JPH047B2 - - Google Patents

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention is applied to metal or resin materials used for the outer panels of automobile bodies, lids such as bonnets and trunk lids, interior and exterior panels of buildings, and panel members of furniture. The present invention relates to a method for forming a composite panel consisting of a plate and a resin foam, in which the plate is integrally formed on the front surface and the resin foam is integrally formed on the back surface of the plate.

In particular, the surface of the panel is a gentle linear or quadratic curved surface and does not undergo plastic deformation even if the surface plate is press-formed in advance, so the plate itself cannot maintain its curved shape and press The object of the present invention is to provide a molding method suitable for molding the composite panel described above, which has a plate on its surface having a relatively large R (R), for example, 1000 R or more, which is difficult to mold.

(Prior art) A metal plate with a surface such as a steel plate used for the outer panels of automobile bodies, lids of bonnets and trunks, interior and exterior panels of buildings, panel members of furniture, etc. A composite panel in which a resin foam is integrally provided on the back surface is disclosed in Japanese Patent Application Laid-Open No. 144955/1983.

In the automobile composite lid shown in JP-A-56-144955, the outer panel made of thin steel plate (the metal plate that becomes the surface of the composite panel) is press-formed in the previous process, and then the injection molding is performed. An upper mold (resin mold) and a lower mold (resin mold) suitable for molding were prepared, and the outer surface of the previously pressed outer plate was brought into close contact with the molding surface of the lower mold. Then, the upper mold is set in the lower mold, the two monomers are mixed by a mixing head, a reinforcing material such as glass fiber is mixed in, and this mixed liquid is placed in the upper mold. Injection is performed through a gate provided for injection molding.

By doing this, the surface quality is better than that of a lid made only of synthetic resin (for example, as shown in JP-A-60-219166), and the ribs provided on the back side for reinforcement make the surface This eliminates the fear that sink marks may occur and the smoothness may be impaired.

(Problem to be Solved by the Invention) However, when the curved surface of the composite panel is a linear or quadratic curved surface with a relatively large R (R), it is necessary to press-form it in advance as described above. Because it is difficult to do this, it is limited to shapes that can be press-formed in advance, or complicated processing is required to form the curved surface of the plate, making it impossible to use.

In addition, if it is not a composite panel, a frame is made of reinforcing material formed from a metal plate such as a steel plate with a gently curved cross section, and the entire frame is also formed with a gently curved surface on the front side. However, by welding a plate such as a steel plate to the surface side of this framework, the outer panels and lids of the above-mentioned automobile bodies can also be obtained. (For example, as shown in Japanese Patent Application Laid-Open No. 160263/1983.) However, since this is not a composite panel,
Manufacturing such as molding, processing, and assembly of the reinforcing material becomes complicated, which not only increases costs, but also causes distortion on the surface due to the precision of the reinforcing material and due to welding.

(Means for Solving the Problems) Therefore, in order to solve the above-mentioned problems, in the present invention, one of the resin molding molds has a molding surface formed to match the curved shape of the surface of the composite panel after molding. and another resin mold having a molding surface that matches the shape of the back surface of the composite panel after molding, a flat plate is provided on the molding surface of the one resin mold, and a flat plate is provided on the molding surface of the one resin mold, and Before or after clamping the resin mold and the other resin mold, a resin foam material is applied to the back side of the flat plate and reacted and hardened to form the resin foam. A method for forming a composite panel, in which the plate is brought into close contact with the molding surface of one of the resin molding molds by the foaming pressure of the body material, and the plate is molded into the curved shape, and the plate and the resin foam are integrally molded. It is characterized by what it did.

(Function) The flat metal or resin plate applied to the molding surface of one of the molds is molded into a curved surface by the foaming pressure of the resin foam material applied to the back surface.

In addition, after the metal or resin plate and the resin foam are integrally molded and cured, even if the metal or resin plate has a gently curved surface that does not undergo plastic deformation, the rigidity of the resin foam will cause it to become flat. It does not return to its original shape and retains its curved shape.

(Example) Fig. 1 shows a method of forming a composite panel according to a first embodiment of the present invention, and Figs. This figure shows an example of use in a car body.

In this first embodiment, surface 1 of composite panel 10
01 and the back surface 102 are metal plates 11 and 1 which are plates.
3 is provided, and a resin foam 12 is provided integrally with both metal plates 11, 13 between both metal plates 11, 13.

First, a coil material of a thin steel plate having a thickness of 0.5 mm is cut to obtain thin steel plates 111 and 131 as flat metal plates 11 and 13 having a predetermined size and shape. (Not shown) After cleaning the surfaces of the flat thin steel plates 111 and 131 (not shown), the composite panel 1 is placed on the molding surface 141 of the lower mold 14 as one of the resin molding molds.
One flat thin steel plate 1 which becomes the surface 101 of 0
11 is applied and mounted, and the other flat thin steel plate 131 that will become the back surface 102 of the composite panel 10 is applied to the molding surface 151 of the upper mold 15 as the other resin molding mold, and the composite panel 10 is assembled into the upper mold 15. The other flat thin steel plate 131 is held by the magnet 152. Incidentally, the holding may be carried out by other holding methods such as suction force using vacuum.

