JP6643698B2 - Manufacturing method of resin parts - Google Patents
Manufacturing method of resin parts Download PDFInfo
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- JP6643698B2 JP6643698B2 JP2015194779A JP2015194779A JP6643698B2 JP 6643698 B2 JP6643698 B2 JP 6643698B2 JP 2015194779 A JP2015194779 A JP 2015194779A JP 2015194779 A JP2015194779 A JP 2015194779A JP 6643698 B2 JP6643698 B2 JP 6643698B2
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- 239000011347 resin Substances 0.000 title claims description 133
- 229920005989 resin Polymers 0.000 title claims description 133
- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 239000006260 foam Substances 0.000 claims description 42
- 238000005187 foaming Methods 0.000 claims description 22
- 230000003014 reinforcing effect Effects 0.000 claims description 18
- 239000000463 material Substances 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 13
- 239000012779 reinforcing material Substances 0.000 claims description 12
- 238000005192 partition Methods 0.000 claims description 9
- 230000002093 peripheral effect Effects 0.000 claims description 9
- 230000002787 reinforcement Effects 0.000 claims description 3
- 238000009423 ventilation Methods 0.000 description 9
- 239000002994 raw material Substances 0.000 description 8
- 239000007788 liquid Substances 0.000 description 4
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000000740 bleeding effect Effects 0.000 description 1
- 238000006757 chemical reactions by type Methods 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
Description
本発明は、樹脂部品及びその製造方法に関する。 The present invention relates to a resin component and a method for manufacturing the same.
自動車のデッキボードなどの樹脂部品は、中空部を有する樹脂パネルによって形成される場合がある。特許文献１には、このような樹脂パネルの強度を向上させるために、液状の発泡用原料を中空部内に注入し、中空部内で発泡用原料を発泡させて樹脂発泡体を形成しているものがある。 A resin component such as an automobile deck board may be formed of a resin panel having a hollow portion. In Patent Document 1, in order to improve the strength of such a resin panel, a liquid foaming material is injected into a hollow portion, and the foaming material is foamed in the hollow portion to form a resin foam. There is.
特許文献１では、中空部内に発泡体を形成することによって強度は向上するものの、樹脂パネルの重量が増大してしまうという問題がある。 In Patent Document 1, although the strength is improved by forming the foam in the hollow portion, there is a problem that the weight of the resin panel increases.
本発明はこのような事情に鑑みてなされたものであり、樹脂部品の重量の増大を抑制しつつ樹脂部品に必要な強度を付与することができる樹脂部品を提供するものである。 The present invention has been made in view of such circumstances, and provides a resin component capable of imparting necessary strength to the resin component while suppressing an increase in the weight of the resin component.
本発明によれば、中空部を有する樹脂成形体を備え、前記中空部の一部に樹脂発泡体が充填されている、樹脂部品が提供される。 According to the present invention, there is provided a resin component including a resin molded body having a hollow portion, wherein a part of the hollow portion is filled with a resin foam.
本発明者は、前述の目的を達成するために、種々検討を重ねてきた。その結果、樹脂成形体の中空部の一部に樹脂発泡体を充填することによって、樹脂部品の重量の増大を抑制しつつ樹脂部品に必要な強度を付与することができることを見出し、本発明の完成に到った。 The inventor has made various studies in order to achieve the above object. As a result, by filling the resin foam into a part of the hollow portion of the resin molded body, the present inventors have found that it is possible to impart the necessary strength to the resin component while suppressing an increase in the weight of the resin component. Completed.
