JP6560955B2 - Manufacturing method of composite member - Google Patents

Manufacturing method of composite member Download PDF

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JP6560955B2
JP6560955B2 JP2015205692A JP2015205692A JP6560955B2 JP 6560955 B2 JP6560955 B2 JP 6560955B2 JP 2015205692 A JP2015205692 A JP 2015205692A JP 2015205692 A JP2015205692 A JP 2015205692A JP 6560955 B2 JP6560955 B2 JP 6560955B2
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fiber body
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JP2017077637A (en
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夕介 橋本
夕介 橋本
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Inoac Corp
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この発明は、不織布からなる繊維体と、この繊維体の一部領域に重ねて形成される樹脂成形体とを備えた複合部材の製造方法に関するものである。   The present invention relates to a method of manufacturing a composite member including a fibrous body made of a nonwoven fabric and a resin molded body formed by being overlapped with a partial region of the fibrous body.

車両のドアトリムなどに用いられる複合部材としては、不織布からなる板状の繊維体を主体とし、この繊維体の裏面に形成された樹脂成形体によって、繊維体を補強したり、車体への取付部分を形成したものがある(例えば特許文献１および２参照)。このような複合部材は、繊維体をセットした型で樹脂成形体を射出成形することで、繊維体に樹脂成形体をなす樹脂を含浸させて、繊維体と樹脂成形体とを接合している。   As a composite member used for vehicle door trims, etc., a plate-like fiber body made of nonwoven fabric is mainly used, and the fiber body is reinforced by a resin molded body formed on the back surface of the fiber body, or attached to the vehicle body. (See, for example, Patent Documents 1 and 2). Such a composite member is formed by injection-molding a resin molded body with a mold in which the fiber body is set, so that the fiber body is impregnated with a resin forming the resin molded body, and the fiber body and the resin molded body are joined. .

特許第５３６９９０４号公報Japanese Patent No. 5369904 特許第５７４８１０５号公報Japanese Patent No. 5748105

前述した射出成形では、樹脂成形体をなす樹脂が繊維体の表面や樹脂成形体の形成部位周辺に染み出してしまい、得られる複合部材の見栄えが悪化してしまうといった問題が指摘される。特許文献２のように、繊維体をプレス成形して高密度にしておくことで、樹脂成形体となる樹脂の染み出しを防止できるが、繊維体を高密度にすることで、繊維特有の吸音性能や断熱性能などが損なわれてしまう。   In the above-described injection molding, a problem is pointed out that the resin forming the resin molded body oozes out on the surface of the fibrous body or around the site where the resin molded body is formed, thereby deteriorating the appearance of the resulting composite member. As described in Patent Document 2, the fiber body is press-molded to a high density to prevent the resin that becomes the resin molded body from leaking out. Performance and heat insulation performance will be impaired.

すなわち本発明は、従来の技術に係る前記問題に鑑み、これらを好適に解決するべく提案されたものであって、繊維体の性能を損なうことなく、繊維体への樹脂の染み出しを防止できる複合部材の製造方法を提供することを目的とする。   That is, the present invention has been proposed in order to suitably solve these problems related to the conventional technology, and can prevent the resin from exuding into the fibrous body without impairing the performance of the fibrous body. It aims at providing the manufacturing method of a composite member.

