JP7231439B2 - Resin molding and its manufacturing method - Google Patents

Resin molding and its manufacturing method Download PDF

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JP7231439B2
JP7231439B2 JP2019030555A JP2019030555A JP7231439B2 JP 7231439 B2 JP7231439 B2 JP 7231439B2 JP 2019030555 A JP2019030555 A JP 2019030555A JP 2019030555 A JP2019030555 A JP 2019030555A JP 7231439 B2 JP7231439 B2 JP 7231439B2
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優栄 田口
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Press Kogyo Co Ltd
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Description

本開示は、樹脂成形体及びその製造方法に関する。 TECHNICAL FIELD The present disclosure relates to resin moldings and methods of manufacturing the same.

一般に、車両のアンダーカバー等に用いられる樹脂成形体には、ポリプロピレン（ＰＰ）等の熱可塑性樹脂を含む成形材（以下、第１成形材）が用いられる。また、成形材としては、熱可塑性樹脂と複数の細孔とを含んだ成形材（以下、第２成形材）が知られている。 In general, a molding material (hereinafter referred to as a first molding material) containing a thermoplastic resin such as polypropylene (PP) is used for a resin molding used for a vehicle undercover or the like. Also, as a molding material, a molding material containing a thermoplastic resin and a plurality of pores (hereinafter referred to as a second molding material) is known.

特開２０１４－２８５１０号公報JP 2014-28510 A 特開２００６－３４２４３７号公報JP 2006-342437 A

上記の第１成形材は、第２成形材に比べて吸音性能が低い等の短所を有する。一方、第２成形材は、第１成形材に比べて強度が低い等の短所を有する。 The above-described first molding material has disadvantages such as lower sound absorbing performance than the second molding material. On the other hand, the second molded material has disadvantages such as lower strength than the first molded material.

他方、これらの問題を解消する手法としては、例えば、第１及び第２成形材の端部同士を重ね合わせて、リベット等の締結部材により接続し、第１成形材を介して第２成形材を車両等に固定することが考えられる。しかしながら、この接続方法では、第１及び第２成形材の接続部の強度を確保できない可能性がある。 On the other hand, as a method for solving these problems, for example, the ends of the first and second molded members are overlapped and connected by a fastening member such as a rivet, and the second molded member is connected through the first molded member. can be fixed to a vehicle or the like. However, with this connection method, there is a possibility that the strength of the connecting portion between the first and second molded members cannot be ensured.

そこで、本開示は、かかる事情に鑑みて創案され、その目的は、複数の成形材の端部同士を接続する接続部の強度を十分に確保できる樹脂成形体及びその製造方法を提供することにある。 Therefore, the present disclosure was created in view of such circumstances, and its object is to provide a resin molded body that can sufficiently secure the strength of the connection portion that connects the ends of a plurality of molded materials, and a method for manufacturing the same. be.

本開示の一の態様によれば、第１熱可塑性樹脂を含む第１成形材と、第２熱可塑性樹脂及び複数の細孔を含む第２成形材と、前記第１成形材の端部と前記第２成形材の端部とが突き合わされて固着されてなる接合部と、を備えることを特徴とする樹脂成形体が提供される。 According to one aspect of the present disclosure, a first molded material comprising a first thermoplastic resin, a second molded material comprising a second thermoplastic resin and a plurality of pores, and an end portion of the first molded material A resin molded body is provided, comprising: a joint portion formed by abutting and fixing an end portion of the second molding material.

好ましくは、前記接合部においては、前記第１熱可塑性樹脂が前記複数の細孔に充填されている。 Preferably, in the joint, the first thermoplastic resin fills the plurality of pores.

また、前記第１成形材は、第１強化繊維を含み、前記第２成形材は、第２強化繊維と、前記第２熱可塑性樹脂及び前記第２強化繊維を覆う表皮材と、を含み、前記第１熱可塑性樹脂及び前記第１強化繊維は、前記第２熱可塑性樹脂及び前記第２強化繊維にそれぞれ固着している。 Further, the first molding material includes first reinforcing fibers, and the second molding material includes second reinforcing fibers, and a skin material covering the second thermoplastic resin and the second reinforcing fibers, The first thermoplastic resin and the first reinforcing fibers are fixed to the second thermoplastic resin and the second reinforcing fibers, respectively.

また、前記第１成形材は、前記第１熱可塑性樹脂からなる第１樹脂層と、前記第１強化繊維からなる強化繊維層とが積層された第１シートにより形成され、前記第２成形材は、前記第２熱可塑性樹脂、前記複数の細孔及び前記第２強化繊維を含む第２樹脂層と、前記第２樹脂層の表面及び裏面にそれぞれ貼設された表側表皮材及び裏側表皮材と、を有する第２シートにより形成され、前記接合部においては、前記第１樹脂層及び前記強化繊維層が、前記表側表皮材と裏側表皮材との間で前記第２樹脂層に固着している。 Further, the first molding material is formed of a first sheet in which a first resin layer made of the first thermoplastic resin and a reinforcing fiber layer made of the first reinforcing fiber are laminated, and the second molding material is a second resin layer containing the second thermoplastic resin, the plurality of pores and the second reinforcing fibers, and a front side skin material and a back side skin material respectively attached to the front surface and the back surface of the second resin layer. and, at the joint portion, the first resin layer and the reinforcing fiber layer are fixed to the second resin layer between the front side skin material and the back side skin material there is

本開示の一の態様によれば、第１熱可塑性樹脂を含む第１成形材と、第２熱可塑性樹脂及び複数の細孔を含む第２成形材と、前記第１成形材の端部と前記第２成形材の端部とが突き合わされて固着されてなる接合部と、を備えた樹脂成形体の製造方法であって、前記第１成形材を加熱して軟化させる第１成形材加熱行程と、前記第２成形材を加熱して軟化及び膨張させる第２成形材加熱行程と、軟化された前記第１成形材の端部と軟化及び膨張された前記第２成形材の端部とを突き合わせて固着させることで、前記接合部を形成する接合工程と、を備えることを特徴とする樹脂成形体の製造方法が提供される。 According to one aspect of the present disclosure, a first molded material comprising a first thermoplastic resin, a second molded material comprising a second thermoplastic resin and a plurality of pores, and an end portion of the first molded material A method for manufacturing a resin molding comprising: a joint portion formed by abutting and fixing an end portion of the second molding material, wherein the first molding material is heated to soften the first molding material. a heating step of heating the second molding material to soften and expand the second molding material; the softened end portion of the first molding material and the softened and expanded end portion of the second molding material; and a joining step of forming the joining portion by abutting and fixing.

好ましくは、前記接合工程においては、前記第１熱可塑性樹脂を前記複数の細孔に充填させる。 Preferably, in the bonding step, the plurality of pores are filled with the first thermoplastic resin.

また、前記接合工程は、軟化された前記第１成形材と、軟化及び膨張された第２成形材とを、プレス金型内に横並びに配置する配置工程と、前記プレス金型により前記第１及び第２成形材を縦方向に加圧して、前記第１成形材を流動させ、その後、前記第１成形材の端部を前記第２成形材の端部に固着させる加圧工程と、を含む。 Further, the joining step includes a placement step of arranging the softened first molding material and the softened and expanded second molding material side by side in a press mold, and and a pressurizing step of applying pressure to the second molded material in the vertical direction to cause the first molded material to flow, and then fixing the end of the first molded material to the end of the second molded material. include.