以下、本発明の種々の実施形態を例示する。以下に示す実施形態は互いに組み合わせ可能である。
好ましくは、前記中空部は、前記樹脂成形体に設けられた仕切り部によって複数の空間に分割されており、前記複数の空間は、充填空間と非充填空間を備え、前記充填空間での前記樹脂発泡体の充填率は、前記非充填空間よりも大きい。
好ましくは、前記充填空間と前記非充填空間は、交互に並ぶように配置される。
好ましくは、前記樹脂成形体内に補強材を備え、前記補強材は、前記樹脂発泡体によって固定される。
好ましくは、前記樹脂成形体内において互いに離間されて配置される複数の補強材を備え、前記樹脂発泡体は、前記複数の補強材を橋渡しするように設けられる。
好ましくは、前記樹脂成形体は、前記中空部を隔てて重ねた表壁と裏壁とを備え、前記仕切り部は、前記裏壁と前記表壁の一方を他方に向かって突出させて形成される。
好ましくは、前記樹脂部品は、使用時に別の部材に当接される複数の当接部を備え、前記樹脂発泡体は、前記複数の当接部を橋渡しするように設けられる。
好ましくは、前記複数の空間は、通気孔を通じて互いに連通されている。
本発明の別の観点によれば、上記記載の樹脂部品の製造方法であって、前記中空部の一部に発泡用原料を注入して発泡させて樹脂発泡体を形成する工程を備える、樹脂部品の製造方法が提供される。
Hereinafter, various embodiments of the present invention will be exemplified. The embodiments described below can be combined with each other.
Preferably, the hollow portion is divided into a plurality of spaces by a partition provided in the resin molded body, the plurality of spaces include a filling space and a non-filling space, and the resin in the filling space The filling rate of the foam is greater than the unfilled space.
Preferably, the filling space and the non-filling space are arranged alternately.
Preferably, a reinforcing material is provided in the resin molded body, and the reinforcing material is fixed by the resin foam.
Preferably, a plurality of reinforcing members are provided separately from each other in the resin molded body, and the resin foam is provided so as to bridge the plurality of reinforcing members.
Preferably, the resin molded body includes a front wall and a back wall stacked with the hollow portion interposed therebetween, and the partition portion is formed by projecting one of the back wall and the front wall toward the other. You.
Preferably, the resin component includes a plurality of contact portions that are in contact with another member during use, and the resin foam is provided so as to bridge the plurality of contact portions.
Preferably, the plurality of spaces communicate with each other through a vent.
According to another aspect of the present invention, there is provided a method for manufacturing a resin component as described above, comprising a step of forming a resin foam by injecting a foaming material into a part of the hollow portion and foaming the material. A method for manufacturing a component is provided.
以下、図面を用いて、本発明の実施形態を説明する。
１．第１実施形態
図１〜図２に示すように、本発明の第１実施形態の樹脂部品は、自動車のデッキボードのような略長方形状の樹脂パネルであり、中空部２を有する樹脂成形体１を備え、中空部２の一部に樹脂発泡体１３が充填されている。樹脂成形体１は、中空部２を隔てて重ねた表壁７と裏壁９とを備える。中空部２の周囲は、周壁８で囲まれている。表壁７は略フラットであり、裏壁９には、裏壁９を表壁７に向かって突出させて形成された長方形状のリブ３が設けられている。リブ３の先端において表壁７と裏壁９は溶着されている。
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1. First Embodiment As shown in FIGS. 1 and 2, a resin component according to a first embodiment of the present invention is a substantially rectangular resin panel such as an automobile deck board, and has a resin molded body having a hollow portion 2. 1 and a part of the hollow portion 2 is filled with a resin foam 13. The resin molded body 1 includes a front wall 7 and a back wall 9 stacked with the hollow portion 2 interposed therebetween. The periphery of the hollow portion 2 is surrounded by a peripheral wall 8. The front wall 7 is substantially flat, and the back wall 9 is provided with a rectangular rib 3 formed by projecting the back wall 9 toward the front wall 7. The front wall 7 and the back wall 9 are welded at the tip of the rib 3.
