WO2020004643A1

WO2020004643A1 - Molded article, structure, and production method for these

Info

Publication number: WO2020004643A1
Application number: PCT/JP2019/025908
Authority: WO
Inventors: 芳裕山崎; 松原　礼宗; 新一田中; 佑太南川; 優五十嵐; 慎司横井
Original assignee: キョーラク株式会社
Priority date: 2018-06-29
Filing date: 2019-06-28
Publication date: 2020-01-02

Abstract

Provided is a molded article having a skin member attached thereto and having a mark for a consumer appropriately added thereto. As a result of the present invention, a molded article can be provided that comprises a resin sheet and a skin member attached thereto. A surface on the skin member side is a design surface. The design surface includes a mark area having a mark added thereto that comprises a concave section and a convex section. The skin member corresponding to the concave section has the resin of the resin sheet impregnated therein.

Description

Molded body, structure, and manufacturing method thereof

The present invention relates to a molded article used as an interior member of an automobile, a method of manufacturing the same, a structure, and a method of manufacturing the structure.

(First viewpoint)
As a molding technique of an automobile interior member such as a door trim, Patent Document 1 discloses a technique in which a single foamed resin sheet is reheated to a softened state and arranged between a pair of split molds. There is disclosed a technique in which a foamed resin sheet is secondarily foamed by vacuum-suctioning the foamed resin sheet to form a thick portion in a foam molded article.

(Second viewpoint)
In the method of manufacturing a structure of Patent Literature 1, a foamed resin sheet heated and softened is placed in a cavity of a split mold, and then the foamed resin sheet is secondarily foamed by suctioning the cavity under reduced pressure. A method of expanding a foamed resin sheet has been proposed.

(Third viewpoint)
In the method of manufacturing a structure of Patent Literature 1, a foamed resin sheet heated and softened is placed in a cavity of a split mold, and then the foamed resin sheet is secondarily foamed by suctioning the cavity under reduced pressure. A method of expanding a foamed resin sheet has been proposed.

JP 2001-310380 A

(First viewpoint)
As described above, the integrally molded article used as an automobile interior member may be provided with a mark (caution mark) for calling some attention to a surface (design surface) visually recognized by a consumer. However, when the skin member is mounted on the design surface, the adhesion mark or the like causes a problem that the caution mark is easily peeled from the skin member.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a molded body to which a mark for a consumer is appropriately provided even if the molded body has a skin member mounted thereon.

(Second viewpoint)
In a method of manufacturing a structure by injection molding, a liquid molten resin is supplied to a cavity of a split mold at a high pressure, so that even when the shape of the cavity is complicated, the molten resin can be easily spread in the cavity. Therefore, in the method of manufacturing a structure by injection molding, it is easy to manufacture a structure having a complicated shape. However, since the method of manufacturing a structure of Patent Document 1 employs a configuration in which one foamed resin sheet is sandwiched between split molds, the method of manufacturing a structure of Patent Document 1 discloses a method of manufacturing a structure by injection molding. As compared with the method, the shape of the structure that can be formed may be more restricted.

The present invention has been made in view of such circumstances, and has a structure in which the shape is suppressed from being restricted by the manufacturing method, and a structure in which the shape of the structure can be restricted. And a method of producing the body.

(Third viewpoint)
In a method of manufacturing a structure by injection molding, a liquid molten resin is supplied to a cavity of a split mold at a high pressure, so that even when the shape of the cavity is complicated, the molten resin can be easily spread in the cavity. Therefore, in the method of manufacturing a structure by injection molding, it is easy to manufacture a structure having a complicated shape. However, since the method of manufacturing a structure of Patent Document 1 employs a configuration in which one foamed resin sheet is sandwiched between split molds, the method of manufacturing a structure of Patent Document 1 discloses a method of manufacturing a structure by injection molding. As compared with the method, the shape of the structure that can be formed may be more restricted.

(First viewpoint)
According to the present invention, a resin sheet and a molded body provided with a skin member mounted on the resin sheet, wherein the surface on the skin member side is a design surface, and the design surface is configured by a concave portion and a convex portion. A molded product is provided in which the skin member including a mark region with a mark and corresponding to the concave portion is impregnated with a resin of the resin sheet.

According to the present invention, since a mark area having a mark composed of a concave portion and a convex portion is formed on the design surface of the molded body, the mark does not peel off unlike the case where an adhesive or the like is used. In addition, since the skin member is impregnated with the resin in the concave portion in the mark area, the fall of the hair of the skin member during the formation of the concave portion is fixed, and the visibility can be prevented from lowering with time.

Hereinafter, various embodiments of the present invention will be exemplified. The embodiments described below can be combined with each other.
Preferably, the thickness of the convex portion of the mark area is smaller than the thickness of a general area outside the mark area on the design surface.
Preferably, the resin sheet is a foamed resin sheet.
In another embodiment of the present invention, the method includes an arranging step and a molding step. In the arranging step, a resin sheet and a skin member are arranged between a first mold and a second mold. The resin sheet and the skin member are formed by the first mold and the second mold, and the concave portion and the convex portion are formed on one of the opposing surfaces of the first mold and the second mold. A mark forming portion including a mark portion, and in the molding step, by pressing the skin member and the resin sheet by the mark forming portion, a mark area provided with a mark constituted by a concave portion and a convex portion is provided. A method is provided for forming
Preferably, the resin sheet is a foamed resin sheet, and the method further comprises an expansion step, wherein in the expansion step, the space is provided between the first mold and the second mold. The first mold and the second mold are brought close to each other, and the resin sheet is expanded into the space by suctioning the resin sheet under reduced pressure from both the first mold and the second mold that are close to each other. .

(Second viewpoint)
According to the present invention, there is provided a base portion, a reinforcing portion, and a hinge portion, wherein the reinforcing portion is provided so as to reinforce the base portion, and at least one of the following configurations (a) and (b): A structure comprising: Configuration (a): the base portion and the reinforcing portion are connected via the hinge portion. Configuration (b): the reinforcing portion includes the hinge portion.

According to the present invention, since at least one of the configuration (a) and the configuration (b) is provided, structures having various shapes can be manufactured by bending the hinge portion. For this reason, according to the present invention, it is suppressed that the shape is restricted by the manufacturing method.

Hereinafter, various embodiments of the present invention will be exemplified. The embodiments described below can be combined with each other.
Preferably, the structure has the configuration (a).
Preferably, the base has a base wall and a flange wall, and the flange wall is formed at an edge of the base wall, and the hinge portion connects the flange wall and an end of the reinforcing portion. Connected.
Preferably, the reinforcing portion has a reinforcing rib, and the reinforcing rib supports a back surface of the base wall.
Preferably, the reinforcing rib is formed so as to project toward a back surface of the base wall.
Preferably, the base has a base edge, the hinge connects the base edge and the reinforcement, and the reinforcement is provided to extend along the base edge. And a structure which is bent toward the base side around the hinge portion as an axis.
Preferably, the structure is configured by superimposing a skin material on a resin molded body, the base has first and second base edges, and the reinforcing part includes first and second reinforcing parts. Wherein the hinge portion has first and second hinge portions, the first hinge portion connects the first base edge portion and the first reinforcing portion, and the second hinge portion has a second base edge portion. The first and second reinforcing portions are plate-shaped members provided so as to extend along the first and second base edges, and the first and second reinforcing portions are connected to each other. The portion is bent toward the base side about the first and second hinge portions so that the first reinforcement portion is sandwiched between the base portion and the second reinforcement portion, and the first reinforcement portion and the second reinforcement portion are bent. Is welded, and the skin material in the first reinforcement portion is impregnated with the resin constituting the resin molded body in the second reinforcement portion. It is.
Preferably, the structure comprises configuration (b).
Preferably, the base has a base wall and a flange wall, and the flange wall is formed at an edge of the base wall.
Preferably, the reinforcing portion has an extending portion, the hinge portion, and a reinforcing rib, the extending portion is connected to the flange wall, and the extending portion and the reinforcing rib are The reinforcement ribs are connected via a hinge portion, and support the back surface of the base.
Preferably, the reinforcing rib has a flat plate shape.
Preferably, the extension portion has first and second extension portions, the hinge portion has first, second, third, and fourth hinge portions, and one end of the reinforcing rib is The reinforcing rib is connected to the first extending portion via the first hinge portion, the other end of the reinforcing rib is connected to the second extending portion via the second hinge portion, and the third and fourth hinge portions are connected to each other. The reinforcing rib is provided at a portion between the one end and the other end.
Preferably, the reinforcing rib and the base wall are welded.
Preferably, the base, the reinforcement, and the hinge are formed by molding the same resin sheet, and the hinge is formed to be thin.
Preferably, the base further includes an upright wall, the base wall has a first edge and a second edge, and the flange wall is formed at the first edge, and The wall is formed at the second edge.
The method for manufacturing a structure according to the embodiment is a method for manufacturing a structure, comprising a forming step and a rotating step. In the forming step, a resin parison is formed to form a base, a reinforcing part, and a hinge. And forming a molded body having a portion, wherein the hinge portion is configured to connect the base portion and the reinforcing portion, and in the rotating step, the whole or a part of the reinforcing portion around the hinge portion as an axis. Rotate.

(Third viewpoint)
According to the present invention, a base material and a reinforcing member are provided, the base material is made of a foamed resin, the reinforcing member has a plate-like portion, and the reinforcing member A structure is provided that is provided to reinforce and has an edge of the plate-shaped portion embedded in the base material.

According to the present invention, the structure includes the base material and the reinforcing member. Here, since the reinforcing member is provided so as to reinforce the base material, that is, the positional relationship between the reinforcing member and the base material is such that the reinforcing member reinforces the base material. The shape made of the base material can be easily mixed. However, according to the present invention, the reinforcing member and the base material are integrally formed by embedding the edge of the plate-shaped portion of the reinforcing member in the base material. That is, according to the present invention, since the edge of the plate-shaped portion of the reinforcing member is embedded in the base material when the structure is manufactured, even if the shape formed by the reinforcing member and the base material is complicated, the foamed resin sheet can be used. The structure can be easily manufactured by the manufacturing method in which the structure is sandwiched by the split molds. For this reason, according to the present invention, it is suppressed that the shape is restricted by the manufacturing method.

Hereinafter, various embodiments of the present invention will be exemplified. The embodiments described below can be combined with each other.
Preferably, the base has a base wall and a flange wall, and the flange wall is connected to the base wall, and the plate portion is embedded in the base wall and the flange wall.
Preferably, the reinforcing member has a plurality of the plate-shaped portions and a connection portion, and the connection portion is connected to the plurality of the plate-shaped portions.
Preferably, a hook portion is formed at the edge of the plate-shaped portion, and the hook portion is engaged with the base material.
Preferably, the vehicle further includes a fall prevention unit, wherein the fall prevention unit is provided on each of both sides of the plate-shaped portion, and the fall prevention unit supports the plate-shaped portion.

The method for manufacturing a structure according to the embodiment is a method for manufacturing a structure using first and second molds, and includes a sheet forming step, an attaching step, and a forming step, wherein the forming step includes: Forming step, mold closing step, and expanding step, the structure includes a base material and a reinforcing member, the reinforcing member has a plate-shaped portion, and in the sheet forming step, The foamed resin was extruded with an extruder to form a foamed resin sheet. In the attaching step, the reinforcing member was attached to a first mold. In the shaping step, the foamed resin sheet was provided with the reinforcing member. Forming is performed along the inner surface of the first mold. In the mold closing step, the first and second molds are closed, and the first and second molds are closed in a state where the first and second molds are closed. A foaming space for foaming the foaming resin is formed between the mold and the mold. Serial molding the substrate in the foam space be foamed the foam resin, in a state in which the expansion process is completed, the edges of the plate-like portion is embedded in the base material.
Preferably, the first mold has a slit, and in the attaching step, the reinforcing member is arranged in the first mold such that the plate-shaped portion is inserted into the slit.
Preferably, the plate-shaped portion is configured to engage with the slit.

FIG. 1A is a perspective view of a molded body 24 according to an embodiment of the first aspect of the present invention. FIG. 1B is an enlarged view of a dotted line part in FIG. 1A. FIG. 1C is a cross-sectional view taken along line XX in FIG. 1A. One example of a foam molding machine 1 that can be used in the production of a molded body 24 is shown. 3A and 3B are perspective views of the first mold 21 and the second mold 22. FIG. FIG. 3C is an enlarged view of a dotted line part in FIG. 3B. FIG. 3 is a view showing an arrangement of a first mold 21, a second mold 22, a foamed resin sheet 23, and a skin member 28. FIG. 5 is a diagram illustrating a state where the foamed resin sheet 23 is suctioned under reduced pressure by a first mold 21 from the state of FIG. 4. FIG. 6 is a diagram showing a state in which a first mold 21 and a second mold 22 are brought closer to each other from the state of FIG. 5. FIG. 7 is a diagram illustrating a state where the foamed resin sheet 23 is suctioned under reduced pressure by a second mold 22 from the state of FIG. 6. FIG. 4 is a view showing a state where a molded body 24 is taken out from a first mold 21 and a second mold 22. 9A is a front view of the structure 30 according to the first embodiment of the second viewpoint, FIG. 9B is a front perspective view of the structure 30 of the first embodiment of the second viewpoint, and FIG. 9C is FIG. FIG. 6 is a rear perspective view in a state where the structure 30 shown in FIG. FIG. 9B is an AA end view of the structure 30 shown in FIG. 9A. 11A is a front view of the structure 300 in a state where the hinge portion H of the structure 30 is not bent, and FIG. 11B is a front perspective view of the structure 300. 12A is a BB end view of the structure 300 shown in FIG. 11A, and FIG. 12B is an enlarged view of a region A shown in FIG. 12A. 1 shows a foam molding machine 1 and first and

second molds

21 and 22 used when manufacturing a structure 30 according to a first embodiment of a second aspect. A state in which the foamed resin sheet 23 is hung between the first mold 21 and the second mold 22 and the skin material 32 is arranged between the first mold 21 and the second mold 22 is shown. . The state where the foamed resin sheet 23 and the skin material 32 are formed in the second mold 22 is shown. 16A shows a state in which the first and

second molds

21 and 22 are closed, FIG. 16B is an enlarged view of a region B shown in FIG. 16A, and FIG. Is shown in an expanded state. The state where the closed first and

second molds

21 and 22 are opened is shown. 18A is a front view of a structure 30B according to a first modification of the first embodiment of the second aspect, and FIG. 18B is a rear perspective view of the structure 30B shown in FIG. 18A in an inverted state. FIG. 19 is an enlarged view of a region C shown in FIG. 18B. FIG. 19A is a front perspective view of the structure 300B in a state where the reinforcing portion 50B of the structure 30B is not bent, and FIG. 19B is a rear perspective view in a state where the structure 300B shown in FIG. 19A is inverted. 19C is an enlarged view of a region D shown in FIG. 19B. 20A is a front view of a structure 30C according to a second modification of the first embodiment of the second aspect, and FIG. 20B is a rear perspective view of the structure 30C shown in FIG. 20A in an inverted state. FIG. 20B is an enlarged view of a region E shown in FIG. 20B. FIG. 21A is a rear perspective view of the structure 300C in a state where the reinforcing portion 50C of the structure 300C is not bent, and FIG. 21B is an enlarged view of a region F shown in FIG. 21A. 22A is a front view of a structure 30D according to a third modification of the first embodiment of the second aspect, FIG. 22B is a perspective view of the structure 30D shown in FIG. 22A, and FIG. 22C is a structure shown in FIG. 22B. It is the perspective view which looked at the body 30D from the arrow Ar direction. FIG. 22B is an end view along XX shown in FIG. 22A. 24A shows a structure 30E according to the second embodiment of the second aspect, FIG. 24B is an enlarged view of a region B shown in FIG. 24A, and FIG. 24C is an enlarged view of a region C shown in FIG. 24A. FIG. 25A shows a structure 300E in which the hinge portion H of the structure 30E is not bent, and FIG. 25B is a perspective view of the structure 300E shown in FIG. 25A. 26A shows a state in which a part of the structure 300E shown in FIG. 25B is cut, and FIG. 26B is an enlarged view of a region B shown in FIG. 26A. FIG. 25B is an end view along XX shown in FIG. 24B. FIG. 28A is a front view of the structure 30 according to the embodiment, FIG. 28B is a front perspective view of the structure 30 according to the embodiment, and FIG. 28C is a rear perspective view of the structure 30 according to the embodiment. It is a rear perspective view showing the state where structure 30 concerning an embodiment was disassembled. FIG. 28B is an AA end view of the structure 30 shown in FIG. 28A. FIG. 31A is an enlarged view of a region A shown in FIG. 30, and FIG. 31B is a BB end view shown in FIG. 28A. 1 shows a foam molding machine 1 and first and

second molds

21 and 22 used when manufacturing a structure 30 according to an embodiment. The foamed resin sheet 23 is suspended between the first mold 21 and the second mold 22, and the skin material 32 is disposed between the first mold 21 and the second mold 22, and the first mold 21 is formed. 2 shows a state in which the reinforcing member 60 is arranged. FIG. 34A shows a state before the reinforcing member 60 is inserted into the slit sr of the core cr1, and FIG. 34B is a perspective view showing a region B of FIG. 33, in which the reinforcing member 60 is inserted into the slit sr of the core cr1. The state where the reinforcing member 60 is arranged on the core cr1 is shown. 3 shows a state in which the foamed resin sheet 23 is shaped into a shape along the inner surface of the first mold 21. 36A shows a state in which the first and

second molds

21 and 22 are closed, FIG. 36B is an enlarged view of a region B shown in FIG. 36A, and FIG. FIG. 36B is a view showing a state where is expanded, corresponding to FIG. 36B. FIG. 36A shows a state in which the first and

second molds

21 and 22 are opened from the state shown in FIG. 36A. 38A is a rear perspective view of a structure 30B according to Modification 1, FIG. 38B is a front perspective view of a reinforcing member 60B shown in FIG. 38A, and FIG. 38C is a rear perspective view of a structure 30C according to Modification 2. 38D is a front perspective view of the reinforcing member 60C shown in FIG. 38C. 39A to 39D are end views at positions corresponding to BB end faces in FIG. 28A, FIG. 39A is an end view of a plate-like portion 61D of a reinforcing member 60D according to Modification 3, and FIG. 39B is a modification. FIG. 39C is an end view of a plate-like portion 61F of a reinforcing member 60F according to a fifth modification, and FIG. 39D is an end view of a plate-like portion 61F of a reinforcing member 60F according to a sixth modification. 39E is an end view of the plate portion 61G, and FIG. 39E is an enlarged view of a region E shown in FIG. 39D. FIG. 40A is a perspective view of a core cr1 and a plate-like portion 61 according to Modification 7, and FIG. 40B is an end view of a reinforcing member 60H according to Modification 7 at a position corresponding to the BB end surface of FIG. 28A. FIG. 40C is an end view of the reinforcing member 60I according to the eighth modification, and is an end view at a position corresponding to the BB end surface of FIG. 28A. 41A is a left side view of the plate-shaped portion 61J according to Modification Example 9, FIG. 41B is a front view of the plate-shaped portion 61J, FIG. 41C is a rear view of the plate-shaped portion 61J, and FIG. 41E is a top view of the portion 61J, FIG. 41E is a left side view of the plate portion 61K according to Modification 10, FIG. 41F is a front view of the plate portion 61K, and FIG. 41G is a rear view of the plate portion 61K. FIG. 41H is a top view of the plate portion 61K. 42A is a perspective view of a plate-like portion 61L (a reinforcing member 60L) according to Modification 11, FIG. 42B is a perspective view showing a state where the plate-like portion 61L is embedded in a base material 140, and FIG. 42C is a modification. 42D is a perspective view of a plate-like portion 61M (reinforcing member 60M) according to Example 12, FIG. 42D is a perspective view showing a state where the plate-like portion 61M is embedded in the base material 140, and FIG. 42F is a perspective view of FIG. 42F, FIG. 42F is a perspective view showing a state where the plate-shaped portion 61N is embedded in the base material 140, FIG. 42G is a perspective view of a reinforcing member 60O according to Modification 14, and FIG. It is a perspective view which shows the state which embedded the shape part 61O in the base material 140.

Hereinafter, embodiments of the present invention will be described. Various features shown in the embodiments described below can be combined with each other. In addition, the invention is independently established for each characteristic item.

(Embodiment of the first aspect)
1. Molded body 24
A molded body 24 according to one embodiment of the present invention will be described with reference to FIGS. 1A to 1C. The molded body 24 includes a foamed resin sheet 23 and a skin member 28, and has a concave cross section. The expansion ratio of the foamed resin constituting the molded body 24 can be, for example, 1.5 to 6 times, but is not limited thereto.

The skin member 28 is mounted on the design surface D of the molded body 24. In an example, the skin member 28 is formed of a nonwoven fabric having air permeability, and specific examples thereof include nylon fibers, cellulose fibers, and aramid fibers, but are not limited thereto.

(1) On the design surface D, as shown in FIG. 1B, a mark area D1 having a mark composed of the concave portion 5 and the convex portion 7 is formed. The mark area D1 is configured such that a predetermined mark is visually recognized by the shapes of the concave portion 5 and the convex portion 7.

More specifically, the concave portion 5 forms a line indicating the contour of the mark and the internal shape thereof. The convex portion 7 forms a region surrounded by the concave portion 5. Thus, the mark area D1 is formed from the concave portions 5 and the convex portions 7. The design surface D further has a general area D2 as an area outside the mark area D1.

マーク As shown in FIG. 1C, the mark area D1 is configured to have a smaller thickness than the general area D2. That is, the thickness of the concave portion 5 and the convex portion 7 is smaller than that of the general region D2. Further, the concave portion 5 is configured to have a smaller thickness than the convex portion 7. As described above, by forming the concave portion 5 and the convex portion 7 so as to be smaller in thickness than the general region D2 on the design surface D, the visibility of the mark indicated by the mark region D1 is secured.

(4) The resin of the foamed resin sheet 23 is impregnated in the concave portion corresponding portion 29 corresponding to the concave portion 5 in the skin member 28. Since the resin is impregnated in the skin member 28 corresponding to the concave portion 5 in the mark region D1, hair fall in the concave portion corresponding portion 29 generated at the time of forming the concave portion 5 is fixed, and gloss is made by the impregnated resin. appear. Thereby, the visibility of the mark area D1 formed on the design surface D is improved.

2. Configuration of Foam Molding Machine 1 With reference to FIG. 2, a description will be given of a foam molding machine 1 that can be used for performing a method of manufacturing a molded body 24 according to an embodiment of the present invention. The foam molding machine 1 includes a resin supply device 2, a T-die 18, a first mold 21, and a second mold 22. The resin supply device 2 includes a hopper 12, an extruder 13, an injector 16, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27.
Hereinafter, each configuration will be described in detail.

<Hopper 12, extruder 13>
The hopper 12 is used for charging the raw material resin 11 into the cylinder 13a of the extruder 13. The form of the raw material resin 11 is not particularly limited, but is usually in a pellet form. The raw material resin is, for example, a thermoplastic resin such as a polyolefin. Examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer, and a mixture thereof.

(4) After the raw material resin 11 is put into the cylinder 13a from the hopper 12, it is melted by being heated in the cylinder 13a to become a molten resin. Further, it is transported toward the tip of the cylinder 13a by the rotation of a screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and conveys the molten resin while kneading it by rotation. A gear device is provided at the base end of the screw, and the screw is driven to rotate by the gear device. The number of screws arranged in the cylinder 13a may be one, or may be two or more.

<Injector 16>
The cylinder 13a is provided with an injector 16 for injecting a blowing agent into the cylinder 13a. The foaming agent injected from the injector 16 includes a physical foaming agent, a chemical foaming agent, and a mixture thereof, and is preferably a physical foaming agent. As the physical foaming agent, use is made of an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, and water, and an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, and dichloroethane, and further, a supercritical fluid thereof. be able to.

As the supercritical fluid, it is preferable to use carbon dioxide, nitrogen or the like. For nitrogen, the critical temperature is 149.1 ° C. and the critical pressure is 3.4 MPa or more. It can be obtained by setting it to 7.4 MPa or more. Examples of the chemical blowing agent include those which generate carbon dioxide gas by a chemical reaction between an acid (eg, citric acid or a salt thereof) and a base (eg, baking soda). The chemical blowing agent may be supplied from the hopper 12 instead of being injected from the injector 16.

<Accumulator 17, T-die 18>
The foamed resin obtained by melt-kneading the raw material resin and the foaming agent is extruded from the resin extrusion port of the cylinder 13 a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b slidable therein, and the foamed resin can be stored in the cylinder 17a. Then, by moving the piston 17b after the foamed resin is stored in the cylinder 17a by a predetermined amount, the foamed resin is pushed out from the slit provided in the T-die 18 through the connecting pipe 27 and hangs down, thereby forming the foamed resin sheet 23. Form.

<First and

second molds

21 and 22>
The first mold 21 and the second mold 22 will be described with reference to FIGS. 3A to 3C. The first mold 21 is configured as a concave mold that forms a cavity 21b on the facing surface 21a. On the other hand, the second mold 22 is configured as a convex mold that forms the core 22b on the facing surface 22a. The first mold 21 and the second mold 22 are arranged such that the cavity 21b and the core 22b face each other.

ピン A pinch-off portion 21c is provided at the peripheral end of the facing surface 21a of the first mold 21 so as to surround the cavity 21b. Further, a pinch-off portion 22c is provided at a peripheral end of the facing surface 22a of the second mold 22 so as to surround the core 22b. When the first mold 21 and the second mold 22 are brought close to each other, as shown in FIG. 6, the pinch-off portion 21c and the pinch-off portion 22c come into contact with each other, and the facing surface 21a and the facing surface 22a form a closed space S. It is configured to:

マーク As shown in FIG. 3B, a mark forming portion 20 is formed on the facing surface 22a of the second mold 22. Although the details will be described later, in the process of manufacturing the molded body 24, the mark forming section 20 presses the foamed resin sheet 23 and the skin member 28 housed in the closed space S so that the design surface D of the molded body 24 is A mark area D1 is formed.

マーク As shown in FIG. 3C, the mark forming part 20 includes a concave part forming part 20a and a convex part forming part 20b. The concave portion forming portion 20a is configured to protrude from the convex portion forming portion 20b with reference to the facing surface 22a. In this way, when the foamed resin sheet 23 and the skin member 28 accommodated in the closed space S are pressed in the step of manufacturing the molded body 24, the concave part 5 is formed in the molded body 24 by the concave part forming part 20a. Then, the convex portion 7 is formed by the convex portion forming portion 20b.

では In the present embodiment, the mark forming unit 20 is formed of a member different from the second mold 22. By doing so, it is possible to change the mark applied to the molded body 24 only by changing the shape of the mark forming section 20. However, the present invention is not limited to this example, and the second mold 22 and the mark forming section 20 may be formed integrally.

１As shown in FIG. 2, the first mold 21 and the second mold 22 are provided with a large number of reduced

pressure suction holes

21d and 22d. Although the details will be described later, the foamed resin sheet 23 housed in the closed space S is suctioned under reduced pressure from the suction holes 21d and 22d, so that the facing surface 21a of the first mold 21 and the facing surface of the second mold 22 are opposed to each other. The foamed resin sheet 23 can be shaped into a shape along the surface 22a.

3. Manufacturing Method of Molded Body 24 With reference to FIGS. 4 to 8, a method of manufacturing the molded body 24 in the embodiment of the present invention will be described. The method of this embodiment includes an arrangement step, a molding step, an expansion step, and a finishing step. The details will be described below.

(1) Arranging Step In the arranging step, as shown in FIG. 4, one foamed resin sheet 23 formed by extruding a molten foamed resin from the slit of the T-die 18 and hanging it down is formed into a first mold 21, It is arranged between the two molds 22. A skin member 28 is further arranged on the second mold 22 side.

Here, the foamed resin sheet 23 hung down from the T-die 18 is cooled to room temperature before molding and is not solidified, and the solidified foamed resin sheet 23 is not heated before molding. Immediately after being extruded from the slit, the foamed resin sheet 23 has a substantially uniform temperature as a whole, and is gradually cooled from the surface by the atmosphere while being suspended.

(4) Since the foamed resin sheet 23 is less affected by cooling by the air toward the center in the thickness direction, the foamed resin sheet 23 has such a property that the temperature is increased and the viscosity is reduced toward the center in the thickness direction. The thickness of the foamed resin sheet 23 is not particularly limited, but is, for example, 0.5 to 5 mm, and preferably 1 to 3 mm.

(2) Forming Step In the forming step, the first suction step and the mold proximity step are performed in this order. In the first suction step, as illustrated in FIG. 5, the foamed resin sheet 23 is suctioned by the first mold 21 under reduced pressure. Thereby, the foamed resin sheet 23 is shaped into a shape along the cavity 21 b of the first mold 21.

In the mold approaching step, as shown in FIG. 6, the first mold 21 and the second mold 22 are brought close to each other. As described above, when the first mold 21 and the second mold 22 are brought close to each other, the pinch-off portion 21c provided on the first mold 21 and the pinch-off portion 22c provided on the second mold 22 come into contact with each other. Thus, a closed space S surrounded by the facing surface 21a and the facing surface 22a is formed. The volume of the sealed space S is not particularly limited, but is preferably 1.1 to 4.0 times the volume of the foamed resin sheet 23. The portions of the foamed resin sheet 23 and the skin member 28 outside the closed space S are burrs 23a and burrs 28a.

At this time, the skin member 28 and the foamed resin sheet 23 are pressed by the mark forming portion 20 formed on the facing surface 22a of the second mold 22, thereby forming the mark area D1. As described above, the concave portion forming portion 20a is configured to protrude from the convex portion forming portion 20b, and the skin member 28 in contact with the concave portion forming portion 20a is impregnated with the resin of the foamed resin sheet 23. It becomes.

Here, preferably, the height of the concave portion forming portion 20a in the protruding direction is configured to match the thickness of the closed space S (that is, the interval between the opposing

surfaces

21a and 22a). By doing so, the pressure applied to the foamed resin sheet 23 corresponding to the concave portion forming portion 20a can be increased, and the skin member 28 corresponding to the concave portion 5 of the molded body 24 (corresponding to the concave portion corresponding portion 29 in FIG. 1C). Thus, more resin can be impregnated.

(3) Expansion Step In the expansion step, as shown in FIG. 7, a second suction step of vacuum-suctioning the foamed resin sheet 23 from both the first mold 21 and the second mold 22 is performed. Thereby, the foamed resin sheet 23 is expanded in the closed space S.

(4) When the foamed resin sheet 23 is suctioned from both the first mold 21 and the second mold 22 under reduced pressure, the foaming of the foamed resin sheet 23 is promoted and the foamed resin sheet 23 expands. Since the foamed resin sheet 23 has the lowest viscosity near the center in the thickness direction (highest fluidity), foaming near the center in the thickness direction is particularly promoted, and the foamed resin sheet 23 expands. As a result, a molded body 24 having a structure in which the average cell diameter in the layer near the center in the thickness direction (center layer) is large and the average cell diameter in the surface layer near the surface is small. Such a molded body 24 is lightweight and highly rigid because the central layer having a large average cell diameter has a sandwich structure sandwiched between surface layers having a small average cell diameter. Here, the average bubble diameter in the entire thickness direction is, for example, 100 to 2000 μm. The average bubble diameter of the surface layer is, for example, 80 to 500 μm. The average cell diameter of the central layer is, for example, 100 to 2000 μm.

(4) Finishing Step In the finishing step, as shown in FIG. 8, the first mold 21 and the second mold 22 are opened, the burrs 23a and the molded body 24 with the burrs 28a are taken out, and the

burrs

23a and 28a are removed. By cutting, the molded body 24 shown in FIG. 1 is obtained. As described above, the molded body 24 in which the skin member 28 is mounted on the foamed resin sheet 23 is formed.

4. Other Embodiments The applicable range of the present invention is not limited to the above embodiment. For example, the reduced pressure suction by the first mold 21 and the second mold 22 may start the reduced pressure suction by the first mold 21 first, or may start the reduced pressure suction by the second mold 22 first. The vacuum suction by the first mold 21 and the second mold 22 may be started simultaneously. Further, the reduced pressure suction by the first mold 21 may be stopped first, the reduced pressure suction by the second mold 22 may be stopped first, and the reduced pressure suction by the first mold 21 and the second mold 22 may be performed. May be stopped at the same time. The reduced pressure suction by the first mold 21 and the second mold 22 may be started before the first mold 21 and the second mold 22 are brought close to each other, or may be started after bringing them close to each other.

Also, the expansion step can be omitted. Further, the resin sheet is not limited to the foamed resin sheet. Further, in the above embodiment, the thickness of the convex portion 7 of the mark area D1 is smaller than the thickness of the general area D2 outside the mark area on the design surface D, but is not limited to this form. The thickness of the portion 7 may be approximately the same as the thickness of the general region D2. In this case, it is preferable to provide the reduced-pressure suction hole 22d so as to communicate with the convex part forming part 20b of the mark forming part 20 provided in the second mold 22. By doing so, it becomes possible to more appropriately shape the foamed resin sheet 23 into a shape along the mark forming portion 20. In these cases, the same effects as in the above embodiment can be obtained.

(Embodiment of the second viewpoint)
1. First embodiment of second viewpoint 1-1. Structure 30
The structure 30 according to the first embodiment is an interior part of a vehicle, and a front surface 43B is formed on the structure 30. A passenger of the vehicle can place an article such as a beverage container on the front surface 43B. it can. As described above, since the front surface 43B is a portion to which the load of the article is applied, the structure 30 has a configuration (a reinforcing portion 50 described later) that reinforces the formation region of the front surface 43B in the structure 30. Have.

構造 As shown in FIGS. 9A to 10, the structure 30 includes a base 40, a reinforcing portion 50, and a hinge portion H. Further, the projecting portion 35 is formed on the structure 30. The protrusion 35 divides the concave space of the structure 30 into a first region R1 and a second region R2. Further, as shown in FIG. 10, the structure 30 has a two-layer structure. That is, the structure 30 includes the resin molded body 31 as the first layer and the skin material 32 as the second layer. The resin molded body 31 is a molded body formed of a foamed resin. The expansion ratio of the resin molded body 31 is not particularly limited, but is, for example, 1.5 to 6 times. In the first embodiment, a case where the constituent resin of the resin molded body 31 is a foamed resin is described as an example, but the resin may not be a foamed resin. Further, in the first embodiment, the case where the structure 30 includes the skin material 32 will be described as an example, but the structure 30 may not include the skin material 32.

1-1-1. Base 40
As shown in FIGS. 9A to 10, the base 40 includes a base main body 41 and a flange wall 42. The base body 41 is formed in a concave shape, and a flange wall 42 is connected to an edge of the base body 41. The base body 41 includes a base wall 43 and an upright wall 44. The base wall 43 is a plate-like member, and in the first embodiment, the base wall 43 is a flat plate. Note that the base wall 43 may be curved. The base wall 43 is supported by the reinforcing portion 50, and when a load is applied to the base wall 43, deformation of the base wall 43 is suppressed. The base wall 43 has a first edge 43A, a second edge 43a, a front surface 43B, and a back surface 43C. The flange wall 42 is connected to the first edge 43A. The front surface 43B is formed on the opposite side of the rear surface 43C, and the rear surface 43C faces the reinforcing portion 50 with an interval. The back surface 43C is a surface supported by the reinforcing portion 50. The standing wall 44 is a plate-shaped member, and the standing wall 44 extends from the base wall 43 so as to rise. In the first embodiment, the standing wall 44 is connected to the second edge 43a. The standing wall 44 has a protrusion 35. The flange wall 42 is connected to the edge of the standing wall 44.

Flange wall 42 is a plate-like member, and in the first embodiment, flange wall 42 is formed in an annular shape. The inner edge of the flange wall 42 is connected to the base wall 43 and the standing wall 44. A hinge portion H is formed on the outer edge of the flange wall 42, and the outer edge of the flange wall 42 is connected to the reinforcing portion 50 via the hinge portion H. An opening 42A is formed in the flange wall 42, and a fixing member (for example, a bolt) for fixing the structure 30 to a vehicle interior component is inserted into the opening 42A.

1-1-2. Reinforcing part 50 and hinge part H
As shown in FIGS. 10, 12A and 12B, the reinforcing portion 50 is rotatably connected to the base 40 via the hinge portion H. In the first embodiment, the structure 30 is provided with two reinforcing portions 50 and two hinge portions H, but the number is not limited to two and may be one or three or more. It may be. The hinge portion H is formed to be thin. Specifically, the thickness of the hinge portion H is smaller than the thickness of the reinforcing portion 50 and the thickness of the base portion 40. For this reason, the hinge portion H is configured such that the reinforcing portion 50 can be bent so that the manufacturer or the manufacturing apparatus can tilt the reinforcing portion 50 toward the back surface 43C of the base wall 43.

The reinforcing portion 50 is a plate-like member formed in a concave shape. The reinforcing part 50 has a reinforcing rib 51 and a fixing part 52. When the reinforcing portion 50 is bent, the reinforcing rib 51 is formed so as to protrude toward the rear surface 43C of the base wall 43. The reinforcing portion 50 is provided to reinforce the base 40. Specifically, in the first embodiment, the reinforcing rib 51 is in contact with the back surface 43C of the base wall 43, whereby the base wall 43 is supported by the reinforcing portion 50. As a result, the base portion 40 is Reinforced. In addition, in the first embodiment, the reinforcing rib 51 is in contact with the base wall 43, but is not limited thereto. The intervening member may be provided between the reinforcing rib 51 and the base wall 43, and the reinforcing rib 51 may not be in contact with the base wall 43. The reinforcing rib 51 is welded to the back surface 43C of the base wall 43. An opening 53 is formed in the fixing portion 52, and a fixing member (for example, a bolt) for fixing the structure 30 to a vehicle interior component is inserted into the opening 53.

1-1-3. Skin material 32
As shown in FIG. 10, the skin material 32 is provided on the entire front surface of the resin molded body 31. The skin material 32 is, for example, made of a nonwoven fabric having air permeability, and specific examples thereof include nylon fibers, cellulose fibers, and aramid fibers, but are not limited thereto.

1-2. Configuration of Foam Molding Machine 1 As shown in FIG. 13, the foam molding machine 1 includes a resin supply device 2, a T die 18, a first mold 21, and a second mold 22. The resin supply device 2 includes a hopper 12, an extruder 13, an injector 16, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27.

1-2-1. Hopper 12 and extruder 13
The hopper 12 is used for charging the raw material resin 11 into the cylinder 13a of the extruder 13. The form of the raw material resin 11 is not particularly limited, but is usually in a pellet form. The raw material resin is, for example, a thermoplastic resin such as a polyolefin. Examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer, and a mixture thereof. The raw material resin 11 is put into the cylinder 13a from the hopper 12, and then melted by being heated in the cylinder 13a to become a molten resin. Further, it is transported toward the tip of the cylinder 13a by the rotation of a screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and conveys the molten resin while kneading it by rotation. A gear device is provided at the base end of the screw, and the screw is driven to rotate by the gear device.

1-2-2. Injector 16
The cylinder 13a is provided with an injector 16 for injecting a blowing agent into the cylinder 13a. The foaming agent injected from the injector 16 includes a physical foaming agent, a chemical foaming agent, and a mixture thereof, and is preferably a physical foaming agent. As the physical foaming agent, use is made of an inorganic physical foaming agent such as air, carbon dioxide, nitrogen gas, and water, and an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, and dichloroethane, and further, a supercritical fluid thereof. be able to. As the supercritical fluid, it is preferable to use carbon dioxide, nitrogen or the like. For nitrogen, the critical temperature is 149.1 ° C. and the critical pressure is 3.4 MPa or more. It can be obtained by setting it to 7.4 MPa or more. Examples of the chemical blowing agent include those which generate carbon dioxide gas by a chemical reaction between an acid (eg, citric acid or a salt thereof) and a base (eg, baking soda). The chemical blowing agent may be supplied from the hopper 12 instead of being injected from the injector 16.

1-2-3. Accumulator 17 and T die 18
The foamed resin obtained by melt-kneading the raw material resin and the foaming agent is extruded from the resin extrusion port of the cylinder 13 a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b slidable therein, and the foamed resin can be stored in the cylinder 17a. Then, by moving the piston 17b after the foamed resin is stored in the cylinder 17a by a predetermined amount, the foamed resin is pushed out from the slit provided in the T-die 18 through the connecting pipe 27 and hangs down, thereby forming the foamed resin sheet 23. Form.

1-2-4. First and

second molds

21 and 22
The foamed resin sheet 23 is guided between the first and

second molds

21 and 22. The first mold 21 has a concave cavity cv. A convex core cr is formed in the second mold 22. The first and

second molds

21 and 22 are provided with a number of reduced-pressure suction holes (not shown). Further, pinch-off

portions

21c and 22c are formed in the first and

second molds

21 and 22 so as to surround the cavity cv.

1-3. Method for Manufacturing Structure 30 The method for manufacturing the structure 30 according to the first embodiment includes an arrangement step, a molding step, a cutting step, a rotation step, and a welding step.

1-3-1. Arrangement Step As shown in FIG. 14, in the arrangement step, one foamed resin sheet 23 formed by extruding the molten foamed resin from the slit of the T-die 18 is divided into a first mold 21 and a second mold 22. Place between A skin material 32 is arranged between the foamed resin sheet 23 and the second mold 22.

1-3-2. Molding Step In the molding step, a resin parison is molded to form a molded body having the base portion 40, the reinforcing portion 50, and the hinge portion H. The molding step includes a suction step, a mold closing step, and an expansion step. As shown in FIG. 15, in the suction step, the foamed resin sheet 23 and the skin material 32 are suctioned from the reduced pressure suction holes of the second mold 22. Thereby, the foamed resin sheet 23 and the skin material 32 are formed into a shape along the core cr of the second mold 22.

As shown in FIG. 16A, in the mold closing step, the first mold 21 and the second mold 22 are brought close to each other, and the first and

second molds

21 and 22 are closed. In the state where the mold closing step is completed, in the portion where the hinge portion H is formed, the space between the first mold 21 and the second mold 22 is very narrow, and the foamed resin sheet 23 and the skin material 32 is crushed. As a result, a thinner hinge portion H is formed in the structure 300. Further, as shown in FIG. 16B, in a state in which the mold closing step is completed, the pinch-off portion 21c and the pinch-off portion 22c are in contact with each other, and a closed space S is formed in the first mold 21 and the second mold 22. . A portion of the foamed resin sheet 23 and the skin material 32 outside the closed space S becomes a burr br. As shown in FIG. 16C, in the expansion step, the pressure in the closed space S is reduced through the reduced-pressure suction holes of the first and

second molds

21 and 22. Thereby, the foamed resin sheet 23 is expanded. When the pressure in the closed space S is reduced, the foaming of the foamed resin sheet 23 is promoted, and the foamed resin sheet 23 expands.

1-3-3. Cutting Step As shown in FIG. 17, the first and

second molds

21 and 22 are opened, and the structure 300 is removed from the first and

second molds

21 and 22. In the cutting step, the burr br formed on the structure 300 is cut.

1-3-4. Rotation Step As shown by a broken arrow in FIG. 12A, in the rotation step, the entire reinforcing portion 50 of the structure 300 is rotated around the hinge H of the structure 300 as an axis. Specifically, the reinforcing portion 50 of the structure 300 is bent so that the reinforcing portion 50 of the structure 300 is tilted toward the back surface 43C of the base wall 43. Thereby, the structure 300 can be deformed into the structure 30. Note that the rotating step may be performed by a manufacturer or may be performed by a manufacturing apparatus.
As described above, in the method of manufacturing the structure 30 according to the first embodiment, the structure 300 is manufactured in the forming step instead of manufacturing the structure 30 in the forming step. That is, the structure 300 is manufactured by a method in which one foamed resin sheet 23 is sandwiched between the first and

second molds

21 and 22, and then the structure 300 is transformed into the structure 30 in the main rotating step. Let it.

1-3-5. Welding Step In the welding step, the back surface 43C of the base wall 43 of the structure 30 and the reinforcing rib 51 of the reinforcing portion 50 of the structure 30 are welded. Accordingly, it is possible to prevent the bent reinforcing portion 50 from returning to the original state, that is, the state before the bending, due to the elastic force of the hinge portion H. In the welding step, ultrasonic welding is employed.

1-4. Effects of the first embodiment of the second aspect In the structure 30 according to the first embodiment, the reinforcing portion 50 is disposed on the back surface side of the base wall 43. The structure having such a configuration can be manufactured relatively easily by a manufacturing method using injection molding. On the other hand, in the manufacturing method in which one foamed resin sheet 23 is sandwiched between the first and

second molds

21 and 22 as in the method for manufacturing the structure 30 according to the first embodiment, the structure 30 is It is difficult to technically mold a structure having a complicated structure. Since the structure 30 according to the first embodiment includes the thinned hinge portion H, even if the reinforcing portion 50 is turned down toward the back surface 43C of the base wall 43, the manufacturer can easily make the structure 300. The state can be changed from the state to the state of the structure 30. That is, since the structure 300 according to the first embodiment includes the thinned hinge portion H, the manufacturer directs the reinforcing portion 50 to the back surface 43C of the base wall 43 without damaging the structure 300. The reinforcing portion 50 can be bent so as to fall down. As described above, the configuration of the structure 30 according to the first embodiment is suppressed from being restricted in shape due to the manufacturing method. Further, the manufacturing method according to the first embodiment is a method capable of suppressing the restriction on the shape of the structure. In particular, the manufacturing method according to the first embodiment is effective when a reinforcing structure is provided on the back side of a structure having a deep drawing shape such as the structure 30.

1-5. Modification 1 of the first embodiment of the second aspect
In the first modification of the first embodiment, description of portions common to the first embodiment will be appropriately omitted. As shown in FIGS. 18A to 19C, a structure 30B according to the first modification includes a base 40 and a reinforcing portion 50B. Modification 1 of the first embodiment is a form in which the reinforcing portion 50B includes a hinge portion H. For this reason, in the rotation process of the structure 30B of the first modification, a part of the reinforcing portion 50B rotates around the hinge H.

The reinforcing portion 50B includes a reinforcing rib 51B, a pair of extending portions 52B, and a hinge portion H. Further, an opening 53B is formed in the reinforcing portion 50B, and a fixing member (for example, a bolt) for fixing the structure 30B to a vehicle interior part is inserted into the opening 53B. The openings 53B are formed in the reinforcing ribs 51B and the extending portions 52B, respectively. When the reinforcing ribs 51B are bent, the openings 53B of the reinforcing ribs 51B are connected to the openings 53B of the extending portions 52B.

The reinforcing rib 51B is a plate-like member, and in the first modification, the reinforcing rib 51B is formed in a flat plate shape. Note that the reinforcing rib 51B may be curved. The reinforcing rib 51B is connected to the extension 52B via the hinge H. When the reinforcing rib 51B is bent around the hinge H, the reinforcing rib 51B is provided on the back surface of the base 40, and the reinforcing rib 51B supports the back surface of the base 40. Specifically, the reinforcing rib 51B is fixed to the standing wall 44, and as a result, the reinforcing rib 51B supports the base wall 43 connected to the standing wall 44. In the first modification of the first embodiment, the reinforcing rib 51B is in contact with the standing wall 44, but is not limited to this. The intervening member may be provided between the reinforcing rib 51B and the standing wall 44, and the reinforcing rib 51B may not be in contact with the standing wall 44. The reinforcing rib 51B is fixed to the standing wall 44 by welding the reinforcing rib 51B to the standing wall 44. As this welding method, for example, ultrasonic welding can be adopted.

