JP7116673B2 - Composite member for vehicle and manufacturing method thereof - Google Patents

Description

TECHNICAL FIELD The present invention relates to a vehicle composite member used for an undercover of an instrument panel, an engine undercover, etc., and a manufacturing method thereof.

In vehicles such as automobiles, there are composite parts for vehicles such as instrument panel undercovers and engine undercovers, in which a porous sheet material is spread within a resin frame to provide weight reduction and sound absorption. do. Some improved inventions have also been proposed (for example, Patent Document 1).

JP 2017-77637 A

Patent Document 1 is an invention document for manufacturing a composite member as shown in FIG. 2(f). FIG. 14 shows a composite member in which FIG. 2(f) is simplified. A resin molded body 92 is formed overlapping a partial region of the back surface of the plate-like fibrous body 91 (the base material 7 of the present invention), and an extension portion 921 (the resin frame 81 of the present invention) and an inner portion that reinforce the fibrous body 91 are formed. The resin molding 92 of the extending portion 929 (the crosspiece 89 of the present invention) is injection molded.

However, in Patent Document 1, the peripheral end 919 of the fibrous body 91 may cause a quality trouble.
In setting the fibrous body 91 to the lower mold T1 in the injection molding process, it is extremely difficult to prepare the fibrous body 91 having the total length L that matches the cavity portion C91. Therefore, the peripheral terminal 919 of the fibrous body 91 is manufactured so as to fit within the terminal arrangement range as shown in FIG. 15(a). Pressure is applied to the end 919 of the fibrous body 91 (b in FIG. 15). As a result, the fiber end 919 is crushed as shown in FIG. 15(c). When the extension part 921 is finished forming, the degree of crushing at each part slightly changes, and the parting position K between the extension part 921 and the fibrous body 91 varies as shown in FIG. 15(d). Variation in the parting position causes a quality defect in which the periphery of the fibrous body 91 twists in the circumferential direction as shown in FIG. In addition, since the winding portion appears on the design surface side of the fibrous body 91, the product becomes defective and the yield is lowered. Furthermore, after demolding, the crushed portion of the fibrous body end 919 may form a densely solidified portion of the fibrous body 919 or a raised portion M on the fibrous body design surface.

It is an object of the present invention to solve the above-mentioned problems, and to provide a composite member for a vehicle and a method of manufacturing the same, which are useful for improving quality by eliminating variations in the parting position appearing on the design side of the product, and also helping to improve the yield. aim.

In order to achieve the above object, the gist of the invention as set forth in claim 1 is that the porous sheet material is three-dimensionally shaped, and the inner surface of the lid from the peripheral edge portion of the lid main portion that maintains the porous structure and forms the lid top surface. A base material in which the brim portion extends by bending to the side, and the brim portion is erected with respect to the lid main portion; A composite member for a vehicle, comprising: a resin frame that surrounds the periphery in a frame shape and is integrally molded with the base material.
A composite member for a vehicle according to the invention of claim 2 is characterized in that the porous sheet material of claim 1 is made of a nonwoven fabric containing fibers of a thermoplastic resin. A vehicle composite member according to claim 3 is the vehicle composite member according to claim 1 or 2, wherein the impregnated hardened part is formed by impregnating the resin raw material from the outer surface of the flange on the inner surface side of the resin frame to the inside of the flange, Further, the single resin layer of the resin frame is laminated on the outer surface of the flange. The vehicle composite member according to claim 4 is the vehicle composite member according to claims 1 to 3, wherein the shape of the lid main portion in plan view is a substantially rectangular shape with notches provided at four corners thereof, and a plate that fills the notches It is characterized in that the piece portion is made of only the resin layer and integrally molded with the resin frame.
The gist of the invention according to claim 5 is that a recess for the lid main part is formed in one of the molds, on the cavity surface of which is formed a bottom surface that will be the shaping surface of the lid top surface related to the lid main part of the thin plate-shaped base material. and a slide mold that is freely movable back and forth with the front mold surface erected against the bottom surface on the four outer sides of the recess, and by clamping with the other mold, the cavity surface of the other mold and the recess, using an injection molding machine equipped with a pair of molds in which the cavity portion of the lid main portion is formed leaving a gap along the peripheral edge of the recess, the required base material is The porous sheet material cut to size is set in one of the molds so that the outer periphery protrudes from the recess forming the gap, and then clamped with the other mold, The lid main portion having a reduced thickness while maintaining a porous structure is molded, and then the front mold surface of the slide mold is advanced to make the outer peripheral portion stand up against the lid main portion and have a porous structure. After that, the front mold surface is retracted, and a resin raw material is injected into the cavity created by this retraction to impregnate the collar and harden it, and the lid A method of manufacturing a composite member for a vehicle is characterized in that a resin frame surrounding a main portion in a frame shape is molded. According to the sixth aspect of the invention, there is provided a method of manufacturing a composite member for a vehicle according to the fifth aspect, wherein the porous sheet material is a nonwoven fabric containing thermoplastic resin fibers. The method for manufacturing a composite member for a vehicle according to claim 7 is characterized in that, in claim 5 or 6, the mold clamping is performed on the other part facing the base region of the outer peripheral portion protruding from the recess forming the gap. A convex portion is provided on the cavity surface of the mold, and the lid main portion is molded by clamping the mold, and the convex portion bites into the base region to bias the outer peripheral portion to stand up against the lid main portion. characterized by