また、前記第１成形材は、第１強化繊維を含み、前記第２成形材は、第２強化繊維と、前記第２熱可塑性樹脂及び前記第２強化繊維を覆う表皮材と、を含み、前記加圧工程においては、前記第１熱可塑性樹脂及び前記第１強化繊維を、前記第２熱可塑性樹脂及び前記第２強化繊維にそれぞれ固着させる。 Further, the first molding material includes first reinforcing fibers, and the second molding material includes second reinforcing fibers, and a skin material covering the second thermoplastic resin and the second reinforcing fibers, In the pressing step, the first thermoplastic resin and the first reinforcing fibers are fixed to the second thermoplastic resin and the second reinforcing fibers, respectively.

また、前記第１成形材は、前記第１熱可塑性樹脂からなる第１樹脂層と、前記第１強化繊維からなる強化繊維層とが積層された第１シートにより形成され、前記第２成形材は、前記第２熱可塑性樹脂、前記複数の細孔及び前記第２強化繊維を含む第２樹脂層と、前記第２樹脂層の表面及び裏面にそれぞれ貼接された表側表皮材及び裏側表皮材と、を有する第２シートにより形成され、前記加圧工程においては、前記第１及び第２成形材の端部同士を固着させる際に、前記第１樹脂層及び前記強化繊維層を、前記表側表皮材と裏側表皮材との間で前記第２樹脂層に固着させる。 Further, the first molding material is formed of a first sheet in which a first resin layer made of the first thermoplastic resin and a reinforcing fiber layer made of the first reinforcing fiber are laminated, and the second molding material is a second resin layer containing the second thermoplastic resin, the plurality of pores and the second reinforcing fibers, and a front side skin material and a back side skin material respectively attached to the front surface and the back surface of the second resin layer. and, in the pressing step, when the ends of the first and second molding materials are fixed together, the first resin layer and the reinforcing fiber layer are placed on the front side It is fixed to the second resin layer between the skin material and the back skin material.

また、前記加圧工程においては、前記第１及び第２成形材の端部同士を固着させると共に、前記プレス金型の型形状に合わせて前記第１及び第２成形材を成形する。 Further, in the pressing step, the ends of the first and second molding materials are fixed together, and the first and second molding materials are molded according to the shape of the press mold.

本開示に係る樹脂成形体及びその製造方法によれば、複数の成形材の端部同士を接続する接続部の強度を十分に確保できる。 According to the resin molded article and the manufacturing method thereof according to the present disclosure, it is possible to sufficiently secure the strength of the connecting portion that connects the ends of the plurality of molding materials.

樹脂成形体の概略断面図である。It is a schematic sectional drawing of a resin molding. 図１に示した左側の樹脂成形体の拡大断面図である。FIG. 2 is an enlarged cross-sectional view of the resin molding on the left side shown in FIG. 1; 第１成形材の材質を示す拡大断面図である。FIG. 4 is an enlarged cross-sectional view showing the material of the first molding material; 第２成形材の材質を示す拡大断面図である。FIG. 4 is an enlarged cross-sectional view showing the material of the second molding material; 図４に示した第２樹脂層の拡大斜視図である。FIG. 5 is an enlarged perspective view of a second resin layer shown in FIG. 4; 樹脂成形体の製造方法を示す工程図である。It is process drawing which shows the manufacturing method of a resin molding. 配置工程を示す概略断面図である。It is a schematic sectional drawing which shows an arrangement|positioning process. 加圧工程を示す概略断面図である。It is a schematic sectional drawing which shows a pressurization process. 加圧する前の状態を示す拡大断面図である。It is an expanded sectional view which shows the state before pressurization. 加圧する途中の状態を示す拡大断面図である。It is an expanded sectional view which shows the state in the middle of pressurizing. 加圧した後の状態を示す拡大断面図である。It is an enlarged cross-sectional view showing a state after pressurization. 変形例を示す樹脂成形体の拡大断面図である。It is an enlarged cross-sectional view of a resin molded body showing a modification.

以下、添付図面を参照して本開示の実施形態を説明する。なお、図中に示す各方向は、説明の便宜上定められたものに過ぎないものとする。 Embodiments of the present disclosure will be described below with reference to the accompanying drawings. It should be noted that each direction shown in the drawing is merely defined for convenience of explanation.

先ず、図１～図５を参照して、本実施形態の樹脂成形体１００の構造について説明する。 First, referring to FIGS. 1 to 5, the structure of the resin molding 100 of this embodiment will be described.

図１に示すように、樹脂成形体１００は、車両のエンジン（不図示）を下側から覆うアンダーカバーである。本実施形態の車両は、キャブオーバ型トラックであり、図中に示す一点鎖線Ｍ１，Ｍ２は、キャブを支持する左右一対のサイドメンバである。但し、樹脂成形体１００は、アンダーカバー以外の製品（例えば、騒音カバー）であっても良い。 As shown in FIG. 1, the resin molded body 100 is an undercover that covers an engine (not shown) of a vehicle from below. The vehicle of this embodiment is a cab-over type truck, and dashed-dotted lines M1 and M2 shown in the figure are a pair of left and right side members that support the cab. However, the resin molding 100 may be a product other than the undercover (for example, a noise cover).

また、樹脂成形体１００は、第１成形材としての第１シート１０と、第２成形材としての第２シート２０と、第１シート１０及び第２シート２０を接合する接合部３０と、を備える。詳細は後述するが、第１シート１０には、熱可塑性プラスチックをガラス長繊維で補強した非多孔質のスタンパブルシート（ＧＭＴ：Ｇｌａｓｓ－Ｍａｔ ｒｅｉｎｆｏｒｃｅｄ Ｔｈｅｒｍｏｐｌａｓｔｉｃｓ）が用いられる。また、第２シート２０には、熱可塑性プラスチック及びガラス短繊維を含む多孔質のスタンパブルシートが用いられる。 In addition, the resin molding 100 includes a first sheet 10 as a first molding material, a second sheet 20 as a second molding material, and a joint portion 30 that joins the first sheet 10 and the second sheet 20. Prepare. Although the details will be described later, the first sheet 10 is a non-porous stampable sheet (GMT: Glass-Mat reinforced Thermoplastics) in which thermoplastic plastic is reinforced with long glass fibers. A porous stampable sheet containing thermoplastic and short glass fibers is used for the second sheet 20 .

第２シート２０は、車両のエンジンの下側を覆うように左右方向に延びて、左右のサイドメンバＭ１，Ｍ２の間の位置に配置される。第１シート１０は、第２シート２０の左右の両側にそれぞれ設けられる。左側の第１シート１０は、第２シート２０と左側のサイドメンバＭ１とを連結し、右側の第１シート１０は、第２シート２０と右側のサイドメンバＭ２とを連結する。なお、本実施形態の樹脂成形体１００は、左右対称の構造である。よって、以下では、左側の第１シート１０、第２シート２０、及び接合部３０について説明し、右側については説明を省略する。 The second seat 20 extends in the left-right direction so as to cover the lower side of the engine of the vehicle, and is arranged between the left and right side members M1 and M2. The first seat 10 is provided on both left and right sides of the second seat 20, respectively. The left first seat 10 connects the second seat 20 and the left side member M1, and the right first seat 10 connects the second seat 20 and the right side member M2. In addition, the resin molding 100 of this embodiment has a symmetrical structure. Therefore, the first sheet 10, the second sheet 20, and the joint portion 30 on the left side will be described below, and the description on the right side will be omitted.

