JP6975891B2 - Manufacturing method of resin panel for vehicles and resin panel for vehicles - Google Patents

Description

The present invention relates to a method for manufacturing a resin panel for a vehicle and a resin panel for a vehicle.

Generally, a vehicle resin panel is manufactured through the following first and second steps. In the first step, a first mold having a first forming surface and a second mold having a second forming surface facing the first forming surface are prepared. Then, a cavity is formed by the first forming surface and the second forming surface. In the second step, the molten resin in which the resin constituting the vehicle resin panel is melted is injected into the cavity. After that, the molten resin solidifies in the cavity to complete the resin panel for the vehicle.

By the way, various structures may be provided on the surface of such a resin panel for a vehicle when it is used in a vehicle. Therefore, from the viewpoint of reducing the number of parts, it is conceivable to integrally form the structure with the resin panel for a vehicle in advance. That is, the vehicle resin panel is formed in a plate shape and extends in the first direction and the second direction orthogonal to the first direction, and is orthogonal to the first direction and the second direction from the surface of the panel body. It includes a structure extending in a third direction. The structure has a tip portion located at the tip in the third direction, and a side wall portion connecting the tip portion and the panel main body. Thereby, the cavity has a main body cavity forming the panel main body, a tip portion cavity forming the tip portion, and a side wall portion cavity forming the side wall portion.

However, in such a cavity, when the molten resin travels from the position where the molten resin is injected into the cavity to the end of the cavity, the distance through the cavity for the tip and the cavity for the side wall to reach the end of the cavity is determined. It is longer than the distance that flows through the cavity for the main body and reaches the end of the cavity. Therefore, the molten resin flowing through the cavity for the tip portion and the cavity for the side wall portion is delayed as compared with the molten resin flowing through the cavity for the main body. Further, the temperature of the molten resin injected into the cavity gradually decreases within the cavity. As a result, the place where the molten resin circulated in the cavity for the tip and the molten resin circulated in the cavity for the side wall meet, the molten resin circulated in the cavity for the tip, and the molten resin circulated in the cavity for the side wall. Weld lines are likely to occur at the points where the molten resin that has flowed through the cavity for the main body merges. Further, due to the occurrence of the weld line, the quality of the resin panel for a vehicle is deteriorated because the aesthetic appearance is deteriorated and the durability is liable to be deteriorated.

Therefore, in the method for manufacturing a resin panel for a vehicle disclosed in Patent Document 1 (hereinafter, simply referred to as a manufacturing method), the mold is heated by a high frequency induction heating device. In this way, in this manufacturing method, the generation of weld lines is suppressed by heating the molten resin in the cavity through the mold.

Japanese Unexamined Patent Publication No. 1-269515

However, in the above-mentioned conventional manufacturing method, the molten resin is heated by the high-frequency induction heating device, and it takes a long time for the molten resin to solidify in the cavity. Therefore, the manufacturing efficiency is lowered. Further, this manufacturing method requires a high frequency induction heating device and a mold that can be heated by the high frequency induction heating device. For these reasons, the manufacturing cost of this manufacturing method increases.

The present invention has been made in view of the above-mentioned conventional circumstances, and provides a method for manufacturing a resin panel for a vehicle and a resin panel for a vehicle, which have high quality and can realize a reduction in manufacturing cost. Is an issue to be solved.

The method for manufacturing a resin panel for a vehicle according to the present invention includes a panel body formed of a resin in a plate shape and extending in a first direction and a second direction orthogonal to the first direction.
A structure integrally formed with the panel body by the resin and extending from the surface of the panel body in the first direction and a third direction orthogonal to the second direction is provided.
The structure is a method for manufacturing a resin panel for a vehicle having a tip portion located at the tip end in the third direction and a side wall portion connecting the tip portion and the panel main body.
A first type having a first forming surface and a second type having a second forming surface facing the first forming surface are prepared, and a cavity is formed by the first forming surface and the second forming surface. 1 process and
A second step of injecting the molten resin in which the resin is melted into the cavity is provided.
The cavity is a side wall portion that is connected to a main body cavity that forms the panel main body, a tip portion cavity that forms the tip portion, and the main body cavity and the tip portion cavity to form the side wall portion. Has a cavity and
The main body cavity has a main region forming a first interval in the third direction.
The tip cavity has a second spacing wider than the first spacing in the third direction.
The side wall cavity is characterized in that the distance between the first forming surface and the second forming surface increases toward the tip cavity side from the main body cavity side.

