JP6589397B2 - 成形構造体及び成形構造体の製造方法 - Google Patents
成形構造体及び成形構造体の製造方法 Download PDFInfo
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- JP6589397B2 JP6589397B2 JP2015118009A JP2015118009A JP6589397B2 JP 6589397 B2 JP6589397 B2 JP 6589397B2 JP 2015118009 A JP2015118009 A JP 2015118009A JP 2015118009 A JP2015118009 A JP 2015118009A JP 6589397 B2 JP6589397 B2 JP 6589397B2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0025—Preventing defects on the moulded article, e.g. weld lines, shrinkage marks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14811—Multilayered articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/04—Making preforms by assembling preformed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C2045/1486—Details, accessories and auxiliary operations
- B29C2045/14868—Pretreatment of the insert, e.g. etching, cleaning
- B29C2045/14877—Pretreatment of the insert, e.g. etching, cleaning preheating or precooling the insert for non-deforming purposes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
- B29K2023/12—PP, i.e. polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0058—Liquid or visquous
- B29K2105/0067—Melt
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/20—Inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2623/00—Use of polyalkenes or derivatives thereof for preformed parts, e.g. for inserts
- B29K2623/10—Polymers of propylene
- B29K2623/12—PP, i.e. polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2677/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, for preformed parts, e.g. for inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3014—Door linings
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Description
本発明の実施形態1を図1ないし図6の図面を参照しながら説明する。
本実施形態におけるドアトリム(「成形構造体」の一例)10は、図1に示すように、トリムボード11にクリップ座などのブラケット(「成形体」の一例)30が溶着されることにより形成されている。なお、トリムボード11には複数のブラケット30が溶着されているものの、説明の便宜のために、各図においては、一つのブラケット30のみを示している。
本実施形態のドアトリム10は、繊維を含む基材20と、基材20の裏面20Bを平坦化する平坦化層25と、平坦化層25を介して、基材20の裏面20Bに溶着されたブラケット30と、を備える。本実施形態によれば、ドアトリム10が平坦化層25を備えるから、仮に平坦化層25を備えない構成に比べて繊維と繊維の隙間を小さいものとすることができ、ブラケット30を基材20の裏面20Bに溶着する際に、溶融したブラケット30の材料(溶融樹脂35)が隙間から漏れる事態を低減することができる。溶融樹脂35の漏れを抑制することができれば、成形体成形工程において、一つのゲートから射出される溶融樹脂35で成形できるブラケット30の数を増やすことができる。その結果、1つのドアトリム10を製造する際に用いる成形装置Mのゲート数を削減することができ、ゲートの開閉等の制御が容易になる。また、仮に成形体成形工程において樹脂漏れが発生した場合には、成形体(ブラケット30)に欠肉が生じたり、漏れた樹脂が固まる際に収縮することに起因して、ドアトリム10の意匠性が損なわれたりする事態が発生し得るが、本実施形態では、そのような事態の発生を抑制することができる。すなわち、本実施形態によれば、軽量化基材を用いた場合であっても、ドアトリム10の歩留まりが低下する事態を抑制することができ、ドアトリム10の軽量化を実現することができる。
[1]実施例と比較例に係る15個のテストピース(1のブラケットが接合された基材の断片)をそれぞれ作成する。
[2]測定装置に対して基材を固定するとともに、測定装置の係止部をブラケットの立壁に係止する。
[3]測定装置の係止部を基材の裏面に対して垂直方向に移動して、ブラケットと基材との接合部分が破断するまで引っ張ったときの応力(N)を測定する。
測定結果は、比較例の接合強度が300〜400(N)であったのに対して、実施例の接合強度が350〜600(N)であった。実施例では、その平均値において、比較例より150(N)程度接合強度が向上した。実施例の接合強度は、一の溶融樹脂で基材とブラケットを一体的に射出成形した従来製品の接合強度と同等又はそれ以上の値であり、ドアトリム10において要求される接合強度値を満足するものであった。
