JPWO2016021111A1 - Resin structure and electric vacuum cleaner using the same - Google Patents

Abstract

The resin structure (14) includes a polyolefin-based fiber reinforced resin laminate sheet (15) and a resin support member (16) made of a resin having high affinity with the fiber reinforced resin laminate sheet (15). Thereby, the delamination between each layer of a junction part of a fiber reinforced resin lamination sheet (15) and a resin support member (16) and a fiber reinforced resin lamination sheet (15) can be prevented. As a result, it is possible to realize a low-cost resin structure (14) that is lightweight and strong in physical strength against bending.

Description

  The present invention relates to a resin structure composed of a fiber-reinforced resin laminate sheet and a resin support member, and a vacuum cleaner using the same.

  Conventionally, a housing in which a plurality of reinforcing fiber fabrics such as carbon fibers and aramid fibers are laminated is known (for example, see Patent Document 1).

  Below, the structure of the housing | casing described in patent document 1 is demonstrated using FIG.

  FIG. 8 is an external perspective view showing a configuration of a conventional casing.

  As shown in FIG. 8, the conventional housing is composed of a first layer 1a and a second layer 2a. The first layer 1a is made of FRP (Fiber Reinforced Plastics) obtained by press-molding a carbon fiber fabric or a material obtained by impregnating a resin into carbon continuous fibers arranged in a sheet shape in one direction. The second layer 2a is formed by injection molding or transfer molding of resin or resin containing reinforcing short fibers. And the 1st layer 1a and the 2nd layer 2a are bonded together with an adhesive agent or adhesive tape, and the case is constituted.

  However, the configuration of the casing has a problem that delamination is likely to occur between the first layer 1a made of FRP using carbon fiber or the like as a reinforcing material and the second layer 2a made of resin or the like. . Moreover, since an expensive material such as carbon fiber is used, there is a problem that the cost is high.

JP 9-46082 A

  The present invention provides a low-cost resin structure that is difficult to delaminate and a vacuum cleaner using the same.

  That is, the resin structure of the present invention includes a fiber reinforced resin laminated sheet made of polyolefin resin and a resin support member made of a resin having high affinity with the fiber reinforced resin laminated sheet.

  According to this configuration, the resin support member is formed of a resin having high affinity for the polyolefin-based resin of the fiber-reinforced resin laminated sheet. Thereby, delamination in the junction part of a resin support member and a fiber reinforced resin lamination sheet can be suppressed. As a result, an inexpensive and highly reliable resin structure can be realized.

  Moreover, the vacuum cleaner of this invention is comprised using the said resin structure for the whole or a part of vacuum cleaner main body. Thereby, weight reduction and cost reduction of a vacuum cleaner can be achieved.

FIG. 1 is an external perspective view of a vacuum cleaner according to an embodiment of the present invention. FIG. 2 is an external perspective view of the main body of the vacuum cleaner as viewed from above. FIG. 3 is a central sectional view of the vacuum cleaner main body of the electric vacuum cleaner. FIG. 4 is an external perspective view of the dust cover of the vacuum cleaner as viewed from the back side. 5 is a cross-sectional view taken along line 5-5 of FIG. FIG. 6 is a cross-sectional view showing a laminated configuration of a fiber-reinforced resin laminated sheet used for the dust lid of the electric vacuum cleaner. FIG. 7 is a partially enlarged plan view of FIG. 5 showing the dust cover of the vacuum cleaner as viewed from the B direction. FIG. 8 is an external perspective view showing a configuration of a conventional casing.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments.

(Embodiment)
Below, the structure and operation | movement of the resin structure in embodiment of this invention and a vacuum cleaner using the same are demonstrated using FIGS. 1-3. In addition, it cannot be overemphasized that it is not restricted especially to a vacuum cleaner.

  FIG. 1 is an external perspective view of a vacuum cleaner according to an embodiment of the present invention. FIG. 2 is an external perspective view of the main body of the vacuum cleaner as viewed from above. FIG. 3 is a central sectional view of the vacuum cleaner main body of the electric vacuum cleaner.