図２に示すように、左側の第１シート（以下、単に「第１シート」）１０は、板状に形成され、右端から左端にかけて略クランク状に曲折された断面形状を有する。第１シート１０は、水平方向に延びる右側端部１１と、右側端部１１の左端から左斜め上方に延びる中間部１２と、中間部１２の左端から左方向に水平に延びる左側端部１３と、を一体的に有する。左側端部１３は、点線で示すボルトＣ１及びナットＣ２を用いて、左側のサイドメンバＭ１の下端部に固定される。 As shown in FIG. 2, the left first seat (hereinafter simply referred to as "first seat") 10 is formed in a plate shape and has a cross-sectional shape that is bent in a substantially crank shape from the right end to the left end. The first seat 10 has a right end portion 11 extending horizontally, an intermediate portion 12 extending obliquely upward to the left from the left end of the right end portion 11, and a left end portion 13 extending horizontally leftward from the left end of the intermediate portion 12. , integrally. The left end portion 13 is fixed to the lower end portion of the left side member M1 using a bolt C1 and a nut C2 indicated by dotted lines.

第１シート１０は、軽量で且つ強度を確保できる板厚に設定される。例えば、右側端部１１及び中間部１２の板厚は、２～３ｍｍであり、左側端部１３の板厚は、４～５ｍｍである。 The thickness of the first sheet 10 is set so that it is lightweight and has sufficient strength. For example, the plate thickness of the right end portion 11 and the intermediate portion 12 is 2 to 3 mm, and the plate thickness of the left end portion 13 is 4 to 5 mm.

第２シート２０は、板状に形成され、左右方向に延びる直線状の断面形状を有する。また、第２シート２０は、主に吸音性能を確保できる板厚（例えば、５～８ｍｍ）に設定される。但し、第２シート２０の左側端部２１は、第１シート１０の右側端部１１と同じ板厚（例えば、２～３ｍｍ）に設定される。 The second sheet 20 is formed in a plate shape and has a linear cross-sectional shape extending in the left-right direction. Also, the second sheet 20 is set to have a plate thickness (for example, 5 to 8 mm) that can mainly ensure sound absorption performance. However, the left end portion 21 of the second sheet 20 is set to have the same plate thickness (for example, 2 to 3 mm) as the right end portion 11 of the first sheet 10 .

接合部３０は、第１シート１０の右側端部１１と第２シート２０の左側端部２１とが突き合わされて固着されてなる。 The joint portion 30 is formed by abutting and fixing the right end portion 11 of the first sheet 10 and the left end portion 21 of the second sheet 20 .

図３は、第１シート１０の材質を説明するための拡大断面図であり、図４及び図５は、第２シート２０の材質を説明するための拡大断面図及び拡大斜視図である。なお、図３（ａ）及び図４（ａ）は、後述する加熱工程における加熱前の状態を示し、図３（ｂ）及び図４（ｂ）は、加熱後の状態を示す。 3 is an enlarged sectional view for explaining the material of the first sheet 10, and FIGS. 4 and 5 are an enlarged sectional view and an enlarged perspective view for explaining the material of the second sheet 20. FIG. 3(a) and 4(a) show the state before heating in the heating step described later, and FIGS. 3(b) and 4(b) show the state after heating.

図３に示すように、第１シート１０は、第１熱可塑性樹脂１４と、第１強化繊維１５と、を含む。第１熱可塑性樹脂１４には、ポリプロピレン（ＰＰ）等の熱可塑性プラスチックが用いられる。第１強化繊維１５には、ガラス長繊維が用いられる。但し、第１強化繊維１５は、ガラス短繊維であっても良く、また、ガラス材料でなくても良い。 As shown in FIG. 3 , the first sheet 10 includes a first thermoplastic resin 14 and first reinforcing fibers 15 . A thermoplastic such as polypropylene (PP) is used for the first thermoplastic resin 14 . Long glass fibers are used for the first reinforcing fibers 15 . However, the first reinforcing fibers 15 may be short glass fibers, and may not be made of a glass material.

また、本実施形態の第１シート１０は、第１熱可塑性樹脂１４からなるシート状の第１樹脂層Ａ１と、第１強化繊維１５からなるシート状の強化繊維層Ａ２とが積層されてなる。本実施形態では、第１樹脂層Ａ１は、３層からなり、強化繊維層Ａ２は、第１樹脂層Ａ１の各層の間に挟まれた２層からなる。 The first sheet 10 of the present embodiment is formed by laminating a sheet-like first resin layer A1 made of the first thermoplastic resin 14 and a sheet-like reinforcing fiber layer A2 made of the first reinforcing fibers 15. . In this embodiment, the first resin layer A1 consists of three layers, and the reinforcing fiber layer A2 consists of two layers sandwiched between each layer of the first resin layer A1.

図４及び図５に示すように、第２シート１０は、第２熱可塑性樹脂２２と、複数の細孔２３と、第２強化繊維２４と、を含む。また、第２シート１０は、第２熱可塑性樹脂２２及び第２強化繊維２４を覆う表皮材２５ａ，２５ｂを含む。第２熱可塑性樹脂２２には、ポリプロピレン（ＰＰ）等の熱可塑性プラスチックが用いられる。第２強化繊維２４には、ガラス短繊維が用いられる。また、表皮材２５ａ，２５ｂには、不織布が用いられる。但し、第１強化繊維１５は、ガラス長繊維であっても良く、また、ガラス素材以外の材質であっても良い。また、表皮材２５ａ，２５ｂは、不織布以外の素材であっても良い。 As shown in FIGS. 4 and 5, the second sheet 10 includes a second thermoplastic resin 22, multiple pores 23, and second reinforcing fibers 24. As shown in FIGS. The second sheet 10 also includes skin materials 25 a and 25 b that cover the second thermoplastic resin 22 and the second reinforcing fibers 24 . A thermoplastic such as polypropylene (PP) is used for the second thermoplastic resin 22 . Short glass fibers are used for the second reinforcing fibers 24 . A non-woven fabric is used for the skin materials 25a and 25b. However, the first reinforcing fibers 15 may be long glass fibers, or may be made of a material other than a glass material. Also, the skin materials 25a and 25b may be made of a material other than the nonwoven fabric.

本実施形態の第２シート２０は、第２熱可塑性樹脂２２の中に複数の細孔２３及び第２強化繊維２４を混入させてなる第２樹脂層Ｂと、第２樹脂層Ｂの表面及び裏面に貼設された表側表皮材２５ａ及び裏側表皮材２５ｂと、を有する。 The second sheet 20 of this embodiment includes a second resin layer B formed by mixing a plurality of pores 23 and second reinforcing fibers 24 in a second thermoplastic resin 22, the surface of the second resin layer B and It has a front side skin material 25a and a back side skin material 25b attached to the back side.