中空部２は、リブ３によって複数の空間に分割されているので、リブ３が中空部２を複数の空間に分割する仕切り部として機能する。複数の空間には、充填空間２ａと非充填空間２ｂが含まれており、充填空間２ａでの樹脂発泡体１３の充填率は、非充填空間２ｂでの樹脂発泡体１３の充填率よりも大きい。充填率とは、所定の空間内で樹脂発泡体１３が占める体積の割合である。充填空間２ａが樹脂発泡体１３で完全に充填されると充填率は１００％となり、非充填空間２ｂに樹脂発泡体１３が全く充填されない場合、充填率は０％となる。充填空間２ａの充填率は、６０％以上が好ましく、７０，８０，９０，９５，又は９９％以上がさらに好ましい。非充填空間２ｂの充填率は、５０％以下が好ましく、４０，３０，２０，１０，５，又は１％以下がさらに好ましい。中空部２の充填率は、１０〜９０％が好ましく、具体的には例えば、１０、１５、２０、２５、３０、３５、４０、４５、５０、５５、６０、６５、７０、７５、８０、８５、９０％であり、ここで例示した数値の何れか２つの間の範囲内であってもよい。 Since the hollow portion 2 is divided into a plurality of spaces by the ribs 3, the ribs 3 function as partitions for dividing the hollow portion 2 into a plurality of spaces. The plurality of spaces include a filling space 2a and a non-filling space 2b, and the filling rate of the resin foam 13 in the filling space 2a is larger than the filling rate of the resin foam 13 in the non-filling space 2b. . The filling rate is a ratio of the volume occupied by the resin foam 13 in a predetermined space. When the filling space 2a is completely filled with the resin foam 13, the filling ratio becomes 100%. When the resin foam 13 is not filled in the non-filling space 2b at all, the filling ratio becomes 0%. The filling rate of the filling space 2a is preferably 60% or more, more preferably 70, 80, 90, 95, or 99% or more. The filling rate of the non-filled space 2b is preferably 50% or less, more preferably 40, 30, 20, 10, 5, or 1% or less. The filling rate of the hollow portion 2 is preferably 10 to 90%, and specifically, for example, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80 , 85, and 90%, and may be in a range between any two of the numerical values exemplified here.
充填空間２ａと非充填空間２ｂは交互に並ぶように配置されている。一対の充填空間２ａが樹脂成形体１の長手方向Ｌの両端に設けられており、一対の充填空間２ａの間に非充填空間２ｂが配置されている。充填空間２ａと非充填空間２ｂの間は通気孔５を通じて互いに連通されている。通気孔５は、リブ３と周壁８の間に設けられている。 The filling spaces 2a and the non-filling spaces 2b are arranged alternately. A pair of filling spaces 2a are provided at both ends in the longitudinal direction L of the resin molded body 1, and a non-filling space 2b is arranged between the pair of filling spaces 2a. The space between the filling space 2a and the non-filling space 2b is communicated with each other through the ventilation hole 5. The ventilation hole 5 is provided between the rib 3 and the peripheral wall 8.
図１（ｄ）中の矢印Ｘで示すように、充填空間２ａ内にノズルを挿入して充填空間２ａ内に発泡用原料を注入すると、充填空間２ａ内で発泡用原料が発泡して充填空間２ａ内に樹脂発泡体１３が形成される。充填空間２ａ内に注入する発泡用原料の種類は特に限定されず、充填空間２ａ内で発泡した後に固化して樹脂発泡体１３を形成可能な任意の原料が利用可能である。発泡用原料の一例は、２液混合による化学反応型ポリウレタン発泡を行う原料である。ポリウレタン発泡の発泡倍率は特に限定されないが、８０倍以下が好ましく、４０倍以下又は２０倍以下がさらに好ましい。この発泡倍率が大きすぎると、樹脂発泡体１３を充填空間２ａに充填したことによる強度向上が不満足になりやすいからである。発泡倍率の下限は特に限定されないが、例えば、５倍又は１０倍である。 As shown by an arrow X in FIG. 1D, when a foaming raw material is injected into the filling space 2a by inserting a nozzle into the filling space 2a, the foaming raw material foams in the filling space 2a and is filled. The resin foam 13 is formed in 2a. The type of the foaming material to be injected into the filling space 2a is not particularly limited, and any material that can be foamed in the filling space 2a and then solidified to form the resin foam 13 can be used. An example of a foaming raw material is a raw material for performing a chemical reaction type polyurethane foaming by mixing two liquids. The expansion ratio of the polyurethane foam is not particularly limited, but is preferably 80 times or less, more preferably 40 times or less or 20 times or less. If the expansion ratio is too large, the improvement in strength due to filling the filling space 2a with the resin foam 13 tends to be unsatisfactory. The lower limit of the expansion ratio is not particularly limited, but is, for example, 5 times or 10 times.
