip can be firmly bonded to each other by melting with the resin material in the substrate. However, in this prior art, it is not assumed that the bonded members are separated again, and cannot be applied to a case where the mounting member is detachably fixed on the base material.

In general, when an attachment member is detachably fixed on a base material, a separate bracket made of metal or synthetic resin is fastened to the base material with a screw or the like. According to this method, the mounting member can be securely fixed on the base material, while it is necessary to provide a screw hole on the base material for mounting or work for screw tightening, which requires a large number of work steps. Also, when using multiple brackets to fix the mounting member, it is necessary to improve the accuracy of the mounting position of each bracket on the base material in accordance with the shape of the mounting member in order to eliminate rattling. In addition, the installation work was difficult. If the base material is formed only of a synthetic resin material, a method of integrally molding the bracket with this is conceivable, but it is also difficult when the base material is formed of a material containing plant fibers. .
Japanese Patent Laid-Open No. 2003-231181 (FIG. 2)

This invention is completed based on the above situations, Comprising: It aims at providing the manufacturing method of the attachment bracket for fixing the attachment member which can be easily formed on a base material. .

As means for achieving the above-mentioned object, the present invention is attached to a base material containing a synthetic resin, and is engaged with an attachment member containing a synthetic resin at an engagement portion, thereby In the method of manufacturing a mounting bracket for removably fixing the mounting member to
After the mounting member is installed in the vicinity of the base material, a molding die is disposed so as to form a cavity with the mounting member, and a thermoplastic resin is supplied into the cavity. Form the mounting bracket to join,
The thermoplastic resin supplied into the cavity is made of the same material as the synthetic resin contained in the base material, and is mixed with the synthetic resin contained in the base material when supplied into the cavity. A fusible material,
Further, the thermoplastic resin supplied into the cavity is made of a material different from the synthetic resin included in the mounting member, and the synthetic resin included in the mounting member when supplied into the cavity. A manufacturing method of the mounting bracket is characterized in that the material is made of a material that suppresses mixing with the resin .

In the present invention , when the thermoplastic resin is supplied into the cavity to form the mounting bracket, the engaging portion is formed in a state of being engaged with the mounting member. .

Further, in the present invention , when the thermoplastic resin is supplied into the cavity to form the mounting bracket, a release portion that releases the engagement between the engagement portion and the mounting member by operating the mounting bracket. Can be formed.

Further, in the present invention , when the thermoplastic resin is supplied into the cavity and the mounting bracket is formed, a part of the thermoplastic resin is caused to leak out from the cavity, so that the surplus portion Can be formed.

According to the present invention, after the mounting member is installed close to the base material, the molding die is arranged so as to form a cavity between the mounting member and the base material, and the synthetic resin material is supplied into the cavity. By attaching to the base material, the mounting bracket that engages and fixes the mounting member can be easily formed on the base material without fastening with screws or the like. In addition, the mounting bracket can be firmly joined to a base material made of a material containing vegetable fibers.

Further, according to the present invention, by providing the release portion that releases the engagement between the engagement portion and the attachment member by operating, the attachment member can be attached to the base member without destroying the bracket. Can be easily detached.

Further, according to the present invention, since the synthetic resin material leaks from the cavity during the molding, the resin pressure in the cavity is reduced, and the mounting member or the base material is not bent or deformed.

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. The upper part in FIG. 7 is the upper part in the description. The mounting bracket 2 according to this embodiment is mounted on a trim board 1 of a vehicle door corresponding to the base material of the present invention, and an ECU case 4 (corresponding to a mounting member of the present invention) is mounted on the trim board 1. It is for fixing so that attachment or detachment is possible (shown in FIG. 1). The trim board 1 includes a substrate 11 formed of a thermoplastic synthetic resin material such as polypropylene, and a skin 12 bonded to one surface thereof. The substrate 11 contains bast plant fibers such as kenaf, and the synthetic resin material functions as a binder.

  As shown in FIGS. 2 and 3, the ECU case 4 is formed of a resin material different from the substrate 11 such as ABS resin, and the mounting bracket 2 is attached to the side surface of the box body 41 having an accommodation space inside. A pair of engaging bracket insertion portions 42 are integrally formed. The bracket insertion portion 42 includes a guide sliding portion 43 having a hook-like cross section extending in the vertical direction so as to face each other. The bracket insertion portion 42 includes an engagement protrusion 44 disposed between the guide sliding portions 43 and a pair of stoppers 45 provided above the engagement protrusion 44 and protruding from the side surface of the box body 41. ing. The oval engagement protrusion 44 protrudes from the side surface of the box 41, and its lower half is an inclined surface 44a (shown in FIG. 3).