第２樹脂層Ｂにおいては、互いに絡み合った第２強化繊維２４の隙間により複数の細孔２３が画成され、また、第２強化繊維２４に第２熱可塑性樹脂２２が付着されている。これにより、第２樹脂層Ｂは、全体として多孔質に形成される。 In the second resin layer B, a plurality of pores 23 are defined by gaps between the second reinforcing fibers 24 that are entangled with each other, and the second thermoplastic resin 22 is adhered to the second reinforcing fibers 24 . Thereby, the second resin layer B is formed to be porous as a whole.

図２に示すように、接合部３０においては、第１樹脂層Ａ１の第１熱可塑性樹脂１４と強化繊維層Ａ２の第１強化繊維１５とが、表側表皮材２５ａと裏側表皮材２５ｂとの間で、第２樹脂層Ｂの第２熱可塑性樹脂２２及び第２強化繊維２４にそれぞれ固着している。また、詳細は後述するが、第１熱可塑性樹脂１４は、複数の細孔２３に充填されて、第１強化繊維１５は、第２強化繊維２４に絡み合っている。 As shown in FIG. 2 , at the joint 30, the first thermoplastic resin 14 of the first resin layer A1 and the first reinforcing fibers 15 of the reinforcing fiber layer A2 are formed between the front side skin material 25a and the back side skin material 25b. Between them, they are fixed to the second thermoplastic resin 22 and the second reinforcing fibers 24 of the second resin layer B, respectively. Although details will be described later, the first thermoplastic resin 14 is filled in the plurality of pores 23 , and the first reinforcing fibers 15 are entangled with the second reinforcing fibers 24 .

なお、本実施形態では、表側表皮材２５ａと第１シート１０の端部１１の上面とが面一になり、また、裏側表皮材２５ｂと第１シート１０の端部１１の下面とが面一になっている。そのため、綺麗な表面形状が形成され、美感が向上される。 In this embodiment, the front skin material 25a and the upper surface of the end portion 11 of the first sheet 10 are flush with each other, and the back surface skin material 25b and the lower surface of the end portion 11 of the first sheet 10 are flush. It has become. Therefore, a beautiful surface shape is formed, and the beauty is improved.

次に、樹脂成形体１００の製造方法について説明する。図６は、樹脂成形体１００の製造方法を示す工程図である。 Next, a method for manufacturing the resin molding 100 will be described. 6A to 6D are process diagrams showing a method of manufacturing the resin molded body 100. FIG.

図６に示すように、樹脂成形体１００の製造方法は、第１シート１０を製造する第１成形材製造行程Ｓ１と、第２シート２０を製造する第２シート製造行程Ｓ２と、を備える。また、樹脂成形体１００の製造方法は、製造された第１シート１０を加熱して軟化させる第１成形材加熱行程Ｓ３と、製造された第２シート２０を加熱して軟化及び膨張させる第２成形材加熱行程Ｓ４と、を備える。 As shown in FIG. 6 , the method for manufacturing the resin molded body 100 includes a first molded material manufacturing process S1 for manufacturing the first sheet 10 and a second sheet manufacturing process S2 for manufacturing the second sheet 20 . Further, the method for manufacturing the resin molded body 100 includes a first molding material heating step S3 in which the manufactured first sheet 10 is heated and softened, and a second molded material heating step S3 in which the manufactured second sheet 20 is heated to soften and expand. and a molding material heating step S4.

また、図６～図８に示すように、樹脂成形体１００の製造方法は、プレス金型４０内で接合部３０を形成する接合工程Ｓ５と、接合部３０が形成された樹脂成形体１００をプレス金型４０から取り出す取り出し工程Ｓ６と、を備える。 Further, as shown in FIGS. 6 to 8, the method for manufacturing the resin molded body 100 includes a bonding step S5 for forming the joint portion 30 in the press die 40, and the resin molded body 100 in which the joint portion 30 is formed. and a take-out step S6 of taking out from the press die 40 .

第１成形材製造行程Ｓ１においては、図３（ａ）に示したように、第１樹脂層Ａ１と強化繊維層Ａ２を下方から順に交互に重ねて積層することで、第１シート１０を完成させる。 In the first molded material manufacturing step S1, as shown in FIG. 3A, the first sheet 10 is completed by alternately stacking the first resin layer A1 and the reinforcing fiber layer A2 from below. Let

第２成形材製造行程Ｓ２においては、図４（ａ）に示した構造の第２樹脂層Ｂの表面に表側表皮材２５ａを貼設し、また、第２樹脂層Ｂの裏面に裏側表皮材２５ｂを貼設することで、第２シート２０を完成させる。 In the second molded material manufacturing step S2, the front surface skin material 25a is attached to the surface of the second resin layer B having the structure shown in FIG. The second sheet 20 is completed by pasting 25b.

第１成形材加熱行程Ｓ３においては、第１成形材製造行程Ｓ１により製造された図３（ａ）に示す第１シート１０を、例えばヒータ（不図示）で所定の軟化温度（例えば、２００℃）にまで加熱する。これにより、図３（ｂ）に示すように、第１シート１０の第１樹脂層Ａ１が軟化される。 In the first molding material heating process S3, the first sheet 10 shown in FIG. 3A manufactured in the first molding material manufacturing process S1 is heated to a predetermined softening temperature (for example, 200° C.) by, for example, a heater (not shown). ). As a result, the first resin layer A1 of the first sheet 10 is softened, as shown in FIG. 3(b).

第２成形材加熱行程Ｓ４においては、第２成形材製造行程Ｓ２により製造された図４（ａ）に示す第２シート２０を、例えばヒータ（不図示）で所定の軟化温度（例えば、２００℃）にまで加熱する。これにより、図４（ｂ）に示すように、第２シート２０の第２樹脂層Ｂが軟化される。また、細孔２３内の空気が熱膨張することで、細孔２３が拡がり、その結果、第２樹脂層Ｂ全体が厚さ方向に膨張する。これにより、第２シート２０は、板厚が１０ｍｍ程度になるまで膨張される。 In the second molding material heating step S4, the second sheet 20 shown in FIG. 4(a) manufactured in the second molding material manufacturing step S2 is heated to a predetermined softening temperature (eg, 200° C.) by, for example, a heater (not shown). ). As a result, the second resin layer B of the second sheet 20 is softened, as shown in FIG. 4(b). Further, the air in the pores 23 expands due to thermal expansion of the pores 23, and as a result, the entire second resin layer B expands in the thickness direction. As a result, the second sheet 20 is expanded to a thickness of approximately 10 mm.

接合工程Ｓ５においては、図７及び図８に示すように、軟化された第１シート１０の端部１１と軟化及び膨張された第２シート２０の端部２１とを突き合わせて固着させる。 In the joining step S5, as shown in FIGS. 7 and 8, the softened end portion 11 of the first sheet 10 and the softened and expanded end portion 21 of the second sheet 20 are butted and fixed.