The molding surface 141 of the lower mold 14 is the composite panel 1
The molding surface 151 of the upper mold is formed on the surface 101 of the composite panel 10 to match the curved shape (3000R) after molding, and the molding surface 151 of the upper mold is formed to match the curved shape of the back surface 102 of the composite panel 10 after molding, and Thickness of body 12
It is formed by forming a forming recess 153 with a thickness of 30 mm and a thickness of 0.5 mm of the thin steel plate 131.

Next, isocyanate and polyol as the resin foam material 16 are mixed and applied to the back surface side (upper surface in the drawing) of one of the flat thin steel plates 111 placed on the lower mold 14.

Subsequently, the upper mold 15 is set on the lower mold 14 and the molds are clamped. After the resin foam material 16 has reacted and hardened, it is demolded and the molded composite panel 10 is taken out.

During this reaction, due to the foaming pressure of the resin foam material 16, both the thin steel plates 111 and 131 are brought into close contact with the molding surfaces 141 and 151, respectively, and are molded from a flat plate shape into a curved surface.

In this embodiment, as shown in FIGS. 2 and 3, the composite panel 10 formed as described above is fixed to the brackets 24 and 34 provided on the pillar 18 as the outer panel 17 of the vehicle body using bolts and nuts 21. . For this reason, the thin steel plate 111 on the front surface 101 is
The outer periphery 35 is made larger than that of the thin steel plate 131 of No. 2, and the thin steel plate 131 of the back surface 102 has a T-shaped steel plate 131 before being applied to the upper mold 15.
The type stud bolt 19 is welded and fixed.

A hole 20 is made in the upper mold 15 for allowing the T-shaped stud bolt 19 to escape.

Further, the composite panel 10 obtained as described above is processed to form holes 36 for fixing with the bolts and nuts 21, and then the thin steel plate on the surface 101 is formed using bending molds 22 and 23. The outer periphery 35 of 111 is bent.

Note that the outer periphery 35 of the thin steel plate 111 on the surface 101 may be bent before applying the thin steel plate 111 to the lower mold 14.

Further, the molding surfaces of the lower mold 14 and the upper mold 15 where the resin foam material 16 contacts are subjected to mold release treatment such as application of a mold release agent in advance.

The thicknesses of the thin steel plates 111, 131 and the resin foam 12 are not limited to those of this embodiment.
131 is 0.7 mm, resin foam 12 is 2.6 mm, etc., depending on the application.

The application of the resin foam material 16 is not limited to this embodiment, and may be performed by injection. In that case, the thin steel plate 13 on the back side 102
1, a hole is made so that this hole coincides with a gate provided in the upper mold 15, and a resin foam material 16 is injected from this gate, and the resin foam material 16 is applied between both thin steel plates 111 and 131. do.

In addition, 25 in FIGS. 2 and 3 indicates a door. Further, as shown in FIGS. 2 and 3, this composite panel 10 has bolts/nuts 21 and stud bolts 1.
9 and both thin steel plates 111 and 131 are pillar 18.
Since it is fixed to the plate, it will not lack strength even if it is a thin plate.

FIG. 4 shows a method of forming a composite panel 10 showing a second embodiment of the present invention, and FIGS.
Composite panel 1 obtained by the molding method of the example
0 is used for a header board 26 of a furniture bed.

The difference between this second embodiment and the first embodiment is that a reinforcing plate 28 for attaching and reinforcing the leg 27 mounting portion is attached to the thin steel plate 111 on the surface 101 in advance.
Before applying the resin foam material 16 to the outer periphery of the thin steel plate 111 on the surface 101 applied to the lower mold 14, in order to provide the molding 29 on the outer periphery of both the thin steel plates 111 and 131, Or, it is fixed by holding it with a jig.
The point is that no bending process is performed. And 4
0 is a bracket on which the bed bottom plate 39 is placed and fixed, and is provided integrally with the reinforcing plate 28. In this example, the thickness of the thin steel plates 111 and 131 was 1 mm, and the thickness of the resin foam 12 was 28 mm.

Further, the molding 29 is partially cut out to provide an air vent. Furthermore, since the molding 29 is also integrated during molding, processing of the outer periphery of the composite panel 10 is easy. In this embodiment, the plate body is the thin steel plate 111, but the plate body may be an aluminum thin plate or a resin plate.

FIG. 7 shows a method for forming a composite panel 10 according to a third embodiment of the present invention, and FIG. 8 shows a composite panel 10 obtained by the molding method of the third embodiment.