As in claims 1 and 5, when the brim extends by bending from the main lid portion and the brim portion stands up with respect to the main lid portion, the end of the brim portion bent with respect to the main lid portion is attached to the resin frame. Since it can be arranged near the peripheral end face of the frame, it becomes possible to avoid the injection pressure of the resin raw material. To stabilize the parting position between the lid main part and the brim part and prevent the peripheral edge of the lid main part from winding in its circumferential direction.

The vehicle composite member and the manufacturing method thereof according to the present invention eliminate variations in the parting position appearing on the design side of the product to improve quality, and since the parting position appears on the design surface of the product, it is also useful for improving yield. Excellent effect.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a composite member viewed from the back side in one embodiment of a composite member for a vehicle and a manufacturing method thereof according to the present invention; FIG. 2 is a sectional view taken along the line II-II of FIG. 1; FIG. 2 is a rear view of FIG. 1; FIG. 2 is a plan view of the porous sheet material used in FIG. 1; (A) is a partially enlarged view of FIG. 2, and (B) is another embodiment view replacing (A). Both (a) and (b) are alternative views in place of FIG. 5(a). FIG. 4 is an explanatory cross-sectional view showing the porous sheet material set in the mold with the mold opened. After FIG. 7, it is explanatory sectional drawing which clamped by one type|mold and the other type|mold. FIG. 9 is an explanatory cross-sectional view in which the slide mold is advanced after FIG. 8 and the outer peripheral portion is compressed; FIG. 10 is an explanatory cross-sectional view after FIG. 9 in which a cavity is formed by retreating the slide mold; After FIG. 10, it is explanatory sectional drawing which inject|poured a resin raw material and finished injection molding of the synthetic resin moldings. FIG. 8 is another aspect diagram that replaces FIG. 7 ; FIG. 9 is another aspect diagram that replaces FIG. 8 ; It is explanatory sectional drawing of a prior art. 1 is a partial cross-sectional view of a prior art; FIG. It is an explanatory image diagram of the conventional technology.

Hereinafter, a composite member for a vehicle (hereinafter also simply referred to as "composite member") according to the present invention and a method for manufacturing the same will be described in detail. 1 to 13 show an embodiment of the composite member of the present invention and its manufacturing method, wherein FIGS. 1 to 3 are a perspective view, a cross-sectional view of the main part, and a back view of the composite member, and FIG. 4 is a plan view of the porous sheet material. Figures, Figures 5 and 6, Figure 5 (a) is an enlarged view of Figure 2, the others are diagrams of other embodiments, Figure 7 is a cross-sectional view of the porous sheet material set in the mold, and Figure 8 is one mold 9 is a cross-sectional view in which the slide mold is advanced, FIG. 10 is a cross-sectional view in which the cavity is formed, FIG. 11 is a cross-sectional view in which the synthetic resin molded body is molded, FIG. , FIG. 13 shows another aspect diagram in place of FIGS. 7 and 8. FIG. Note that hatching for cross-section display is omitted from the base material 7 . In order to facilitate understanding, each drawing is simplified and the main part of the invention is emphasized.

