JP5413671B2 - VEHICLE BOARD MEMBER AND VEHICLE BOARD MEMBER MANUFACTURING METHOD - Google Patents

Description

  The present invention relates to a vehicle board member and a method for manufacturing a vehicle board member.

  2. Description of the Related Art Conventionally, a vehicle board member having a board body in which a core material is wrapped with a surface material is known. For example, each of the vehicle board members described in Patent Documents 1 to 3 below has a configuration in which the ends of the board body are rounded and the ends of the surface material are abutted against each other. . According to such a configuration, as shown in FIG. 9, the bending of the end 2 of the board body 1 becomes gentle, so that the end 2 is placed on the lower stage 3 </ b> B of the stepped shelf 3. When receiving an impact from the side, there is a problem that the end portion 2 can easily ride on the upper stage 3 </ b> A of the shelf portion 3. In addition, a large gap S is formed in the parting line between the upper stage 3A of the shelf 3 and the upper surface 1A of the board body 1, and there is a problem that small items fall into the gap S and the appearance is impaired.

  Further, as another form of the vehicle board member, as shown in FIG. 10, one in which the back surfaces of the end portions of the surface material 5 are overlapped is known. According to this vehicle board member, since a large gap is not formed in the parting line between the upper stage 3A of the shelf 3 and the upper surface 4A of the board body 4, the appearance is not impaired.

JP 51-125595 A JP 2006-103027 A JP 2007-237419 A

  However, since the surface materials 5 are superposed on each other at the end 6 of the board body 4 and bonded by thermocompression bonding, burrs are formed at the end 6 at the time of crimping, which is not preferable in terms of appearance quality and the like. . In addition, since the lower surface of the end portion 6 of the board body 4 has a gently curved shape, the end portion 6 of the board body 4 is also likely to ride on the upper stage 3A of the shelf 3 when subjected to an impact from the side. . Further, since the curved surface portion on the lower surface of the end portion 6 of the board main body 4 cannot be supported, the lower stage 3C of the shelf portion 3 needs to be formed longer to support the planar portion on the lower surface of the end portion 6 of the board main body 4. There is. Thus, it cannot be said that it is preferable in terms of aligning parts with other parts such as the shelf 3.

  The present invention has been completed based on the above-described circumstances, and an object of the present invention is to provide a vehicle board member that ensures the appearance quality and improves the alignment of components with respect to other components.

  The present invention is a vehicular board member having a board body formed in a board shape with a core material sandwiched between surface materials, and the surface materials are brought into contact with each other at the end portions of the board body. An overlapping portion provided protruding from the inside of the board body in the state, a one-side folded portion continuous from the overlapping portion to one surface side of the board body, and an other-side folded portion continuous from the overlapping portion to the other surface side of the board body. The one-side folded portion and the other-side folded portion are characterized in that they are connected to each other in a form that is recessed toward the core material side in the overlapping portion.

  According to such a configuration, since the one-side folded portion and the other-side folded portion are formed at the end portion of the board main body, the degree of bending of each folded portion can be made abrupt. For this reason, the clearance gap formed in the parting line of a board main body and another component can be made small, and the component alignment with respect to another component can be improved. Moreover, since the superposition | polymerization part which is easy to generate | occur | produce at the time of shaping | molding has been arrange | positioned inside the core material, external appearance quality can be ensured.

The following configuration is preferable as an embodiment of the present invention.
A pair of corners may be formed at the end of the board body, and a standing surface extending in the thickness direction of the board body may be formed between the corners.
According to such a configuration, since the standing surface can be directed to other parts such as a shelf supporting the end of the board main body, the end of the board main body can ride on other parts such as the shelf. Can be regulated.

A superposition | polymerization part is good also as a structure which heat-welds the surfaces of the surface material in the edge part of a board main body.
According to such a configuration, for example, the board body is kept in a softened state by heating, and the surface of the surface material at the end of the board body is brought into contact with each other and heat-welded, thereby maintaining the overlapping portion in a contact state. Can do.

The overlapping portion may be configured by sewing a line passing through the overlapping portion at the end of the board body.
According to such a structure, the surface of the surface material in the edge part of a board main body can be hold | maintained in a contact state by sewing the edge part of a board main body.