This third embodiment differs from the first and second embodiments in that a flat aluminum thin plate 112 is used as the metal plate 11 on the surface 101 of the composite panel 10,
The back side of this thin aluminum plate 112 (top surface in the drawing)
A reinforcing rib 30 is integrally formed on this resin foam 33, and the back surface 102 of the composite panel 10 is made of the resin foam 33 having this rib 30. The outer periphery 37 of the resin foam 33 is closer to the outer periphery 3 of the thin aluminum plate 112 than the outer periphery 37 of the resin foam 33.
8 is molded to be slightly larger and caulked by hem molding.

In this third embodiment, the composite panel 10
A flat aluminum thin plate 112 is placed on the molding surface 311 of the lower mold 31, which is one of the resin molding molds, and has a molding surface 311 formed to match the curved shape of the surface 101 after molding. The shape of the back surface 102 of the composite panel 10 after molding, that is,
A mold release process is performed on the upper mold 32, which is the other resin mold, and has a molding surface 321 formed in the shape of a resin foam 33 having ribs 30.

Next, isocyanate and polyol mixed with glass fiber reinforcing material are applied as resin foam material 16 to the back side (upper surface in the drawing) of the flat aluminum thin plate 112 placed on the lower mold 31, and The upper mold 32 is set on the mold 31 and the mold is clamped. After the resin foam material 16 has reacted and hardened, it is removed from the mold and the molded composite panel 10 is taken out.

Thereafter, the outer periphery of the thin aluminum plate 112 is hemmed and the outer periphery of the resin foam 33 is caulked. By forming the hem, the outer periphery of the composite panel 10 can be made to look good.

In the above examples, a type of resin that reacts and foams by mixing two liquids was used as the resin foam material. A foam product obtained by completing initial foaming of styrene foam with steam may also be used.

Further, in the first embodiment, the dam rubber may be provided at the outer periphery of the resin foam, and then the resin foam material may be applied.

Further, in the second embodiment, a molding was integrally provided on the outer periphery of the composite panel during molding, but a weather strip may be provided instead of the molding. In this case, it becomes easy to attach the window frame portion of the automobile.

Furthermore, in the case of this second embodiment, the front plate is made of a transparent resin such as acrylic or polycarbonate, and a pattern is placed on the front plate in advance between the resin foam and this front plate. It is a good idea to paste printed pictures, photographs, text, etc.

(Effect of the invention) In the present invention, when molding a resin foam, the flat metal or resin surface plate can be molded into a curved surface at the same time as the resin foam is molded using the foaming pressure. It's okay.

Furthermore, after molding, the surface metal or resin plate does not return to its flat shape due to the rigidity of the resin foam.

Therefore, it is possible to easily obtain a composite panel with a relatively large radius and a gently curved surface, which is difficult to form in advance.

[Brief explanation of drawings]

FIG. 1 is a process diagram showing a method for forming a composite panel according to a first embodiment of the present invention, and FIG. 2 is a perspective view of an automobile using the composite panel obtained by the method of forming a composite panel according to the first embodiment. Figure 3 is A-A of Figure 2.
A sectional view, FIG. 4 is a process diagram showing a method of forming a composite panel according to a second embodiment of the present invention, and FIG.
FIG. 6 is a perspective view of a bed showing an example using a composite panel obtained by the molding method of the embodiment, FIG. 6 is a view along arrow B in FIG. 5 including a cross section, and FIG. FIG. 8 is a process diagram showing a method for forming a composite panel according to an embodiment, and is a perspective view of a composite panel obtained by a method for forming a composite panel according to a third embodiment. 10...Composite panel, 101...Surface, 102
... Back side, 11, 13 ... Metal plate (plate body), 12,
33... Resin foam, 111, 133... Thin steel plate, 14, 31... Lower mold (one resin mold),
141,311...Molding surface, 15,32...Upper mold (the other resin mold), 151,321...Molding surface, 16...Resin foam material, 112...Aluminum thin plate.

Claims (1)

[Claims] 1. In a method for forming a composite panel consisting of a plate and a resin foam, the surface of which is a plate of metal or resin, and a resin foam is provided on the back side of the plate, the curved shape of the surface of the composite panel after molding. One resin molding mold has a molding surface formed to match the shape of the back surface of the composite panel after molding, and the other resin molding mold has a molding surface matching the shape of the back surface of the composite panel after molding. A flat plate is provided on the molding surface, and before or after clamping one resin mold and the other resin mold,
Applying a resin foam material to the back side of the flat plate body, reacting and curing it, and bringing the plate body into close contact with the molding surface of one of the resin molds by the foaming pressure of the resin foam material, A method for molding a composite panel, comprising molding into the curved shape and integrally molding the plate and the resin foam.