  As shown in FIG. 1, the electric vacuum cleaner of the present embodiment includes at least a vacuum cleaner body 1, a suction tool 2, an extension pipe 3, a hose 4, and the like. And the whole or one part of the cleaner body 1 is comprised with the resin structure mentioned later. The suction tool 2 sucks dust on a surface to be cleaned such as a floor. The extension pipe 3 has one end connected to the suction tool 2 and the other end connected to the hose 4. The hose 4 has one end connected to the extension pipe 3 and the other end connected to the cleaner body 1. Needless to say, the suction tool 2 and the extension pipe 3 may also be configured using a resin structure described later.

  Further, as shown in FIGS. 2 and 3, the cleaner body 1 includes at least a lower body body 5, a front wheel 6, a rear wheel 7, a front cover 8, a handle 9, and a body body upper 10, It consists of a body attainer 11 and a dust lid 13. The lower body body 5 forms the outer lower surface of the cleaner body 1. The front wheel 6 is rotatably fitted to the lower body body 5. Similarly, the rear wheel 7 is configured as a pair of left and right under the main body body 5 and is disposed so as to be rotatable in the front-rear direction. The front cover 8 is locked to the lower body body 5 and holds the other end of the hose 4. The handle 9 is locked to the front cover 8 and used for carrying the user. The body attainer 11 covers and decorates the main body body top 10 that forms the outer and upper surfaces of the vacuum cleaner main body 1 and a part of the main body body top 10. The dust lid 13 is rotatably fitted on the main body body 10 to prevent air leakage from the dust collecting portion 12. And the resin structure which is the point of this Embodiment is employ | adopted as at least one part of the cleaner main body 1, such as the body attainer 11 and the dust cover 13, for example.

  Hereinafter, the resin structure of the present embodiment will be described using the dust cover 13 as an example with reference to FIGS. 4 and 5.

  FIG. 4 is an external perspective view of the dust cover of the vacuum cleaner as viewed from the back side. 5 is a cross-sectional view taken along line 5-5 of FIG.

  The resin structure 14 constituting the dust lid 13 is configured by integrally molding a fiber reinforced resin laminated sheet 15 and a resin support member 16. The fiber reinforced resin laminate sheet 15 is formed by laminating, for example, a polyolefin resin as a basic material. The resin support member 16 constitutes a member generally called a rib or a boss, and is made of, for example, a polyolefin-based resin. The resin structure 14 forms a housing such as an outer shell of the cleaner body 1. The polyolefin resin support member 16 is specifically a polypropylene resin.

  Next, a specific laminated structure of the fiber reinforced resin laminated sheet 15 used in the dust lid 13 shown in FIGS. 4 and 5 will be described with reference to FIG.

  FIG. 6 is a cross-sectional view showing a laminated configuration of a fiber-reinforced resin laminated sheet used for the dust lid of the electric vacuum cleaner.

  As shown in FIG. 6, the fiber reinforced resin laminated sheet 15 has a laminated structure of a fiber reinforced layer 23 and a cover layer 24. The fiber reinforced layer 23 includes a core layer 17, fabric layers 18a and 18b, adhesive layers 19a, 19b, and 19c. The cover layer 24 includes a transparent layer 20, a colored layer 21, a transparent protective layer 22, and the like.

  Specifically, the fiber reinforced layer 23 of the fiber reinforced resin laminated sheet 15 is configured by bonding the fabric layer 18a and the fabric layer 18b to both surfaces of the core layer 17 via the adhesive layer 19a and the adhesive layer 19b. .

  The core layer 17 of the fiber reinforced layer 23 is made of, for example, a resin whose main component is polypropylene, and is laminated in a sheet shape or a film shape. The core layer 17 is preferably made of, for example, a non-foamed polypropylene sheet. This is because, in the non-foamed polypropylene sheet, the laminated layers are not easily crushed during press molding. Further, the non-foamed polypropylene sheet can be easily formed by vacuum forming or bending forming utilizing thermal deformation.

  The woven fabric layer 18a and the woven fabric layer 18b of the fiber reinforced layer 23 are composed of, for example, a core-sheath composite fiber yarn in which the core component is a polypropylene resin and the sheath component is a polyolefin resin having a melting point lower than that of the core component. By making the sheath component a polyolefin resin component having a low melting point, heat adhesion is facilitated. The fabric of the fabric layer 18a and the fabric layer 18b may be a fabric of any structure such as plain weave, twill weave (oblique fabric), satin weave, and other changed weaves.