具体的には、接合工程Ｓ５は、図６に示すように、第１成形材加熱行程Ｓ３により軟化された第１シート１０と、第２成形材加熱行程Ｓ４により軟化及び膨張された第２シート２０とを、プレス金型４０内に横並びに配置する配置工程Ｓ５ａを含む。また、接合工程Ｓ５は、プレス金型４０により第１シート１０及び第２シート２０を縦方向すなわち厚さ方向に加圧して、第１シート１０を流動させ、その後、第１シート１０の端部１１を第２シート２０の端部２１に固着させる加圧工程Ｓ５ｂを含む。 Specifically, as shown in FIG. 6, in the joining step S5, the first sheet 10 softened in the first molding material heating step S3 and the second sheet softened and expanded in the second molding material heating step S4 20 side by side in the press die 40. In the joining step S5, the press die 40 presses the first sheet 10 and the second sheet 20 in the vertical direction, ie, the thickness direction, to flow the first sheet 10, and then the end portion of the first sheet 10 is pressed. 11 to the end portion 21 of the second sheet 20.

図７に示すように、プレス金型４０は、樹脂成形体１００の製品形状（図１を参照）に合わせて形成された上型４１及び下型４２を含む。 As shown in FIG. 7, the press die 40 includes an upper die 41 and a lower die 42 formed to match the product shape of the resin molded body 100 (see FIG. 1).

配置工程Ｓ５ａにおいては、下型４２の左右方向の中央部分に第２シート２０を載置し、下型４２の左右の両端部に第１シート１０をそれぞれ載置する。第１シート１０と第２シート２０とは、互いに間隔を空けて配置される。本実施形態のプレス金型４０は、左右対称の構造であるので、以下では、左側のプレス金型４０を参照して加圧工程Ｓ５ｂを説明し、右側については説明を省略する。 In the placement step S5a, the second sheet 20 is placed on the center portion of the lower mold 42 in the left-right direction, and the first sheets 10 are placed on both left and right end portions of the lower mold 42, respectively. The first sheet 10 and the second sheet 20 are spaced apart from each other. Since the press die 40 of this embodiment has a bilaterally symmetrical structure, the pressurizing step S5b will be described below with reference to the press die 40 on the left side, and the description on the right side will be omitted.

図９及び図１０に示すように、加圧工程Ｓ５ｂにおいては、上型４１を下降させて、第１シート１０及び第２シート２０を厚さ方向に加圧する。これにより、第１シート１０は、上型４１と下型４２との間で押し潰されて、第２シート２０に向かって右側に流動すると共に、第２シート２０よりも左側に位置するプレス金型４０内に充填される。 As shown in FIGS. 9 and 10, in the pressing step S5b, the upper die 41 is lowered to press the first sheet 10 and the second sheet 20 in the thickness direction. As a result, the first sheet 10 is crushed between the upper die 41 and the lower die 42 and flows to the right toward the second sheet 20, and the press metal positioned to the left of the second sheet 20 is pressed. It is filled in the mold 40 .

また、図１１に示すように、加圧工程Ｓ５ｂにおいては、樹脂成形体１００の製品形状が成形される位置まで上型４１を下降させる。これにより、第１シート１０及び第２シート２０が更に押し潰されて、第１シート１０の右側端部１１が第２シート２０の左側端部２１に固着される。そして、この状態でプレス金型４０を放置して冷却することで、第１及び第２シート１０，２０が冷却、硬化され、第１及び第２シート１０，２０の端部１１，２１同士の固着が終了する。 Further, as shown in FIG. 11, in the pressurizing step S5b, the upper mold 41 is lowered to a position where the product shape of the resin molded body 100 is molded. As a result, the first sheet 10 and the second sheet 20 are further crushed, and the right edge 11 of the first sheet 10 is fixed to the left edge 21 of the second sheet 20 . By leaving the press die 40 to cool in this state, the first and second sheets 10 and 20 are cooled and hardened, and the ends 11 and 21 of the first and second sheets 10 and 20 are separated from each other. Sticking ends.

固着の際、第１熱可塑性樹脂１４及び第１強化繊維１５は、第２熱可塑性樹脂２２及び第２強化繊維２４にそれぞれ固着される。また、第１熱可塑性樹脂１４は、第２熱可塑性樹脂２２及び第２強化繊維２４に固着するときに、複数の細孔２３に入り込んで充填される。そして、第１強化繊維１５は、第２強化繊維２４に絡み合って固定され、アンカー効果を生じさせる。これにより、第１及び第２シート１０，２０の端部１１，２１同士が強固に接合される。 During fixing, the first thermoplastic resin 14 and the first reinforcing fibers 15 are fixed to the second thermoplastic resin 22 and the second reinforcing fibers 24, respectively. Further, when the first thermoplastic resin 14 adheres to the second thermoplastic resin 22 and the second reinforcing fibers 24 , the first thermoplastic resin 14 enters and fills the plurality of pores 23 . The first reinforcing fibers 15 are entangled with and fixed to the second reinforcing fibers 24 to produce an anchor effect. As a result, the ends 11 and 21 of the first and second sheets 10 and 20 are firmly joined together.

また、加圧工程Ｓ５ｂにおいては、第１及び第２シート１０，２０の端部１１，２１同士を固着させると共に、プレス金型４０の型形状に合わせて第１及び第２シート１０，２０を成形する。これにより、樹脂成形体１００の製品形状が成形される。 In the pressurizing step S5b, the ends 11 and 21 of the first and second sheets 10 and 20 are fixed together, and the first and second sheets 10 and 20 are pressed in accordance with the shape of the press die 40. to mold. Thereby, the product shape of the resin molding 100 is molded.

取り出し工程Ｓ６においては、プレス金型４０を開いて、製品形状に成形された樹脂成形体１００を取り出す。 In the take-out step S6, the press die 40 is opened to take out the resin molding 100 molded into the product shape.

次に、本実施形態に係る樹脂成形体１００及びその製造方法の作用効果を説明する。 Next, the effects of the resin molding 100 and the manufacturing method thereof according to this embodiment will be described.

一般的に、車両のアンダーカバー等に用いられる樹脂成形体は、上述した第１シート１０のようなスタンパブルシート（ＧＭＴ）のみで成形される。 In general, a resin molded body used for a vehicle undercover or the like is molded only from a stampable sheet (GMT) such as the first sheet 10 described above.

第１シート１０は、強度が高く（変形し難く）、衝撃に強く（破砕し難く）、プレス金型により複雑な成形（例えば、深絞り）が可能であるいう長所を有する。また、第１シート１０には、繊維含有率に応じて高い強度に調整可能であり、ボルト締めの軸力を十分に確保できる等の長所もある。 The first sheet 10 has the advantages of high strength (hard to deform), high impact resistance (hard to crush), and capable of complex molding (for example, deep drawing) using a press mold. In addition, the first sheet 10 has the advantage that it can be adjusted to have a high strength according to the fiber content, and that a sufficient axial force for bolting can be ensured.

しかしながら、第１シート１０には、吸音性能や断熱性能が低く、また、重量が重いという短所がある。特に、第１シート１０で成形された樹脂成形体では、例えばエンジン音を遮音すべく、樹脂成形体の表面にグラスウール等からなるインシュレータを取り付けることがあるが、この場合には、更に重量が増加してしまう等の問題が生じる。 However, the first sheet 10 has drawbacks such as low sound absorption performance and heat insulation performance and heavy weight. In particular, in the resin molding molded from the first sheet 10, an insulator made of glass wool or the like may be attached to the surface of the resin molding in order to insulate engine noise, for example. problems such as

一方、成形材としては、上述した第２シート２０のような多孔質のスタンパブルシートが知られている。 On the other hand, as a molding material, a porous stampable sheet such as the second sheet 20 described above is known.

