JP6908832B2 - Resin panel and its manufacturing method - Google Patents

Description

The present invention relates to resin panels such as package trays, deck boards, and floor boards installed in the luggage compartment of a vehicle.

According to Patent Document 1, a resin panel used as a deck board or the like is provided with a skin material, which is a cloth having fluff in the outward direction, in order to give the panel a design effect and improve the feel. A technique for heat welding is disclosed.

Japanese Unexamined Patent Publication No. 10-235720

In the resin panel of Patent Document 1, no skin material is provided on the back wall, and the resin molded body is exposed. When such a resin panel is installed in a vehicle, there is a problem that abnormal noise is generated due to vibration of the vehicle or the like.

The present invention has been made in view of such circumstances, and provides a resin panel capable of suppressing the generation of abnormal noise.

According to the present invention, the front wall side skin material, the front wall, the back wall, and the back wall side skin material are provided in this order, and the front wall and the back wall face each other at intervals, and the front wall and the front wall and the front wall are provided. A resin panel is provided which includes a peripheral wall connecting the periphery of the back wall, and the back wall side skin material is integrally molded with the back wall so as to cover a part of the area of the back wall.

In the resin panel of the present invention, the back wall side skin material is integrally molded on the back wall so as to cover a part of the back wall area. According to such a configuration, the generation of abnormal noise can be suppressed by providing the back wall side skin material in the region where the resin panel comes into contact with the vehicle or the like. Further, by integrally molding the back wall side skin material on the back wall, it is not necessary to attach the back wall side skin material as a post-process after forming the resin molded body, so that the production efficiency is high.

Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with each other.
Preferably, the back wall side skin material is provided along at least one side edge of the resin panel.
Preferably, the area where the back wall side skin material is provided on the back wall is a covering area, and the area where the back wall side skin material is not provided on the back wall is an exposed area. The thickness in the covering region is larger than the thickness in the exposed region.
Preferably, the thickness at the covering region is configured to approach the thickness at the exposed region as the distance from the side edges increases.
Preferably, a reinforcing member is provided between the front wall and the back wall, and the reinforcing member is arranged so that one end thereof overlaps the covering region in a plan view.
Preferably, the back wall side skin material comprises first and second back wall side skin materials, and the resin panel has first and second side edges facing each other, and the first and second back wall sides. The skin material is provided along the first and second side edges, respectively, and one end and the other end of the reinforcing member overlap the first and second back wall side skin materials in a plan view, respectively. Is placed in.
Preferably, a spacer member is provided between the front wall and the back wall, and the reinforcing member is supported by the spacer member.
Preferably, the back wall side skin material is provided so as to extend from the back wall to the peripheral wall.
Preferably, the back wall side skin material is provided so as to come into contact with the front wall side skin material.
Preferably, the front wall side skin material is integrally molded with the front wall so as to cover the entire area of the front wall.

According to another aspect of the present invention, a hanging step and a mold clamping step are provided, and in the hanging step, the first and second resin sheets are hung between the first and second molds, and the first mold is formed. A front wall side skin sheet is arranged between the first resin sheet and the first resin sheet, a back wall side skin sheet is arranged between the second mold and the second resin sheet, and the back wall side skin sheet is viewed in a plan view. In the mold clamping step, a method for manufacturing a resin panel is provided, which is arranged so as to overlap a part of a region of a cavity of the second mold, and molds the first and second molds. ..
Preferably, the back wall side skin sheet is provided along at least one side edge of the cavity of the second mold.
Preferably, the second mold includes an arrangement area in which the back wall side skin sheet is arranged and a non-arrangement area in which the back wall side skin sheet is not arranged, and the cavity of the second mold has the arrangement. The depth in the region is deeper than the depth in the non-arranged region.
Preferably, the depth in the placement region is configured to approach the depth in the non-placement region as it moves away from the side edges.
Preferably, an insert step is provided between the hanging step and the mold clamping step, in which the insert member is welded to the first or second resin sheet, and the insert member is supported by a reinforcing member by a spacer member. The reinforcing member is arranged so that one end thereof overlaps the back wall side skin sheet in a plan view.

It is a perspective view (cross-sectional perspective view which was partially cut out) of the resin panel 1 of one Embodiment of this invention. It is an enlarged view of the part indicated by the arrow X of FIG. It is a perspective view of the display state which removed a part of the back wall 4 and the back wall side skin material 5 of the resin panel 1 of FIG. It is a block diagram (longitudinal sectional view about the molds 21 and 31 and the member in the vicinity) of the molding machine 1 which can be used for manufacturing the resin panel 1 of one Embodiment of this invention. FIG. 5 is a cross-sectional perspective view taken along the line AA in FIG. FIG. 6 is a cross-sectional view taken along the line AA in FIG. It is an enlarged view of the region Y in FIG. It is sectional drawing which corresponds to the AA cross section in FIG. 4 which shows the shaping process. It is an enlarged view of the region Y in FIG. It is sectional drawing which corresponds to the AA cross section in FIG. 4 which shows the insertion process. It is sectional drawing which corresponds to the AA cross section in FIG. 4 which shows the mold clamping process. It is a vertical cross-sectional view corresponding to FIG. 4 which shows the state which the back wall side skin sheet 34 is installed in the mold 31 in a loose state.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The various features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each feature.

1. 1. Structure of Resin Panel As shown in FIGS. 1 to 3, the resin panel 1 according to the embodiment of the present invention includes a front wall side skin material 2, a front wall 3, a back wall 4, and a back wall side skin. The material 5 is provided in this order. The front wall 3 and the back wall 4 face each other with a gap. The periphery of the front wall 3 and the back wall 4 is connected by a peripheral wall 6. The back wall side skin material 5 is integrally molded with the back wall 4 so as to cover a part of the back wall 4.

The resin panel 1 has a pair of side edges 1a facing each other. The pair of side edges 1a are separated from each other in the longitudinal direction of the resin panel 1. A pair of back wall side skin materials 5 are provided along each of the pair of side edges 1a. The front wall side skin material 2 is integrally molded with the front wall 3 so as to cover the entire area of the front wall 3. The back wall side skin material 5 is provided so as to extend from the back wall 4 to the peripheral wall 6, and the back wall side skin material 5 and the front wall side skin material 2 come into contact with each other at a position near the front wall 3. There is.

Assuming that the area where the back wall side skin material 5 is provided on the back wall 4 is the covering area R1 and the area where the back wall side skin material 5 is not provided on the back wall 4 is the exposed area R2, the resin panel 1 is covered. The thickness in the region R1 is larger than the thickness in the exposed region R2. In another expression, the back wall side skin material 5 is provided so as to rise from the exposed region R2 of the back wall 4. The difference in thickness between the covering region R1 and the exposed region R2 is, for example, 0.5 to 5 mm, preferably 1 to 3 mm, and specifically, for example, 0.5, 1, 1.5, 2, ... It is 2.5, 3, 3.5, 4, 4.5, 5 mm, and may be within the range between any two of the numerical values exemplified here.

The covering region R1 is provided with a tapered region 1b and a flat region 1c. The tapered region 1b is provided between the flat region 1c and the exposed region R2. According to such a configuration, the thickness in the covering region R1 approaches the thickness in the exposed region R2 as the distance from the side edge 1a increases, so that a step is formed between the covering region R1 and the exposed region R2. It is deterred. Further, when the flat region 1c comes into contact with a vehicle or the like, the occurrence of rattling is suppressed. The angle of the taper region 1b is, for example, 1 to 15 degrees, preferably 2 to 10 degrees, and specifically, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, It is 12, 13, 14, and 15 degrees, and may be within the range between any two of the numerical values exemplified here.

The covering region R1 may be provided with a step between the covering region R1 and the exposed region R2 without providing the tapered region 1b. However, in such a form, when the back wall side skin material 5 is integrally molded with the back wall 4 in a state where the edge of the back wall side skin material 5 is displaced from the position of the step due to manufacturing variation, the back wall side skin material 5 is integrally molded. Since there is a problem that the deviation becomes conspicuous, it is preferable to provide the taper region 1b.

It is preferable that the front wall side skin material 2 and the back wall side skin material 5 are each made of a non-woven fabric. The non-woven fabric is preferably composed of resin fibers. The resin fiber is preferably composed of a resin having a higher picat softening point than the resin constituting the front wall 3, the back wall 4, and the peripheral wall 6. In this case, the front wall side skin material 2 and the back wall side skin material 5 are suppressed from being deformed during manufacturing.

A reinforcing member 8 is provided between the front wall 3 and the back wall 4. The reinforcing member 8 is made of metal (aluminum or the like) or hard plastic. The reinforcing member 8 preferably has an elongated shape, has a constant cross-sectional shape along the longitudinal direction thereof, and has a length ratio to a width of 10 or more. The reinforcing member 8 preferably has an H-shaped cross section, but may have other shapes.

As shown in FIG. 3, the reinforcing member 8 is arranged along the longitudinal direction of the resin panel 1. The reinforcing member 8 is arranged so that one end 8a and the other end 8b of the reinforcing member 8 overlap the covering region R1 in a plan view. The one end 8a and the other end 8b of the reinforcing member 8 are preferably arranged so as to overlap the flat region 1c in a plan view. According to such a configuration, when the resin panel 1 is mounted on the vehicle or the like so that the covering regions R1 provided at both ends in the longitudinal direction of the resin panel 1 abut on the vehicle or the like, the resin panel 1 is formed. Curvature deformation is suppressed. In another expression, the "planar view" means a state when viewed from a direction perpendicular to the main surface of the back wall 4.

A spacer member 7 is provided between the front wall 3 and the back wall 4. The spacer member 7 is a member for securing a space between the front wall 3 and the back wall 4, and is preferably made of a foam. The reinforcing member 8 is preferably supported by the spacer member 7. In the present embodiment, the two reinforcing members 8 are supported by the spacer member 7 divided into three parts.

2. Molding machine 10
Next, with reference to FIG. 4, a molding machine 10 that can be used for carrying out the method for manufacturing a resin panel according to an embodiment of the present invention will be described. The molding machine 10 includes a pair of resin sheet forming devices 20 and dies 21 and 31. Each resin sheet forming device 20 includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18. 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 to put 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 the form of pellets. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and 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 charged into the cylinder 13a from the hopper 12 and then heated in the cylinder 13a to be melted into a molten resin. Further, it is conveyed toward the tip of the cylinder 13a by the rotation of the screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and the molten resin is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device. The number of screws arranged in the cylinder 13a may be one or two or more.

<Accumulator 17, T-die 18>
The molten resin is extruded from the resin extrusion port of the cylinder 13a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b slidable inside the cylinder 17a, so that molten resin can be stored in the cylinder 17a. Then, by moving the piston 17b after a predetermined amount of the molten resin is stored in the cylinder 17a, the molten resin is pushed out from the slit provided in the T die 18 through the connecting pipe 27 and hung down to be a molten resin sheet. Form 23, 33.

<Molds 21, 31>
The resin sheets 23 and 33 are hung between the molds 21 and 31. The molds 21 and 31 have cavities 21a and 31a, and pinch-off portions 21b and 31b are provided so as to surround the cavities 21a and 31a. Decompression suction holes (not shown) are provided in the cavities 21a and 31a, and the resin sheets 23 and 33 are decompressed and sucked through the decompression suction holes along the inner surfaces of the cavities 21a and 31a of the molds 21 and 31. It is possible to shape it into a plastic shape. The decompression suction hole is a very small hole, one end of which is communicated to the inner surface of the cavities 21a and 31a through the inside of the molds 21 and 31, and the other end is connected to the decompression device.

3. 3. Method for Manufacturing Resin Panel Here, a method for manufacturing a resin panel according to an embodiment of the present invention will be described with reference to FIGS. 4 to 11. The method of the present embodiment includes a hanging step, a shaping step, an insert step, and a mold clamping step. Hereinafter, a detailed description will be given.

3-1. In the hanging step, as shown in FIGS. 4 to 7, the resin sheets 23 and 33 are hung between the dies 21 and 31. The front wall side skin sheet 24 is arranged between the mold 21 and the resin sheet 23, and the back wall side skin sheet 34 is arranged between the mold 31 and the resin sheet 33. The front wall side skin sheet 24 and the back wall side skin sheet 34 are fixed to the molds 21 and 31 by clips (not shown) or the like, respectively. The front wall side skin sheet 24 is provided so as to cover the entire region of the cavity 21a of the mold 21. On the other hand, the back wall side skin sheet 34 is arranged so as to overlap a part of the region of the cavity 31a of the mold 31 in a plan view. More specifically, the back wall side skin sheet 34 is provided along the side edge of the cavity 31a of the mold 31. As shown in FIG. 4, the back wall side skin sheet 34 may be arranged in a stretched state so as to be a straight line in the vertical cross-sectional view, or may be arranged so as to be curved in the vertical cross-sectional view as shown in FIG. It may be placed in a loose state. By arranging the back wall side skin sheet 34 so as to be straight, the positioning accuracy of the back wall side skin sheet 34 is improved, and wrinkles are suppressed from being generated on the back wall side skin sheet 34. The effect is obtained. More specifically, each of the pair of back wall side skin sheets 34 is provided along the pair of opposite side edges of the cavity 31a of the mold 31. In addition, here, "planar view" means a state when viewed from the mold clamping direction in another expression.

As shown in FIG. 7, assuming that the area where the back wall side skin sheet 34 is arranged is the arrangement area S1 and the area where the back wall side skin sheet 34 is not arranged is the non-arrangement area S2, the cavity in the arrangement area S1. The depth of 31a is deeper than the depth of the cavity 31a in the non-arrangement region S2. According to such a configuration, the resin of the resin sheet 33 is less likely to be pushed away by the back wall side skin sheet 34, so that problems associated with the resin of the resin sheet 33 being pushed away are suppressed. The difference in thickness between the arranged region S1 and the non-arranged region S2 is, for example, 0.5 to 5 mm, preferably 1 to 3 mm, and specifically, for example, 0.5, 1, 1.5, 2. , 2.5, 3, 3.5, 4, 4.5, 5 mm, and may be within the range between any two of the numerical values exemplified here. The arrangement region S1 and the non-arrangement region S2 correspond to the covering region R1 and the exposed region R2 of the resin panel 1, respectively.

The arrangement region S1 is provided with a tapered region 31c and a flat region 31d. The tapered region 31c is provided between the flat region 31d and the non-arranged region S2. According to such a configuration, the depth in the arrangement region S1 approaches the depth in the non-arrangement region S2 as the distance from the side edge of the cavity 31a increases, so that a step is formed between the arrangement region S1 and the non-arrangement region S2. Is deterred. The tapered region 31c and the flat region 31d correspond to the tapered region 1b and the flat region 1c of the resin panel 1, respectively. The angle of the taper region 31c is, for example, 1 to 15 degrees, preferably 2 to 10 degrees, and specifically, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, It is 12, 13, 14, and 15 degrees, and may be within the range between any two of the numerical values exemplified here.

3-2. Shaped step In the shaping step, as shown in FIGS. 8 to 9, the resin sheets 23 and 33 are brought into contact with the pinch-off portions 21b and 31b, respectively, and vacuum suction is performed by the molds 21 and 31. The resin sheets 23 and 33 are shaped along the inner surfaces of the cavities 21a and 31a. At this time, the skin sheets 24 and 34 are pressed against the molds 21 and 31 by the resin sheets 23 and 33, respectively, and integrally molded with the resin sheets 23 and 33. In the skin sheets 24 and 34, the skin sheets 24 and 34 are welded to the resin sheets 23 and 33, or the resin of the resin sheets 23 and 33 soaks into the cloth-like skin sheets 24 and 34, so that the skin sheets 24 and 34 are formed. It is integrally molded by being stuck in the resin sheets 23 and 33.

3-3. Insert step In the insert step, as shown in FIG. 10, the insert member 26 is welded to the resin sheet 23 or the resin sheet 33. The insert member 26 is configured by supporting the reinforcing member 8 by a spacer member 7 made of a foam, and the insert member 26 is welded to the resin sheet by melting the foam by the heat of the resin sheet 33. The insert member 26 may be welded to either the resin sheet 23 or the resin sheet 33, but the resin sheet 23 is in contact with the mold 21 via the skin sheet 24 arranged in the entire region of the cavity 21a. Therefore, it is less likely to be cooled by the mold than the resin sheet 33. Therefore, from the viewpoint of reliably welding the insert member 26 to prevent it from falling, it is preferable that the insert member 26 is welded to the resin sheet 23. The insert member 26 is arranged so that one end 8a and the other end 8b of the reinforcing member 8 overlap the skin sheet 34 in a plan view.

3-4. Die-clamping step In the mold-clamping step, the molds 21 and 31 are clamped as shown in FIG. As a result, the resin panel 1 having a shape along the inner surface of the cavity formed by the pair of molds 21 and 31 can be obtained. The outside of the pinch-off portions 21b and 31b is the burr 41. After that, the resin panel 1 shown in FIG. 1 is obtained by opening the molds 21 and 31 to take out the resin panel 1 and removing the burrs 41.