前記課題を克服し、所期の目的を達成するため、本願の請求項１に係る発明の複合部材の製造方法は、
不織布からなる板状の繊維体と、この繊維体の一部領域に重ねて形成される樹脂成形体とを備えた複合部材の製造方法であって、
型閉じした成形型の型面で挟んで、前記繊維体を板厚方向へ圧縮し、
型閉じした前記成形型において前記繊維体との間に画成されるキャビティに樹脂材料を充填して、樹脂成形体を成形し、
前記繊維体の圧縮により前記型面に引っ掛かった該繊維体を、前記成形型の型開きに伴って板厚方向へ膨らませるようにしたことを要旨とする。
請求項１に係る発明によれば、繊維体を圧縮した状態で樹脂成形体を一体成形することで、圧縮により繊維体が高密度になるから、繊維体の繊維間を伝って樹脂材料が広い範囲に染み出すことを抑制することができる。また、圧縮した繊維体を型開きに伴って型面に引っ掛けて膨らませるので、圧縮によって高くなった密度が回復されて、不織布からなる繊維体の性能を損なうことはない。このように、圧縮により性能が悪化することなく、樹脂材料の染み出しがなくて見栄えのよい繊維体を備えた複合部材を簡単に得ることができる。 In order to overcome the above-mentioned problems and achieve the intended purpose, a method for manufacturing a composite member according to claim 1 of the present application is as follows.
A method for producing a composite member comprising a plate-like fiber body made of a nonwoven fabric and a resin molded body formed by being superimposed on a partial region of the fiber body,
Sandwiched between mold surfaces of a closed mold, and compressing the fibrous body in the thickness direction,
Filling a cavity defined between the fibrous body in the mold closed with a resin material, and molding a resin molded body,
The gist of the invention is that the fibrous body caught on the mold surface by the compression of the fibrous body is expanded in the thickness direction as the mold is opened.
According to the first aspect of the present invention, since the fiber body becomes dense due to compression by integrally molding the resin molded body in a state where the fiber body is compressed, the resin material is wide through the fibers of the fiber body. Exudation into the range can be suppressed. Further, since the compressed fiber body is hooked on the mold surface and expanded when the mold is opened, the density increased by the compression is recovered, and the performance of the fiber body made of the nonwoven fabric is not impaired. Thus, the composite member provided with a good-looking fiber body without seepage of the resin material can be easily obtained without deteriorating performance due to compression.

請求項２に係る発明では、前記成形型における前記繊維体に当接する型面に突出して形成された突部を、繊維体を圧縮する際に該繊維体に差し込み、
前記成形型の型開きに伴って、前記繊維体を前記突部に引っ掛けて引っ張るようにしたことを要旨とする。
請求項２に係る発明によれば、繊維体に当接する型面に形成した突部に引っ掛けて繊維体の繊維を引っ張ることで、型開きする際に繊維体の表面を起毛させることができる。 In the invention according to claim 2, when the fiber body is compressed, the protrusion formed to protrude from the mold surface contacting the fiber body in the mold is inserted into the fiber body,
The gist of the invention is that the fibrous body is hooked and pulled by the protrusion as the mold is opened.
According to the second aspect of the present invention, the surface of the fibrous body can be raised when the mold is opened by hooking on the protrusion formed on the mold surface contacting the fibrous body and pulling the fiber of the fibrous body.

請求項３に係る発明では、前記繊維体を圧縮する際に、該繊維体における前記樹脂成形体の形成部位周辺を、型開き時に繊維体と引っ掛からない型面で押さえるようにしたことを要旨とする。
請求項３に係る発明によれば、繊維体における樹脂成形体の形成部位周辺を、型開き時に繊維体と引っ掛からない型面で押さえているので、型面が繊維体に引っ掛かることに伴う樹脂材料の染み出しを防止できる。これにより、樹脂成形体を成形した際に、樹脂成形体を形成した部位の周辺への樹脂材料の染み出しをより確実に防止できる。 The gist of the invention according to claim 3 is that when the fiber body is compressed, the periphery of the formation part of the resin molded body in the fiber body is pressed by a mold surface that is not caught by the fiber body when the mold is opened. To do.
According to the invention of claim 3, since the periphery of the portion where the resin molded body is formed in the fibrous body is pressed by the mold surface that does not catch the fibrous body when the mold is opened, the resin material accompanying the mold surface being caught by the fibrous body Can be prevented from seeping out. Thereby, when the resin molded body is molded, it is possible to more reliably prevent the resin material from bleeding to the periphery of the portion where the resin molded body is formed.

請求項４に係る発明では、前記繊維体を圧縮する際に、該繊維体における前記樹脂成形体の形成部位周辺を、繊維体におけるその他の部位よりも圧縮するようにしたことを要旨とする。
請求項４に係る発明によれば、繊維体における樹脂成形体の形成部位周辺を、繊維体におけるその他の部位よりも圧縮することで、繊維体における樹脂成形体の形成部位周辺を比較的高密度にすることができる。これにより、樹脂成形体を成形した際に、樹脂成形体を形成した部位の周辺への樹脂材料の染み出しをより確実に防止できる。 The gist of the invention according to claim 4 is that, when the fiber body is compressed, the vicinity of the formation part of the resin molded body in the fiber body is compressed more than the other parts in the fiber body.
According to the invention which concerns on Claim 4, the periphery of the formation part of the resin molding in a fiber body is compressed rather than the other site | part in a fiber body, The periphery of the formation part of the resin molding in a fiber body is comparatively high-density Can be. Thereby, when the resin molded body is molded, it is possible to more reliably prevent the resin material from bleeding to the periphery of the portion where the resin molded body is formed.

本発明に係る複合部材の製造方法によれば、繊維体の性能を損なうことなく、繊維体への樹脂の染み出しを防止できる。   According to the method for producing a composite member of the present invention, it is possible to prevent the resin from exuding into the fiber body without impairing the performance of the fiber body.

本発明の好適な実施例に係る製造方法で得られる複合部材を示す概略斜視図である。It is a schematic perspective view which shows the composite member obtained with the manufacturing method which concerns on the suitable Example of this invention. 実施例の製造工程を示す説明図である。It is explanatory drawing which shows the manufacturing process of an Example. 実施例の製造工程の要部を拡大して示す説明図である。It is explanatory drawing which expands and shows the principal part of the manufacturing process of an Example.

次に、本発明に係る複合部材の製造方法につき、好適な実施例を挙げて、添付図面を参照して以下に説明する。   Next, the manufacturing method of the composite member according to the present invention will be described below with reference to the accompanying drawings by way of preferred examples.

図１に示すように、実施例に係る製造方法で得られる複合部材１０は、不織布からなる板状の繊維体１２と、表面が意匠面となる繊維体１２の裏面に形成された樹脂成形体１４とから構成されている。繊維体１２は、ポリエステル繊維、ポリオレフィン繊維、アラミド繊維、ガラス繊維、セルロース繊維、ナイロン繊維、ビニロン繊維、レーヨン繊維などの不織布からなる板状体であり、不織布に由来する吸音や断熱などの所定の機能を発揮するように構成される。樹脂成形体１４は、繊維体１２の板面全体を覆わないように、繊維体１２の裏面における一部領域に重ねて形成され、繊維体１２を補強する骨格部分や、複合部材１０を取り付ける際の相手方との取付部分などを構成する。実施例の樹脂成形体１４は、矩形状の繊維体１２の外周縁に沿った枠状に形成された外延部分１４ａと、この外延部分１４ａの内側に縦横に延在する格子状に形成された内延部分１４ｂとを備え、繊維体１２を補強するよう構成されている。このような複合部材１０は、車両におけるトランクルームのデッキ部分、ドアトリム、天井、ピラーなどの車両内装部材、エンジンアンダーカバー、フェンダーライナーなど、車両を構成する部材として好適に用いることができる。   As shown in FIG. 1, a composite member 10 obtained by the manufacturing method according to the example includes a plate-like fiber body 12 made of a nonwoven fabric and a resin molded body formed on the back surface of the fiber body 12 whose surface is a design surface. 14. The fiber body 12 is a plate-like body made of a nonwoven fabric such as a polyester fiber, a polyolefin fiber, an aramid fiber, a glass fiber, a cellulose fiber, a nylon fiber, a vinylon fiber, or a rayon fiber, and has a predetermined sound absorption or heat insulation derived from the nonwoven fabric. Configured to perform. The resin molded body 14 is formed so as to overlap a partial region on the back surface of the fiber body 12 so as not to cover the entire plate surface of the fiber body 12, and when the skeleton part that reinforces the fiber body 12 or the composite member 10 is attached. The attachment part with the other party is configured. The resin molded body 14 of the example was formed in a lattice shape extending vertically and horizontally inside the extended portion 14a, and the extended portion 14a formed in a frame shape along the outer peripheral edge of the rectangular fiber body 12. An inward extending portion 14b, and is configured to reinforce the fibrous body 12. Such a composite member 10 can be suitably used as a member constituting a vehicle, such as a deck portion of a trunk room in a vehicle, a vehicle interior member such as a door trim, a ceiling, and a pillar, an engine under cover, and a fender liner.