  The adhesive layers 19a, 19b, 19c of the fiber reinforced layer 23 are made of, for example, a transparent heat-sealable polyolefin film. As a result, the core layer 17 can be bonded to the fabric layer 18a and the fabric layer 18b by heat and pressure. As a result, the fiber reinforced layer 23 can be easily laminated and integrated.

  The fiber reinforced resin laminate sheet 15 is formed by integrating the cover layer 24 on one surface layer of the fiber reinforced layer 23 via the adhesive layer 19c.

  At this time, the cover layer 24 is preferably composed of, for example, a transparent polyolefin resin sheet. That is, it is preferable that the cover layer 24 has transparency enough to allow the fabric layer 18a to be seen through the outside. By seeing the fabric layer 18a from the outside, the fiber-reinforced resin laminated sheet 15 looks high in strength. Furthermore, the beautiful appearance of the fiber reinforced resin laminate sheet 15 can be kept high.

  Specifically, the cover layer 24 is configured by laminating a transparent layer 20 of a polypropylene resin sheet, a colored layer 21 and a protective layer 22 of a polypropylene resin sheet. By putting the thin colored layer 21 between the protective layer 22 and the transparent layer 20, it is possible to make the fabric layer 18a of the white fiber reinforced layer 23 look like a dyed texture.

  That is, in the fiber reinforced resin laminated sheet 15 of the present embodiment, first, the fabric layers 18a and 18b are bonded and integrated on both surfaces of the core layer 17 of the fiber reinforced layer 23 via the adhesive layers 19a and 19b. . Thereby, the fiber reinforced layer 23 is formed.

  Next, the transparent layer 20, the colored layer 21, and the protective layer 22 forming the cover layer 24 are laminated and integrated on the surface of the fabric layer 18a of the fiber reinforced layer 23 via the adhesive layer 19c. Thereby, the fiber reinforced resin laminated sheet 15 is formed.

  The transparent layer 20, the colored layer 21, and the protective layer 22 may be laminated in advance and integrated as the cover layer 24. In this case, the integrated cover layer 24 is laminated and integrated with the fiber reinforced layer 23 via the adhesive layer 19c. Thereby, the fiber reinforced resin laminated sheet 15 is formed.

  As described above, the fiber-reinforced resin laminated sheet 15 of the present embodiment is formed.

  Below, the specific method of forming a dust cover using the said fiber reinforced resin lamination sheet is demonstrated.

  First, as a first step, the fiber reinforced resin laminated sheet 15 laminated and integrated is punched to cut unnecessary portions.

  Next, as a second step, the punched fiber-reinforced resin laminated sheet 15 is subjected to pressure bending processing, for example, with a hot press machine in accordance with the three-dimensional shape of the product outer shell (in this case, a dust lid).

  Next, as a third step, resin support members 16 such as ribs and bosses necessary for performing the function as the dust lid 13 are formed on the fiber reinforced resin laminated sheet 15 bent into the shape of the dust lid by, for example, insert injection molding. The resin structure 14 is formed by integral molding. As a result, it is possible to form the resin structure 14 in which the fiber reinforced resin laminated sheet 15 made of a polyolefin resin and the resin support member 16 that are difficult to be bonded with an adhesive are firmly connected.

  The fiber reinforced resin laminated sheet 15 made of polyolefin resin has a high resistance to bending, stretching, impact, and the like. Therefore, compared with the conventional ABS resin ((Acrylonitrile Butadiene Styrene) copolymer synthetic resin) etc., the fiber reinforced resin laminated sheet 15 having a thinner thickness can obtain the same or higher performance. In general, the polyolefin resin has a low specific gravity. Therefore, the weight can be reduced as compared with the case where the fiber-reinforced resin laminated sheet is formed of carbon fiber or glass fiber. Furthermore, the polyolefin resin is inexpensive in terms of cost. As a result, the fiber-reinforced resin laminated sheet 15 can be obtained with higher productivity and at a lower cost.