In a form in which the depth of the cavity 31a in the arrangement region S1 is the same as the depth of the cavity 31a in the non-arrangement region S2, the resin of the resin sheet 33 is sandwiched between the back wall side skin sheet 34 and the reinforcing member 8. Resin surplus is likely to be generated by being pushed away, and when the surplus resin is contracted, it is likely to be bulged to protrude toward the back wall 4 side by riding on the reinforcing member 8. However, in the present embodiment, the arrangement area S1 is likely to occur. Since the depth of the cavity 31a in the above is deeper than the depth of the cavity 31a in the non-arranged region S2, the resin of the resin sheet 33 is less likely to be pushed away, and the above problem is less likely to occur.

1: Resin panel 1a: Side edge 1b: Tapered area 1c: Flat area 2: Front wall side skin material 3: Front wall 4: Back wall 5: Back wall side skin material 6: Peripheral wall 7: Spacer member 8: Reinforcement Member 8a: One end 8b: Other end 10: Molding machine 11: Raw material resin 12: Hopper 13: Extruder 13a: Cylinder 17: Accumulator 17a: Cylinder 17b: Piston 18: T-die 20: Resin sheet forming device 21: Mold 21a : Cavity 21b: Pinch-off portion 23: Resin sheet 24: Front wall side skin sheet 25: Connecting pipe 26: Insert member 27: Connecting pipe 31: Mold 31a: Cavity 31b: Pinch-off portion 31c: Tapered region 31d: Flat region 33: Resin sheet 34: Back wall side skin sheet 41: Burr R1: Covering area R2: Exposed area S1: Arrangement area S2: Non-arrangement area

Claims (13)

The front wall side skin material, the front wall, the back wall, and the back wall side skin material are provided in this order.
The front wall and the back wall face each other at a distance.
A peripheral wall connecting the front wall and the periphery of the back wall is provided.
The back wall side skin material is integrally molded on the back wall so as to cover a part of the back wall .
The back wall side skin material is provided along at least one side edge of the resin panel.
Assuming that the area where the back wall side skin material is provided on the back wall is the covering area and the area where the back wall side skin material is not provided on the back wall is the exposed area.
The resin panel is a resin panel in which the thickness in the covering region is larger than the thickness in the exposed region . The resin panel according to claim 1 , wherein the thickness in the covering region is configured to approach the thickness in the exposed region as the distance from the side edge increases. A reinforcing member is provided between the front wall and the back wall.
The resin panel according to claim 1 or 2, wherein the reinforcing member is arranged so that one end thereof overlaps the covering region in a plan view. The back wall side skin material includes first and second back wall side skin materials.
The resin panel comprises opposing first and second side edges.
The first and second back wall side skin materials are provided along the first and second side edges, respectively.
The resin panel according to claim 3 , wherein one end and the other end of the reinforcing member are arranged so as to overlap the first and second back wall side skin materials in a plan view, respectively. The resin panel according to claim 3 or 4, wherein a spacer member is provided between the front wall and the back wall, and the reinforcing member is supported by the spacer member. The back wall surface material, wherein the back wall is provided so as to extend up to the peripheral wall, a resin panel according to any one of claims 1 to 5. The resin panel according to claim 6 , wherein the back wall side skin material is provided so as to come into contact with the front wall side skin material. The resin panel according to any one of claims 1 to 7 , wherein the front wall side skin material is integrally molded on the front wall so as to cover the entire area of the front wall. Equipped with a hanging process and a mold clamping process,
In the hanging step, the first and second resin sheets are hung between the first and second molds.
A front wall side skin sheet is placed between the first mold and the first resin sheet.
A back wall side skin sheet is placed between the second mold and the second resin sheet.
The back wall side skin sheet is arranged so as to overlap a part of the cavity of the second mold in a plan view.
In the mold clamping step, the first and second molds are molded and molded .
The second mold cavity, said the arrangement area back wall side skin sheet is placed, the back wall side surface sheet is not disposed Ru blank region is provided, the production method of the resin panel. The method according to claim 9 , wherein the back wall side skin sheet is provided along at least one side edge of the cavity of the second mold. The method according to claim 10 , wherein the cavity of the second mold has a depth in the arrangement region deeper than a depth in the non-arrangement region. 11. The method of claim 11 , wherein the depth in the placement region is configured to approach the depth in the non-placement region as the distance from the side edges increases. An insert process is provided between the hanging process and the mold clamping process.
In the insert step, the insert member is welded to the first or second resin sheet.
The insert member is configured such that a reinforcing member is supported by a spacer member.
The method according to any one of claims 10 to 12, wherein the reinforcing member is arranged so that one end thereof overlaps the back wall side skin sheet in a plan view.

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