(1) Method for manufacturing a composite member for a vehicle The composite member 6 is formed by reducing the sheet thickness of the porous sheet material 5 by mold clamping compression and forming the base material 7 into a three-dimensional sheet-like panel body. , a resin frame 81 that surrounds and retains the shape of a vehicle such as an automobile (FIG. 1). The composite member 6 is composed of a base material 7 in which the porous sheet material 5 is three-dimensionally shaped, and a flange portion 76 extends from the peripheral portion of the lid main portion 71 forming the lid top surface 71a to the lid inner surface 71b side. and a resin frame 81 integrally molded with the base material 7 to surround the periphery of the lid main portion 71 in a frame shape by impregnating and curing the resin raw material g in the collar portion 76 .
The composite member 6 of this embodiment is applied to the undercover of the instrument panel shown in FIGS. 1-3. The manufacturing method uses an injection molding machine 1 having a mold 2 as shown in FIGS. After setting the preheated porous sheet material 5 in one mold 3 , the molds are clamped with the other mold 4 to compress the porous sheet 5 in the plate thickness direction and shape it into the lid main portion 71 . Next, the slide mold 36f advances to mold the base material 7 having the collar portion 76 formed thereon, and then the resin frame 81 that retains and integrates the base material 7 is injection-molded to form the composite member 6. As shown in FIG.

Prior to the composite member manufacturing method, an injection molding machine 1 having a composite member mold 2 is prepared (FIG. 3).
The mold 2 of the injection molding machine 1 includes a pair of molds, one mold 3 (here, a fixed mold on the lower mold side) and the other mold 4 (here, a movable mold on the upper mold side). On the side of the fixed mold 3, the cavity surface 30 has a stepped bottom surface 311 which serves as a shaping surface of the lid top surface 71a related to the lid main portion 71 of the thin plate-like substrate 7 in the composite member 6. A part recess 31 is formed. A slide die 36f is provided on the four outer sides of the recess 31 so that the front die surface 361 is erected with respect to the bottom surface 311 (FIG. 7). Here, a hydraulic cylinder 36d is used for advancing and retreating the slide die 36f. When the fixed mold 3 and the movable mold 4 are clamped together, the cavity surface 401 (cavity surface 40) for the lid main part of the movable mold 4 and the recess 31 form an outer periphery of the porous sheet material along the periphery of the recess 31. A cavity portion C7 for the lid main portion 71 and a cavity portion C89 for the crosspiece 89 are formed leaving a gap ε corresponding to the cross section of the base region of the portion 56 (FIG. 8). A reference numeral 41 denotes a groove portion for the crosspiece 89 provided in the lid main portion cavity surface 401 of the movable mold 4 . After the porous sheet material 5 is set in the mold 2, the thin plate-like lid main portion 71 is shaped by clamping, and the collar portion 76 can be shaped by advancing the rod 36e of the slide mold 36f. After that, a synthetic resin raw material g (hereinafter also referred to simply as "resin raw material") is injected into the cavity C including the space S formed by retracting the slide mold 36f, and integrated with the base material 7 as shown in FIG. The resin frame 81, and more specifically, the synthetic resin molding 8 including the resin frame 81 and the crosspiece 89 can be molded.

The porous sheet material 5 is a sheet-like body having a porous structure obtained by cutting a porous sheet made of nonwoven fabric, foamed sheet, or the like into a size required for the base material 7 . The "sheet" of the porous sheet material 5 includes a thick plate-like material. The composite member 6 of this embodiment is substantially rectangular in plan view as shown in FIG. The lid main portion 71 is expanded. Therefore, as shown in FIG. 4, a lid main portion corresponding portion 51 having a rectangular shape in plan view and having notches 50 for the plate pieces 85 provided at the four corners, and extending from each long side of the lid main portion corresponding portion 51 in four directions. The porous sheet material 5 has a rectangular outer peripheral portion 56 for the existing collar portion 76 .
The porous sheet material 5 here is a nonwoven fabric containing fibers of a thermoplastic resin. The porous sheet material 5 is, for example, a nonwoven fabric containing fibers of a two-component composite thermoplastic resin in which a low-melting point material and a high-melting point material are mixed. There is a non-woven fabric having a sheath-core structure in which each fiber has a core made of a high-melting-point material and a sheath made of a low-melting-point material, and this embodiment adopts this. After the porous sheet material 5 made of the non-woven fabric is heated to soften the sheath, it is set in the mold 2 and clamped. The sheath at the heating temperature is thermally bonded, and the core is formed into a predetermined shape. can be shaped

The composite member 6 is manufactured using the injection molding machine 1 and the porous sheet material 5, for example, as follows. 7 to 11 used in the following description show respective manufacturing process diagrams in cross-sectional views taken along the line II-II in FIG.
First, with the mold 2 opened, the porous sheet material 5 softened by heating to a predetermined temperature is set on the fixed mold 3 on the lower mold side (FIG. 7). The lid main portion corresponding portion 51 of the porous sheet material 5 cut to the required size of the base material 7 is placed on the bottom surface 311 of the recess 31, and set so that the outer peripheral portion 56 protrudes from the portion forming the gap ε. . Here, the outer peripheral portion 56 protruding from the recess 31 is in a state of leaning against the front mold surface 361 of the slide mold 36f.