  The fiber reinforced resin laminated sheet 15 includes the transparent cover layer 24 as described above. Thereby, while giving a glossy feeling to the surface of the fiber reinforced resin lamination sheet 15, damage can be prevented. At the same time, the underlying fabric layer 18a of the fiber reinforced resin laminate sheet 15 can be seen as three-dimensional and deep. As a result, the fiber-reinforced resin laminate sheet 15 can be made more beautiful and can be given a high-class feeling. Further, the colored layer 21 provided between the protective layer 22 and the transparent layer 20 can make it appear as if the white fabric layer 18a is dyed. As a result, the color development of the fiber reinforced resin laminated sheet 15 becomes easier.

  The resin structure 14 of the present embodiment is formed by integrally molding a polyolefin-based fiber reinforced resin laminate sheet 15 and a polyolefin-based resin support member 16 made of polypropylene resin by insert injection molding. That is, the resin structure 14 is composed of a resin in which both the fiber-reinforced resin laminate sheet 15 and the resin support member 16 are made of the same type of polyolefin-based material. Therefore, the joint part of the fiber reinforced resin laminated sheet 15 and the resin support member 16 has affinity with the same type of polyolefin-based material. As a result, delamination at the joint between the fiber-reinforced resin laminate sheet 15 and the resin support member 16 can be more reliably suppressed. In addition, the adhesion of each layer between the laminations of the fiber reinforced resin laminate sheet 15 is also made of polyolefin-based resin, and thus has an affinity. Therefore, the delamination of each layer between the laminations of the fiber reinforced resin laminate sheet 15 is more It can be reliably suppressed. As a result, it is possible to realize a fiber-reinforced resin laminate sheet 15 that is inexpensive and lightweight and has high physical strength against bending (mechanical strength).

  Further, the electric vacuum cleaner of the present embodiment is configured by applying the resin structure 14 to at least a part of the housing (in the present embodiment, the cleaner main body 1). Thereby, weight reduction and cost reduction of a vacuum cleaner can be achieved.

  Below, the detailed structure of the junction part of the fiber reinforced resin lamination sheet 15 and the resin support member 16 is demonstrated using FIG. 7, referring FIG.

  FIG. 7 is a partially enlarged plan view of FIG. 5 showing the dust cover of the vacuum cleaner as viewed from the B direction.

  As shown in FIG. 7, the resin structure 14 of the present embodiment is formed by integrally molding a polyolefin resin support member 16 in the fiber braid portion 25 of the fabric layer 18 b of the fiber reinforced resin laminate sheet 15. At this time, the polyolefin resin of the resin support member 16 having affinity melts and enters the fiber braid portion 25 on the surface of the fabric layer 18b. Thereby, the textile layer 18b of the fiber reinforced resin laminated sheet 15 and the resin support member 16 can be made difficult to peel off. Hereinafter, the above phenomenon is referred to as an anchor effect.

  At this time, the surface layer (joint surface) of the fabric layer 18b of the fiber reinforced resin laminate sheet 15 may be intentionally roughened to provide the fine uneven portion 26. Thereby, the anchor effect can be further enhanced and the fiber-reinforced resin laminated sheet 15 and the resin support member 16 can be firmly connected.

  Further, as shown in FIGS. 5 and 6, the resin structure 14 of the present embodiment has a T-shape at the root of the resin support member 16 (on the side where the fiber-reinforced resin laminated sheet 15 is joined), for example, in a cross-sectional view. A shaped extension 27 may be provided. Thereby, the contact | adherence area of the fiber reinforced resin lamination sheet 15 and the resin support member 16 can be expanded, and a fusion strength can be raised. Here, in addition to the above, the shape of the extended portion 27 may be arbitrary as long as the contact area can be enlarged, such as an L shape.

  As described above, the resin structure of the present invention may be composed of a fiber reinforced resin laminate sheet made of polyolefin resin and a resin support member made of a resin having high affinity with the fiber reinforced resin laminate sheet. .

  According to this configuration, the resin support member is formed of a resin having high affinity for the polyolefin-based resin of the fiber-reinforced resin laminated sheet. Thereby, delamination in the junction part of a resin support member and a fiber reinforced resin lamination sheet can be suppressed. As a result, an inexpensive and highly reliable resin structure can be realized.

  In the resin structure of the present invention, the resin support member may be formed of a polyolefin resin.