前記複合部材１０は、図２および３に示すように、プレス成形型(以下成形型という)２０を用いた射出成形により製造される。成形型２０は、第１型２２と、この第１型２２と相対的に開閉可能に構成された第２型２４とを備えている。また、成形型２０は、第１型２２と第２型２４との間に繊維体１２をセットした状態で型閉じすることで、繊維体１２を賦形すると共に、繊維体１２と第１型２２との間に樹脂成形体１４に合わせたキャビティ２６を画成するようになっている。成形型２０は、型閉じした際に、第１型２２と第２型２４との間隔が繊維体１２の板厚よりも小さくなるように設定され、型閉じに伴って第１型２２と第２型２４との間にセットした繊維体１２を板厚方向に挟んで圧縮するよう構成される。   The composite member 10 is manufactured by injection molding using a press mold (hereinafter referred to as a mold) 20 as shown in FIGS. The mold 20 includes a first mold 22 and a second mold 24 configured to be openable and closable relative to the first mold 22. In addition, the mold 20 closes the fiber body 12 in a state where the fiber body 12 is set between the first mold 22 and the second mold 24, thereby shaping the fiber body 12, and the fiber body 12 and the first mold. A cavity 26 is defined between the resin molded body 14 and the cavity 26. The mold 20 is set so that the distance between the first mold 22 and the second mold 24 is smaller than the plate thickness of the fiber body 12 when the mold is closed. The fiber body 12 set between the two molds 24 is sandwiched in the plate thickness direction and compressed.

図３(ａ)〜(ｄ)に示すように、第１型２２および第２型２４には、型閉じした際に繊維体１２に当接する型面２２ｂ,２４ａに、複数の突部２８,３０が突出するように形成されている。突部２８,３０は、根元と比べて先端が細く形成された突起であり、型閉じ時に繊維体１２に差し込み可能で、かつ型開き時に繊維体１２を構成する繊維に引っ掛かるように構成される。突部２８,３０は、根元から先端に向かうにつれて成形型２０の開閉方向に対して傾く形状(実施例)としたり、先端を屈曲させるまたは返しを設けて鉤状とするなどにより、型閉じ時に差し込まれた繊維体１２の繊維に型開き時に引っ掛かるようになっている。また、突部２８,３０は、根元から先端まで突出寸法が、繊維体１２の圧縮時の板厚よりも小さく設定されている。そして、実施例では、第１型２２の型面２２ｂに設けられた第１突部(突部)２８の先端と、第２型２４の型面２４ａに設けられた第２突部(突部)３０の先端とが、互いにずらして配置されている。   As shown in FIGS. 3A to 3D, the first mold 22 and the second mold 24 include a plurality of protrusions 28, 24a on the mold surfaces 22b, 24a that contact the fiber body 12 when the mold is closed. 30 is formed so as to protrude. The protrusions 28 and 30 are protrusions that have a narrower tip than the base, and can be inserted into the fiber body 12 when the mold is closed, and can be hooked on the fibers constituting the fiber body 12 when the mold is opened. . The protrusions 28 and 30 have a shape (example) that is inclined with respect to the opening / closing direction of the molding die 20 from the base toward the tip, or are bent or bent so that the tip is bent into a bowl shape. The fibers of the inserted fiber body 12 are caught when the mold is opened. In addition, the protrusions 28 and 30 are set such that the protruding dimension from the base to the tip is smaller than the plate thickness when the fiber body 12 is compressed. In the embodiment, the tip of the first protrusion (projection) 28 provided on the mold surface 22b of the first mold 22 and the second protrusion (projection) provided on the mold surface 24a of the second mold 24 are used. ) 30 tips are arranged offset from each other.

図３(ａ)〜(ｄ)に示すように、前記第１型２２は、樹脂成形体１４の外延部分１４ａおよび内延部分１４ｂに合わせて第２型２４側に開口する凹状に形成された凹状型面２２ａによって、キャビティ２６を画成している。また、第１型２２は、型閉じ時に繊維体１２に当接する型面として、第１突部２８が設けられて繊維体１２に引っ掛け可能に構成された係合型面２２ｂと、繊維体１２と引っ掛からないように構成された押圧型面２２ｃとを備えている。押圧型面２２ｃは、繊維体１２における樹脂成形体１４の形成位置周辺に型閉じ時に当接する部位に対応して設けられ、凹状型面２２ａに連なって該凹状型面２２ａの開口縁を構成している。ここで、押圧型面２２ｃは、凹凸があっても繊維体１２を構成する繊維の隙間よりも大きいことで、繊維体１２に差し込まれない面形状などであればよく、実施例では、平坦な面で構成されている。また、押圧型面２２ｃは、係合型面２２ｂにおける突部２８の根元よりも第２型２４側に延在するように形成され、型閉じした際に、繊維体１２における押圧型面２２ｃに当接する部位を、係合型面２２ｂに当接する部位よりも圧縮するように設定してある。なお、実施例では、押圧型面２２ｃと突部２８の先端とが揃っている。   As shown in FIGS. 3A to 3D, the first mold 22 is formed in a concave shape that opens to the second mold 24 side in accordance with the outer extending part 14 a and the inner extending part 14 b of the resin molded body 14. A cavity 26 is defined by the concave mold surface 22a. In addition, the first mold 22 has an engagement mold surface 22b that is configured to be hooked on the fiber body 12 by being provided with a first protrusion 28 as a mold surface that contacts the fiber body 12 when the mold is closed, and the fiber body 12. And a pressing mold surface 22c configured not to be caught. The pressing mold surface 22c is provided around the position where the resin molded body 14 is formed in the fiber body 12 so as to be in contact with the mold when the mold is closed. The pressing mold surface 22c is connected to the concave mold surface 22a to form an opening edge of the concave mold surface 22a. ing. Here, the pressing mold surface 22c may be a surface shape that is not inserted into the fiber body 12 because it is larger than the gap between the fibers constituting the fiber body 12 even if there is unevenness. It is composed of planes. Further, the pressing mold surface 22c is formed to extend to the second mold 24 side from the base of the protrusion 28 in the engagement mold surface 22b, and when the mold is closed, the pressing mold surface 22c is formed on the pressing mold surface 22c of the fibrous body 12. The abutting part is set so as to be compressed more than the part abutting on the engagement type surface 22b. In the embodiment, the pressing mold surface 22c and the tip of the protrusion 28 are aligned.

次に前述した成形型２０を用いた複合部材１０の製造方法について説明する。なお、実施例では、熱可塑性樹脂繊維の不織布で構成された繊維体１２で複合部材１０を構成する場合である。まず、繊維体１２をヒータ等の加熱手段３２で加熱し、繊維体１２を軟化させる(図２(ａ))。 軟化した繊維体１２を第１型２２と第２型２４との間にセットし(図２(ｂ)および図３(ａ))、型閉じすることで、第１型２２の型面２２ｂ,２２ｃと第２型２４の型面２４ａとの間で繊維体１２を挟んで、繊維体１２を板厚方向に圧縮する(図２(ｃ),(ｄ)および図３(ｂ))。なお、実施例では、板厚５ｍｍの繊維体１２を板厚１ｍｍまで圧縮している。また、繊維体１２を圧縮するのに合わせて、第１型２２の第１突部２８および第２型２４の第２突部３０が繊維体１２に差し込まれる。このように、型閉じに伴って繊維体１２を圧縮することで、繊維体１２の繊維の隙間が詰まって高密度になる。ここで、繊維体１２を圧縮する際に、繊維体１２における樹脂成形体１４の形成部位周辺が、係合型面２２ｂで押される部位(繊維体１２におけるその他の部位)よりも圧縮するように、押圧型面２２ｃによって押される。これにより、繊維体１２における樹脂成形体１４の形成部位周辺を、より高密度にしている。そして、型閉じによって、軟化した繊維体１２が第１型２２および第２型２４で所定形状に成形されると共に、第１型２２の凹状型面２２ａの開口を塞ぐ繊維体１２と凹状型面２２ａとの間にキャビティ２６が画成される(図２(ｄ)および図３(ｂ))。   Next, a method for manufacturing the composite member 10 using the mold 20 described above will be described. In addition, in an Example, it is a case where the composite member 10 is comprised with the fiber body 12 comprised with the nonwoven fabric of the thermoplastic resin fiber. First, the fiber body 12 is heated by a heating means 32 such as a heater to soften the fiber body 12 (FIG. 2A). The softened fiber body 12 is set between the first mold 22 and the second mold 24 (FIGS. 2 (b) and 3 (a)), and the mold is closed so that the mold surfaces 22b, The fibrous body 12 is sandwiched between 22c and the mold surface 24a of the second mold 24, and the fibrous body 12 is compressed in the plate thickness direction (FIGS. 2C, 2D, and 3B). In the embodiment, the fibrous body 12 having a plate thickness of 5 mm is compressed to a plate thickness of 1 mm. In addition, as the fiber body 12 is compressed, the first protrusions 28 of the first mold 22 and the second protrusions 30 of the second mold 24 are inserted into the fiber body 12. Thus, by compressing the fiber body 12 as the mold is closed, the gaps between the fibers of the fiber body 12 are clogged and the density becomes high. Here, when the fiber body 12 is compressed, the periphery of the formation part of the resin molded body 14 in the fiber body 12 is compressed more than the part pressed by the engagement mold surface 22b (the other part in the fiber body 12). And pressed by the pressing mold surface 22c. Thereby, the formation site | part periphery of the resin molding 14 in the fiber body 12 is made more dense. Then, the fiber body 12 softened by the mold closing is molded into a predetermined shape by the first mold 22 and the second mold 24, and the fiber body 12 and the concave mold surface closing the opening of the concave mold surface 22a of the first mold 22 Cavity 26 is defined between 22a and 22a (FIGS. 2D and 3B).

前記キャビティ２６に樹脂材料を圧力をかけつつ充填し、樹脂成形体１４を成形する(図３(ｃ))。この際に、繊維体１２は、圧縮されて繊維が高密度になっているので、キャビティ２６に充填された樹脂材料が繊維体１２に浸透し難く、樹脂材料が繊維体１２の表面や樹脂成形体１４の形成部位周辺などの広い範囲に染み出すことを防止できる。しかも、繊維体１２は、樹脂成形体１４の形成部位周辺がその他の部位よりも大きく圧縮されて繊維がより高密度になっているので、キャビティ２６に充填された樹脂原料を、キャビティ２６に隣接する樹脂成形体１４の形成部位周辺に、より染み出し難くすることができる。また、繊維体１２における樹脂成形体１４の形成部位周辺を、第１突部２８が設けられていない平坦な押圧型面２２ｃで押さえているので、キャビティ２６の開口縁を好適に封止することができる。そのため、キャビティ２６に充填された樹脂原料が、キャビティ２６に隣接する樹脂成形体１４の形成部位周辺に染み出すことを防止できる。更に、繊維体１２は、第１型２２において開口する凹状型面２２ａに臨む樹脂成形体１４の形成部位も、周辺が圧縮されることに追従して圧縮されるが、その圧縮度合いが周辺と比べて小さくなる。これにより、キャビティ２６に面する繊維体１２における樹脂成形体１４の形成部位に、樹脂材料をある程度含浸させて、繊維体１２と成形された樹脂成形体１４とを強固に接合することができる。   The cavity 26 is filled with a resin material while applying pressure to mold the resin molded body 14 (FIG. 3C). At this time, since the fiber body 12 is compressed and the fibers have a high density, the resin material filled in the cavity 26 does not easily penetrate into the fiber body 12, and the resin material is formed on the surface of the fiber body 12 or resin molding. It can be prevented that it oozes out over a wide area such as around the site where the body 14 is formed. Moreover, since the fiber body 12 is compressed more in the periphery of the part where the resin molded body 14 is formed than in other parts and the fibers are denser, the resin raw material filled in the cavity 26 is adjacent to the cavity 26. It is possible to make it more difficult to ooze out around the portion where the resin molded body 14 is formed. Moreover, since the periphery of the formation part of the resin molded body 14 in the fiber body 12 is pressed by the flat pressing mold surface 22c where the first protrusion 28 is not provided, the opening edge of the cavity 26 is preferably sealed. Can do. Therefore, it is possible to prevent the resin raw material filled in the cavity 26 from oozing out around the formation site of the resin molded body 14 adjacent to the cavity 26. Further, the fibrous body 12 is also compressed in accordance with the compression of the periphery of the formation part of the resin molded body 14 facing the concave mold surface 22a opened in the first mold 22, but the degree of compression is Smaller than that. As a result, the resin material 14 is impregnated to some extent in the portion of the fibrous body 12 facing the cavity 26 where the resin molded body 14 is formed, and the fibrous body 12 and the molded resin molded body 14 can be firmly bonded.