第２シート２０は、第１シート１０に比べて吸音性能や断熱性能が高いという長所を有する。そのため、第２シート２０で成形された樹脂成形体では、吸音性能等を確保するためにインシュレータを設ける必要がなく、軽量化を図ることができる。また、第２シート２０には、用途に応じて表皮材を選択可能であり、また、板厚で剛性を調整できる等の長所もある。 The second sheet 20 has the advantage of having higher sound absorption performance and heat insulation performance than the first sheet 10 . Therefore, the resin molded body molded from the second sheet 20 does not need to be provided with an insulator in order to ensure sound absorption performance, etc., and can be made lighter. In addition, the second sheet 20 has the advantage that the skin material can be selected according to the application, and the rigidity can be adjusted by changing the plate thickness.

しかしながら、第２シート２０には、第１シート１０に比べて、強度が低く（変形し易く）、また、衝撃に弱い（破砕し易い）という短所がある。特に、第２シート２０の強度では、ボルト締めの軸力を十分に確保できず、車両のサイドメンバ等に直接固定することが困難である。また、第２シート２０には、第１シート１０に比べて、複雑な成形が難しく、材料の歩留まりが悪く、また、端部を潰して内部の樹脂層が漏れるのを防止する必要がある等の短所もある。 However, the second sheet 20 has the disadvantages that it has a lower strength (easier to deform) and weaker impact resistance (easier to crush) than the first sheet 10 . In particular, due to the strength of the second seat 20, sufficient axial force for bolting cannot be secured, making it difficult to directly fix the second seat 20 to a side member or the like of the vehicle. In addition, the second sheet 20 is more difficult to form intricately than the first sheet 10, has a poor material yield, and needs to be crushed at the ends to prevent the internal resin layer from leaking out. There are also disadvantages.

これに対して、本実施形態では、図１及び図２に示したように、第１及び第２シート１０，２０の端部１１，２１同士を接合し、強度が高い第１シート１０を介して、吸音性能が高い第２シート２０をサイドメンバＭ１，Ｍ２に固定する。そのため、第１シート１０によって、ボルト締めが可能な軸力を確保できると共に、第２シート２０によって、広い面積でエンジン音を遮音すると同時に軽量化を図ることが可能になる。その結果、インシュレータを取り付けた場合と比較して、樹脂成形体１００の重量を格段に軽くすることができる。 On the other hand, in the present embodiment, as shown in FIGS. 1 and 2, the ends 11 and 21 of the first and second sheets 10 and 20 are joined to each other, and the first sheet 10 having high strength is interposed therebetween. Then, the second seat 20 having high sound absorption performance is fixed to the side members M1 and M2. Therefore, the first sheet 10 can secure an axial force that enables bolt tightening, and the second sheet 20 can insulate engine noise over a wide area and reduce weight. As a result, the weight of the resin molding 100 can be significantly reduced as compared with the case where the insulator is attached.

他方、図示しないが、第１及び第２シート１０，２０の端部同士を接続する手法としては、これらの端部同士を重ね合わせて、リベット等の締結部材や超音波カシメ等の接続方法によって接続することが考えられる。 On the other hand, although not shown, as a method of connecting the ends of the first and second sheets 10 and 20, these ends are overlapped and connected by a fastening member such as a rivet or a connection method such as ultrasonic crimping. It is conceivable to connect

しかしながら、これらの手法は、第１及び第２シートを分離不能に一体に成形するわけではない。また、第２シートは、強度が低いので、車両の振動等の影響で引張応力が負荷されたときに、リベット等によって変形ないし破損する虞がある。その結果、第２シートが第１シートから剥がれる等、接続部の強度を確保できない虞がある。 However, these techniques do not form the first and second sheets inseparably integrally. Further, since the second sheet has a low strength, it may be deformed or damaged by rivets or the like when a tensile stress is applied due to the influence of vehicle vibration or the like. As a result, there is a possibility that the strength of the connecting portion cannot be ensured, such as the second sheet being separated from the first sheet.

これに対して、図１及び図２に示したように、本実施形態の接合部３０は、第１及び第２シート１０，２０の端部同士１１，２１を突き合わせて固着されてなる。そのため、接合部３０においては、これら端部同士１１，２１が分離不能に一体に成形される。これにより、第２シート２０は、引張応力が負荷されたときでも、第１シート１０から分離されるのを抑制できる。 On the other hand, as shown in FIGS. 1 and 2, the joint portion 30 of the present embodiment is formed by abutting the ends 11 and 21 of the first and second sheets 10 and 20 and fixing them. Therefore, at the joint portion 30, these end portions 11 and 21 are integrally formed inseparably. Thereby, the second sheet 20 can be prevented from being separated from the first sheet 10 even when a tensile stress is applied.

よって、本実施形態に係る樹脂成形体１００であれば、第１及び第２成形材１０，２０の端部１１，２１同士を接続する接続部の強度を十分に確保できる。 Therefore, with the resin molded body 100 according to the present embodiment, sufficient strength can be ensured at the connecting portion that connects the ends 11 and 21 of the first and second molded members 10 and 20 to each other.

また、接合部３０においては、第１シート１０の第１熱可塑性樹脂１４が、第２シート２０の複数の細孔２３に充填される。そのため、第１熱可塑性樹脂１４は、第２シート２０の内部に確実に侵入して固着される。これにより、例えば端面同士を溶着させただけの場合と比較して、端部１１，２２同士の一体性が向上し、接合部３０の強度を高めることが可能になる。 Also, in the joint portion 30 , the first thermoplastic resin 14 of the first sheet 10 is filled into the plurality of pores 23 of the second sheet 20 . Therefore, the first thermoplastic resin 14 reliably penetrates into the inside of the second sheet 20 and is fixed. As a result, the integrity between the end portions 11 and 22 is improved and the strength of the joint portion 30 can be increased as compared with the case where the end faces are only welded together, for example.

また、接合部３０においては、第１樹脂層Ａ１及び強化繊維層Ａ２が、表側表皮材２５ａと裏側表皮材２５ｂとの間で第２樹脂層Ｂ２に固着している。そのため、表皮材２５ａ，２５ｂによる干渉を抑えつつ、第１樹脂層Ａ１及び強化繊維層Ａ２を第２樹脂層Ｂに確実に固着できる。 Also, in the joint portion 30, the first resin layer A1 and the reinforcing fiber layer A2 are fixed to the second resin layer B2 between the front side skin material 25a and the back side skin material 25b. Therefore, the first resin layer A1 and the reinforcing fiber layer A2 can be reliably fixed to the second resin layer B while suppressing interference by the skin materials 25a and 25b.

また、本実施形態の製造方法によれば、加熱して軟化させた第１シート１０と、加熱して軟化及び膨張させた第２シート２０とを、プレス金型４０に配置して加圧するだけで、容易に接合部３０を成形できる。 Further, according to the manufacturing method of the present embodiment, the first sheet 10 softened by heating and the second sheet 20 softened and expanded by heating are placed in the press die 40 and pressed. , the joint portion 30 can be easily formed.