  The mounting bracket 2 is integrally formed of the same kind of synthetic resin material as that of the trim board 1 such as polypropylene, and is coupled to the substrate 11. As shown in FIGS. 4 and 5, the mounting bracket 2 has a pair of guide portions 21 extending in the vertical direction on both side ends so as to engage with the guide sliding portion 43 of the bracket insertion portion 42. Is formed with an oval concave portion 22 (corresponding to the engaging portion of the present invention) that engages with the engaging protrusion 44. The guide portion 21 and the concave portion 22 have a shape that matches the outer shape of the other side so as to be fitted to the guide sliding portion 43 and the engaging protrusion 44, respectively, and the lower half of the concave portion 22 is a slope 22a. ing. In addition, the upper part of the guide part 21 is opened so that the guide sliding part 43 can be inserted from above. Further, a release piece 23 (corresponding to the release portion of the present invention) that can be bent downward is integrally formed at the upper end portion of the mounting bracket 2 and extends forward in FIG.

  When the ECU case 4 is fixed to the trim board 1, the mounting bracket 2 and the bracket insertion portion 42 are moved by lowering the ECU case 4 from above with respect to the trim board 1 placed with the substrate 11 as the upper surface. Engage. When the guide sliding portions 43 of the bracket insertion portion 42 are respectively inserted into the guide portions 21 from above, the mounting bracket 2 rides on the engaging protrusion 44 from the inclined surface 44a while being bent, and then the recess 22 Is engaged with the engagement protrusion 44, and the mounting bracket 2 and the bracket insertion portion 42 are engaged, and the attachment of the ECU case 4 to the trim board 1 is completed (shown in FIGS. 6 to 8). In the case of engaging both, even if the engagement protrusion 44 goes too far with respect to the recess 22 due to an excessive load, the upper surface of the mounting bracket 2 comes into contact with the stopper 45 of the bracket insertion portion 42. The movement is stopped. As shown in FIG. 8, the ECU case 4 is held at a predetermined interval from the trim board 1 in order to prevent the noise from being generated by interference with the trim board 1 due to vibration or the like. Yes.

  When removing the ECU case 4 fixed on the trim board 1, the release case 23 is operated by pushing it down by hand (shown in FIG. 9), and the engagement between the recess 22 and the engagement protrusion 44 is released. This is performed by pulling 4 upward from the trim board 1 (shown in FIG. 10).

  Next, a method for forming the mounting bracket 2 according to the present embodiment will be described with reference to FIGS. 11 and 12. First, the trim board 1 is placed on the pedestal 61 with the substrate 11 as an upper surface. A pair of spacers 62 are installed on the substrate 11 so as to contact each other at the end portions, and the ECU case 4 is placed thereon, and the ECU case 4 is held at a position close to the substrate 11. Further, the lower mold 63 is disposed so as to face the bracket insertion portion 42 and have a predetermined interval with respect to the side surface of the ECU case 4. Further, an upper mold 64 is installed so as to contact the lower mold 63 and the upper surface of the ECU case 4, and as shown in FIG. 12, a spacer 62, a lower mold 63, and an upper mold 64 (generally, the molding mold of the present invention is used). And a cavity CV having a predetermined shape is formed between the bracket insertion portion 42 of the ECU case 4 and the substrate 11. As shown in FIG. 12, the cavity CV faces the substrate 11.

  In this state, a synthetic resin material of the same type as the molten trim board 1 is injected into the cavity CV from the gate hole GT formed in the upper mold 64 and communicating with the cavity CV. The melted synthetic resin material melts the resin material contained in the trim board 1 by heat and mixes them with each other, and is firmly bonded to the trim board 1 after curing. Thus, the mounting bracket 2 that can be fitted to the bracket insertion portion 42 of the ECU case 4 is fixed on the trim board 1. The ECU case 4 is placed on the spacer 62 when the mounting bracket 2 is molded, so that the ECU case 4 is held at a predetermined distance from the trim board 1 when engaged with the mounting bracket 2 after molding. Is done.

According to this embodiment, after installing the ECU case 4 so as to be close to the trim board 1, the spacer 62, the lower mold 63 and the upper mold 64 are arranged so as to form a cavity CV with the ECU case 4. Then, by supplying the synthetic resin material into the cavity CV, the mounting bracket 2 coupled to the trim board 1 is formed, so that it has a shape that can be fitted to the bracket insertion portion 42 of the ECU case 4 and is engaged therewith. Thus, the mounting bracket 2 for fixing the ECU case 4 can be easily formed on the trim board 1 without being fastened with screws or the like. Moreover, when applied to the trim board 1 formed of a material containing vegetable fibers, the supplied resin material and the resin material of the trim board 1 are mixed and joined, and the resin material is placed in the gap between the fibers. The mounting bracket 2 can be firmly joined by the effect of entering and catching on the fibers.
Furthermore, even if the resin material of the trim board 1 and the resin material of the mounting bracket 2 are different, the resin material enters the gaps between the fibers, and the mounting bracket 2 can be firmly bonded due to the catching effect on the fibers. .

  Further, by using different resin materials for the ECU case 4 and the mounting bracket 2, the ECU case 4 and the mounting bracket 2 are not mixed when the synthetic resin material is supplied into the cavity CV. Furthermore, the concave portion 22 that engages with the engaging protrusion 44 of the bracket insertion portion 42 and the release piece 23 that releases the engagement between the engaging protrusion 44 and the concave portion 22 by operation are provided. The ECU case 4 can be easily detached from the trim board 1 manually without destroying the bracket 2. Further, since the ECU case 4 is used as one of the molds for the mounting bracket 2, the number of molds used at the time of molding can be reduced. Further, the ECU case 4 can be engaged with the mounting bracket 2 only by forming the mounting bracket 2, and a separate process for fixing the ECU case 4 on the trim board 1 is not required.