充填空間２ａ内に発泡用原料を注入する前は、充填空間２ａ内には気体が含まれているが、発泡用原料が発泡するにつれて充填空間２ａ内の気体が通気孔５を通じて非充填空間２ｂに移動するので、充填空間２ａ内の気体によって発泡用原料の発泡が妨げられることがない。このため、充填空間２ａ内の空気を抜くための通気孔を樹脂成形体１の外面に設ける必要がなく、樹脂成形体１の美観が向上する。また、通気孔５は、発泡用原料の移動を抑制するサイズに形成されているので、発泡用原料は、充填空間２ａから非充填空間２ｂにはほとんど移動しない。 Before the foaming material is injected into the filling space 2a, the gas is contained in the filling space 2a. However, as the foaming material foams, the gas in the filling space 2a flows through the vent hole 5 to the non-filling space 2b. The foaming of the foaming raw material is not hindered by the gas in the filling space 2a. For this reason, it is not necessary to provide a vent hole for bleeding air in the filling space 2a on the outer surface of the resin molded body 1, and the appearance of the resin molded body 1 is improved. Further, since the ventilation holes 5 are formed in a size that suppresses the movement of the foaming raw material, the foaming raw material hardly moves from the filling space 2a to the non-filling space 2b.
本実施形態では、図２に示すように、樹脂成形体１の裏壁９の対向する２辺の当接部９ａ，９ｂが部材１１に当接して、樹脂成形体１が部材１１上に支持される（２辺受けされる）ことが想定されている。この場合、図２（ｃ）の矢印Ｆで示すように樹脂成形体１に荷重が加わると当接部９ａ，９ｂを支点として樹脂成形体１の短手方向Ｓの中央部が沈むように樹脂成形体１が湾曲変形されやすい。しかし、本実施形態では、図２（ｃ），（ｄ）に示すように、２辺の当接部９ａ，９ｂを橋渡しするように樹脂発泡体１３が設けられているので、樹脂成形体１の強度が高められて樹脂成形体１の変形が抑制される。さらに、本実施形態では、２辺の当接部９ａ，９ｂを橋渡しするようにリブ３が設けられているので、樹脂成形体１の変形が一層抑制される。 In this embodiment, as shown in FIG. 2, the contact portions 9 a and 9 b on two opposite sides of the back wall 9 of the resin molded body 1 abut against the member 11, and the resin molded body 1 is supported on the member 11. (Two sides are received). In this case, when a load is applied to the resin molded body 1 as indicated by an arrow F in FIG. 2C, the resin molding is performed such that the center of the resin molded body 1 in the short direction S sinks around the contact portions 9a and 9b as fulcrums. The body 1 is easily deformed by bending. However, in the present embodiment, as shown in FIGS. 2C and 2D, the resin foam 13 is provided so as to bridge the contact portions 9a and 9b on two sides. And the deformation of the resin molded body 1 is suppressed. Further, in the present embodiment, since the ribs 3 are provided so as to bridge the contact portions 9a and 9b on two sides, the deformation of the resin molded body 1 is further suppressed.
また、樹脂成形体１は、長手方向Ｌの中央部よりも、長手方向Ｌの端部近傍で変形が起こりやすい。従って、樹脂成形体１の長手方向Ｌの端部近傍に充填空間２ａを配置して充填空間２ａ内に樹脂発泡体１３を充填することによって、樹脂発泡体１３の充填量を減らしつつ必要な強度を確保することが可能になる。これによって、樹脂部品の製造コストの低減及び軽量化が可能になる。 In addition, the resin molded body 1 is more likely to be deformed near the end in the longitudinal direction L than in the central part in the longitudinal direction L. Therefore, by placing the filling space 2a near the end of the resin molded body 1 in the longitudinal direction L and filling the filling space 2a with the resin foam 13, the required strength while reducing the filling amount of the resin foam 13 is achieved. Can be secured. As a result, the manufacturing cost and weight of the resin component can be reduced.