射出成形により樹脂成形体１４を成形した後に、第１型２２と第２型２４とを型開きする(図２(ｅ)および図３(ｄ))。型開きする際に、繊維体１２に差し込まれた第１突部２８および第２突部３０が繊維体１２の繊維に引っ掛かるので、相対的に互いに離間する第１型２２および第２型２４に繊維体１２が追従して、圧縮されていた繊維体１２が板厚方向へ膨らむ。これにより、繊維体１２は、圧縮していた状態よりも密度が小さくなるように繊維がほぐされる。この際に、繊維体１２に当接する型面２２ｂ,２４ａに形成した突部２８,３０に引っ掛けて繊維体１２の繊維を引っ張るので、型開きに伴って繊維体１２の表面を起毛させることができる。更に型開きすることで、第１突部２８および／または第２突部３０を繊維体１２から抜き出し、圧縮状態から繊維の状態が復元された繊維体１２を備える複合部材１０を脱型する(図２(ｆ)および図３(ｅ))。このように、型開きを利用して繊維体１２を圧縮状態から復元するので、設備を簡単にできると共に、工数の増加を招かない。なお、突部２８,３０を繊維体１２から抜き出して複合部材１０が脱型可能になるまで連続して型開きしても、突部２８,３０が繊維体１２から外れない程度型開きした後に、更に型開きするように段階的に行ってもよい。また、型開き時に突部２８,３０が繊維体１２に引っ掛かった状態で第１型２２および／または第２型２４を振動させたり、繊維体１２に空気を吹き込むなどを行って、圧縮した繊維体１２の復元を補助してもよい。   After the resin molded body 14 is molded by injection molding, the first mold 22 and the second mold 24 are opened (FIGS. 2E and 3D). When the mold is opened, the first protrusions 28 and the second protrusions 30 inserted into the fiber body 12 are caught by the fibers of the fiber body 12, so that the first mold 22 and the second mold 24 that are relatively separated from each other The fiber body 12 follows, and the compressed fiber body 12 swells in the plate thickness direction. Thereby, as for the fiber body 12, a fiber is loosened so that a density may become smaller than the state which was compressed. At this time, since the fibers of the fiber body 12 are pulled by being hooked on the protrusions 28 and 30 formed on the mold surfaces 22b and 24a contacting the fiber body 12, the surface of the fiber body 12 can be raised with the mold opening. it can. Further, by opening the mold, the first protrusion 28 and / or the second protrusion 30 are extracted from the fiber body 12, and the composite member 10 including the fiber body 12 in which the fiber state is restored from the compressed state is removed from the mold ( FIG. 2 (f) and FIG. 3 (e)). Thus, since the fiber body 12 is restored from the compressed state using the mold opening, the equipment can be simplified and the number of man-hours is not increased. Note that after the protrusions 28 and 30 are extracted from the fiber body 12 and the mold is continuously opened until the composite member 10 can be removed from the mold, the protrusions 28 and 30 are not opened from the fiber body 12 until the protrusions are opened. Further, it may be performed step by step so as to open the mold. Further, the compressed fiber is produced by vibrating the first mold 22 and / or the second mold 24 while the protrusions 28 and 30 are caught on the fiber body 12 when the mold is opened, or by blowing air into the fiber body 12. The restoration of the body 12 may be assisted.

このように、型開きに伴って、先の工程で圧縮した繊維体１２を型面２２ｂ,２４ａに引っ掛けて膨らませるので、圧縮によって高くなった繊維の密度を回復させることができる。そして、得られた複合部材１０は、繊維体１２が圧縮状態から繊維がほぐされているので、繊維がある程度の隙間を有することで発現する繊維体１２の吸音性能や断熱性能などの所定の性能が損なわれることがなく、所望の性能を確保できる。また、複合部材１０は、樹脂材料の染み出しを防止するために、高目付量の不織布から繊維体１２を用いた場合のように、繊維体１２の重量が嵩むことがなく、全体として軽量化できる。更に、樹脂材料が染み出してしまうために使用できなかった低目付量の不織布からなる繊維体１２であっても、前述したように圧縮した状態で樹脂成形体１４を成形することで染み出しを防止した後に復元できるので、繊維体１２の設計の自由度が高くなる。このように前述した製造方法によれば、繊維体１２の性能を損なうことなく、樹脂材料の染み出しがなくて見栄えのよい繊維体１２を備えた複合部材１０を簡単に得ることができる。   Thus, as the mold is opened, the fiber body 12 compressed in the previous step is hooked on the mold surfaces 22b and 24a to be inflated, so that the fiber density increased by the compression can be recovered. And since the fiber body 12 is loosened from the compressed state, the obtained composite member 10 has predetermined performance such as sound absorption performance and heat insulation performance of the fiber body 12 that is manifested when the fiber has a certain gap. The desired performance can be secured without being damaged. Further, the composite member 10 does not increase the weight of the fiber body 12 as in the case where the fiber body 12 is used from a nonwoven fabric with a high basis weight in order to prevent the resin material from seeping out, and the overall weight is reduced. it can. Furthermore, even if the fibrous body 12 is made of a nonwoven fabric with a low basis weight that could not be used because the resin material oozes out, the bleed out can be obtained by molding the resin molded body 14 in a compressed state as described above. Since it can be restored after prevention, the degree of freedom in designing the fiber body 12 is increased. As described above, according to the manufacturing method described above, it is possible to easily obtain the composite member 10 including the fibrous body 12 that does not seep out of the resin material and has a good appearance without impairing the performance of the fibrous body 12.