  According to this configuration, both the fiber-reinforced resin laminated sheet and the resin support member are made of a resin made of the same type of polyolefin-based material. Therefore, the joint portion between the fiber-reinforced resin laminate sheet and the resin support member has affinity. Thereby, delamination of a fiber reinforced resin lamination sheet and a resin support member can be controlled. As a result, it is possible to realize a resin structure that is inexpensive and lightweight and has excellent reliability with increased physical strength against bending.

  The resin structure of the present invention may be formed by fusing a resin support member to a fiber reinforced resin laminated sheet by an integral molding method including insert molding.

  Thereby, a fiber reinforced resin lamination sheet and a resin support member can be more firmly fused with an affinity material, and delamination can be suppressed. As a result, it is possible to realize a beautiful resin structure having a three-dimensional feeling that is inexpensive and lightweight and has increased physical strength against bending.

  Moreover, the resin structure of the present invention may have an extended portion on the end surface of the resin support member, and may be formed by fusing the extended portion and the fiber-reinforced resin laminated sheet.

  Thereby, the contact | adherence area of a fiber reinforced resin lamination sheet and a resin support member can be expanded, and fusion strength can be raised. As a result, it is possible to realize a resin structure having a strong outer shell that hardly causes delamination.

  Further, the resin structure of the present invention may be configured such that the resin melted during the integral molding of the resin support member enters the knitted portion on the surface of the fabric layer of the fiber reinforced resin laminated sheet.

  Thereby, the melt | fusion strength of a fiber reinforced resin lamination sheet and a resin support member can further be raised. As a result, it is possible to realize a resin structure having a strong outline in which delamination is less likely to occur.

  Moreover, the resin structure of this invention may provide an uneven | corrugated | grooved part in the surface of a fiber braided part.

  Thereby, the melt | fusion strength of a fiber reinforced resin lamination sheet and a resin support member can further be raised.

  Moreover, you may comprise the vacuum cleaner of this invention using the said resin structure for the whole or a part of vacuum cleaner main body.

  Thereby, an inexpensive and lightweight vacuum cleaner having a vacuum cleaner body can be realized.

  The resin structure of the present invention uses a polyolefin-based fiber reinforced resin laminated sheet for a housing such as a product. Therefore, it is not necessary to use expensive materials such as carbon fiber and aramid fiber. Thereby, it is possible to provide a product that is inexpensive, thin, and resistant to impact. As a result, it can be effectively used for an electric device such as a vacuum cleaner, a structure, or the like that is required to be thin and light in weight.

DESCRIPTION OF SYMBOLS 1 Vacuum cleaner main body 1a 1st layer 2 Suction tool 2a 2nd layer 3 Extension pipe 4 Hose 5 Under body body 6 Front wheel 7 Rear wheel 8 Front cover 9 Handle 10 On body body 11 Body attainer 12 Dust collecting part 13 Dust cover 14 Resin structure Body 15 Fiber reinforced resin laminated sheet 16 Resin support member 17 Core layer 18a, 18b Textile layer 19a, 19b, 19c Adhesive layer 20 Transparent layer 21 Colored layer 22 Protective layer 23 Fiber reinforced layer 24 Cover layer 25 Fiber braided portion 26 Uneven portion 27 Extension

Claims (7)

A fiber reinforced resin laminate sheet made of polyolefin resin;
A resin support member made of a resin having a high affinity with the fiber-reinforced resin laminate sheet;
A resin structure composed of The resin structure according to claim 1, wherein the resin support member is made of a polyolefin-based resin. The resin structure according to any one of claims 1 and 2, wherein the resin support member is formed by fusing the fiber reinforced resin laminated sheet with an integral molding method including insert molding. The resin support member has an extended portion on an end surface;
The resin structure according to claim 3, wherein the extended portion and the fiber-reinforced resin laminated sheet are formed by fusing. The resin structure according to any one of claims 3 and 4, wherein a resin melted during integral molding of the resin support member enters a fiber braided portion on the surface of the fabric layer of the fiber reinforced resin laminated sheet. body. The resin structure according to claim 5, wherein an uneven portion is provided on a surface of the fiber braided portion. The vacuum cleaner comprised using the resin structure of Claim 1 for the whole or a part of vacuum cleaner main body.

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