次に、本実施形態の樹脂部品の製造方法について説明する。
まず、図３（ａ）に示すように、樹脂成形体１の形状に応じた一対の金型２１，２２を用意し、溶融樹脂シート（パリソン）２３，２４を金型２１，２２側から吸引することにより、溶融樹脂シート２３，２４を金型２１，２２に密着させる。
Next, a method for manufacturing the resin component of the present embodiment will be described.
First, as shown in FIG. 3A, a pair of molds 21 and 22 corresponding to the shape of the resin molded body 1 are prepared, and the molten resin sheets (parisons) 23 and 24 are suctioned from the molds 21 and 22 side. By doing so, the molten resin sheets 23 and 24 are brought into close contact with the dies 21 and 22.
次に、図３（ｂ）に示すように、金型２１，２２を型締めし、溶融樹脂シート２３，２４で挟み込む。金型２１，２２には、金型２１，２２の内部に形成されるキャビティを取り囲むようにピンチオフ部２１ｂ，２２ｂが設けられており、溶融樹脂シート２３，２４がピンチオフ部２１ｂ，２２ｂによって挟まれて潰される。溶融樹脂シート２３，２４のうちキャビティの外側にある部分がバリ２６となり、ピンチオフ部２１ｂ，２２ｂによって挟まれた部分がバリ２６の切り取り線となる。型締め後には、キャビティ内にエアーの吹き込みを行っても行わなくてもよい。 Next, as shown in FIG. 3B, the molds 21 and 22 are clamped and sandwiched between the molten resin sheets 23 and 24. The dies 21 and 22 are provided with pinch-off portions 21b and 22b so as to surround a cavity formed inside the dies 21 and 22. The molten resin sheets 23 and 24 are sandwiched between the pinch-off portions 21b and 22b. Crushed. A portion of the molten resin sheets 23 and 24 outside the cavity becomes a burr 26, and a portion sandwiched between the pinch-off portions 21b and 22b becomes a cut line of the burr 26. After clamping, air may or may not be blown into the cavity.
次に、金型２１，２２を開いて成形品を取り出し、ピンチオフ部２１ｂ，２２ｂによって成形品に形成された切り取り線でバリ２６を切断して除去する。以上の工程で、図１に示す樹脂成形体１が形成される。なお、樹脂成形体１は、円筒状のパリソンを用いて形成してもよい。 Next, the molds 21 and 22 are opened, the molded product is taken out, and the burrs 26 are cut and removed at the cut lines formed on the molded product by the pinch-off portions 21b and 22b. Through the above steps, the resin molded body 1 shown in FIG. 1 is formed. Note that the resin molded body 1 may be formed using a cylindrical parison.
次に、樹脂成形体１の充填空間２ａ内に発泡用原料を注入すると、充填空間２ａ内で液状樹脂が発泡して充填空間２ａ内に樹脂発泡体１３が形成されることによって、本実施形態の樹脂部品が得られる。 Next, when a foaming raw material is injected into the filling space 2a of the resin molded body 1, the liquid resin foams in the filling space 2a to form the resin foam 13 in the filling space 2a. The resin part of is obtained.
本発明は、以下の態様でも実施可能である。
・上記実施形態では、裏壁９が表壁７に向かって凹まされて形成されたリブ（所謂、スリットリブ）３が仕切り部として機能しているが、図４に示すように、裏壁９が凹まないように形成されたインナーリブ３ａを仕切り部として機能させることもできる。また、図５に示すように、多数の点リブ３ｂを仕切り部として機能させてもよい。この場合、隣接する２つの点リブ３ｂの間の隙間が通気孔５となる。点リブ３ｂの断面形状は、円、楕円、多角形（正方形、長方形、六角形など）などの何れであってもよい。何れのリブも、表壁７と裏壁９の一方を他方に向かって突出させることによって形成することができる。
・上記実施形態では、リブ３と周壁８の間に通気孔５が設けられているが、図６に示すように、リブ３と表壁７の間に通気孔５を設けてもよい。
・表壁７と裏壁９の間に別の部材（例：補強材）を配置して仕切り部として機能させてもよい。
・通気孔５を設けずに、充填空間２ａと非充填空間２ｂを仕切ってもよい。この場合、充填空間２ａと樹脂成形体１の外部を連通する通気孔を設けることが好ましい。
・充填空間２ａの数は、１つであっても３つ以上であってもよい。
The present invention can be implemented in the following aspects.