すなわち、接合工程Ｓ５においては、第１及び第２シート１０，２０をプレス金型４０に横並びに配置して縦方向に加圧するだけで、第１シート１０をプレス金型４０内で流動させて、第１シート１０の端部１１を第２シート２０の端部２１に容易に固着できる。 That is, in the joining step S5, the first sheet 10 is caused to flow within the press die 40 simply by arranging the first and second sheets 10 and 20 side by side in the press die 40 and applying pressure in the vertical direction. , the edge 11 of the first sheet 10 can be easily fixed to the edge 21 of the second sheet 20 .

本実施形態では、第２シート２０を加熱して膨張させた状態で、第１シート１０を固着させる。そのため、熱膨張により拡がった細孔２３に対して、第１熱可塑性樹脂１４を確実に充填できる。 In this embodiment, the first sheet 10 is fixed while the second sheet 20 is heated and expanded. Therefore, the pores 23 expanded by thermal expansion can be reliably filled with the first thermoplastic resin 14 .

また、一度のプレス成形のみで第１及び第２シート１０，２０の製品形状と接合部３０とを成形できるので、製造工程を減らして、製造コストの増加を抑えることが可能になる。 In addition, since the product shape of the first and second sheets 10 and 20 and the joint portion 30 can be formed by press molding only once, it is possible to reduce the number of manufacturing steps and suppress an increase in manufacturing cost.

なお、本実施形態であれば、上述したようなリベット等の締結部品や超音波カシメ等の設備が不要になるので、部品点数や設備コストを抑えることが可能になる。 In the present embodiment, since fastening parts such as rivets and facilities such as ultrasonic caulking as described above are not required, it is possible to reduce the number of parts and facility costs.

以上、本開示の基本実施形態を詳細に述べたが、本開示は以下のような変形例またはそれら変形例の組み合わせとすることができる。 Although the basic embodiment of the present disclosure has been described in detail above, the present disclosure can be modified as follows or a combination thereof.

（変形例１）
第１及び第２シート１０，２０は、それぞれ複数重ねて用いられても良い。例えば、図１２に示すように、第１変形例の第２シート２０は、３枚の表皮材２５と、各表皮材２５の間に挟まれた２層の第２樹脂層Ｂと、を有する。この場合、第１シート１０の第１樹脂層Ａ１及び強化繊維層Ａ２は、各表皮材２５の間で２層の第２樹脂層Ｂにそれぞれ固着される。 (Modification 1)
A plurality of the first and second sheets 10 and 20 may be used by stacking them. For example, as shown in FIG. 12, the second sheet 20 of the first modified example has three skin materials 25 and two second resin layers B sandwiched between the skin materials 25. . In this case, the first resin layer A<b>1 and the reinforcing fiber layer A<b>2 of the first sheet 10 are respectively fixed to the two second resin layers B between the skin materials 25 .

（変形例２）
樹脂成形体は、プレス成形以外の方法で製造されても良い。図示しないが、第２変形例では、射出成形により樹脂成形体を製造する。 (Modification 2)
The resin molding may be manufactured by a method other than press molding. Although not shown, in the second modified example, a resin molded body is manufactured by injection molding.

具体的には、第２変形例の製造方法では、先ず、射出成形用の金型内に軟化及び膨張された第２シートを配置しておく。そして、例えばガラス短繊維を含んだ第１成形材としての熱可塑性樹脂を金型内に射出する。これにより、熱可塑性樹脂が金型内で流動し、第２シートの端部に固着する。その結果、熱可塑性樹脂と第２シートの端部同士が接合され、接合部が形成されると共に、製品形状が形成される。 Specifically, in the manufacturing method of the second modified example, first, the softened and expanded second sheet is placed in the mold for injection molding. Then, a thermoplastic resin as a first molding material containing short glass fibers, for example, is injected into the mold. This allows the thermoplastic resin to flow within the mold and adhere to the ends of the second sheet. As a result, the ends of the thermoplastic resin and the second sheet are joined together to form a joined portion and a product shape.

（変形例３）
第２成形材には、第２シート２０の代わりに、ウレタンフォーム等の発泡素材が用いられても良い。 (Modification 3)
A foam material such as urethane foam may be used as the second molding material instead of the second sheet 20 .

具体的には、第３変形例の発泡素材は、細孔としての連続気泡を含む。そのため、軟化された第１シートと発泡素材の端部同士が固着され、第１シートの第１熱可塑性樹脂が、発泡素材の連続気泡に充填される。 Specifically, the foam material of the third modification includes open cells as pores. Therefore, the softened first sheet and the ends of the foam material are fixed to each other, and the open cells of the foam material are filled with the first thermoplastic resin of the first sheet.

（変形例４）
第１シートは、強度等を確保できる場合には、第１強化繊維を含まない実施態様とすることも可能である。また、第２シートは、第２樹脂層の材質に応じて、第２強化繊維や表皮材を含まないで形成されても良い。 (Modification 4)
If the first sheet can ensure strength, etc., it is possible to adopt an embodiment in which the first sheet does not contain the first reinforcing fibers. Moreover, the second sheet may be formed without including the second reinforcing fiber and the skin material according to the material of the second resin layer.

前述の各実施形態の構成は、特に矛盾が無い限り、部分的にまたは全体的に組み合わせることが可能である。本開示の実施形態は前述の実施形態のみに限らず、特許請求の範囲によって規定される本開示の思想に包含されるあらゆる変形例や応用例、均等物が本開示に含まれる。従って本開示は、限定的に解釈されるべきではなく、本開示の思想の範囲内に帰属する他の任意の技術にも適用することが可能である。 The configurations of the respective embodiments described above can be partially or wholly combined as long as there is no contradiction. Embodiments of the present disclosure are not limited to the above-described embodiments, and include all modifications, applications, and equivalents encompassed by the concept of the present disclosure defined by the claims. Accordingly, the present disclosure should not be construed in a restrictive manner, and can be applied to any other technology that falls within the spirit of the present disclosure.

１０ 第１シート（第１成形材）
１１ 端部（第１成形材の端部）
１４ 第１熱可塑性樹脂
１５ 第１強化繊維
２０ 第２シート（第２成形材）
２１ 端部（第２成形材の端部）
２２ 第２熱可塑性樹脂
２３ 細孔
２４ 第２強化繊維
２５ａ 表側表皮材
２５ｂ 裏側表皮材
３０ 接合部
４０ プレス金型
１００ 樹脂成形体
Ａ１ 第１樹脂層
Ａ２ 強化繊維層
Ｂ 第２樹脂層 10 First sheet (first molding material)
11 end (end of first molding material)
14 First thermoplastic resin 15 First reinforcing fiber 20 Second sheet (second molding material)
21 end (end of second molded material)
22 Second thermoplastic resin 23 Pore 24 Second reinforcing fiber 25a Front side skin material 25b Back side skin material 30 Joint portion 40 Press mold 100 Resin molding A1 First resin layer A2 Reinforcing fiber layer B Second resin layer

Claims (7)