<Embodiment 2>
Next, a second embodiment of the present invention will be described with reference to FIGS. The mounting bracket 2A according to the present embodiment is coupled to the substrate 11 of the trim board 1 in the same manner as the mounting bracket 2 according to the first embodiment. A pair of thin plate-like surplus portions 24 are formed at both end portions of the mounting bracket 2A so as to extend laterally. The surplus portion 24 is formed by providing a gap between the ECU case 4 and the lower mold 63 so that the synthetic resin material leaks from the cavity CV during the molding of the mounting bracket 2A. Since the other configuration related to the mounting bracket 2A is the same as that of the mounting bracket 2 according to the first embodiment, detailed description thereof is omitted. According to this embodiment, since the synthetic resin material leaks from the cavity CV during the molding, the resin pressure due to the injection in the cavity CV is reduced, and the ECU case 4 or the trim board 1 may be bent or deformed. Absent. Further, by providing the surplus portion 24, the resin material can be dispersed in the cavity CV and molding defects can be prevented.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to 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 departing from the gist of the invention other than the following. Various modifications can be made.
(1) If a stud bolt is erected and fixed on a base material for fixing the mounting member, and the mounting bracket is insert-molded on the base material so as to wrap the stud bolt, the base material of the mounting bracket is obtained by the anchor effect of the stud bolt. The bond strength to can be increased. Also, this method makes it possible to bond the mounting bracket to a base material such as metal.
(2) In the second embodiment, a silicon pad is interposed between the contact surface of the ECU case and the lower mold so that the pad is bent by the resin pressure when the mounting bracket is molded, and the molten resin leaks from the cavity. It may be.
(3) The mounting bracket according to the present invention can also be formed on a synthetic resin base material that does not contain plant fibers.
(4) Not only injection molding but also any resin molding such as compression molding or transfer molding can be applied to the mounting bracket molding method.
(5) In the present embodiment, in order to prevent the generation of abnormal noise, the ECU case is arranged with a predetermined interval between the ECU case and the ECU case or the substrate. If an abnormal noise prevention process is performed in advance, the ECU case may be placed directly on the substrate.

It is a perspective view of the mounting bracket by Embodiment 1 couple | bonded with the trim board, and ECU case engaged with it. It is a top view of ECU case. It is a front view of the bracket insertion part of ECU case. It is a front view of the mounting bracket by Embodiment 1 couple | bonded with the trim board. FIG. 5 is a rear view of FIG. 4. It is a top view of ECU case engaged with the attachment bracket shown in FIG. It is the front view seen from the attachment bracket side of FIG. It is sectional drawing of FIG. It is sectional drawing which shows the place which operated the release piece in order to remove ECU case from a trim board. It is sectional drawing which shows the place which removed the ECU case from the trim board. It is a perspective view which shows the shaping | molding die for shape | molding a mounting bracket. It is sectional drawing which shows the place which has shape | molded the attachment bracket. It is a perspective view of the mounting bracket by Embodiment 2 couple | bonded with the trim board. It is a front view of the state engaged with ECU case about the attachment bracket shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Trim board 2, 2A ... Mounting bracket 4 ... ECU case 22 ... Recess 23 ... Release piece 24 ... Surplus part 42 ... Bracket insertion part 44 ... Engagement protrusion 62 ... Spacer 63 ... Lower mold 64 ... Upper mold CV ... cavity

Claims (4)

A mounting bracket for fixing the mounting member to the base material in a detachable manner by being attached to the base material including the synthetic resin and engaging with the mounting member including the synthetic resin at the engaging portion. In the manufacturing method,
After the mounting member is installed in the vicinity of the base material, a molding die is disposed so as to form a cavity with the mounting member, and a thermoplastic resin is supplied into the cavity. the mounting bracket is formed such that binding to,
The thermoplastic resin supplied into the cavity is made of the same material as the synthetic resin contained in the base material, and is mixed with the synthetic resin contained in the base material when supplied into the cavity. A fusible material,
Further, the thermoplastic resin supplied into the cavity is made of a material different from the synthetic resin included in the mounting member, and the synthetic resin included in the mounting member when supplied into the cavity. A method of manufacturing a mounting bracket, characterized by being made of a material that suppresses mixing with resin .   2. The attachment according to claim 1, wherein when the thermoplastic resin is supplied into the cavity to form the attachment bracket, the engagement portion is formed in an engaged state with the attachment member. Manufacturing method of bracket.   When the thermoplastic resin is supplied into the cavity to form the mounting bracket, an operation is performed to form a release portion that releases the engagement between the engagement portion and the mounting member. The manufacturing method of the mounting bracket of Claim 1 or Claim 2 characterized by the above-mentioned.   When the thermoplastic resin is supplied into the cavity to form the mounting bracket, a part of the thermoplastic resin is leaked out of the cavity to form an extra portion. The manufacturing method of the mounting bracket as described in any one of Claim 1 thru | or 3.

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