Next, the fixed mold 3 and the movable mold 4 are clamped to compress the porous sheet material 5 to reduce the thickness, and even if the porous structure is crushed to some extent, the porous structure is maintained. A portion 71 is molded (FIG. 8). Under mold clamping, the gap between the bottom surface 311 of the recess 31 and the cavity surface 401 for the lid main portion of the movable mold 4 facing it is set to be smaller than the thickness t1 of the porous sheet material 5, and the lid main portion 71 is formed. facilitates the molding of
The porous sheet material 5 is sandwiched between the cavity surface 40 of the movable mold 4, more specifically, the cavity surface 401 for the lid main portion and the cavity surface 30 of the recess 31 related to the fixed mold 3, and is compressed. The cover main portion corresponding portion 51 of the porous sheet material 5 having the initial thickness t1 is compressed in the thickness direction while leaving the porous structure for sound absorption, compression hardening progresses, and the thickness is reduced while forming the slope 61 shown in FIG. It is three-dimensionally formed into the lid main part 71 of t2. As the fixed mold 3 and the movable mold 4 are clamped together, the lid main part 71 is molded in the lid main part cavity part C7. In the region of the cutout 50 of the blank sheet material 5 there is still a void for the plate piece 85 .
In the present invention, a porous sheet material 5 having a sound absorbing function is used, and the porous sheet material is compressed to form a three-dimensional lid main portion 71 having an inclined surface 61 as shown in FIG. The sound absorbing function is still retained. The porous sheet material 5 here is a nonwoven fabric having a basis weight in the range of 300 g/m ² to 1,600 g/m ² . When PET is used for the core portion of the nonwoven fabric of the core-sheath structure fiber, the feeling of settling is small, and the shape retention of the base material 7 is excellent. The sheet-shaped non-woven fabric has heat-sealing properties in the sheath portion when heated, and while the entire thickness changes to t2, the core portion deforms into the three-dimensional shape of the lid main portion 71, and the temperature drops. It is shaped into a lid main part 71 that maintains a sound-absorbing porous structure. If a non-woven fabric using fibers with a core-sheath structure in which a low-melting-point PET sheath is arranged in a core of high-melting-point PET is used, the base material 7 becomes even less sag-like, and this embodiment also adopts this. do.

Subsequently, the front mold surface 361 of the slide mold 36f is advanced, and the outer peripheral portion 56 is erected to form the collar portion 76 by the front mold surface 361 and the resin frame cavity surface 406 of the movable mold 4. As shown in FIG. The resin frame cavity surface 406 is provided on the side wall of the movable mold 4 . The rod 36e is extended as shown by the white arrow in FIG. 8 to advance the slide die 36f. By this advance, the tilted outer peripheral portion 56 stands up and is further compressed while leaving a porous structure, and the collar portion 76 as shown in FIG. It is shaped so as to stand up with respect to the lid main portion 71 .
In this embodiment, as shown in FIG. 8, the slide die 36f is allowed to slide by contacting its lower surface with the horizontal die surface of the fixed die 3 following the recess 31. The lower surface of 36f moves back and forth on substantially the same plane as the cavity surface 401 for the lid main portion 71. As shown in FIG. Thus, the upright peripheral portion 56 is compressed in the thickness direction to reduce its thickness. A base material that is three-dimensionally formed from the porous sheet material 5 by leaving the peripheral edge of the lid main part 71 and standing up against the lid main part 71 at a place where the collar part 76 slightly enters the inside of the lid main part 71 from here. 7 is built (Fig. 9). Except for the notch 50 , the main cover portion 71 is buried in the entire bottom surface of the recess 31 , and the base material 7 having the flange portion 76 extending from the main cover portion 71 is formed. The peripheral edge of the lid main portion 71 projects outward from the flange portion 76 to form the outer peripheral edge of the composite member 6 in plan view, thereby forming the three-dimensionally shaped base material 7 .

However, even if the base material 7 is increased in strength by being compressed from the thickness t1 to the thickness t2 (FIG. 9), it is difficult to say that the three-dimensional shape maintaining the sound absorbing porous structure is robust. Even if a PET nonwoven fabric with a three-dimensional network structure, which does not feel sag, is used, the rigidity and mechanical strength required for the composite member 6 are insufficient.
In order to solve such a lack of strength, the present invention retracts the slide mold 36f while the fixed mold 3 and the movable mold 4 are clamped to remove the cavity portion C81 of the resin frame 81 in which the flange portion 76 is accommodated. Further, the resin raw material g is injected into the cavity portion C81 from the nozzle of the injection molding machine 1 through the runner 22 and the gate 21 (see FIG. 3), and the resin frame 81 for retaining the shape of the base material 7 is integrally molded. Adopt manufacturing method.