実施形態1の変形例1として、基材20の構成が実施形態1と相違するものについて例示する。
本発明の実施形態2を図7及び図8によって説明する。上記実施形態と同一部分には、同一符号を付して重複する説明を省略する。本実施形態においては、平坦化層125の層の構成が上記実施形態と相違する。
本発明の実施形態3を図9によって説明する。上記実施形態と同一部分には、同一符号を付して重複する説明を省略する。本実施形態においては、平坦化層形成工程の態様が上記実施形態と相違する。
本発明は上記記述及び図面によって説明した実施形態に限定されるものではなく、例えば次のような実施形態も本発明の技術的範囲に含まれる。
(1)上記実施形態では、基材に用いられる繊維として、木質繊維や靭皮植物繊維を例示したが、繊維の種類はこれに限定されない。また、基材の密度については、上記実施形態以外の密度のものを適宜用いてもよい。
Claims (2)
- 繊維を含む基材と、
前記基材の一の面を平坦化する平坦化層と、
前記平坦化層を介して、前記基材の前記一の面に溶着された成形体と、を備え、
前記基材は、前記繊維が熱可塑性樹脂によって結着されてなり、
前記成形体は、熱可塑性樹脂を成形してなり、
前記平坦化層は、前記基材側の面と前記成形体側の面とが少なくとも熱可塑性樹脂を含む層で構成され、
前記平坦化層は、前記基材側の面を構成する基材側層と、前記成形体側の面を構成する成形体側層と、前記基材側層と前記成形体側層の間に介在するとともに、前記基材側層及び前記成形体側層より融点が高い熱可塑性樹脂を含む中間層と、を備えて構成されている成形構造体。 - 繊維を含む基材の一の面に、前記基材側の面を構成する熱可塑性樹脂を含む基材側層と、成形体側の面を構成する熱可塑性樹脂を含む成形体側層と、前記基材側層と前記成形体側層の間に介在するとともに、前記基材側層及び前記成形体側層の熱可塑性樹脂より融点が高い熱可塑性樹脂を含む中間層と、からなる平坦化層を形成して、前記一の面を平坦化する平坦化層形成工程と、
前記平坦化層が形成された前記基材の前記一の面に、前記成形体を成形するための成形空間を有する成形型を配置するとともに、前記成形空間内に溶融樹脂を射出して、前記成形体を前記基材と一体的に成形する成形体成形工程と、を備え、
前記平坦化層形成工程において、前記基材側層を前記基材に溶着するとともに、成形体側層を平坦化し、
前記成形体成形工程において、前記中間層の熱可塑性樹脂を溶融させないことを特徴とする成形構造体の製造方法。
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JP2015118009A JP6589397B2 (ja) | 2015-06-11 | 2015-06-11 | 成形構造体及び成形構造体の製造方法 |
DE102016109033.6A DE102016109033A1 (de) | 2015-06-11 | 2016-05-17 | Formbauteil und Verfahren zum Herstellen desselbigen |
US15/163,958 US20160361850A1 (en) | 2015-06-11 | 2016-05-25 | Molded member and method of manufacturing the same |
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JP2015118009A JP6589397B2 (ja) | 2015-06-11 | 2015-06-11 | 成形構造体及び成形構造体の製造方法 |
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JP2017001300A JP2017001300A (ja) | 2017-01-05 |
JP6589397B2 true JP6589397B2 (ja) | 2019-10-16 |
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JP6996288B2 (ja) | 2017-12-26 | 2022-01-17 | トヨタ紡織株式会社 | 複合成形体 |
DE102020206378B4 (de) | 2019-05-20 | 2022-06-30 | Ford Global Technologies, Llc | Verfahren zur Herstellung einer Belüftungslamelle mit schallabsorbierendem Schaum |
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AU2682595A (en) * | 1994-06-17 | 1996-01-15 | Araco Kabushiki Kaisha | Laminated body and method of manufacturing the same |
JPH10138354A (ja) * | 1996-11-08 | 1998-05-26 | Yamaha Corp | 炭素繊維強化樹脂成形物とその製造方法 |
JP5186883B2 (ja) | 2007-11-02 | 2013-04-24 | トヨタ紡織株式会社 | 成形構造体の製造方法 |
TW201023715A (en) * | 2008-12-04 | 2010-06-16 | Pegatron Corp | Fiber-reinforced polymeric casing and method of fabricating the same |
JP5771985B2 (ja) * | 2010-12-28 | 2015-09-02 | 東レ株式会社 | 複合成形体の製造方法 |
WO2014112501A1 (ja) * | 2013-01-15 | 2014-07-24 | 東レ株式会社 | 成形体 |
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US20160361850A1 (en) | 2016-12-15 |
DE102016109033A1 (de) | 2016-12-15 |
JP2017001300A (ja) | 2017-01-05 |
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Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |