JP2019142073A - Molded structure and manufacturing method thereof - Google Patents

Abstract

To provide a molded structure and a manufacturing method thereof capable of further improving rigidity.SOLUTION: A molded structure 10 has a body member 20 composed of at least fibers and a thermoplastic resin, and a molding member 30 composed of at least a thermoplastic resin and joined to the body member 20. The body member 20 has a constitution including an impregnated resin layer 33 that is continuous from the molding member 30 between a front surface 20A and a back surface 20B, and that is formed by impregnating the thermoplastic resin from the molded member 30.SELECTED DRAWING: Figure 7

Description

  The present invention relates to a molded structure and a method for manufacturing the same.

  Conventionally, what is described in Patent Document 1 is known as a molded structure and a manufacturing method thereof. In the molded structure and the manufacturing method thereof described in Patent Document 1, a base material including a thermoplastic resin, and a molded body molded in a state bonded to the base material by injecting a molten resin onto the base material, In the base material, the first peripheral portion positioned around the joint portion with the molded body has a density higher than that of the second peripheral portion positioned around the first peripheral portion. Is disclosed as a high-density part. With this configuration, when the molten resin is injected onto the base material (joining portion) to form a molded body, the molten resin is less likely to penetrate into the first peripheral portion, and the surface of the first peripheral portion The molten resin does not ooze out. Therefore, it is described that the situation where the bonding area between the base material and the molded body increases can be suppressed, and the situation where unevenness is generated on the opposite side of the base material due to the thermal contraction of the molded body can be suppressed. Yes.

Japanese Patent No. 5803572

  In the configuration disclosed in Patent Document 1, a protrusion having a substantially trapezoidal shape in cross-section in which the protrusion amount increases toward the center is provided in the lower mold, thereby compressing the preboard, thereby providing a base having a high-density portion. The material was molded. Then, the high-density portion has a thin plate thickness and tends to be less rigid than other portions, and it is desired to improve the rigidity in the portion.

  The present invention has been completed based on the above circumstances, and an object of the present invention is to provide a molded structure that can realize further improvement in rigidity and a method for manufacturing the same.

  The present invention is a molded structure comprising at least a main body member composed of fibers and a thermoplastic resin, and a molded member composed of at least a thermoplastic resin and joined to the main body member, The resin layer is continuous with the molded member between the front surface and the back surface, and is characterized by having an impregnated resin layer formed by impregnating a thermoplastic resin from the molded member.

  According to such a molded structure, since the impregnated resin layer connected to the molded member is formed in the main body member, the bonding force between the main body member and the molded member is reinforced, and fractures at the interface between the two. It becomes difficult to cause defects.

  The said structure WHEREIN: The said main body member is located in the circumference | surroundings of the 1st surrounding part located in the circumference | surroundings of the junction part with the said shaping | molding member, and the 2nd thicker than the said 1st surrounding part. And the impregnating resin layer is formed so as to extend from the joint portion to the second peripheral portion. According to such a molded structure, the thickness of the first peripheral portion is smaller than that of the second peripheral portion, and the density is increased. On the other hand, the thickness of the first peripheral portion around the joint portion is small. The rigidity tends to be lower than that of the other part (second peripheral part). However, in the above configuration, the main body member has the impregnated resin layer formed to extend not only to the first peripheral portion having a small plate thickness but also to the second peripheral portion having a large plate thickness. The rigidity of the first peripheral portion can be increased, and the breakage at the first peripheral portion having a small plate thickness can be suppressed.

  Further, the present invention is a method for producing a molded structure comprising: a main body member composed of at least fibers and a thermoplastic resin; and a molded member composed of at least a thermoplastic resin and joined to the main body member. , A preboard molding step of molding a preboard for forming the main body member, and pressing the preboard with an upper mold and a lower mold, while making the thermoplastic resin constituting the molded member of the upper mold or the lower mold And a main molding step of forming a molding structure in which the molding member is joined to the preboard, and the main molding step heats the preboard above the melting point of the thermoplastic resin. The preboard is disposed between the upper mold and the lower mold, and the upper mold and the lower mold are closed and held for a predetermined time. A step of cooling and solidifying the surface, and a step of injecting a thermoplastic resin into a space provided in at least one of the upper die or the lower die and following the shape of the molded member. .