Specifically, after molding the base material 7 in FIG. 9, the front mold surface 361 of the slide mold 36f is retracted until the lower end of the front mold surface 361 substantially coincides with the peripheral edge of the lid main portion 71 (see FIG. 10). ). By this movement, a cavity portion C81 of the resin frame 81 in which the flange portion 76 is accommodated is formed, and a space S for the resin frame 81 that is not filled with the flange portion 76 is formed.
Here, in this embodiment, when the outer peripheral portion 56 of the porous sheet material 5 is set in the cavity portion C81 of the resin frame 81 and is moved from the outer peripheral portion 56 to the collar portion 76, the height exceeds the cavity portion C81 of the resin frame 81. I try not to be like that. Referring to FIG. 10, the space S is set above the collar portion 76 that is housed in the cavity portion C81 of the resin frame 81 . When the composite member 6 is completed, as shown in FIG. 5(a), the outer periphery of FIG. A height h of the portion 56 is set. Even if the outer peripheral height h increases due to a dimensional error, the outer peripheral edge 569, in other words, the position of the end 769 of the flange 76 reaches the frame peripheral end face 819 of the resin frame 81 shown in FIG. This is because up to

After that, the resin raw material g is injected into the space S (the cavity portion C81 of the resin frame 81), impregnated into the flange portion 76, and cured so that the lid main portion 71 is surrounded in a frame shape as shown in FIG. A resin frame 81 is molded. By clamping, a cavity portion C89 of the crosspiece 89 formed on the back surface 7b side of the base material 7 and a cavity C of an empty portion for the plate piece portion 85 still remaining in the lid main portion cavity portion C7 are formed. , a resin raw material g is injected into these cavities C to form a synthetic resin molding 8 . A raw material such as a polypropylene resin is used as the resin raw material g. A resin raw material g is injected into the cavity C through the gate 21 of FIG. The resin frame 81 and crosspieces 89 of the synthetic resin molding 8 bear the rigidity and mechanical strength that the base material 7 lacks.

In the cavity portion C81 for the resin frame 81 in which the collar portion 76 is accommodated, the injected resin raw material g fills the space S and impregnates into the collar portion 76 from the outer surface 76a of the collar portion 76 which maintains the porous structure. to form an impregnated hardened portion 812 . In the impregnating and curing portion 812, this is combined with the flange portion 76 to form a bonding layer F between the base material 7 and the resin frame 81, and the two are firmly integrated. A resin raw material g is injected into the space S, impregnated into the collar portion 76 and hardened, and a resin single layer 811 filling the space S is formed on the outer surface 76 a of the collar portion to surround the lid main portion 71 . A frame 81 is integrally formed.

As described above, the porous sheet material 5 has an outer peripheral portion 56 that closes the recess bottom surface 311 and has a terminal, except for the portion of the notch 50 , and the lid main portion 71 covers the entire recess bottom surface 311 . Since it is accommodated, the parting position between the resin frame 81 and the peripheral portion of the lid main portion 71 is not disturbed. In the cavity S (FIG. 10) accommodating the brim portion 76 extending upward from the main lid portion 71, the inner surface 71b of the main lid portion filling the bottom surface 311 of the recessed portion 311 is located downward. Since the resin raw material g is injected, the peripheral edge of the lid main portion 71 does not bend in its circumferential direction as shown in FIG.

Thus, the synthetic resin molded body 8 having the resin frame 81 for retaining the shape of the base material 7 and the crosspiece 89 is integrally molded. When the mold is removed after the integral molding, the resin frame 81 surrounds the base material 7 to retain the shape of the base material 7, and the desired composite member can be obtained without variation at the parting position between the resin frame 81 and the lid main part 71. 6 is obtained (Fig. 1, Fig. 2).
Reference numeral 36 denotes a slide device, reference numeral 36d denotes its cylinder, reference numeral 406 denotes a resin frame cavity surface in the movable mold 4, and reference numeral 42 denotes a biting projection, which prevents the resin raw material g from passing through the cavity portion C89 of the crosspiece 89 during molding of the crosspiece 89. It suppresses permeation into the lid main part 71 as necessary. A reference numeral 714 indicates a trace of a biting projection appearing on the lid main portion 71 .