In the above embodiment, the rib (so-called slit rib) 3 formed by recessing the back wall 9 toward the front wall 7 functions as a partition, but as shown in FIG. The inner rib 3a formed so as not to be depressed can also function as a partition. Further, as shown in FIG. 5, a large number of point ribs 3b may function as partition portions. In this case, a gap between two adjacent point ribs 3b becomes the ventilation hole 5. The cross-sectional shape of the point rib 3b may be any of a circle, an ellipse, a polygon (square, rectangle, hexagon, etc.). Both ribs can be formed by projecting one of the front wall 7 and the back wall 9 toward the other.
In the above embodiment, the ventilation hole 5 is provided between the rib 3 and the peripheral wall 8, but the ventilation hole 5 may be provided between the rib 3 and the front wall 7, as shown in FIG.
-Another member (example: reinforcing material) may be arranged between the front wall 7 and the back wall 9 to function as a partition.
The filling space 2a and the non-filling space 2b may be partitioned without providing the ventilation hole 5. In this case, it is preferable to provide a ventilation hole that communicates the filling space 2a with the outside of the resin molded body 1.
-The number of the filling spaces 2a may be one or three or more.
２．第２実施形態
次に、図７を用いて、本発明の第２実施形態について説明する。本実施形態の樹脂部品は、第１実施形態に類似しており、樹脂成形体１内に補強材１５が配置されている点が主な相違点である。以下、相違点を中心に説明する。
2. Second Embodiment Next, a second embodiment of the present invention will be described with reference to FIG. The resin component of the present embodiment is similar to the first embodiment, and is mainly different in that a reinforcing material 15 is disposed in the resin molded body 1. Hereinafter, the differences will be mainly described.
本実施形態では、樹脂成形体１内に複数の補強材１５が互いに離間されて配置されている。本実施形態では、リブ３と周壁８の間の隙間が第１実施形態よりも大きく、この隙間に補強材１５が配置されている。通気孔５は、補強材１５とリブ３の間と、補強材１５と周壁８の間に設けられる。補強材１５は、樹脂成形体１の長手方向Ｌに沿って配置されている。補強材１５は、細長い形状を有しており、その断面形状はＨ型である。補強材１５の断面形状は特に限定されず、円、楕円、多角形（六角形、正方形、長方形など）などであってもよい。補強材１５は、棒状であってもよく、筒状であってもよい。補強材１５の材質は特に限定されず、金属や硬質のプラスチックなどで形成可能である。補強材１５は、充填空間２ａと非充填空間２ｂの両方に渡って設けられている。 In the present embodiment, a plurality of reinforcing members 15 are arranged in the resin molded body 1 so as to be separated from each other. In the present embodiment, the gap between the rib 3 and the peripheral wall 8 is larger than in the first embodiment, and the reinforcing member 15 is disposed in this gap. The ventilation holes 5 are provided between the reinforcing member 15 and the ribs 3 and between the reinforcing member 15 and the peripheral wall 8. The reinforcing member 15 is arranged along the longitudinal direction L of the resin molded body 1. The reinforcing member 15 has an elongated shape, and its cross-sectional shape is H-shaped. The cross-sectional shape of the reinforcing member 15 is not particularly limited, and may be a circle, an ellipse, a polygon (a hexagon, a square, a rectangle, or the like). The reinforcing material 15 may be rod-shaped or cylindrical. The material of the reinforcing member 15 is not particularly limited, and can be formed of metal, hard plastic, or the like. The reinforcing material 15 is provided over both the filling space 2a and the non-filling space 2b.
補強材１５の一部を充填空間２ａ内に配置した状態で充填空間２ａ内に発泡用原料を注入して充填空間２ａ内に樹脂発泡体１３を充填すると、充填空間２ａ内で補強材１５が樹脂発泡体１３によって固定される。このため、補強材１５が樹脂成形体１内で移動することによる異音の発生が抑制される。また、複数の補強材１５が樹脂発泡体１３で橋渡しされることによって樹脂発泡体１３の変形が一層抑制される。 When the foaming material is injected into the filling space 2a and the resin foam 13 is filled in the filling space 2a in a state where a part of the reinforcing material 15 is arranged in the filling space 2a, the reinforcing material 15 is filled in the filling space 2a. It is fixed by the resin foam 13. For this reason, generation of abnormal noise due to the movement of the reinforcing member 15 in the resin molded body 1 is suppressed. Moreover, the deformation of the resin foam 13 is further suppressed by bridging the plurality of reinforcing members 15 with the resin foam 13.