  According to such a method for producing a molded structure, the thermoplastic resin is melted while maintaining the shape of the preboard by the fibers by heating the preboard to a temperature higher than the melting point of the thermoplastic resin. Then, in the step of cooling and solidifying the front and back surfaces of the preboard, the upper mold and the lower mold are closed and held for a predetermined time, whereby the heated front and back surfaces of the preboard are cooled by the upper mold and the lower mold. Then, the thermoplastic resin close to the front and back surfaces can be solidified. On the other hand, the thermoplastic resin present between the solidified thermoplastic resins near the front and back surfaces is in a molten state. At this time, if the thermoplastic resin is injected into the second molding space, the thermoplastic resin fills the second molding space and further penetrates into the preboard from the interface between the molding member formed from the second molding space and the preboard. To do. At this time, since the front and back surfaces of the main body member are solidified, the impregnating thermoplastic resin does not leak through the front and rear surfaces of the main body member. If this is cooled, an impregnated resin layer connected to the molded member can be formed in the main body member.

  In the above configuration, the preboard may contain a foam material. According to such a method for producing a molded structure, a preboard having a thickness larger than usual can be produced by heating the preboard and expanding the foam material. Then, it becomes possible to create a main body member having a large difference in plate thickness when pressing compared to a main body member formed from a preboard not mixed with a foam material. Accordingly, it is possible to provide a molded structure that is lightweight and strong.

  ADVANTAGE OF THE INVENTION According to this invention, it becomes possible to provide the molded structure which endures a tensile load, and is hard to fracture | rupture, and its manufacturing method.

Front transmission diagram of the molded structure according to Embodiment 1 of the present invention Enlarged perspective view showing the molded structure Sectional drawing which shows this shaping | molding process (before press) (corresponding to the II-II line section of Drawing 2) Sectional view showing the main molding process (after pressing) Sectional drawing which shows the process of injecting a thermoplastic resin Sectional drawing which shows the aspect which a thermoplastic resin impregnates to the 1st circumference part Sectional drawing which shows the aspect which a thermoplastic resin impregnates to the 2nd circumference part

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. In FIG. 3, the left side is the left side, the right side is the right side, the upper side is the upper side, and the lower side is the lower side.

  The door trim 10 (molded structure) is attached to a vehicle door, and is formed by joining a bracket 30 (molded member) such as a clip seat to the trim board 20 (main body member) as shown in FIG. Has been. The trim board 20 has a flat plate shape and is configured by impregnating fibers with polypropylene (thermoplastic resin). The trim board 20 is formed by press-molding the mat-like preboard P1 (see FIG. 3) to reduce the thickness (thickness of the plate) and to make the density higher than that of the preboard P1. In addition, as a fiber used for the trim board 20, for example, a wood fiber obtained by weaving wood or the like, a bast plant fiber such as kenaf, or the like is used, but the type of the fiber is not limited thereto. In the trim board 20, polypropylene plays a role as a binder for connecting fibers. Moreover, you may form the trim board 20 with the mixture of thermoplastic resins other than polypropylene, such as a polyethylene terephthalate, and a fiber.

  The bracket 30 is formed of, for example, polypropylene, and is formed so as to protrude from the back surface (surface outside the passenger compartment) 20B of the trim board 20 as shown in FIGS. The front end surface portion 31 of the bracket 30 is bent with respect to the wall portion 32. In addition, the attachment surface 34 which can attach a clip (not shown), for example is formed in the front end surface part 31, and the bracket 30 and the trim board 20 are attached to a door inner panel (not shown) via this clip. It is configured to be attached to. The thermoplastic resin constituting the bracket 30 is impregnated into the trim board 20 from the base end portion 39 of the bracket 30, whereby an impregnated resin layer 33 connected to the bracket 30 is formed in the trim board 20. (Details will be described later).

  As shown in FIGS. 3 to 7, the bracket 30 is formed by injecting molten resin onto the preboard P1 (trim board 20) in a state where the preboard P1 is set in a mold (details will be described later). . That is, the bracket 30 is joined to the preboard P1 at the same time as molding.

  The joint portion 21 of the trim board 20 with the bracket 30 has a density (in this embodiment, the weight of the thermoplastic resin and fibers per unit volume) rather than the periphery of the joint portion 21 (first peripheral portion 22 described later). Is considered to be a low density part. This is because when the preboard P1 is press-molded by the molding apparatus 40 described later, the joint portion 21 becomes a portion that is not compressed (or the degree of compression is small) by closing the upper mold 42 and the lower mold 41. .

  The low density portion is formed from the joint portion 21 to the surface 20A of the trim board 20 (in other words, over the almost entire length in the plate thickness direction). In the trim board 20, the plate thickness of the first peripheral portion 22 positioned around the joint portion 21 is smaller than the plate thickness of the second peripheral portion 23 positioned around the first peripheral portion 22. . The first peripheral portion 22 is formed so as to surround the joint portion 21, and the second peripheral portion 23 is formed so as to surround the first peripheral portion 22. It can also be said that the second peripheral portion 23 is a portion disposed on the opposite side of the joint portion 21 with respect to the first peripheral portion 22.

  As shown in FIG. 3, the pre-board P1 before the trim board 20 is formed has a uniform thickness and density over the entire surface, for example. Then, as shown in FIG. 4, the trim board 20 is formed by press-forming the pre-board P <b> 1 with a lower die 41 and an upper die 42 having a protruding portion 50. For this reason, the first peripheral portion 22 is a portion having a larger amount of depression than the second peripheral portion 23.

  Further, the thickness of the trim board 20 gradually decreases from the second peripheral portion 23 toward the joint portion 21. More specifically, the back surface 20B (the molding surface of the bracket 30) of the first peripheral portion 22 in the trim board 20 is an inclined surface 20B1. For this reason, the density of the trim board 20 gradually increases (for example, linearly) from the second peripheral portion 23 toward the joint portion 21 in the first peripheral portion 22. Moreover, the surface 20A (surface on the opposite side to the molding surface of the bracket 30) in the trim board 20 has, for example, a flat surface and is a surface on the design surface side.

  As shown in FIGS. 2, 6, and 7, the trim board 20 has a front surface (surface layer or surface portion constituting a predetermined thickness from the front surface) 20 </ b> A and a back surface (back surface constituting a predetermined thickness from the back surface). Layer or back surface portion) 20B, which is a resin layer continuous from the bracket 30 and is impregnated with the thermoplastic resin from the bracket 30, and from the joint portion 21 to the first peripheral portion 22 or from the joint portion 21 to the second portion. It has an impregnated resin layer 33 that extends to the peripheral portion 23.

  Next, the shaping | molding apparatus 40 which manufactures the door trim 10 is demonstrated. As shown in FIGS. 3 to 7, the molding apparatus 40 in this embodiment is an injection molding apparatus, and includes a molding die composed of an upper die 42 and a lower die 41 that are arranged to face each other, and an injection device 45. ing. The injection device 45 is, for example, a screw type, and is provided in the upper die 42 in the present embodiment (as another embodiment, the injection device 45 may be provided in the lower die 41). A gate 48 that allows the molten resin to pass therethrough is routed inside the upper mold 42. The upper mold 42 is formed with a second molding space S <b> 2 (cavity) that communicates with the shape of the bracket 30, and the gate 48 is located above the second molding space S <b> 2 (a position corresponding to the tip surface portion 31 of the bracket 30). ). Accordingly, the molten resin can be injected from the injection device 45 into the second molding space S2 through the gate 48.

  The upper mold 42 is a movable mold that can move with respect to the lower mold 41 by a driving device (not shown) (for example, an electric motor, an air cylinder, a hydraulic cylinder, or the like). The upper die 42 can be closed and opened by moving the upper die 42 closer to and away from the lower die 41. In the following description, the upper mold 42 and the lower mold 41 (molding mold) shown in FIG. 3 are opened, and the upper mold 42 and the lower mold 41 shown in FIGS. 4 to 7 are closed. Is called a closed state.

  Between the upper mold 42 and the lower mold 41 in the open state, as shown in FIG. 3, a facing surface 42 </ b> A of the upper mold 42 facing the lower mold 41 and a facing surface 41 </ b> A of the lower mold 41 facing the upper mold 42. In this manner, a space for forming the trim board 20 is formed. As a result, when the preboard P1 is pressed by the upper mold 42 and the lower mold 41, the preboard P1 is compressed in a shape corresponding to the shape of each of the opposing surfaces 41A and 42A as shown in FIG. Is formed. Further, the above-described second molding space S2 communicates with the first molding space S1 through the opening 49, and the communicating portion corresponds to the joint portion 21 in the trim board 20.

  A protruding portion 50 that protrudes toward the lower mold 41 is formed on a surface 42 </ b> A of the upper mold 42 that faces the lower mold 41. The protruding portion 50 is for forming the first peripheral portion 22 (a portion having a smaller thickness and higher density than the second peripheral portion 23) in the trim board 20, and the protruding amount increases toward the center. The shape is made. The first molding space S <b> 1 and the second molding space S <b> 2 are configured to communicate with each other through the opening 49 at the tip of the protruding portion 50.

  Further, a part of the upper mold 42 is a slide mold 43 that is slidable with respect to a main body portion 47 of the upper mold 42 (a portion other than the slide mold 43 in the upper mold 42). The slide die 43 is slid by a drive device (not shown), so that the upper die 42 can be removed while the front end surface portion 31 serving as an undercut portion exists in the bracket 30. In addition, the slide mold 43 constitutes a part of the second molding space S2 and a part of the protrusion 50 described above. The configuration of the slide mold 43 is not limited to that shown in FIG. 3 and can be changed as appropriate.

  Next, a method for manufacturing the door trim 10 using the molding apparatus 40 will be described with reference to FIGS. 3 to 7. The manufacturing method of the door trim 10 according to the present embodiment is roughly divided into a preboard molding step for molding the preboard P1 and a main molding step for molding the door trim 10 by pressing the preboard P1 and simultaneously injecting a thermoplastic resin. . The main molding step includes a step of heating the preboard P1, a step of cooling and solidifying the front and back surfaces 20A and 20B of the preboard P1, and a step of injecting a thermoplastic resin into the second molding space S2.

<Preboard molding process>
In the preboard molding process, a mat material in which fibers, polypropylene (thermoplastic resin), and a foam material are mixed is heated and press-molded, and this is subjected to a predetermined length (for example, the length dimension of the trim board 20 after molding). The pre-board P1 is formed by cutting with a longer dimension (not shown). Since the mat material before heating contains a foam material in addition to fibers and polypropylene, when this is heated, the foam material expands and the thickness of the mat material becomes larger than usual.

<Main molding process>
First, as shown in FIG. 3, the preboard P1 molded by the preboard molding step is heated again to such an extent that the thermoplastic resin melts and softens (a step of heating the preboard above the melting point of the thermoplastic resin). As a result, the thermoplastic resin is softened (melted) while maintaining the shape of the preboard P1 with the fibers.

  Subsequently, the pre-board P1 in a state where the thermoplastic resin is softened is disposed between the upper mold 42 and the lower mold 41 (or may be set so as to be placed on the lower mold 41). Thereafter, as shown in FIG. 4, the upper mold 42 and the lower mold 41 are closed and held for a predetermined time. As a result, the preboard P1 is press-molded by the molding die to form the trim board 20, and the closed state is maintained for a predetermined time, so that the thermoplastic resin 62 having a predetermined thickness from the front surface 20A of the preboard P1 and the back surface 20B are retained. The thermoplastic resin 61 having a predetermined thickness is cooled and solidified by taking heat away from the lower mold 41 and the upper mold 42 (step of cooling and solidifying the front and back surfaces of the preboard). On the other hand, the thermoplastic resin 63 inside the solidified thermoplastic resin has not been deprived of heat by the upper and lower molds 42 and 41 and remains softened.

  At the time of press molding, the portion of the preboard P1 that faces the second molding space S2 is not compressed by the molding die (or the compression amount is smaller than other portions), and therefore enters the opening 49 and relatively surrounds it. It will be in a raised state (thickness state). This raised portion becomes a joint portion 21 with the bracket 30 in the trim board 20.

  Further, in the present embodiment, the protrusion 50 is formed on the upper mold 42. For this reason, the portion of the trim board 20 that faces the protruding portion 50 (that is, the first peripheral portion 22 that is the periphery of the joint portion 21) is compared to the portion that faces the periphery of the protruding portion 50 (second peripheral portion 23). And it press-molds so that the plate | board thickness may become small. Thereby, the density of the first peripheral portion 22 is higher than the density of the second peripheral portion 23. That is, the first peripheral portion 22 is a high density portion. Moreover, the density of the junction part 21 shall be lower than the 2nd surrounding part 23, for example.

  Further, since the protruding portion 50 has a shape in which the protruding amount increases toward the center thereof, the thickness of the trim board 20 is directed from the second peripheral portion 23 to the joint portion 21 in the first peripheral portion 22. As a result, it is formed in a shape that gradually becomes smaller (a shape that gradually changes), and an inclined surface 20B1 that is inclined on the back surface 20B is formed.

  Next, as shown in FIG. 5, while the trim board 20 (preboard P <b> 1) is pressed by the upper mold 42 and the lower mold 41, the molten thermoplastic resin is injected into the gate 48 by the injection device 45 provided in the upper mold 42. Is injected into the second molding space S2 (step of injecting a thermoplastic resin). The injected molten resin fills the second molding space S2 to form the bracket 30, and further penetrates into the trim board 20 while pushing the softened thermoplastic resin around the joint 21 downward. Naturally, the density inside increases.) Note that the thermoplastic resin injected from the injection device 45 and the thermoplastic resin contained in the trim board 20 may be the same or different, as long as they are mixed with each other when heated.

  Since the front and back surfaces 20A and 20B of the trim board 20 are cooled and solidified, the thermoplastic resin that has penetrated into the trim board 20 does not penetrate through the front and back surfaces 20A and 20B of the trim board 20 and leak out. That is, the thermoplastic resin impregnates the softened portion between the front and back surfaces that are cooled and solidified. Then, although the thermoplastic resin that has penetrated into the trim board 20 is restricted from moving in the vertical direction, it penetrates and spreads (impregnates) in the left-right and front-back directions where the softened thermoplastic resin spreads. Thereby, the trim board 20 is a resin layer continuous from the bracket 30 between the front surface 20A and the back surface 20B of the trim board 20, and is a layer formed by impregnating the thermoplastic resin from the bracket 30 (impregnated resin layer). ) 33 is formed. 6 shows an embodiment in which the impregnated resin layer 33 is formed so as to extend from the joint portion 21 to the first peripheral portion 22, and in FIG. 7, the impregnated resin layer 33 is from the joint portion 21 to the second peripheral portion 23. The aspect currently formed by expanding is shown. These can be adjusted by the amount and speed of the thermoplastic resin injected from the injection device 45.

  The thermoplastic resin that has penetrated into the trim board 20 and formed the impregnated resin layer 33 is mixed (mixed) with the softened thermoplastic resin in the trim board 20. In this manner, the second molding space S2 is filled with the thermoplastic resin, and the thermoplastic resin is cooled, so that the bracket 30 is molded in a state of being joined to the trim board 20. Thereafter, by opening the molds 41 and 42 and moving the slide mold 43, the trim board 20 molded with the bracket 30 as shown in FIGS. The mold can be removed, and the manufacture of the door trim 10 is completed.