FIGS. 12 and 13 show another aspect of the composite member 6 in place of FIGS. 7 and 8. FIG. By clamping the mold, a convex portion 402 is additionally formed on the cavity surface 40 of the movable mold 4 facing the base region of the outer peripheral portion 56 protruding from the portion of the recess 31 forming the gap ε. Referring to FIG. 13, the base region of the outer peripheral portion 56 forms a convex portion 402 that runs in the direction perpendicular to the plane of the drawing. A convex portion 402 is provided, and the lid main portion 71 is molded by clamping. It is configured to be biased to stand up. Other than that, the manufacturing method is the same as the present manufacturing method described with reference to FIGS. A composite member 6 is obtained.

(2) Composite member for vehicle A composite member for vehicle 6 (here, “instrument panel undercover”) obtained by the above-described manufacturing method shown in FIGS. (Figures 1 to 6).
The base material 7 is a three-dimensional sheet-like panel formed by shaping the single porous sheet material 5 while maintaining the porous structure. The porous sheet material 5 is three-dimensionally shaped by compressing the sheet thickness t1. While maintaining the porous structure, a flange portion 76 is bent from the peripheral portion of the lid main portion 71 forming the lid top surface 71 a toward the lid inner surface 71 b side, and the flange portion 76 extends from the lid main portion 71 . is the base material 7 which stood up. For example, the porous sheet material 5 is cut in advance to the size of the base material 7 as shown in FIG. In this embodiment, the lid main portion 71 has a substantially rectangular shape in plan view and has notches 50 at its four corners. The porous sheet material 5 is a piece of porous sheet material 5 having an extending outer peripheral portion 56 . The porous sheet material 5 is a nonwoven fabric containing fibers of a thermoplastic resin, the porous structure is maintained, the thickness t2 is made smaller than the initial thickness t1 of the nonwoven fabric, and the three-dimensional shape shown in FIGS. 1 and 2 is formed. It is assumed that the base material 7 is formed.

The resin frame 81 is a molded resin portion integrally formed with the base material 7 by forming an impregnated and cured portion 812 of the resin raw material g in the flange portion 76 to surround the periphery of the lid main portion 71 in a frame shape.
In the present embodiment, the composite member 6 is substantially rectangular in plan view, and the lid main portion 71 of the base material 7 is extended within the substantially rectangular resin frame 81 . A brim portion 76 bent and extended from the lid main portion 71 toward the lid inner surface 71b side and erected is arranged on the inner surface 81b side of the resin frame 81, and the resin frame 81 is integrally formed with the brim portion 76 (the base material 7). be done. Specifically, an impregnated and hardened portion 812 is formed by impregnating and curing the resin raw material g from the collar portion outer surface 76a to the collar portion 76 on the inner surface 81b side of the resin frame 81, and the resin single layer of the resin frame 81 is formed on the collar portion outer surface 76a. 811 is laminated.

The resin frame 81 is a constituent part of the synthetic resin molded body 8 which is formed by injection molding together with the plate piece portion 85 and the crosspiece 89, as described in (1) Manufacturing method of composite member for vehicle. By the injection molding, the resin frame 81, the plate piece portion 85, and the crosspiece 89 are combined and integrated.
The plate piece portion 85 is for attaching the composite member 6 to the mating member, and a through hole 850 is provided in the plate piece portion 85 . The shape of the lid main portion 71 in plan view is substantially rectangular with notches 50 provided at four corners thereof, and the plate piece portions 85 fill the notches 50 during the molding process of the composite member 6 . In the composite member 6 shown in FIGS. 1 and 2, the plate piece portion 85 filling the notch 50 forms the design surface 6a. The lid top surface 76a forms the design surface 6a.
The crosspieces 89 are strip plates that are erected in the strip width direction on the lid inner surface 71b side of the lid main portion 71 and arranged at a predetermined pitch (here, two strips), and are joined to the resin frame 81 at both ends. In FIG. 2, the lower end face of the strip plate raised in the band width direction abuts against the lid main portion 71, and the resin raw material g is impregnated into the lid main portion 71, which abuts during the injection molding of the crosspiece 89, and hardens to form a lid. The shape retention of the main portion 71 is reinforced.

Regarding the resin frame 81, as shown in FIG. The composite member 6 may be such that the end 769 of the flange portion 76 reaches the frame peripheral end face 819 of the resin frame single layer 811 as shown in FIG. 5(b). Conversely, even if the flange portion 76 becomes smaller, the height of the flange portion 76 will be lowered as shown in FIG. good too. Furthermore, a composite member 6 having a resin frame 81 as shown in FIG. Furthermore, as long as the resin frame 81 can be formed, although illustration is omitted, the collar portion outer surface 76a may reach the resin frame outer surface 81a.
The rest of the configuration is the same as the configuration described in (1) Manufacturing method of vehicle composite member, and the description thereof is omitted.