本実施形態では、図７に示すように、樹脂成形体１の裏壁９の４隅の当接部９ａ〜９ｄが部材１１に当接して、樹脂成形体１が部材１１上に支持される（４点受けされる）ことが想定されている。この場合、図７（ｃ）の矢印Ｆに荷重が加わると当接部９ｃ，９ｄを支点として樹脂成形体１の短手方向Ｓの中央部が沈むように湾曲変形されやすく、図７（ｂ）の矢印Ｇで示すように荷重が加わると当接部９ａ，９ｃを支点として樹脂成形体１の長手方向Ｌの中央部が沈むように湾曲変形されやすい。しかし、本実施形態では、図７（ａ）〜（ｄ）に示すように、樹脂成形体１の長手方向Ｌに延びるように且つ当接部９ａと９ｃ及び当接部９ｂと９ｄをそれぞれ橋渡しするように補強材１５が配置されており、且つ複数の補強材１５を橋渡しするように樹脂発泡体１３が設けられているので、樹脂成形体１の強度が高められて樹脂成形体１の変形が抑制される。 In the present embodiment, as shown in FIG. 7, the contact portions 9 a to 9 d at the four corners of the back wall 9 of the resin molded body 1 abut on the member 11, and the resin molded body 1 is supported on the member 11. (4 points). In this case, when a load is applied to the arrow F in FIG. 7C, the resin molded body 1 is easily bent and deformed so that the central portion in the lateral direction S of the resin molded body 1 sinks around the contact portions 9c and 9d as a fulcrum. When a load is applied as indicated by the arrow G, the resin molded body 1 is easily curved and deformed so that the central portion in the longitudinal direction L of the resin molded body 1 sinks around the contact portions 9a and 9c. However, in the present embodiment, as shown in FIGS. 7A to 7D, the contact portions 9a and 9c and the contact portions 9b and 9d are bridged so as to extend in the longitudinal direction L of the resin molded body 1. The reinforcing member 15 is disposed so as to perform the above-described operation, and the resin foam 13 is provided so as to bridge the plurality of reinforcing members 15. Therefore, the strength of the resin molded body 1 is increased, and the resin molded body 1 is deformed. Is suppressed.
次に、本実施形態の樹脂部品の製造方法について説明する。
まず、第１実施形態と同様に、図３（ａ）に示すように、樹脂成形体１の形状に応じた一対の金型２１，２２を用意し、溶融樹脂シート（パリソン）２３，２４を金型２１，２２側から吸引することにより、溶融樹脂シート２３，２４を金型２１，２２に密着させる。
Next, a method for manufacturing the resin component of the present embodiment will be described.
First, similarly to the first embodiment, as shown in FIG. 3A, a pair of molds 21 and 22 corresponding to the shape of the resin molded body 1 are prepared, and molten resin sheets (parisons) 23 and 24 are prepared. The molten resin sheets 23 and 24 are brought into close contact with the dies 21 and 22 by suction from the dies 21 and 22.
次に、溶融樹脂シート２３，２４の一方に補強材１５を貼り付けた後に、第１実施形態と同様に、金型２１，２２を型締めして樹脂成形体１を形成する。 Next, after attaching the reinforcing material 15 to one of the molten resin sheets 23 and 24, the resin molded body 1 is formed by clamping the molds 21 and 22 as in the first embodiment.
次に、第１実施形態と同様に、樹脂成形体１の充填空間２ａ内に発泡用原料を注入すると、充填空間２ａ内で液状樹脂が発泡して充填空間２ａ内に樹脂発泡体１３が形成されることによって、本実施形態の樹脂部品が得られる。 Next, as in the first embodiment, when a foaming material is injected into the filling space 2a of the resin molded body 1, the liquid resin foams in the filling space 2a, and a resin foam 13 is formed in the filling space 2a. By doing so, the resin component of the present embodiment is obtained.