第１熱可塑性樹脂を含む第１成形材と、
第２熱可塑性樹脂及び複数の細孔を含む第２成形材と、
前記第１成形材の端部と前記第２成形材の端部とが突き合わされて固着されてなる接合部と、を備え、
前記第１成形材は、第１強化繊維を含み、
前記第２成形材は、第２強化繊維と、前記第２熱可塑性樹脂及び前記第２強化繊維を覆う表皮材と、を含み、
前記第１熱可塑性樹脂及び前記第１強化繊維は、前記第２熱可塑性樹脂及び前記第２強化繊維にそれぞれ固着し、
前記第１成形材は、前記第１熱可塑性樹脂からなる第１樹脂層と、前記第１強化繊維からなる強化繊維層とが積層された第１シートにより形成され、
前記第２成形材は、前記第２熱可塑性樹脂、前記複数の細孔及び前記第２強化繊維を含む第２樹脂層と、前記第２樹脂層の表面及び裏面にそれぞれ貼設された表側表皮材及び裏側表皮材と、を有する第２シートにより形成され、
前記接合部においては、前記第１樹脂層及び前記強化繊維層が、前記表側表皮材と裏側表皮材との間で前記第２樹脂層に固着している
ことを特徴とする樹脂成形体。 a first molding material containing a first thermoplastic resin;
a second molding material comprising a second thermoplastic resin and a plurality of pores;
a joint portion formed by abutting and fixing an end portion of the first molding material and an end portion of the second molding material ;
The first molding material includes a first reinforcing fiber,
The second molding material includes second reinforcing fibers and a skin material covering the second thermoplastic resin and the second reinforcing fibers,
The first thermoplastic resin and the first reinforcing fibers are respectively fixed to the second thermoplastic resin and the second reinforcing fibers,
The first molding material is formed of a first sheet in which a first resin layer made of the first thermoplastic resin and a reinforcing fiber layer made of the first reinforcing fiber are laminated,
The second molding material includes a second resin layer containing the second thermoplastic resin, the plurality of pores, and the second reinforcing fibers, and front skins respectively attached to the front and back surfaces of the second resin layer. formed by a second sheet having a material and a back skin material,
At the joint portion, the first resin layer and the reinforcing fiber layer are fixed to the second resin layer between the front side skin material and the back side skin material.
A resin molding characterized by: 前記接合部においては、前記第１熱可塑性樹脂が前記複数の細孔に充填されている
請求項１に記載の樹脂成形体。 2. The molded resin article according to claim 1, wherein said first thermoplastic resin is filled in said plurality of pores in said joint portion. 第１熱可塑性樹脂を含む第１成形材と、
第２熱可塑性樹脂及び複数の細孔を含む第２成形材と、
前記第１成形材の端部と前記第２成形材の端部とが突き合わされて固着されてなる接合部と、を備えた樹脂成形体の製造方法であって、
前記第１成形材を加熱して軟化させる第１成形材加熱行程と、
前記第２成形材を加熱して軟化及び膨張させる第２成形材加熱行程と、
軟化された前記第１成形材の端部と軟化及び膨張された前記第２成形材の端部とを突き合わせて固着させることで、前記接合部を形成する接合工程と、を備え、
前記接合工程は、
軟化された前記第１成形材と、軟化及び膨張された第２成形材とを、プレス金型内に横並びに配置する配置工程と、
前記プレス金型により前記第１及び第２成形材を縦方向に加圧して、前記第１成形材を流動させ、その後、前記第１成形材の端部を前記第２成形材の端部に固着させる加圧工程と、を含む
ことを特徴とする樹脂成形体の製造方法。 a first molding material containing a first thermoplastic resin;
a second molding material comprising a second thermoplastic resin and a plurality of pores;
A method for manufacturing a resin molded body comprising a joint portion in which an end portion of the first molding material and an end portion of the second molding material are butted and fixed,
a first molding material heating step of heating and softening the first molding material;
a second molded material heating step of heating the second molded material to soften and expand;
a joining step of forming the joining portion by butting and fixing the softened end of the first molded material and the softened and expanded end of the second molded material ;
The bonding step includes
an arrangement step of arranging the softened first molded material and the softened and expanded second molded material side by side in a press die;
The first and second molding materials are pressurized in the vertical direction by the press die to flow the first molding material, and then the end of the first molding material is attached to the end of the second molding material. and a pressurizing step to adhere
A method for producing a resin molding characterized by: 前記接合工程においては、前記第１熱可塑性樹脂を前記複数の細孔に充填させる
請求項３に記載の樹脂成形体の製造方法。 4. The method of manufacturing a resin molding according to claim 3 , wherein in the bonding step, the plurality of pores are filled with the first thermoplastic resin. 前記第１成形材は、第１強化繊維を含み、
前記第２成形材は、第２強化繊維と、前記第２熱可塑性樹脂及び前記第２強化繊維を覆う表皮材と、を含み、
前記加圧工程においては、前記第１熱可塑性樹脂及び前記第１強化繊維を、前記第２熱可塑性樹脂及び前記第２強化繊維にそれぞれ固着させる
請求項３または４に記載の樹脂成形体の製造方法。 The first molding material includes a first reinforcing fiber,
The second molding material includes second reinforcing fibers and a skin material covering the second thermoplastic resin and the second reinforcing fibers,
5. The production of the resin molding according to claim 3, wherein in the pressing step, the first thermoplastic resin and the first reinforcing fibers are fixed to the second thermoplastic resin and the second reinforcing fibers, respectively. Method. 前記第１成形材は、前記第１熱可塑性樹脂からなる第１樹脂層と、前記第１強化繊維からなる強化繊維層とが積層された第１シートにより形成され、
前記第２成形材は、前記第２熱可塑性樹脂、前記複数の細孔及び前記第２強化繊維を含む第２樹脂層と、前記第２樹脂層の表面及び裏面にそれぞれ貼接された表側表皮材及び裏側表皮材と、を有する第２シートにより形成され、
前記加圧工程においては、前記第１及び第２成形材の端部同士を固着させる際に、前記第１樹脂層及び前記強化繊維層を、前記表側表皮材と裏側表皮材との間で前記第２樹脂層に固着させる
請求項５に記載の樹脂成形体の製造方法。 The first molding material is formed of a first sheet in which a first resin layer made of the first thermoplastic resin and a reinforcing fiber layer made of the first reinforcing fiber are laminated,
The second molding material includes a second resin layer containing the second thermoplastic resin, the plurality of pores, and the second reinforcing fibers, and a front skin adhered to the front surface and the back surface of the second resin layer, respectively. formed by a second sheet having a material and a back skin material,
In the pressing step, when the ends of the first and second molding materials are fixed together, the first resin layer and the reinforcing fiber layer are interposed between the front side skin material and the back side skin material. The method for producing a resin molding according to claim 5 , wherein the resin molding is fixed to the second resin layer. 前記加圧工程においては、前記第１及び第２成形材の端部同士を固着させると共に、前記プレス金型の型形状に合わせて前記第１及び第２成形材を成形する
請求項３～６何れか一項に記載の樹脂成形体の製造方法。 In the pressurizing step, the ends of the first and second molding materials are fixed together, and the first and second molding materials are molded according to the shape of the press mold . A method for producing a resin molded product according to any one of items.
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US20150174874A1 (en) 2011-11-14 2015-06-25 The Boeing Company Aircraft Interior Panels and Methods of Panel Fabrication

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