(変更例)
前述した実施例に限らず、例えば以下のようにも変更可能である。
(１)突部は、大きさや形状を全て同じであってもよく、突出寸法などの大きさや形状を部位によって変更してもよい。
(２)突部は、所定間隔で並べて配置しても、ランダムに配置しても、何れであってもよい。
(３)第２型の第２突部は、型面の全体に設けても、一部領域だけに設けても、何れであってもよい。
(４)成形した樹脂成形体を第１型で保持できる構成であれば、第１型の第１突部を省略してもよい。 (Example of change)
For example, the present invention can be modified as follows.
(1) The protrusions may all have the same size and shape, and the size and shape such as the protruding dimension may be changed depending on the part.
(2) The protrusions may be arranged side by side at a predetermined interval or randomly.
(3) The second protrusion of the second mold may be provided on the entire mold surface or only in a partial region.
(4) The first protrusion of the first mold may be omitted as long as the molded resin molded body can be held by the first mold.

１２ 繊維体，１４ 樹脂成形体，２０ 成形型，２２ｂ 係合型面(型面)，
２２ｃ 押圧型面(型面)，２４ａ 型面，２６ キャビティ，２８ 第１突部(突部)，
３０ 第２突部(突部) 12 fiber body, 14 resin molded body, 20 mold, 22b engagement mold surface (mold surface),
22c pressing mold surface (mold surface), 24a mold surface, 26 cavity, 28 first protrusion (protrusion),
30 Second protrusion (protrusion)

Claims (4)

不織布からなる板状の繊維体と、この繊維体の一部領域に重ねて形成される樹脂成形体とを備えた複合部材の製造方法であって、
型閉じした成形型の型面で挟んで、前記繊維体を板厚方向へ圧縮し、
型閉じした前記成形型において前記繊維体との間に画成されるキャビティに樹脂材料を充填して、樹脂成形体を成形し、
前記繊維体の圧縮により前記型面に引っ掛かった該繊維体を、前記成形型の型開きに伴って板厚方向へ膨らませるようにした
ことを特徴とする複合部材の製造方法。 A method for producing a composite member comprising a plate-like fiber body made of a nonwoven fabric and a resin molded body formed by being superimposed on a partial region of the fiber body,
Sandwiched between mold surfaces of a closed mold, and compressing the fibrous body in the thickness direction,
Filling a cavity defined between the fibrous body in the mold closed with a resin material, and molding a resin molded body,
A method for producing a composite member, characterized in that the fibrous body caught on the mold surface by the compression of the fibrous body is expanded in the thickness direction as the mold is opened. 前記成形型における前記繊維体に当接する型面に突出して形成された突部を、繊維体を圧縮する際に該繊維体に差し込み、
前記成形型の型開きに伴って、前記繊維体を前記突部に引っ掛けて引っ張るようにした請求項１記載の複合部材の製造方法。 A protrusion formed on the mold surface that contacts the fiber body in the mold is inserted into the fiber body when compressing the fiber body,
The method of manufacturing a composite member according to claim 1, wherein the fibrous body is hooked and pulled by the protrusion as the mold is opened. 前記繊維体を圧縮する際に、該繊維体における前記樹脂成形体の形成部位周辺を、型開き時に繊維体と引っ掛からない型面で押さえるようにした請求項１または２記載の複合部材の製造方法。   3. The method of manufacturing a composite member according to claim 1, wherein when the fiber body is compressed, the periphery of a portion where the resin molded body is formed in the fiber body is pressed by a mold surface that does not catch the fiber body when the mold is opened. . 前記繊維体を圧縮する際に、該繊維体における前記樹脂成形体の形成部位周辺を、繊維体におけるその他の部位よりも圧縮するようにした請求項１〜３の何れか一項に記載の複合部材の製造方法。   The composite according to any one of claims 1 to 3, wherein, when the fiber body is compressed, the periphery of the formation part of the resin molded body in the fiber body is compressed more than other parts in the fiber body. Manufacturing method of member.
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