  The present invention also includes a setting step of setting a board body formed in a board shape with a core material sandwiched between surface materials on a jig while being softened by heating, and an end of the board body set in the jig The separation step of separating the end of the board body by piercing and cutting the cutting blade provided on the terminal mold, and the cutting blade is retracted and the molding surface provided on the terminal mold is advanced, and the cutting blade A folding step of folding back the end of the board body separated by the molding surface along the molding surface, and a molding step of molding the overlapping portion by bringing the surfaces of the surface material at the end of the board body folded back by the molding surface into contact with each other. It is good also as a manufacturing method of the board member for vehicles provided.

  In this way, the board body in the softened state is set in a jig in the setting process, and the end of the board body is cut and separated by piercing the end of the board body in the separation process, and separated in the molding process. By aligning the end portion of the board body along the molding surface, the overlapping portion protruding into the board body is formed in a state where the surfaces of the surface materials at the end portions of the board body are in contact with each other. As a result, it is possible to manufacture a vehicle board member that ensures the appearance quality and improves the alignment of components with respect to other components.

After the terminal mold is retracted in the molding process, the end of the board body may be further sandwiched between the crimping molds.
If it does in this way, the surface of the surface material in the edge part of a board main body can be reliably stuck by the crimping | compression-bonding type | mold.

You may provide the sewing process which sews the line which passes along the superposition | polymerization part in the edge part of a board main body after a formation process.
If it does in this way, the surface of the surface material in the edge part of a board main body can be hold | maintained in a contact state by sewing the edge part of a board main body.

  ADVANTAGE OF THE INVENTION According to this invention, the board member for vehicles which can ensure external appearance quality and can improve the components alignment with respect to other components can be provided.

The figure which shows the state (setting process) which set the board main body to the jig | tool in Embodiment 1. The figure which shows the state (separation process) which stabbed and cut | disconnected the edge of the board main body, and cut | disconnected it. The figure which shows the state which formed the return part by making the edge part of a board body follow a molding surface The figure which shows the state (molding process) which shape | molded the superposition part by pinching the edge part of a board main body with a crimping | compression-bonding type | mold. The figure which shows the state which installed the board member for vehicles in the shelf part The figure which shows the process of extruding a board member The figure which shows the state (sewing process) which sewed the line which passes along the overlap part in the edge part of a board main body in Embodiment 2. FIG. The figure which shows the state (separation process) which stabbed and cut | disconnected and cut | disconnected the cutting blade in the edge part of the board main body in other embodiment. The figure which shows the state which installed the conventional board member for vehicles (type which edge | butted edges) on the shelf The figure which shows the state which installed the conventional board member for vehicles (type which piled up edge parts) in the shelf part

<Embodiment 1>
Embodiment 1 of the present invention will be described with reference to the drawings of FIGS. The board member for vehicles in this embodiment has the board main body 10 which makes a substantially plate shape. As shown in FIG. 5, the board body 10 is a hollow laminated plate formed by laminating a core material 20 having a large number of recesses 21 so as to be wrapped with an upper surface material 30 and a lower surface material 40. In addition, the board member for vehicles of this embodiment can be used for the deck board arrange | positioned in the luggage compartment of a vehicle, the seat back which comprises the seat of a vehicle, a headrest, the ceiling base material of a vehicle, a door trim etc., for example.

  The core material 20 has a so-called honeycomb structure in which concave portions 21 that are open on the upper side are formed side by side. Here, the honeycomb structure is a “Honeycomb”, that is, a honeycomb-like structure, in which a large number of conical trapezoidal shapes, small hexagonal columnar shapes (hexagonal fine holes), and round columnar shapes (cylindrical fine holes) are continuous. This is a panel. The upper surface 20A of the core material 20 is joined to the upper surface material 30 by welding means such as ultrasonic welding or heat welding. On the other hand, the lower surface 20B of the core material 20 is joined to the lower surface material 40 by the same welding means as the upper surface 20A. In addition, a skin material may be further adhered to the surface of the upper surface material 30.

  In addition, the core material 20 of this embodiment is formed from engineering plastics (abbreviation engineering plastic), an olefin resin, etc., for example. Here, engineering plastics is a synthetic resin with heat resistance, wear resistance, dimensional stability, electrical properties, etc., and the main ones are polycarbonate, polyamide, modified polyphenylene ether, polyethylene terephthalate, polybutylene terephthalate. , Polyacetal, polyphenylene sulfide and the like. Examples of the olefin resin include polyethylene, polypropylene, TPO (a mixture of PP and a rubber component), and the like. On the other hand, the upper surface material 30 and the lower surface material 40 are made of a board material formed of polypropylene, engineering plastics, olefin resin, or the like.