(3) Effect The vehicle composite member configured in this way and its manufacturing method leave the porous structure in the lid main portion 71 corresponding to the panel body portion, so that weight reduction is achieved and sound absorption characteristics are maintained.
Also, in the base material 7 having a flange 76 erected from the peripheral portion of the lid main portion 71, the resin raw material g is impregnated into the flange 76 and hardened to surround the lid main portion 71 in a frame shape. Since the resin frame 81 integrated with the flange portion 76 is provided, the shape of the base material 7 can be retained by the resin frame 81 . The resin frame 81 can complement the rigidity and mechanical strength of the base material 7 . Since the lid main part 71 of the base material 7 is assisted by the resin frame 81, it is not necessary to strongly compress the porous sheet material 5 to give the lid main part 71 and the base material 7 originally required strength. A resin frame 81 that surrounds and reinforces the periphery of the lid main portion 71 and a crosspiece 89 are integrally connected to the lid main portion 71 to complement the lack of rigidity and strength of the lid main portion 71 . Therefore, the base material 7 is not subject to strict restrictions on the rigidity and mechanical strength required for itself, and can be shaped from the porous sheet material 5 to achieve the desired weight reduction. can be made into the composite member 6 exhibiting the sound absorbing performance while maintaining the
In addition, after heating the porous sheet material 5 using the mold 2 as shown in FIG. , the resin raw material g is injected into the cavity C to mold the synthetic resin molding 8 such as the resin frame 81 and the beam 89, so that the manufacturing time of the composite member 6 can be shortened.

Then, a flange portion 76 extends from the peripheral edge portion of the lid main portion 71 toward the lid inner surface 71b side, and a resin frame 81 impregnated and cured with the resin raw material g is provided in the flange portion 76, and a bending line is formed. Since it can be divided at 53, it is possible to mold the resin frame 81 in which the impregnated hardened portion 812 is provided by concentrating on the collar portion 76. FIG. Impregnation of the resin raw material g to the lid main portion 71 side with the bend line 53 as a boundary can be suppressed. The parting position between the lid main part 71 and the resin frame 81 is not disturbed in the peripheral direction of the lid main part 71 . Quality improvement can be achieved by eliminating variations in the parting position appearing on the design surface 6a side of the product.
In particular, in the molding of the resin frame 81, when the flange end 769, which is also the outer peripheral edge 569, is positioned at the upper end of the flange 76 as shown in FIG. The fiber end 919 as seen in c) is not crushed to cause a problem. Further, in the molding process of the flange portion 76, the peripheral edge of the lid main portion 71 protrudes outward from the flange portion 76, and has already formed the outer peripheral edge of the composite member 6 in plan view (FIG. 10). The peripheral edge of the lid main portion 71 is not disturbed by the injection pressure of the resin raw material g into. In parallel with the formation of the single resin layer 811 with the resin raw material g injected into the space S, the bonding layer F is formed on the brim portion 76 connected to the lid main portion 71 . It regulates that the periphery is disturbed. Since the peripheral edge of the lid main part 71 protruding on the side of the design surface 6a of the composite member 6 has a uniform and smooth shape without winding in the circumferential direction, the quality is stabilized and the yield is improved.

When the porous sheet material 5 is made of a nonwoven fabric containing fibers of a thermoplastic resin, the lid main portion 71 and the collar portion 76 are three-dimensionalized using the injection molding machine 1 having the mold 2 as shown in FIG. The base material 7 can be easily shaped. When the porous sheet material 5 is made of a nonwoven fabric in which a low-melting point material and a high-melting point material are mixed, the nonwoven fabric is heated and then clamped. 71, the shape of the collar part 76 can be changed, and the shape can be easily maintained by the adhesiveness of the low-melting-point fiber material. When the nonwoven fabric of the core-sheath structure fiber is used, the sheath portion is made of a low-melting-point fiber and heat-sealed, so that the lid main portion 71 and the collar portion 76 having a porous structure can be smoothly shaped.
In addition, when an impregnation hardening portion 812 is formed on the inner surface 81b side of the resin frame 81 by impregnating the resin raw material g from the flange outer surface 76a into the flange portion 76, the impregnation hardening portion 812 hardens the flange portion 76 and the resin. Since the bonding layer F of the frame 81 is formed, the shape retention of the lid main portion 71 is reinforced by the resin frame 81 . In addition, when the single resin layer 811 of the resin frame 81 is laminated on the outer surface 76 a of the flange portion 76 , the space S can be used to smoothly inject the resin raw material g for the resin frame 81 . molding becomes easier. Since the resin frame outer surface 81a surrounding the lid main portion 71 is formed only of glossy resin, the appearance is improved. Moreover, using the mold 2 having the slide mold 36f, the composite member 6 can be smoothly manufactured through a series of operations from FIG. 7 to FIG. 11, which contributes to an improvement in productivity.