  Then, the effect of this embodiment is demonstrated. The present invention is a molded structure 10 comprising a main body member 20 composed of at least fibers and a thermoplastic resin, and a molded member 30 composed of at least a thermoplastic resin and joined to the main body member 20. The member 20 is configured to have an impregnating resin layer 33 formed by impregnating a thermoplastic resin from the molded member 30 between the front surface 20A and the back surface 20B. Yes. According to such a molded structure 10, since the impregnated resin layer 33 continuous with the molded member 30 is formed in the main body member 20, the bonding force between the main body member 20 and the molded member 30 is reinforced, and the boundary between the two Problems such as breaking at the surface are less likely to occur.

  In the above configuration, the main body member 20 is positioned around the first peripheral portion 22 around the joint portion 21 with the molding member 30, and is thicker than the first peripheral portion 22. The impregnating resin layer 33 can be formed so as to extend from the joint portion 21 to the second peripheral portion 23. According to such a molded structure 10, the first peripheral portion 22 has a smaller plate thickness than the second peripheral portion 23, and a higher density is achieved, while the first peripheral portion 22 around the joint portion 21 is Since the plate thickness is small, the rigidity tends to be lower than that of other portions (second peripheral portion 23). However, in the above configuration, the main body member 20 includes the impregnating resin layer 33 that extends not only to the first peripheral portion 22 having a small plate thickness but also to the second peripheral portion 23 having a large plate thickness. The rigidity of the first peripheral portion 22 of the main body member 20 can be increased by 33, and the breakage at the first peripheral portion 22 having a small plate thickness can be suppressed.

  In addition, the present invention provides a method for manufacturing a molded structure 10 including a main body member 20 composed of at least fibers and a thermoplastic resin, and a molded member 30 composed of at least a thermoplastic resin and joined to the main body member 20. The preboard P1 forming step for forming the preboard P1 for forming the main body member 20, and the thermoplastic resin constituting the forming member 30 is raised while pressing the preboard P1 with the upper die 42 and the lower die 41. And a main molding step of forming a molding structure 10 in which the molding member 30 is joined to the preboard P1 by being injected from at least one of the mold 42 and the lower die 41. The main molding step is made of a thermoplastic resin. The step of heating the preboard P1 above the melting point, the preboard P1 is disposed between the upper mold 42 and the lower mold 41, and the upper mold 42 and the lower mold 41 are closed and held for a predetermined time. Thus, a step of cooling and solidifying the front and back surfaces 20A and 20B of the preboard P1 and a space provided in at least one of the upper die 42 or the lower die 41 and communicating in accordance with the shape of the molding member 30 (second molding space S2) And a step of injecting a thermoplastic resin. According to such a manufacturing method of the molded structure 10, by heating the preboard P1 above the melting point of the thermoplastic resin, the thermoplastic resin melts while maintaining the shape of the preboard P1 with the fibers. Then, in the process of cooling and solidifying the front and back surfaces 20A and 20B of the preboard P1, the upper mold 42 and the lower mold 41 are closed and held for a predetermined time, so that the heated front surface 20A and back surface 20B of the preboard P1 are connected to the upper mold 42. And cooled by the lower mold 41. Then, the thermoplastic resin close to the front and back surfaces 20A and 20B can be solidified. On the other hand, the thermoplastic resin present between the solidified thermoplastic resins near the front and back surfaces 20A and 20B is in a molten state. At this time, if the thermoplastic resin is injected into the second molding space S2, the thermoplastic resin fills the second molding space S2, and further from the interface between the molding member 30 and the preboard P1 formed from the second molding space S2. It penetrates into the inside of the preboard P1. At this time, since the front and back surfaces 20A and 20B of the main body member 20 are solidified, the impregnating thermoplastic resin does not leak through the front and back surfaces 20A and 20B of the main body member 20. If this is cooled, the impregnated resin layer 33 connected to the molded member 30 can be formed in the main body member 20.

  In the above configuration, the preboard P1 may contain a foam material. According to such a manufacturing method of the molded structure 10, the preboard P1 having a thickness larger than usual can be produced by heating the preboard P1 and expanding the foam material. Then, it becomes possible to create the main body member 20 having a large difference in plate thickness when pressing compared to the main body member 20 formed from the preboard in which the foam material is not mixed. Therefore, it is possible to provide a molded structure 10 that is lightweight and strong.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, within the scope not departing from the gist of the invention other than the following. Various modifications can be made.

  (1) In addition to the above embodiment, the position where the injection device and the gate are provided can be changed as appropriate. In the present embodiment, the gate is routed at a position corresponding to the tip surface portion of the bracket and the injection device is disposed so as to be connected to the upper mold, but the present invention is not limited to this. For example, a gate may be routed near the opening, and the injection device may be disposed so as to connect to the gate. According to such a configuration, before the injected thermoplastic resin fills the second molding space, that is, before the heated preboard completely cools to the inside, the injected thermoplastic resin is brought into the trim board. Can be impregnated.

  (2) In the above-described embodiment, the first peripheral portion may be configured not to surround the entire periphery of the joint portion. Further, the second peripheral portion may be configured not to surround the entire circumference of the first peripheral portion.

  (3) In the above embodiment, the door trim is exemplified as the molded structure, the trim board is exemplified as the main body member, and the bracket is exemplified as the molded member. However, the present invention is not limited to this. The molded structure is molded by molding a molded member by injection molding a molten resin to a main body member including a thermoplastic resin such as a backboard of a sheet, and simultaneously bonding the main body member and the molded member. It may be a thing.

  (4) The molded structures exemplified in the above embodiments are not limited to those provided for vehicles, and may be provided in various vehicles. For example, the molded structure can be applied to vehicles such as trains and amusement vehicles as ground vehicles, airplanes and helicopters as flying vehicles, and ships and submersibles as marine and underwater vehicles.

  DESCRIPTION OF SYMBOLS 10 ... Door trim (molding structure), 20 ... Trim board (main body member), 20A ... Front surface, 20B1 ... Inclined surface, 20B ... Back surface, 21 ... Joining part, 22 ... 1st surrounding part, 23 ... 2nd surrounding part, DESCRIPTION OF SYMBOLS 30 ... Bracket (molding member), 31 ... Front end surface part, 32 ... Base end wall part, 33 ... Impregnation resin layer, 34 ... Mounting hole, 39 ... Base end part, 40 ... Molding apparatus, 41 ... Lower mold | type, 41A ... Opposite Surface 42, upper die, 42A ... opposing surface, 43 ... slide die, 45 ... injection device, 47 ... main body, 48 ... gate, 49 ... opening, 50 ... projection, P1 ... pre-board, S1 ... first molding Space, S2 ... Second molding space

Claims (4)

A body member composed of at least a fiber and a thermoplastic resin;
A molded structure comprising at least a thermoplastic resin and a molded member joined to the main body member,
The main body member has a resin layer continuous from the molded member between the front surface and the back surface, and an impregnated resin layer formed by impregnating a thermoplastic resin from the molded member. Structure. The body member is
A first peripheral portion located around a joint portion with the molded member;
A second peripheral portion located around the first peripheral portion and having a thickness larger than that of the first peripheral portion;
2. The molded structure according to claim 1, wherein the impregnated resin layer is formed to extend from the joint portion to the second peripheral portion. A body member composed of at least a fiber and a thermoplastic resin;
A molded member comprising at least a thermoplastic resin and joined to the main body member,
A preboard molding step of molding a preboard for forming the body member;
A shape in which a thermoplastic resin constituting the molding member is injected from at least one of the upper die or the lower die while the preboard is pressed with an upper die and a lower die, and the molding member is joined to the preboard. And a main molding step of forming a molding structure of
The main molding step
Heating the preboard above the melting point of the thermoplastic resin;
Placing the preboard between the upper mold and the lower mold, and closing and holding the upper mold and the lower mold for a predetermined time to cool and solidify the front and back surfaces of the preboard;
And a step of injecting a thermoplastic resin into a space provided in at least one of the upper mold or the lower mold and communicating in accordance with the shape of the molded member.   The said preboard contains a foaming material, The manufacturing method of the molded structure of Claim 3 characterized by the above-mentioned.

Images