  Inside the board body 10, a plurality of hollow chambers 22 are formed by sealing the opening 21 </ b> A of the recess 21 that opens upward with the upper surface material 30. Thereby, the board main body 10 is reduced in weight, and has rigidity and heat insulation.

  That is, the board body 10 includes a large number of hollow chambers 22 and thus has bending rigidity, compression rigidity, and shock absorbing action that restores the original shape even when the board body 10 is crushed or curved. The board main body 10 is lightweight because air is sealed in a large number of hollow chambers 22, and has excellent heat insulation properties because the air blocks heat.

  The upper surface material 30 and the lower surface material 40 are folded back in directions facing each other at the end 11 of the board body 10. The end portion 11 of the board body 10 includes an upper folded portion 31 that continues to the upper surface material 30 and a lower folded portion 41 that continues to the lower surface material 40. The end surface 32 of the upper folded portion 31 that is continuous with the surface of the upper surface material 30 and the end surface 42 of the lower folded portion 41 that is continuous with the surface of the lower surface material 40 are joined by pressure bonding or welding. Part 50.

  The overlapping portion 50 is provided so as to protrude inside the end portion of the board body 10. Further, the upper folded portion 31 and the lower folded portion 41 are connected to each other in a form recessed in the core material 20 side in the overlapping portion 50. For this reason, in the superposition | polymerization part 50, although a burr | flash may generate | occur | produce at the time of a crimping | compression-bonding or welding, since the superposition | polymerization part 50 is arrange | positioned inside the board main body 10, a burr | flash is not visible from the exterior, but appearance quality This is not a problem.

  The upper folded portion 31 and the lower folded portion 41 are connected to each other in a form recessed in the core material 20 side in the overlapping portion 50. At the end portion 11 of the board body 10, the folded portions 31 and 41 are arranged side by side in the plate thickness direction. For this reason, it is possible to make the bent portions 31 and 41 bend more rapidly than when a single folded portion is provided at the end 11 of the board body 10. Thereby, a pair of corner | angular part 12 can be formed in the up-and-down both ends in the edge part 11 of the board main body 10, A pair of perpendicular | vertical surface (the "standing surface" of this invention) extended between an up-down direction between both the corners 12. An example) 13 can be formed.

  Examples of the place where the end 11 of the board body 10 is installed include a shelf 60 in which an upper stage 61 and a lower stage 62 are connected in a step shape by a side wall 63 as shown in FIG. The height dimension of the side wall 63 is set so as to substantially match the thickness of the board body 10. Therefore, in a state where the end 11 of the board main body 10 is placed on the upper surface of the lower stage 62, the upper surface of the end 11 of the board main body 10 and the upper surface of the upper stage 61 are substantially flush with each other and are arranged in the horizontal direction. Has been.

  In addition, since the corner portion 12 has a substantially right-angled shape, a large gap is not formed in the parting line BL between the end portion 11 of the board body 10 and the shelf portion 60, and the board body with respect to the side wall 63 of the shelf portion 60. The component alignment of the ten end portions 11 can be improved. As a result, it is possible to effectively restrict small articles from falling into the parting line BL. Further, since the pair of vertical surfaces 13 can contact the side wall 63 of the shelf 60 at two locations, the end 11 of the board main body 10 can be attached to the shelf 60 even when subjected to an impact from the side. It is difficult to get on the upper stage 61, and the board body 10 can be held in a fixed position.

The present embodiment is configured as described above. Next, a method for manufacturing a vehicle board member will be described.
First, the extrusion molding process of the board body 10 will be described with reference to FIG. The extrusion molding apparatus includes a molding roll 90, a first extruder 91 and a second extruder 92 installed around the molding roll 90, a third extruder 93 and a third extruder installed on the downstream side of the molding roll 90. 93, a cutting machine 94 installed on the downstream side of 93, and the like. The melted resin of the core material 20 extruded from the first extruder 91 is vacuum-formed before being brought into contact with the forming roll 90, whereby the recess 21 is formed.

  The core material 20 in which the recess 21 is formed is conveyed in contact with the outer peripheral surface of the forming roll 90, and the molten resin of the lower surface material 40 extruded from the second extruder 92 is laminated on the surface of the core material 20. Is done. After the lower surface material 40 is laminated, the core material 20 is separated from the outer peripheral surface of the forming roll 90 and conveyed to the third extruder 93 side. The molten resin of the upper surface material 30 extruded from the third extruder 93 is laminated on the surface of the core material 20 opposite to the lower surface material 40 and formed into a belt-like board body 10. The board body 10 is conveyed to the cutting machine 94 side and cut into a standard size by the cutting machine 94 (extrusion molding process).

  The board main body 10 cut into a fixed size is in a softened state by heating by extrusion molding, and is set on the jig 70 in a heated state. As shown in FIG. 1, the jig 70 includes an upper mold 71 and a lower mold 72, and holds the board body 10 between the upper and lower molds 71 and 72. In this state, the end portion 11 of the board body 10 protrudes laterally from the end surfaces of the upper and lower molds 71 and 72. End portions of the upper surface material 30 and the lower surface material 40 in the protruding portion are separated from each other, and the core material 20 laminated between both surface materials 30 and 40 faces the side. Therefore, at this time, the folded portions 31 and 41 are not formed on the end portion 11 of the board body 10 (setting process).

  Here, the configuration of the terminal mold 73 will be briefly described. The terminal mold 73 is disposed on the side of the jig 70, and the cutting blade 74 is disposed on the side of the end 11 of the board body 10 held by the jig 70. The cutting blade 74 is movable between a retracted position shown in FIG. 1 and a cutting position shown in FIG. Further, in the terminal mold 73, a pair of arc-shaped molding surfaces 75 are recessed on both upper and lower sides of the cutting blade 74. In other words, both molding surfaces 75 have a substantially M-shaped curved surface shape in which arc surfaces are formed on both upper and lower sides with the cutting blade 74 in the retracted position as the center. The terminal mold 73 itself is movable between the retracted position shown in FIG. 2 and the advanced position shown in FIG.

  Next, the end 11 of the board main body 10 is separated vertically by piercing and cutting the cutting blade 74 provided in the terminal mold 73 with respect to the core member 20 at the end 11 of the board main body 10. Thereby, the end portion 11 of the board body 10 is separated into the upper surface material 30 and the lower surface material 40. Thus, both surface materials 30 and 40 are disposed on both the upper and lower sides of the cutting blade 74 (separation step).

  Subsequently, as shown in FIG. 3, the terminal mold 73 is moved from the retracted position to the advanced position, and the end portions of the surface materials 30 and 40 are molded in a folded shape along the molding surfaces 75 and 75, respectively. The cutting blade 74 is moved from the cutting position to the retracted position. Thereby, the edge part of each surface material 30 and 40 is shape | molded by each folding | returning part 31 and 41, respectively. In addition, each folding | returning part 31 and 41 can be hold | maintained in folding shape by pulling out the cutting blade 74 in the state to which each folding | returning part 31 and 41 was addressed to each shaping | molding surface 75 and 75 (folding process).

  Next, the terminal molding die 73 is moved from the forward movement position to the backward movement position, and the end portion 11 of the board body 10 is sandwiched from above and below using a pair of upper and lower crimping dies 76, 76. On the mating surfaces of both the crimping dies 76, a substantially rectangular recess 77 having the same height as the board thickness of the board body 10 and opening to the end 11 side of the board body 10 is formed. As a result, a pair of corners 12 and a pair of vertical surfaces 13 are formed at the end 11 of the board body 10, and the overlapping portion 50 is formed. Thereafter, both the crimping dies 76 and 76 are opened in the vertical direction, the upper and lower dies 71 and 72 are opened in the vertical direction, and the board body 10 is released to obtain the vehicle board member shown in FIG. Molding process).

  As described above, according to the present embodiment, the end portion 11 of the board body 10 is constituted by the pair of upper and lower folded portions including the upper folded portion 31 and the lower folded portion 41, so And a pair of vertical surfaces 13 can be formed. As a result, the gap formed in the parting line BL between the end 11 of the board body 10 and the shelf 60 can be reduced. Therefore, it is possible to prevent small items from falling along the parting line BL and to improve the appearance of the parting line BL.

  Further, when the board main body 10 receives an impact from the side, the upper vertical surface 13 contacts the upper portion of the side wall 63 and the lower vertical surface 13 contacts the lower portion of the side wall 63. It is possible to restrict the ride on the upper stage 61 of the shelf 60 easily. In addition, since the overlapping portion 50 is disposed inside the end portion 11 of the board body 10, even when a burr at the time of welding is formed on the overlapping portion 50, the burr is not visible from the outside, and the appearance quality is improved. Can be secured. Thus, in this embodiment, the board member for vehicles which can ensure external appearance quality and can improve the alignment of the components with respect to the shelf part 60 can be provided.