The extension 52B is a plate-like member, and one end of the extension 52B is connected to the outer edge of the flange wall 42, and the other end of the extension 52B is connected to the reinforcing rib 51B via the hinge H. ing. The extending portions 52B are provided on the base wall 43 at intervals. Although the hinge portion H is not provided at the connection portion between the extension portion 52B and the flange wall 42, the hinge portion H may be formed at the connection portion between the extension portion 52B and the flange wall 42. In this case, the extension 52B is provided in parallel with the flange wall 42 immediately after molding with a mold.

The hinge portion H is formed to be thin, and the thickness of the hinge portion H is smaller than the thickness of the reinforcing rib 51B, the thickness of the extension portion 52B, and the thickness of the base portion 40.

As shown by the broken line arrow in FIG. 19C, the manufacturer bends the hinge portion H and the reinforcing rib 51B to thereby transform the structure 300B shown in FIG. 19A into the structure 30B shown in FIG. 18A. Can be.

1-6. Modification 2 of the first embodiment of the second aspect
Also in Modification 2 of the first embodiment, description of portions common to the first embodiment will be appropriately omitted. As shown in FIGS. 20A to 21B, a structure 30C according to Modification 2 includes a base 40 and a reinforcing portion 50C. Similar to the first modification of the first embodiment, the second modification of the first embodiment also has a configuration in which the reinforcing portion 50C includes the hinge portion H. For this reason, in the rotation process of the structure 30C of the second modification, a part of the reinforcing portion 50C rotates around the hinge H. The manufacturer can transform the structure 300C into the structure 30C by performing the rotation process.

The reinforcing portion 50C includes a reinforcing rib 51C, a pair of extending portions 52C, and a hinge portion H. An opening 53C is formed in the reinforcing portion 50C, and a fixing member (for example, a bolt) for fixing the structure 30C to a vehicle interior part is inserted into the opening 53C.

The extension 52C has the same configuration as the extension 52B described in the first modification. In the second modification of the first embodiment, one of the pair of extending portions 52C is referred to as a first extending portion 52C1, and the other of the pair of extending portions 52C is referred to as a second extending portion 52C2.

In addition, in the second modification of the first embodiment, the hinge portion H includes a first hinge portion h1, a second hinge portion h2, a third hinge portion h3, and a fourth hinge portion h4. The first hinge part h1, the second hinge part h2, the third hinge part h3, and the fourth hinge part h4 extend in parallel. The first hinge part h1 is provided at one end of the reinforcing rib 51C, and the second hinge part h2 is provided at the other end of the reinforcing rib 51C. The third hinge portion h3 and the fourth hinge portion h4 are provided in a portion between one end and the other end of the reinforcing rib 51C.

The reinforcing rib 51C is a plate-like member, and the reinforcing rib 51C has a pair of first plate-like portions c1 and a second plate-like portion c2. The first extension 52C1 and one of the first plate portions c1 are connected via a first hinge portion h1, and the second extension portion 52C2 and the other first plate portion c1 are connected to each other by a second hinge. They are connected via a section h2. Further, one first plate-shaped portion c1 and the second plate-shaped portion c2 are connected via a third hinge portion h3, and the other first plate-shaped portion c1 and the second plate-shaped portion c2 are connected to each other. They are connected via four hinges h4.

In the state where the reinforcing rib 51C is bent around the hinge H, the reinforcing rib 51C is provided on the back surface of the base 40, and the reinforcing rib 51C supports the back surface of the base 40. Specifically, the second plate-shaped portion c2 is in contact with the back surface 43C of the base wall 43, whereby the base wall 43 is supported by the reinforcing portion 50C. As a result, the base portion 40 is reinforced by the reinforcing portion 50C. You. In the second modification of the first embodiment, the second plate-shaped portion c2 is in contact with the base wall 43, but is not limited thereto. The intervening member may be provided between the second plate-shaped portion c2 and the base wall 43, and the second plate-shaped portion c2 may not be in contact with the base wall 43. The second plate-shaped portion c2 is fixed to the base wall 43 by being welded to the base wall 43. As in the first embodiment and the first modification of the first embodiment, ultrasonic welding can be adopted as this welding method.

The extension 52C is a plate-like member, and one end of the extension 52C is connected to the outer edge of the flange wall 42. A first hinge portion h1 is provided at an end portion of the first extension portion 52C1 facing the second extension portion 52C2, and the first hinge portion h1 is provided at an end portion of the second extension portion 52C2. A second hinge h2 is provided at the opposite end. The extension portion 52C is provided on the base wall 43 with an interval. Note that the hinge portion H is not provided at the connection portion between the extension portion 52C and the flange wall 42, but the hinge portion H may be formed at the connection portion between the extension portion 52C and the flange wall 42. In this case, the extension 52C of the structure 30C immediately after being formed by the mold is provided in parallel with the flange wall 42.

The hinge portion H is formed to be thin, and the thickness of the hinge portion H is smaller than the thickness of the reinforcing rib 51C, the thickness of the extension portion 52C, and the thickness of the base portion 40.

As shown by a dashed arrow Ar1 shown in FIG. 21B, the manufacturer bends one of the first plate-like portions c1 from the first extension portion 52C1 around the first hinge portion h1 and makes the third hinge portion h3 an axis. Then, the first plate-shaped portion c1 and the second plate-shaped portion c2 are bent. Next, as shown by a dashed arrow Ar2 shown in FIG. 21B, the manufacturer bends the other first plate-like portion c1 from the second extension portion 52C2 around the second hinge portion h2 and makes the fourth hinge portion The other first plate-shaped portion c1 and second plate-shaped portion c2 are bent around h4 as an axis. As a result, the reinforcing rib 51C shown in FIG. 21B is turned over to the state shown in FIG. 20C. That is, the manufacturer can transform the structure 300C shown in FIG. 21A into the structure 30C shown in FIG. 20B. Note that the operation order of the dashed arrow Ar1 and the dashed arrow Ar2 may be reversed.

1-7. Modification 3 of the first embodiment of the second aspect
Also in the third modification of the first embodiment, description of portions common to the first embodiment will be appropriately omitted. As shown in FIG. 22A, a structure 30D according to Modification 3 includes a base 40 and a reinforcing portion 50D. In the third modification, as in the first embodiment, the reinforcing portion 50D is rotatably connected to the base 40 via the hinge H (see the arrow Br in FIG. 22B). Note that the state before the rotation of the reinforcing portion 50D is the same as that of the first embodiment, and a description thereof will be omitted.

Modification 3 is different from Modification 3 in that the depth dp (height) of the reinforcement rib 51D of the reinforcement 50D of the reinforcement 50 is greater than the depth (height) of the reinforcement rib 51 of the reinforcement 50 of the first embodiment. This is different from the first embodiment.
Further, in the first embodiment, the depth (height) of each reinforcing rib 51 is the same, but in the third modification, the depth (height) of each reinforcing rib 51D is different. Specifically, the depth (height) of the reinforcing rib 51D shown on the near side in FIG. 22B is larger than the depth (height) of the reinforcing rib 51D shown on the far side in FIG. 22B. Thus, even when the structure 30D has a plurality of reinforcing ribs 51D and the depths (heights) of the reinforcing ribs 51D are different, the structure 30D is formed in the forming step described in the first embodiment. It is possible, and the same effect as in the first embodiment can be obtained.

Here, when the depth dp is set to be large, the portion constituting the reinforcing portion 50D of the foamed resin sheet is extended in the molding process, and the reinforcing rib 51D of the reinforcing portion 50D is easily thinned. . When the thickness of the reinforcing rib 51D is reduced, the strength of the reinforcing portion 50D may be reduced. Therefore, also in Modification 3, 1-3-5. As described in the welding step, the back surface 43C of the base wall 43 and the bottom 50D1 (see FIG. 22C) of the reinforcing rib 51D are welded. Also in Modification 3, similarly to the first embodiment, ultrasonic welding can be adopted as the welding method.

As shown in FIG. 23, when the back surface 43C and the bottom portion 50D1 are welded, the resin molded body 31 (foamed resin) of the back surface 43C and the resin molded body 31 (foamed resin) of the bottom portion 50D1 are melted. The resin molded body 31 soaks into the skin material 32 provided on the bottom 50D1. Thereby, the back surface 43C and the bottom portion 50D1 are more firmly connected, and a decrease in the strength of the reinforcing portion 50D is avoided. In other words, in the third modification, the base wall 43 (the back surface 43C) and the reinforcing portion 50D (the bottom portion 50D1) are welded so that the foam resin penetrates into the skin material 32 provided on the bottom portion 50D1. Thereby, even if the depth dp of the reinforcing portion 50D is large, a decrease in the strength of the reinforcing portion 50D is avoided.

When the manufacturer welds the back surface 43C and the bottom portion 50D1, the manufacturer does not press the ultrasonic welding tool against the skin material 32 provided on the back surface 43C, but provides the tool on the reinforcing portion 50D. To the skin material 32 that is being used. Thereby, the melted resin molded body 31 permeates into the skin material 32 provided in the reinforcing portion 50D. In other words, since the foamed resin constituting the resin molded body 31 is inherently difficult to permeate into the skin material 32, the portion on the side where the ultrasonic welding tool is pressed (the skin material 32 of the bottom portion 50D1) is provided. The melted foam resin is preferentially soaked, while on the other hand, it is avoided that the melted foam resin soaks into the part (the skin material 32 on the back surface 43C) on which the ultrasonic welding tool is not pressed. Is done. Since the skin material 32 on the back surface 43C is a design surface, the modification 3 can avoid a loss in design property of the structure 30D.
That is, in the third modification, even if the depth dp is large, a decrease in the strength of the reinforcing portion 50D can be avoided, and the design of the structure 30D can be prevented from being impaired.

2. Second Embodiment of Second Aspect In the second embodiment, description of portions common to the first embodiment will be omitted as appropriate. The structure 30E according to the second embodiment has a structure for reinforcing the periphery of the base 40E.

2-1. Structure 30E
As shown in FIG. 24A, a structure 30E according to the second embodiment is a plate-like member. The structure 30E includes a base 40E, a reinforcing portion 50E, and a hinge H. The structure 30 </ b> E is configured by superimposing a skin material 32 on a resin molded body 31. That is, as shown in FIGS. 26A and 26B, the structure 30E includes a resin molded body 31 as a first layer and a skin material 32 as a second layer. The base 40E has a front surface 43B and a back surface 43C, the skin material 32 of the base 40E forms the front surface 43B, and the back surface 43C of the base 40E forms the back surface 43C. The shape of the structure 30E can be changed as appropriate. For example, a concave portion may be formed in the center of the base 40E, and the structure 30E may be configured in a container shape.

2-1-1. Base 40E
As shown in FIGS. 24A and 25A, the base 40E is a trapezoidal plate-shaped member. The base 40E has four base edges 40E1, and each base edge 40E1 is provided with a hinge H. The hinge portion H is provided so as to extend along each base edge portion 40E1 of the base portion 40E. Here, as shown in FIG. 26B, similarly to the first embodiment, the hinge portion H is formed to be thin. That is, the thickness of the hinge portion H is smaller than the thickness of the reinforcing portion 50E and the thickness of the base portion 40E. For this reason, the hinge portion H is configured such that the reinforcing portion 50 can be bent so that the manufacturer or the manufacturing apparatus can tilt the reinforcing portion 50E toward the back surface 43C of the base portion 40E.

2-1-2. Reinforcing part 50E and hinge part H
As shown in FIGS. 26A and 26B, the reinforcing portion 50E is rotatably connected to the base 40E via the hinge portion H. In the second embodiment, the structure 30E has four reinforcing portions 50E, and the reinforcing portions 50E are plate-shaped members provided so as to extend along the base edge portion 40E1. As shown in FIG. 26B, each hinge portion H connects each base edge portion 40E1 and each reinforcing portion 50E. The hinge portion H is formed to be thin. Specifically, the thickness of the hinge portion H is smaller than the thickness of the reinforcing portion 50E and the thickness of the base portion 40E. For this reason, the hinge portion H is configured such that the reinforcing portion 50 can be bent so that the manufacturer or the manufacturing apparatus can tilt the reinforcing portion 50E toward the back surface 43C of the base portion 40E.

As shown in FIG. 24B, FIG. 24C, and FIG. 27, a pair of adjacent reinforcing portions 50E are connected to each hinge portion H such that one reinforcing portion 50E is sandwiched between the base portion 40E and the other reinforcing portion 50E. It is bent toward the base 40E as an axis. Here, the pair of adjacent reinforcing portions 50E refers to two reinforcing portions 50E adjacent in the circumferential direction of the base 40E. For this reason, at the longitudinal ends of the pair of adjacent reinforcing portions 50E, one reinforcing portion 50E and the other reinforcing portion 50E overlap.

One of the adjacent reinforcing portions 50E corresponds to the first reinforcing portion, and the other reinforcing portion 50E corresponds to the second reinforcing portion. Further, the hinge portion H and the base edge portion 40E1 provided on the one reinforcing portion 50E correspond to the first hinge and the first base edge portion, and the hinge portion H provided on the other reinforcing portion 50E. And the base edge 40E1 corresponds to the second hinge and the second base edge.

2-1-3. Skin material 32
The skin material 32 (see FIG. 26B) is provided on the entire front surface of the resin molded body 31. As in the first embodiment, also in the second embodiment, the skin material 32 is made of, for example, a nonwoven fabric having air permeability, and specific examples thereof include nylon fibers, cellulose fibers, and aramid fibers. However, it is not limited to the example.

2-2. Method for Manufacturing Structure 30E The method for manufacturing the structure 30E according to the second embodiment includes an arrangement step, a molding step, a cutting step, a rotation step, and a welding step. The arrangement step, the molding step, and the cutting step of the second embodiment are the same as the arrangement step, the molding step, and the cutting step of the first embodiment, and thus description thereof is omitted.

2-2-1. Rotating Step In the rotating step, the reinforcing portion 50E of the structure 300E is rotated around the hinge H of the structure 300E. Specifically, the reinforcing portion 50E of the structure 300E is bent so that the reinforcing portion 50E of the structure 300E is turned down toward the back surface 43C of the base 40E. Here, as shown in (1) of FIG. 25B, the manufacturer or the manufacturing apparatus first bends the reinforcing portion 50E provided at the upper edge of the base 40E, and then, as shown in (2), The manufacturer or the manufacturing apparatus bends the reinforcing portions 50E provided on the left and right edges of the base 40E, and as shown in (3), the manufacturer or the manufacturing apparatus starts the reinforcing provided on the lower edge of the base 40E. Fold the part 50E. Thus, each reinforcing portion 50E is bent toward the base 40E. Accordingly, the base 40E is reinforced by the reinforcing portion 50E, and the manufacturer or the manufacturing apparatus can deform the structure 300E into the structure 30E. Then, the strength of the structure 30E is effectively improved in the welding step described later by bending the reinforcing portion 50E in the order of (1) to (3) described above.

2-2-2. Welding Step In the welding step, the reinforcing portions 50E are welded to each other. In the second embodiment, the reinforcing portions 50E are welded to each other at each of the four corners of the base 40E. Here, as shown in FIG. 24B, FIG. 24C, and FIG. 27, one reinforcing portion 50E (lower reinforcing portion 50E) of the pair of reinforcing portions 50E is connected to the other reinforcing portion at the longitudinal end. The ends in the longitudinal direction of 50E (upper reinforcing portion 50E) are overlapped. The overlapping ends are welded together.
In FIG. 27, the manufacturer presses the ultrasonic welding tool against the other reinforcing portion 50E (upper reinforcing portion 50E), and the one reinforcing portion 50E (lower reinforcing portion 50E) and the other reinforcing portion 50E. (Upper reinforcing portion 50E). Here, in FIG. 27, the resin molding 31 of the other reinforcing portion 50E (upper reinforcing portion 50E) is disposed on the skin material 32 of one reinforcing portion 50E (lower reinforcing portion 50E). . Therefore, the foam molding (foam resin) of the other reinforcing portion 50E (upper reinforcing portion 50E) permeates into the skin material 32 of the one reinforcing portion 50E (lower reinforcing portion 50E). Thereby, the one reinforcing portion 50E (the lower reinforcing portion 50E) and the other reinforcing portion 50E (the upper reinforcing portion 50E) are firmly connected to each other, and the base portion 40E is further reinforced by the reinforcing portion 50E.

2-4. Effects of the second embodiment of the second aspect In the structure 30E according to the second embodiment, the reinforcing portion 50E, which is a plate-like member, is bent toward the base 40E with the hinge H as an axis. It is reinforced stiffly by the reinforcing portion 50E. Further, as shown by the arrow Ar in FIG. 27, the skin material 32 is arranged at the edge of the structure 30E, so that the design of the structure 30E is improved. That is, since the foam molded article (foam resin) is prevented from being exposed at the edge of the structure 30E, the design of the structure 30E is improved.

In the structure 30E according to the second embodiment, the foam molding (foam resin) of the other reinforcing portion 50E (upper reinforcing portion 50E) is made of the skin material 32 of one reinforcing portion 50E (lower reinforcing portion 50E). Is soaked in. Therefore, the one reinforcing portion 50E (the lower reinforcing portion 50E) and the other reinforcing portion 50E (the upper reinforcing portion 50E) are firmly connected to each other, and as a result, the base portion 40E is more firmly connected to the reinforcing portion 50E. Reinforced.

(Embodiment of the third aspect)
1. Structure 30
The structure 30 according to the embodiment is an interior part of an automobile. The surface 30a is formed on the structure 30, and a passenger of the automobile can place an article such as a drink container on the surface 30a. As described above, since the surface portion 30a is a portion to which a load of an article is applied, the structure 30 includes a configuration (a reinforcing member 60 described later) that reinforces a region of the structure 30 where the surface 30a is formed.

Ａ As shown in FIGS. 28A to 29, the structure 30 includes a base material 40t, a skin material 32, and a reinforcing member 60. Since the front surface of the base material 40t is covered with the skin material 32, the base material 40t is hidden by the skin material 32 and cannot be seen in FIGS. 28A and 28B. Here, since the skin material 32 is provided along the front surface of the base material 40t, the shape of the skin material 32 and the shape of the base material 40t are the same. For this reason, in FIGS. 28A and 28B, it is assumed that the lead line of the reference numeral indicating the configuration of the base material 40 t indicates the configuration of the base material 40 t instead of the skin material 32.

構造 As shown in FIG. 30, the structure 30 has a two-layer structure. That is, in the structure 30, the base material 40t is the first layer, and the skin material 32 is the second layer. The base material 40t is a molded body formed of a foamed resin. The expansion ratio of the base material 40t is not particularly limited, but is, for example, 1.5 to 6 times. In the embodiment, the case where the structure 30 includes the skin material 32 will be described as an example. However, the structure 30 may not include the skin material 32. Further, the projecting portion 35 is formed on the structure 30. The protrusion 35 divides the concave space of the structure 30 into a first region R1 and a second region R2.

1-1. Base material 40t
As shown in FIGS. 28A to 29, the base material 40t includes a base material body 41t and a flange wall 42. The base body 41t is formed in a concave shape, and a flange wall 42 is connected to an edge of the base body 41t. The base material body 41t includes a base wall 43 and a standing wall 44. The base wall 43 is a plate-like member, and in the embodiment, the base wall 43 is a flat plate. Note that the base wall 43 may be curved. The base wall 43 is supported by the reinforcing member 60, and when a load is applied to the base wall 43, deformation of the base wall 43 is suppressed. The base wall 43 has a first edge 43A, a second edge 43a, a covering surface 43D (see FIG. 31A), and an embedding surface 43E (see FIG. 31A). The flange wall 42 is connected to the first edge 43A. The covering surface 43D is formed on the opposite side of the embedding surface 43E, and the covering surface 43D is covered with the skin material 32. The covering surface 43D is formed in a range where the above-described surface portion 30a is provided. A part of the reinforcing member 60 is embedded in the embedding surface 43E. The embedding surface 43E is a surface supported by the reinforcing member 60. The standing wall 44 is a plate-shaped member, and the standing wall 44 extends from the base wall 43 so as to rise. In the embodiment, the standing wall 44 is connected to the second edge 43a. The flange wall 42 is connected to the edge of the standing wall 44.

The flange wall 42 is a plate-like member. The flange wall 42 has a first wall 42AA, a second wall 42B, and a third wall 42C. The first wall 42AA has an annular portion 42AA1 and legs 42AA2. The annular portion 42AA1 is formed in an annular shape, the inner edge of the annular portion 42AA1 is connected to the first edge 43A, and the outer edge of the annular portion 42AA1 is connected to the leg portion 42AA2. An opening 42a is formed in the annular portion 42AA1, and a fixing member (for example, a bolt) for fixing the structure 30 to a vehicle interior part is inserted into the opening 42a. The second wall 42B is provided so as to face the embedding surface 43E of the base wall 43. One end of the second wall 42B is connected to the first wall 42AA, and the other end of the second wall 42B is connected to the third wall 42C. The distance between the second wall 42B and the embedding surface 43E increases from the first wall 42AA to the third wall 42C. An opening 42C1 is formed in the third wall 42C, and a fixing member (for example, a bolt) for fixing the structural body 30 to a vehicle interior part is inserted into the opening 42C1.

1-2. Reinforcement member 60
As shown in FIG. 29, the reinforcing member 60 is formed of a plate-shaped portion 61. In the embodiment, the reinforcing member 60 is configured by the plate-shaped portion 61, but is not limited thereto, and the reinforcing member 60 may have a configuration other than the plate-shaped portion 61. The plate-shaped portion 61 is a flat plate, and the plate-shaped portion 61 is provided to stand on the base wall 43 and the flange wall 42. As shown in FIGS. 30 to 31B, the plate-shaped portion 61 has an edge 61a. The edge 61 a is a part of the plate-shaped portion 61, and the edge 61 a is provided on the periphery of the plate-shaped portion 61. The edge 61a is embedded in the base material 40t. As shown in FIGS. 31A and 31B, in the embodiment, the edge 61 a is embedded in the base wall 43 and the flange wall 42. Specifically, the edge 61a is embedded in the base wall 43, the first wall 42AA, the second wall 42B, and the third wall 42C. By embedding the edge portion 61a in the base wall 43 and the flange wall 42 in this manner, the reinforcing member 60 is firmly fixed to the base material 40t, and as a result, the surface portion 30a (the base wall 43) is strengthened. Strongly reinforced to 60. The edge portion 61a does not need to be embedded in all of the base wall 43, the first wall 42AA, the second wall 42B, and the third wall 42C, that is, all of the four configurations listed here. What is necessary is just to be embedded in at least one of the four listed configurations.

1.3. Skin material 32
As shown in FIG. 30, the skin material 32 is provided on the entire front surface of the base material 40t. The skin material 32 is, for example, made of a nonwoven fabric having air permeability, and specific examples thereof include nylon fibers, cellulose fibers, and aramid fibers, but are not limited thereto.

2. Configuration of Foam Molding Machine 1 The description of the foam molding machine 1 according to the third aspect is described in 1-2. Since the configuration is the same as that of the foam molding machine 1, the description is omitted.

2-1. Hopper 12 and extruder 13
The description of the hopper 12 and the extruder 13 of the third aspect is described in 1-2-1 of the second aspect. The description is omitted because it is the same as the hopper 12 and the extruder 13.

2-2. Injector 16
The description of the injector 16 of the third aspect is given in 1-2-2 of the second aspect. The description is omitted because it is the same as the injector 16.

2-3. Accumulator 17 and T die 18
The accumulator 17 and the T-die 18 according to the third aspect are described in 1-2-3. Since they are the same as the accumulator 17 and the T-die 18, their description is omitted.

2-4. First and

second molds

21 and 22
The foamed resin sheet 23 is guided between the first and

second molds

21 and 22. The first mold 21 has a concave cavity cv1 and a convex core cr1. As shown in FIG. 34A, a slit sr is formed in the core cr1, and the slit sr is configured so that the plate-shaped portion 61 of the reinforcing member 60 can be inserted. As shown in FIG. 34B, when the plate-shaped portion 61 is inserted into the slit sr, the plate-shaped portion 61 is sandwiched by the core cr1, and the plate-shaped portion 61 is fixed to the core cr1. The second mold 22 has a convex core cr2 and a concave cavity cv2. In the movement direction of the first and

second molds

21 and 22, the core cr2 faces the cavity cv1, and the cavity cv2 faces the core cr1. The first and

second molds

21 and 22 are provided with a number of reduced-pressure suction holes (not shown). The first and

second molds

21 and 22 are formed with convex pinch-off

portions

21c and 22c.

3. Method of Manufacturing Structure 30 The method of manufacturing the structure 30 according to the present embodiment includes a sheet forming step, an attaching step, a forming step, and a cutting step.

3-1. Sheet Forming Step As shown in FIG. 32, in the sheet forming step, the molten foamed resin is extruded from the slit of the T-die 18 to form the foamed resin sheet 23. When extruded from the slit of the T-die 18, the foamed resin sheet 23 hangs down in a space between the first mold 21 and the second mold 22.

3-2. Attachment Step As shown in FIG. 33, in the attachment step, the foamed resin sheet 23 and the skin material 32 are arranged between the first mold 21 and the second mold 22. In addition, as shown in FIGS. 34A and 34B, the reinforcing member 60 is attached to the first mold 21 in the attaching step. Specifically, the plate-shaped portion 61 is inserted into the slit sr of the core cr1 of the first mold 21, the plate-shaped portion 61 is sandwiched between the cores cr1, and the plate-shaped portion 61 is fixed to the core cr1. In addition, as shown in FIG. 34B, in a state where the reinforcing member 60 is disposed in the first mold 21, the edge 61a of the plate-shaped portion 61 protrudes from the core cr1.

3-2. Forming Step In the forming step, the structure 30 having the base material 40t, the skin material 32, and the reinforcing member 60 is formed. The molding step includes a shaping step, a mold closing step, and an expansion step. As shown in FIG. 35, in the shaping step, the foamed resin sheet 23 and the skin material 32 are sucked through the reduced-pressure suction holes of the second mold 22. Thereby, the foamed resin sheet 23 and the skin material 32 are shaped into a shape along the inner surface of the second mold 22.

ＡAs shown in FIG. 36A, in the mold closing step, the first mold 21 and the second mold 22 are brought close to each other, and the first and

second molds

21 and 22 are closed. In the state where the mold closing step is completed, the portion of the plate-shaped portion 61 protruding from the core cr1, that is, the edge 61a of the plate-shaped portion 61 may or may not enter the foamed resin sheet 23. Is also good. Further, as shown in FIGS. 36A and 36B, in a state where the mold closing step is completed, the pinch-off portion 21c and the pinch-off portion 22c come into contact with each other, and the first mold 21 and the second mold 22 have a closed space S. It is formed. The closed space S is a foaming space for foaming the foamed resin. A portion of the foamed resin sheet 23 and the skin material 32 outside the closed space S becomes a burr br. As shown in FIG. 36C, in the expansion step, the pressure in the closed space S is reduced through the reduced-pressure suction holes of the first and

second molds

21 and 22. When the pressure in the closed space S is reduced, the foaming of the foamed resin sheet 23 is promoted, the foamed resin sheet 23 expands, and the base material 40t is formed. In a state where the expansion step is completed, the edge 61a of the plate-shaped portion 61 is embedded in the base material 40t.

3-3. Cutting Step As shown in FIG. 37, the first and

second molds

21 and 22 are opened, and the structure 30 is taken out from the first and

second molds

21 and 22. In the cutting step, the burr br formed on the structure 30 is cut.

4. Effect of Embodiment of Third Viewpoint The structure 30 according to the embodiment includes a base member 40t and a reinforcing member 60. Here, since the reinforcing member 60 is provided so as to reinforce the base member 40t, the positional relationship between the reinforcing member 60 and the base member 40t is such that the reinforcing member 60 is disposed on the back side (back side) of the base member 40t. And the shape composed of the reinforcing member 60 and the base material 40t is complicated. The structure having such a configuration can be manufactured relatively easily by a manufacturing method using injection molding. On the other hand, in a manufacturing method in which one foamed resin sheet 23 is sandwiched between the first and

second molds

21 and 22 as in the manufacturing method of the structure 30 according to the embodiment, the structure like the structure 30 is used. It is difficult to technically mold a structure having In the structure 30 according to the embodiment, the reinforcing member 60 and the base material 40t are integrally formed by embedding the edge 61a of the plate-shaped portion 61 of the reinforcing member 60 in the base material. That is, since the edge 61a of the plate-shaped portion 61 of the reinforcing member 60 is embedded in the base material 40t when the structure 30 is manufactured, even if the shape of the reinforcing member 60 and the base material 40t is complicated, the foamed resin sheet The structure 30 can be easily manufactured by a manufacturing method in which 23 is sandwiched between the first and

second molds

21 and 22. Therefore, the structure 30 according to the embodiment has a configuration in which the shape is not restricted by the manufacturing method. Further, the manufacturing method according to the embodiment is a method capable of suppressing the restriction on the shape of the structure. In particular, the manufacturing method according to the first embodiment is effective when a reinforcing structure is provided on the back side (back side) of a structure having a deep drawing shape such as the structure 30.

Since the edge 61a of the plate portion 61 of the structure 30 according to the embodiment is embedded in the base material 40t, the plate portion 61 is firmly fixed to the base material 40t, and as a result, the base wall 43 (FIG. ) Is reinforced by the plate-shaped portion 61. In particular, as shown in FIG. 30, the rigidity of the structure 30 with respect to the load in the direction of the arrow Ar1 is improved. In the embodiment, since the plate-shaped portion 61 is in contact with the first wall 42AA and the second wall 42B, the load applied to the base wall 43 is received by the first wall 42AA and the second wall 42B. That is, the load applied to the base wall 43 is distributed to the first wall 42AA and the second wall 42B. Therefore, when a load is applied to the base wall 43, the deformation of the structure 30 is suppressed.

5.

Modifications

1 and 2 of Embodiment of Third Perspective: Plural Plates and Connections As shown in FIGS. 38A and 38C, the reinforcing

members

60B and 60C of the

structures

30B and 30C according to

Modifications

1 and 2 are different from each other. , A plurality of plate-shaped

portions

61B and 61C. In the first and second modifications, the number of the plate-shaped

portions

61B and 61C may be two or more. Since the reinforcing

members

60B and 60C have the plurality of

plate portions

61B and 61C, the base member 40t is more strongly reinforced by the reinforcing

members

60B and 60C.

Ａ As shown in FIGS. 38A and 38B, the reinforcing member 60B according to the first modification includes a plurality of plate-shaped portions 61B and a connecting portion 62B. A notch or a through hole is formed in the plate-shaped portion 61B, and the connecting portion 62B is inserted into the notch or the through hole. In the first modification, a notch is formed in the plate-shaped portion 61B. The connecting portion 62B is a flat member. The connecting portion 62B is connected to each plate-shaped portion 61B. Since the reinforcing member 60B has the connecting portion 62B, the reinforcing member 60B is unitized, so that the work load of attaching the reinforcing member 60B to the first mold 21 is suppressed. In addition, since the reinforcing member 60B has the connecting portion 62B, the structure 30B has not only rigidity against a load in the direction of the arrow Ar1 (direction from the upper side to the lower side) but also the direction of the arrow Ar2 (the direction from the front side to the rear side). The rigidity with respect to the load is improved.

38C and 38D, the reinforcing member 60C according to the second modification includes a plurality of plate-shaped portions 61C and a connecting portion 62C. A notch or a through-hole is formed in the plate-shaped portion 61C, and the connecting portion 62C is inserted into the notch or the through-hole. In the second modification, a notch is formed in the plate-shaped portion 61C. The connecting portion 62C is connected to each plate-shaped portion 61C. The connecting portion 62C is a rod-shaped member. The width of the connecting portion 62C according to the second modification in the short direction is wider than the width of the connecting portion 62B according to the first modification in the short direction. The reinforcing member 60C according to Modification 2 has the same effect as the reinforcing member 60B according to Modification 1.

6. Modifications 3 to 6 of Embodiment of Third View: Hook Portion Since the plate portions 61D to 61G of the modification examples 3 to 6 have the hook portions 63D to 63G that engage with the base material 40t, the plate portions 61D to 61G. Are more strongly connected to the base material 40t.

３９As shown in FIG. 39A, a hook 63D is formed at the edge of the plate-like portion 61D of the reinforcing member 60D according to the third modification. The hook 63D is formed so as to protrude from the surface of the plate-shaped portion 61D, and the hook 63D is embedded in the base material 40t. As shown in FIG. 39B, a hook 63E is formed at the edge of the plate-like portion 61E of the reinforcing member 60E according to the fourth modification. The hook 63E is formed so as to protrude from the surface of the plate-shaped portion 61E. The hook 63E is formed so as to increase in width toward the tip, and the cross-sectional shape of the hook 63E is tapered. The hook 63E is embedded in the base material 40t.

３９As shown in FIG. 39C, a hook 63F is formed on the edge of the plate-like portion 61F of the reinforcing member 60F according to the fifth modification. The hook 63F is formed so as to protrude from the surface of the plate-like portion 61F, and the cross-sectional shape of the hook 63F is arc-shaped. The hook 63F is embedded inside the base material 40t. As shown in FIGS. 39D and 39E, a hook 63G is formed at the edge of the plate-like portion 61G of the reinforcing member 60G according to the sixth modification. The hook 63G is formed with a narrow portion 63G1 whose width becomes narrower toward the tip, and the narrow portion 63G1 has a claw structure.

7.

Modifications

7 and 8 of Embodiment of Third Perspective: Fall Prevention Unit The configurations of

Modifications

7 and 8 include the fall prevention units 64 </ b> H and 64 </ b> I that prevent the plate-shaped portion 61 from falling. As shown in FIG. 40A, a fall prevention portion 64H according to Modification 7 is formed on a base material 40t. The fall prevention portions 64H are provided on both sides of the plate portion 61, respectively, and the fall prevention portions 64H support the plate portion 61. The overturn prevention portion 64H is formed by raising a portion of the base material 40t in which the edge portion 61a is embedded. Here, as shown in FIG. 40B, the core cr1 of the first mold 21 is formed with a tapered surface tp. When the foamed resin sheet enters between the surface of the plate-shaped portion 61 and the tapered surface tp, the fall prevention portion 64H is formed in the portion of the base material 40t where the edge portion 61a is embedded.

ＣAs shown in FIG. 40C, the overturn prevention portions 64I according to Modification 8 are provided on both sides of the plate portion 61, respectively, and the overturn prevention portions 64I support the plate portion 61. The plan view shape of the fall prevention portion 64I is a triangular shape, and the fall prevention portion 64I is a plate-like member. The fall prevention portion 64I is provided so as to contact the surface of the plate-shaped portion 61 and the surface of the base material 40t.

8. Modifications 9 and 10 of Third Embodiment:

Engaging Structure Protrusions

65J and 65K are formed on the plate-

like portions

61J and 61K of Modifications 9 and 10, respectively. As shown in FIGS. 41A to 41D, the surface of the protrusion 65J according to Modification 9 is formed in a curved surface, and as shown in FIGS. 41E to 41H, the protrusion 65K according to Modification 10 is formed in a triangular prism shape. Have been. Since the protruding

portions

65J and 65K are formed on the plate-shaped

portions

61J and 61K, the plate-shaped

portions

61J and 61K engage with the core cr1 of the first mold 21, and the displacement of the plate-shaped

portions

61J and 61K is reduced. Is suppressed.