本発明は、以下の態様でも実施可能である。
・補強材１５は、樹脂成形体１を形成した後に、樹脂成形体１内に挿入してもよい。この場合、補強材１５の挿入後に充填空間２ａ内に発泡用原料を注入して充填空間２ａ内に樹脂成形体１３を充填することによって、補強材１５を樹脂発泡体１３で固定することができる。
・図８に示すように、樹脂成形体１が１辺（当接部９ａ）及び２点（当接部９ｂ，９ｃ）受けされる場合には、当接部９ａの側には補強材１５は不要であり、当接部９ｂ，９ｃを橋渡しするように補強材１５を配置すればよい。
The present invention can be implemented in the following aspects.
The reinforcing member 15 may be inserted into the resin molded body 1 after the resin molded body 1 is formed. In this case, the reinforcing material 15 can be fixed by the resin foam 13 by injecting the foaming material into the filling space 2a after the reinforcing material 15 is inserted and filling the resin molding 13 into the filling space 2a. .
As shown in FIG. 8, when the resin molded body 1 is received on one side (contact portion 9a) and two points (contact portions 9b and 9c), the reinforcing member 15 is provided on the contact portion 9a side. Is unnecessary, and the reinforcing member 15 may be arranged so as to bridge the contact portions 9b and 9c.
１：樹脂成形体、２：中空部、２ａ：充填空間、２ｂ：非充填空間、３：リブ、５：通気孔、７：表壁、８：周壁、９：裏壁、１１：部材、１３：樹脂発泡体、１５：補強材 1: resin molded body, 2: hollow portion, 2a: filled space, 2b: unfilled space, 3: rib, 5: vent hole, 7: front wall, 8: peripheral wall, 9: back wall, 11: member, 13 ： Resin foam, 15 ： Reinforcement
Claims (7)
前記樹脂部品は、中空部を有する樹脂成形体を備え、
前記中空部は、前記樹脂成形体に設けられた仕切り部によって複数の空間に分割されており、
前記複数の空間は、充填空間と非充填空間を備え、
前記充填空間に発泡用原料を注入して発泡させて樹脂発泡体を形成する工程を備え、
前記樹脂成形体は、前記中空部を隔てて重ねた表壁と裏壁と、前記中空部を囲む周壁を備え、
前記仕切り部は、前記裏壁と前記表壁の一方を他方に向かって突出させて形成され、
前記充填空間は、前記周壁に接しており、
前記発泡用原料は、前記周壁を通じて注入される、方法。 A method for manufacturing a resin component,
The resin component includes a resin molded body having a hollow portion,
The hollow portion is divided into a plurality of spaces by a partition provided in the resin molded body,
The plurality of spaces includes a filling space and a non-filling space,
A step of injecting a foaming material into the filling space and foaming to form a resin foam ,
The resin molded body includes a front wall and a back wall that are stacked with the hollow part interposed therebetween, and a peripheral wall surrounding the hollow part,
The partition is formed by projecting one of the back wall and the front wall toward the other,
The filling space is in contact with the peripheral wall,
The foaming material is Ru is injected through the peripheral wall, the method.
前記補強材は、前記樹脂発泡体によって固定される、請求項１〜請求項３の何れか１つに記載の方法。 With a reinforcing material in the resin molded body,
The method according to claim 1, wherein the reinforcement is fixed by the resin foam.
前記樹脂発泡体は、前記複数の補強材を橋渡しするように設けられる、請求項１〜請求項４の何れか１つに記載の方法。 It comprises a plurality of reinforcing members spaced apart from each other in the resin molded body,
The method according to claim 1, wherein the resin foam is provided to bridge the plurality of reinforcements.
前記樹脂発泡体は、前記複数の当接部を橋渡しするように設けられる、請求項１〜請求項５の何れか１つに記載の方法。 The resin component includes a plurality of contact portions that are in contact with another member during use,
The method according to any one of claims 1 to 5, wherein the resin foam is provided so as to bridge the plurality of contact portions.
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