<Embodiment 2>
Next, Embodiment 2 of the present invention will be described with reference to the drawing of FIG. In the present embodiment, the end 11 of the board body 10 is further sewn in the board member for the vehicle according to the first embodiment, and other common configurations, functions, and effects are duplicated. Omitted. A sewing line SL for sewing at the end 11 of the board body 10 is set at a position passing through the overlapping portion 50 in the vertical direction. For this reason, the end portion 11 of the board body 10 is fastened by the thread 80 in a state where the upper surface material 30, the overlapping portion 50, and the lower surface material 40 are overlapped. If it does in this way, the joint strength of the superposition | polymerization part 50 can be raised rather than Embodiment 1. FIG. Moreover, since a stitch pattern is formed along the outer periphery of the board main body 10, it can contribute to the improvement of the external appearance of the board member for vehicles.

<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.
(1) In the above embodiment, a flat board member for a vehicle is illustrated. However, according to the present invention, other forms may be used as long as the form follows the shape of the mating member on which the vehicle board member is installed. .

  (2) Although the upper surface material 30 and the lower surface material 40 are illustrated in the above embodiment, according to the present invention, in the case of the interior material attached to the side wall of the vehicle interior, the left surface material and the right surface material It is good.

  (3) Although the surface material is cut into the upper surface material 30 and the lower surface material 40 in the above embodiment, according to the present invention, without cutting into the upper surface material 30 and the lower surface material 40, What formed the superposition | polymerization part as integral is also included. That is, the board body 10 may be formed in a state where the core material 20 is wrapped with a surface material in which the upper surface material 30 and the lower surface material 40 are integrated.

(4) Although the superposition part 50 is heat-welded in Embodiment 2 and sewing is performed, according to the present invention, sewing may be performed without heat-welding.
(5) In the above embodiment, the cutting blade 74 is pierced deeply into the inside of the board body 10, but according to the present invention, the cutting blade 74 is shallower than in the above embodiment as shown in FIG. The board main body 10 may be pierced.

DESCRIPTION OF SYMBOLS 10 ... Board main body 11 ... End part 12 ... Corner | angular part 13 ... Vertical surface (standing surface)
20 ... Core material 30 ... Upper surface material (one side surface material)
31 ... Upper folded part (one folded part)
40 ... Lower surface material (other surface material)
41 ... Lower folded part (other folded part)
DESCRIPTION OF SYMBOLS 50 ... Superposition | polymerization part 70 ... Jig 71 ... Upper die 72 ... Lower die 73 ... Terminal shaping | molding die 74 ... Cutting blade 75 ... Molding surface

Claims (7)

A vehicle board member having a board body formed in a board shape with a core material sandwiched between surface materials,
The surface material is a protruding portion provided inside the board body in a state in which the surfaces of the surface materials at the end of the board body are in contact with each other, and from the overlapping portion to one surface side of the board body. It is configured to include a continuous one-side folded portion and an other-side folded portion continuous from the overlapping portion to the other surface side of the board body,
The board member for a vehicle according to claim 1, wherein the one-side folded portion and the other-side folded portion are connected to each other in a form that is recessed toward the core material side in the overlapping portion.   2. The vehicle according to claim 1, wherein a pair of corner portions is formed at an end portion of the board main body, and a standing surface extending in a thickness direction of the board main body is formed between the two corner portions. Board member.   The vehicular board member according to claim 1 or 2, wherein the overlapping portion is obtained by heat-welding the surfaces of the surface materials at the end of the board main body.   4. The vehicle board member according to claim 1, wherein the overlapping portion is formed by sewing a line passing through the overlapping portion at an end portion of the board main body. 5. A setting step of setting the board body formed in a board shape with the core material sandwiched between the surface materials in a state of being softened by heating;
A separation step of separating the end of the board body by piercing and cutting the cutting blade provided in the terminal mold at the end of the board body set in the jig;
A folding step of retreating the end of the board main body separated by the cutting blade by retreating the cutting blade and advancing the molding surface provided in the terminal mold;
A method for manufacturing a vehicular board member, comprising: a molding step in which the surfaces of the surface materials at the ends of the board body folded back by the molding surface are brought into contact with each other to mold a superposed portion.   6. The method for manufacturing a vehicle board member according to claim 5, wherein after the terminal molding die is retracted in the molding step, the end portion of the board body is further sandwiched by a crimping die.   The manufacturing method of the board member for vehicles of Claim 5 or Claim 6 provided with the sewing process which sews the line which passes along the said superimposition part in the edge part of the said board main body after the said formation process.

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