9. Modifications 11 to 14 of the third embodiment
In the embodiment and Modifications 1 to 10, the reinforcing member is applied to the substrate having the deep drawing shape, but is not limited thereto. The reinforcing member can be applied to a flat base material.

縁 As shown in FIGS. 42A and 42B, the edge of the plate-shaped portion 61L of the reinforcing member 60L according to Modification 11 is embedded in the flat base material 140. As shown in FIGS. 42C and 42D, the reinforcing member 60M according to Modification 12 has a plurality of plate-shaped portions 61M. Otherwise, Modification 12 is the same as Modification 11.

Modification 13 is a form having functions similar to those of

Modifications

1 and 2. As shown in FIGS. 42E and 42F, a reinforcing member 60N according to Modification 13 has a plurality of plate-shaped portions 61N and a plurality of connecting portions 62N. Each connecting portion 62N is connected to a plurality of plate-shaped portions 61N.
Modification 14 has the same function as Modification 8. As shown in FIGS. 42G and 42H, a reinforcing member 60O according to Modification 14 has a plate-shaped portion 61O and a fall prevention portion 64O. Note that the broken line shown in FIG. 42H indicates a portion of the fall prevention portion 64O that is embedded in the base material 140. The fall prevention portions 64O are provided on both sides of the plate portion 61O, respectively, and the fall prevention portions 64O support the plate portion 61O.

1: foam molding machine, 2: resin supply device, 5: concave portion, 7: convex portion, 11: raw material resin, 12: hopper, 13: extruder, 13a: cylinder, 16: injector, 17: accumulator, 17a: cylinder 17b: piston, 18: T die, 20: mark forming part, 20a: concave part forming part, 20b: convex part forming part, 21: first mold, 21a: facing surface, 21b: cavity, 21c: pinch-off part, 21d: reduced pressure suction hole, 22: second mold, 22a: facing surface, 22b: core, 22c: pinch-off portion, 22d: reduced pressure suction hole, 23: foamed resin sheet, 23a: burr, 24: molded body, 25: Connecting pipe, 27: connecting pipe, 28: skin member, 28a: burr, 29: recessed portion, 30: structure, 30B: structure, 30C: structure, 30D: structure, 30E: structure, 30a: Part, 31: resin molded body, 32: skin material, 35: protrusion, 40: base, 40t: base material, 40E: base, 40E1: base edge, 41: base body, 41t: base body, 42: Flange wall, 42A: Opening, 42a: Opening, 42AA: First wall, 42AA1: Annular part, 42AA2: Leg, 42B: Second wall, 42C: Third wall, 42C1: Opening, 43: Base wall 43A: first edge, 43B: front surface, 43C: back surface, 43D: covering surface, 43E: embedded surface, 43a: second edge, 44: standing wall, 50: reinforcing portion, 50B: Reinforcing part, 50C: reinforcing part, 50D: reinforcing part, 50D1: bottom part, 50E: reinforcing part, 51: reinforcing rib, 51B: reinforcing rib, 51C: reinforcing rib, 51D: reinforcing rib, 52: fixing part, 52B: extending Outgoing part, 52C: extending part, 52C1: first extending part, 5 C2: second extension, 53: opening, 53B: opening, 53C: opening, 60: reinforcing member, 60B: reinforcing member, 60C: reinforcing member, 60D: reinforcing member, 60E: reinforcing member, 60F: Reinforcement member, 60G: Reinforcement member, 60H: Reinforcement member, 60I: Reinforcement member, 60L: Reinforcement member, 60M: Reinforcement member, 60N: Reinforcement member, 60O: Reinforcement member, 61: Plate portion, 61B: Plate portion, 61C: plate portion, 61D: plate portion, 61E: plate portion, 61F: plate portion, 61G: plate portion, 61J: plate portion, 61K: plate portion, 61L: plate portion, 61M: Plate portion, 61N: plate portion, 61O: plate portion, 61a: edge portion, 62B: connection portion, 62C: connection portion, 62N: connection portion, 63D: hook portion, 63E: hook portion, 63F: hook portion. , 63G: hook portion, 63G1: narrow portion, 64H: fall prevention portion, 64I: fall prevention part, 64O: fall prevention part, 65J: protrusion, 65K: protrusion, 140: base material, 300: structure, 300B: structure, 300C: structure, 300E: structure, D: design Surface, D1: mark area, D2: general area, H: hinge part, R1: first area, R2: second area, S: closed space, br: burr, c1: first plate-shaped part, c2: second Plate portion, cr: core, cr1: core, cr2: core, cv: cavity, cv1: cavity, cv2: cavity, dp: depth, h1: first hinge portion, h2: second hinge portion, h3: number 3 hinge part, h4: fourth hinge part, sr: slit, tp: tapered surface.

Claims

A resin sheet and a molded body provided with a skin member attached thereto,
The surface on the skin member side is a design surface,
The design surface includes a mark area with a mark composed of a concave portion and a convex portion,
A molded product, wherein the skin member corresponding to the concave portion is impregnated with a resin of the resin sheet.
It is a molded object according to claim 1,
A molded body, wherein the thickness of the convex portion of the mark area is smaller than the thickness of a general area outside the mark area on the design surface.
The molded article according to claim 1 or claim 2,
The molded article, wherein the resin sheet is a foamed resin sheet.
A method for producing a molded article, comprising:
Including an arrangement step and a molding step,
In the arranging step, a resin sheet and a skin member are arranged between the first mold and the second mold,
In the molding step, the resin sheet and the skin member are molded by the first mold and the second mold,
A mark forming part including a concave part forming part and a convex part forming part is provided on one of the opposing surfaces of the first die and the second die,
In the molding step, a method of forming a mark region with a mark formed of a concave portion and a convex portion by pressing the skin member and the resin sheet by the mark forming portion.
5. The method according to claim 4, wherein
The resin sheet is a foamed resin sheet,
The method further comprises an inflation step,
In the expanding step, the first mold and the second mold are brought close to each other so that a space is provided between the first mold and the second mold,
A method of expanding the resin sheet into the space by vacuum-suctioning the resin sheet from both the first mold and the second mold that are close to each other.
With a base, a reinforcing part, and a hinge part,
The reinforcing portion is provided to reinforce the base portion,
A structure having at least one of the following structures (a) and (b).
Configuration (a): the base portion and the reinforcing portion are connected via the hinge portion.
Configuration (b): the reinforcing portion includes the hinge portion.
The structure according to claim 6, wherein
A structure having the configuration (a).
The structure according to claim 7, wherein:
The base has a base wall and a flange wall,
The flange wall is formed at an edge of the base wall,
The said hinge part is a structure which connects the said flange wall and the edge part of the said reinforcement part.
The structure according to claim 8, wherein:
The reinforcing portion has a reinforcing rib,
The structure, wherein the reinforcing rib supports a back surface of the base wall.
The structure according to claim 9, wherein:
The structure, wherein the reinforcing rib is formed so as to project toward a back surface of the base wall.
The structure according to claim 7, wherein:
The base has a base edge,
The hinge portion connects the base edge portion and the reinforcing portion,
The structure, wherein the reinforcing portion is a plate-shaped member provided so as to extend along the base edge portion, and is bent toward the base portion around the hinge portion as an axis.
The structure according to claim 11, wherein
The structure is configured by superimposing a skin material on a resin molded body,
The base has first and second base edges,
The reinforcing portion has first and second reinforcing portions,
The hinge has a first and a second hinge,
A first hinge portion connecting the first base edge portion and the first reinforcement portion, a second hinge portion connecting the second base edge portion and the second reinforcement portion,
The first and second reinforcing portions are plate-shaped members provided so as to extend along the first and second base edge portions, and the first and second reinforcing portions are such that the first reinforcing portion has the same shape as the base portion. The first and second hinge parts are bent toward the base so as to be sandwiched between the second reinforcement part,
A structure in which a first reinforcing portion and a second reinforcing portion are welded, and the skin material of the first reinforcing portion is impregnated with a resin constituting the resin molded body of the second reinforcing portion.
The structure according to claim 6, wherein
A structure having the configuration (b).
The structure according to claim 13, wherein:
The base has a base wall and a flange wall,
The structure, wherein the flange wall is formed at an edge of the base wall.
The structure according to claim 14, wherein
The reinforcing portion has an extending portion, the hinge portion, and a reinforcing rib,
The extension is connected to the flange wall,
The extending portion and the reinforcing rib are connected via the hinge portion,
The structure, wherein the reinforcing rib supports a back surface of the base.
The structure according to claim 15, wherein
The structure, wherein the reinforcing rib is configured in a flat plate shape.
The structure according to claim 15, wherein
The extension has a first and a second extension,
The hinge portion has first, second, third and fourth hinge portions,
One end of the reinforcing rib is connected to a first extension via a first hinge, and the other end of the reinforcement rib is connected to a second extension via a second hinge,
The third and fourth hinge portions are provided at a portion between the one end and the other end of the reinforcing rib.
The structure according to any one of claims 9, 10, 15 to 17,
The structure, wherein the reinforcing ribs and the base wall are welded.
The structure according to any one of claims 6 to 18, wherein
The base portion, the reinforcing portion and the hinge portion are formed by molding the same resin sheet,
The said hinge part is a structure body formed thin.
The structure according to any one of claims 8 to 10, and claims 14 to 17,
The base further includes an upright wall,
The base wall has a first edge and a second edge,
The flange wall is formed at a first edge,
The structure, wherein the standing wall is formed at a second edge.
A molding method, comprising a rotating step, a method for manufacturing a structure,
In the molding step, by molding a resin parison, a molded body having a base, a reinforcing portion, and a hinge portion is formed, and the hinge portion is configured to connect the base portion and the reinforcing portion,
In the rotating step, the whole or a part of the reinforcing portion is rotated around the hinge portion as an axis.
Comprising a base material and a reinforcing member,
The base material is made of a foamed resin,
The reinforcing member has a plate-like portion, and the reinforcing member is provided to reinforce the base material,
A structure in which an edge of the plate-like portion is embedded in the base material.
The structure according to claim 22, wherein
The base material has a base wall and a flange wall,
The flange wall is connected to the base wall,
The structure, wherein the plate-like portion is embedded in the base wall and the flange wall.
A structure according to claim 22 or claim 23,
The reinforcing member has a plurality of the plate-shaped portions and a connecting portion,
The said connection part is a structure connected with the some said plate-shaped part.
The structure according to any one of claims 22 to 24, wherein
A hook portion is formed at the edge of the plate-like portion,
The structure, wherein the hook portion is engaged with the base material.
The structure according to any one of claims 22 to 25, wherein
Further equipped with a fall prevention part,
The structure in which the overturn prevention portions are provided on both sides of the plate-shaped portion, respectively, and the overturn prevention portion supports the plate-shaped portion.
A method for manufacturing a structure using first and second molds,
A sheet forming step, an attaching step, and a forming step,
The molding step includes a shaping step, a mold closing step, and an expansion step,
The structure includes a substrate and a reinforcing member, the reinforcing member has a plate-shaped portion,
In the sheet forming step, the molten foamed resin is extruded by an extruder to form a foamed resin sheet,
In the attaching step, attaching the reinforcing member to a first mold,
In the shaping step, the foamed resin sheet is shaped along an inner surface of a first mold in which the reinforcing member is arranged,
In the mold closing step, the first and second molds are closed, and the foamed resin is foamed between the first mold and the second mold in a state where the first and second molds are closed. Foaming space is formed,
In the expansion step, the base material is formed by foaming the foamed resin in the foaming space, and in a state where the expansion step is completed, an edge of the plate-shaped portion is embedded in the base material. Is the way.
28. The method according to claim 27, wherein
The first mold has a slit,
In the attaching step, the reinforcing member is arranged in a first mold so that the plate-shaped portion is inserted into the slit.
29. The method according to claim 28, wherein
The method, wherein the plate is configured to engage the slit.