Further, the shape of the lid main portion 71 in a plan view is changed from a substantially rectangular shape to a shape in which notches 50 are provided at the four corners thereof, and the plate piece portion 85 filling the notches 50 is made of only the resin layer and integrated with the resin frame 81. When molded, by providing through holes 850 in the leaflet portion 85, the leaflet portion 85 can serve as a mounting plate for attaching the composite member 6 to a mating member.
Furthermore, if the design surface 6a other than the plate piece portion 85 is composed of the lid main portion 71, the entire design surface 6a of the composite member 6, except for the plate piece portion 85, can be replaced as shown in FIG. Since it is occupied by the portion 71, it is useful not only for weight reduction and excellent sound absorption characteristics but also for improving the appearance.

It should be noted that the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention according to the purpose and application. The shape, size, material, etc. of the porous sheet material 5 can be appropriately selected according to the application. In the present embodiment, the lid main portion 71 is formed into a three-dimensional shape having the slope 61, but the lid main portion 71 may have a planar shape instead of a three-dimensional shape. In the present embodiment, the porous sheet material 5 is heated and then shaped by the mold 2. However, if there is no problem in shaping the porous sheet material 5, heating may be omitted. Furthermore, in this embodiment, one mold 3 is fixed and the other mold 4 is movable, but one mold 3 may be movable and the other mold 4 may be fixed. Although the composite member 6 of the present embodiment is used as an undercover for an instrument panel, it can of course be applied to an engine undercover or the like.

1 injection molding machine 2 mold 3 one mold (fixed mold)
31 recess 36f slide mold 4 other mold (movable mold)
40 Cavity surface 402 Protruding portion 5 Porous sheet material 50 Notch 56 Peripheral portion 6 Composite member for vehicle (composite member)
7 base material 71 lid main part 76 collar part 81 resin frame 812 impregnation hardening part 85 plate piece part C7 cavity part of lid main part (cavity part for lid main part)

Claims (5)

A porous sheet material is three-dimensionally shaped, and a flange portion extends from a peripheral edge portion of a lid main portion that maintains a porous structure and forms a lid top surface, bending toward the lid inner surface side and extending to the lid main portion. a base material in which the collar portion stands up;
and a resin frame integrally formed with the base material, forming an impregnated and cured portion of resin raw material in the brim portion, surrounding the periphery of the lid main portion in a frame shape. Composite member. 2. A composite member for a vehicle according to claim 1, wherein said porous sheet material comprises a non-woven fabric containing thermoplastic resin fibers. The impregnation hardening part is formed on the inner surface side of the resin frame by impregnating the resin raw material from the outer surface of the flange into the flange, and the single resin layer of the resin frame is laminated on the outer surface of the flange. The vehicle composite member according to claim 1 or 2. The lid main part has a substantially rectangular plan view shape with notches at four corners thereof, and the plate pieces filling the notches are made of only the resin layer and are integrally formed with the resin frame. Item 4. The composite member for a vehicle according to any one of Items 1 to 3. One of the molds has, on its cavity surface, a recess for the lid main part formed with a bottom surface that serves as a shaping surface for the top surface of the lid relating to the lid main part of the thin plate-shaped base material, and on the four sides of the recess. has a slide mold whose front mold surface is erected against the bottom surface so as to be movable forward and backward, and when the mold is clamped with the other mold, the lid main portion is formed by the cavity surface of the other mold and the recess. Using an injection molding machine equipped with a mold consisting of a pair of molds in which the cavity portion of is formed leaving a gap along the periphery of the recess,
A porous sheet material cut to the required size of the base material is set in one of the molds so that the outer peripheral part protrudes from the part of the recess that forms the gap, and then the other mold is pressed. The mold is clamped to form the lid main portion with a reduced thickness while maintaining a porous structure, and then the front mold surface of the slide mold is advanced to make the outer peripheral portion stand up against the lid main portion, Then, the porous structure is left in the compressed collar portion, and then the front mold surface is retracted, and the resin raw material is injected into the void created by this retraction to impregnate and harden the collar portion. A method of manufacturing a composite member for a vehicle, characterized in that a resin frame is molded to surround the lid main portion in a frame shape.

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