Also in the manufacturing method of the present invention, when the resin travels from the position where the resin is injected into the cavity to the end of the cavity, the distance through the cavity for the tip and the cavity for the side wall to reach the end of the cavity is the main body. It is longer than the distance that flows through the cavity and reaches the end of the cavity. In this respect, in this manufacturing method, the interval in the third direction in the cavity for the tip portion is wider than the interval in the third direction in the cavity for the main body. Further, in the side wall cavity portion, the distance between the first forming surface and the second forming surface is increased from the main body cavity side toward the tip portion cavity side. For these reasons, the molten resin injected into the cavity is more likely to flow through the cavity for the tip portion and the cavity for the side wall portion than the cavity for the main body.

Therefore, in this manufacturing method, when the molten resin travels from the position where the molten resin is injected into the cavity to the end of the cavity, the molten resin that flows through the cavity for the tip portion and the cavity for the side wall portion and the cavity for the main body are circulated. The difference with the molten resin becomes small. Therefore, the place where the molten resin circulated in the cavity for the tip and the molten resin circulated in the cavity for the side wall meet, the molten resin circulated in the cavity for the tip, and the molten resin circulated in the cavity for the side wall. Weld lines are unlikely to occur at the points where the molten resin that has flowed through the cavity for the main body merges. As a result, according to this manufacturing method, not only the appearance of the resin panel for a vehicle can be enhanced, but also the durability can be enhanced.

Further, in this manufacturing method, it is not necessary to separately heat the molten resin injected into the cavity in order to suppress the generation of weld lines. Therefore, the manufacturing efficiency can be increased by shortening the time until the molten resin solidifies in the cavity. Further, a heating device such as a high frequency induction heating device and a mold capable of heating by the heating device are not required.

Therefore, according to the method for manufacturing a resin panel for a vehicle of the present invention, it is possible to manufacture a resin panel for a vehicle having high quality and capable of reducing the manufacturing cost.

In the manufacturing method of the present invention, the panel body may have a base portion and a connecting portion connecting the base portion and the side wall portion. The main body cavity preferably has a main region forming a base portion and a sub-region forming a connecting portion having a third interval narrower than the first interval in the third direction.

In this case, as compared with the configuration in which the side wall portion is directly connected to the base portion, the distance between the first forming surface and the second forming surface of the side wall portion cavity is appropriately adjusted, and the tip portion is from the cavity side for the main body. It becomes possible to suitably increase the distance between the first forming surface and the second forming surface toward the cavity side. Therefore, in this manufacturing method, the molten resin can more easily flow through the cavity for the side wall portion. Therefore, in this manufacturing method, it is possible to suitably form the side wall portion, and thus the structure, while appropriately suppressing the generation of weld lines.

In the second step, it is preferable to bring the first mold and the second mold into contact with each other while pressurizing the first mold and the second mold in the mold clamping direction. In this case, the molten resin injected into the cavity can be suitably spread over the entire cavity. As a result, molding defects are less likely to occur in this manufacturing method.

The vehicle resin panel of the present invention has a panel body formed of a resin in a plate shape and extending in a first direction and a second direction orthogonal to the first direction.
A structure integrally formed with the panel body by the resin and extending from the surface of the panel body in the first direction and a third direction orthogonal to the second direction is provided.
The panel body has a base having a first plate thickness in the third direction.
The structure is located at the tip in the third direction, has a tip portion having a second plate thickness thicker than the first plate thickness in the third direction, and a side wall connecting the tip portion and the panel main body. Has a part and
The side wall portion is characterized in that it becomes thicker than the first plate thickness toward the tip end portion side from the panel main body side.

In the resin panel for vehicles of the present invention, the plate thickness of the tip portion and the side wall portion is thicker than the plate thickness of the panel body. Therefore, in this resin panel for a vehicle, a weld line is unlikely to occur at a place where the tip portion and the side wall portion meet or at a place where the tip portion, the side wall portion and the panel main body meet at the time of manufacturing.

Further, in this resin panel for a vehicle, it is not necessary to heat by a high frequency induction heating device or the like in order to suppress the generation of weld lines. Therefore, the production can be facilitated.

Therefore, the resin panel for a vehicle of the present invention has high quality and can realize low manufacturing cost.

In the vehicle resin panel of the present invention, the panel body may have a connecting portion connecting the base portion and the side wall portion. The connecting portion preferably has a third plate thickness thinner than the first plate thickness in the third direction. In this case, since weld lines are less likely to occur at the tip portion, the side wall portion, and the portion where the panel main body joins during manufacturing, the quality of this vehicle resin panel can be further improved.

According to the method for manufacturing a resin panel for a vehicle of the present invention, it is possible to manufacture a resin panel for a vehicle having high quality and capable of reducing the manufacturing cost. Further, the resin panel for a vehicle of the present invention has high quality and can realize a reduction in manufacturing cost.

FIG. 1 is a top view showing a vehicle using a resin panel for a vehicle manufactured by the manufacturing method of the embodiment. FIG. 2 is a top view showing a resin panel for a vehicle manufactured by the manufacturing method of the embodiment. FIG. 3 is a cross-sectional view showing a cross section taken along the line AA of FIG. 2 with respect to the resin panel for a vehicle manufactured by the manufacturing method of the embodiment. FIG. 4 is a cross-sectional view showing a BB cross section of FIG. 2 with respect to the vehicle resin panel manufactured by the manufacturing method of the embodiment. FIG. 5 is an enlarged cross-sectional view of a main part in the same direction as that of FIG. 4, showing a structure of a resin panel for a vehicle manufactured by the manufacturing method of the embodiment. FIG. 6 is an enlarged cross-sectional view of a main part showing a CC cross section of FIG. 2 with respect to a vehicle resin panel manufactured by the manufacturing method of the embodiment. FIG. 7 is a schematic cross-sectional view showing a first mold, a second mold, a cavity, and the like according to the manufacturing method of the embodiment. FIG. 8 is an enlarged schematic cross-sectional view of a main part showing a first mold, a second mold, a cavity, and the like according to the manufacturing method of the embodiment. FIG. 9 is an enlarged schematic cross-sectional view of a main part showing a state in which the molten resin is injected into the cavity according to the manufacturing method of the embodiment. FIG. 10 is a schematic cross-sectional view showing a state in which the molten resin flows through the cavity according to the manufacturing method of the embodiment. FIG. 11 is an enlarged schematic cross-sectional view of a main part showing a state in which the molten resin is solidified in the cavity according to the manufacturing method of the embodiment. FIG. 12 is a schematic cross-sectional view showing a state in which the molten resin flows through the cavity according to the manufacturing method of the comparative example.

Hereinafter, examples embodying the present invention will be described with reference to the drawings.

The roof panel 1 shown in FIG. 1 is used in the vehicle 100. The roof panel 1 is an example of the "resin panel for a vehicle" of the present invention. In this embodiment, each arrow shown in FIG. 1 defines the front-rear direction and the width direction of the roof panel 1, the left-right direction, and the front-rear direction and the left-right direction of the vehicle 100. Then, in FIGS. 2 and 2, the front-rear direction and the left-right direction of the roof panel 1 are defined corresponding to FIG. Further, in FIG. 3 and the like, the vertical direction of the roof panel 1 is defined. The front-rear direction corresponds to the "first direction" of the present invention, and the left-right direction corresponds to the "second direction" of the present invention. Further, the vertical direction corresponds to the "third direction" of the present invention. These front-back directions, left-right directions, and up-down directions are orthogonal to each other. It should be noted that each of these directions is an example for convenience of explanation and can be changed as appropriate.

As shown in FIG. 1, the vehicle 100 includes a body 101. The body 101 forms a passenger compartment CR substantially in the center of the vehicle 100 in the front-rear direction. The body 101 has a front pillar panel 102, a rear pillar panel 103, a first mounting rail 104, and a second mounting rail 105.

The front pillar panel 102 is arranged on the front side of the body 101. The front pillar panel 102 extends toward the rear side of the body 101 while being inclined toward the upper side of the vehicle 100. A front window 106 is fixed to the front pillar panel 102. Further, front side mounting portions 102a and 102b are provided at the rear end of the front pillar panel 102. The rear pillar panel 103 is arranged on the rear side of the body 101 and is separated from the front pillar panel 102. The rear pillar panel 103 extends toward the rear side of the body 101 while being inclined toward the lower side of the vehicle 100. A rear window 107 is fixed to the rear pillar panel 103. Further, rear side mounting portions 103a and 103b are provided at the front end of the rear pillar panel 103. The number of front side mounting portions 102a and 102b and the number of rear side mounting portions 103a and 103b can be appropriately designed.

The first mounting rail 104 and the second mounting rail 105 have symmetrical shapes. The first mounting rail 104 and the second mounting rail 105 extend along the front pillar panel 102 and the rear pillar panel 103 in a substantially arcuate shape in the front-rear direction of the body 101. The first mounting rail 104 has first to sixth mounting portions 104a to 104f in order from the front to the rear. Similarly, the second mounting rail 105 also has the first to sixth mounting portions 105a to 105f in order from the front to the rear.

In the first mounting rail 104, the first and second fixing portions 104a and 104b are fixed to the left end of the front pillar panel 102 by a plurality of mounting screws 108, and the fifth and sixth fixing portions 104e and 104f are the rear pillar panel 103. It is fixed to the left end of. In this way, the first mounting rail 104 is fixed to the left side of the body 101. On the other hand, in the second mounting rail 105, the first and second fixing portions 105a and 105b are fixed to the right end of the front pillar panel 102 by a plurality of mounting screws 108, and the fifth and sixth fixing portions 105e and 105f are rear pillars. It is fixed to the right end of the panel 103. In this way, the second mounting rail 105 is fixed to the right side of the body 101.

In the body 101, a substantially rectangular mounting space 109 is formed by the rear end of the front pillar panel 102, the front end of the rear pillar panel 103, and the first and second mounting rails 104 and 105. Similar to a known vehicle, the body 101 is provided with a door panel or the like, and the vehicle 100 is provided with a power device, a control device, or the like necessary for traveling.

As shown in FIGS. 1 and 2, the roof panel 1 includes a panel main body 11 and an antenna cover 13. The antenna cover 13 is an example of the "structure" of the present invention. The roof panel 1 is made of a resin containing polycarbonate as a main component.

The panel main body 11 extends in the front-rear direction and the left-right direction corresponding to the mounting space 109, and has a substantially rectangular plate shape. As a result, the panel main body 11 has a front surface 11a and a back surface 11b located on the opposite side of the front surface 11a, as shown in FIGS. 3 to 6. The panel main body 11 has a shape that curves with a predetermined curvature from the back surface 11b side to the front surface 11a side in the front-rear direction and the left-right direction. Although not shown, the back surface 11b is provided with a plurality of mounting holes through which the mounting screws 108 can be inserted.

As shown in FIG. 2, the panel main body 11 is composed of a base portion 110 and a connecting portion 111. The base 110 occupies most of the panel main body 11 and is formed by the first plate thickness T1 shown in FIG. As shown in FIG. 2, the connection portion 111 is located on the rear side of the panel main body 11 and is located substantially at the center in the left-right direction. That is, the connection portion 111 is located around the antenna cover 13, and is connected to the base portion 110 and the antenna cover 13, more specifically, the side wall portion 13b of the antenna cover 13 described later. As shown in FIG. 6, the connecting portion 111 is formed with a third plate thickness T3. Here, the third plate thickness T3 is set thinner than the first plate thickness T1. As a result, in the panel main body 11, the connecting portion 111 is formed to be thinner than the base portion 110.

As shown in FIG. 2, the antenna cover 13 is located on the rear side of the panel main body 11 and is located substantially in the center in the left-right direction. The antenna cover 13 is integrally formed with the panel main body 11, and is formed in a fin shape forming a substantially triangular shape. More specifically, as shown in FIGS. 3 to 6, the antenna cover 13 gradually extends upward from the surface 11a of the panel main body 11 from the front side to the rear side of the antenna cover 13. As a result, the antenna cover 13 has a tip portion 13a, a side wall portion 13b, and a standing wall portion 13c, and is hollow.

As shown in FIG. 6, the tip portion 13a is located at the upper tip of the antenna cover 13. The side wall portions 13b are a pair on the left and right, and extend upward from the surface 11a side of the panel main body 11 toward the tip portion 13a. That is, the side wall portion 13b is continuous with the connection portion 111 of the panel main body 11 at the root portion located at the lower end, and is continuous with the tip portion 13a at the upper end. Further, the side wall portion 13b is inclined at a predetermined angle from the surface 11a side of the panel main body 11 toward the tip portion 13a side so as to approach each other in the left-right direction. As shown in FIG. 5, the vertical wall portion 13c is located at the rear end of the antenna cover 13, and extends from the tip portion 13a side toward the surface 11a side while being inclined. The vertical wall portion 13c is continuous with the tip portion 13a, the side wall portion 13b, and the panel main body 11. The antenna cover 13 can accommodate the antenna device (not shown) of the vehicle 100 inside.

As shown in FIGS. 5 and 6, in the antenna cover 13, the plate thickness of the tip portion 13a is set to the second plate thickness T2, which is thicker than the first and third plate thicknesses T1 and T3. Further, the side wall portion 13b is formed so that the plate thickness gradually changes from the connection portion 111 side of the panel main body 11 toward the tip portion 13a side. That is, in the side wall portion 13b, the plate thickness gradually increases from the panel main body 11 side toward the tip portion 13a side as compared with the first plate thickness T1. Further, in the side wall portion 13b, the longest portion in the vertical direction has a length L1. Then, in the vertical wall portion 13c, the plate thickness is set to the second plate thickness T2 as in the case of the tip portion 13a. In addition, in FIGS. 3 to 6 and the like, the shapes of the panel main body 11 and the antenna cover 13 including the first to third plate thicknesses T1 to T3 and the length L1 are exaggerated for the sake of explanation. ..

Here, in this roof panel 1, the values and lengths of the second and third plate thicknesses T2 and T3 so that the rate of change in the plate thickness at the longest portion in the vertical direction in the side wall portion 13b satisfies the following formula. The value of L1 is set.
<Formula>
(T2-T3) /L1> 0.015

Further, in the roof panel 1, the value of the third plate thickness T3 is set so that 1.5 times the third plate thickness T3 is smaller than the second plate thickness T2.

Specifically, in this roof panel 1, the first plate thickness T1 is set to 3.5 mm. Further, the second plate thickness T2 is set to 4.6 mm. Further, the third plate thickness T3 is set to 3.0 mm. The length L1 of the side wall portion 13b is set to 100 mm. As a result, in the roof panel 1, the rate of change in the plate thickness at the longest portion in the vertical direction in the side wall portion 13b is 0.016, which satisfies the above formula. Further, even if the value of the third plate thickness T3 is multiplied by 1.5, it is smaller than the value of the second plate thickness T2. If the first plate thickness T1 is thicker than the third plate thickness T3 and the second plate thickness T2 is set to be thicker than the first plate thickness T1, the values of the first to third plate thicknesses T1 to T3 are set. In addition to the values of the length L1 and the length L1, the shape of the antenna cover 13 can be appropriately designed.

By providing such an antenna cover 13, in the roof panel 1, as shown in FIGS. 2 to 4, a virtual first point P1 is set on the front end side, and a virtual second point P2 is set on the rear end side. When set, the distance from the first point P1 to the second point P2 differs between the place where the antenna cover 13 does not exist and the place where the antenna cover 13 exists. Specifically, as shown by the arrows in FIG. 3, in the roof panel 1, in the place where the antenna cover 13 does not exist, that is, in the place where only the panel main body 11 is composed, the first point P1 to the second point P2. The distance is the first distance D1. On the other hand, as shown by the arrow in FIG. 3, in the roof panel 1, the portion where the antenna cover 13 exists, that is, the portion composed of the panel main body 11 and the antenna cover 13, passes through the antenna cover 13. , The distance from the first point P1 to the second point P2 is long. As a result, in the place where the antenna cover 13 exists, the distance from the first point P1 to the second point P2 is the second distance D2 which is longer than the first distance D1.

The roof panel 1 is manufactured by the manufacturing method of the embodiment. In this manufacturing method, first, the first step is performed. In the first step, as shown in FIG. 7, the first mold 15 and the second mold 17 are prepared. The first type 15 and the second type 17 are arranged so as to face each other in the vertical direction. A first forming surface 15a is recessed on the upper surface of the first mold 15. On the other hand, a second forming surface 17a is recessed on the lower surface of the second mold 17. Further, the second mold 17 is formed with an injection port 17b capable of injecting the first molten resin 30, which will be described later. As shown in FIG. 10, the injection port 17b is formed on the front end side of the second type 17 at a position overlapping the first point P1. As shown in FIG. 7, an injection machine 19 is connected to the injection port 17b. Depending on the size of the roof panel 1, a plurality of injection ports 17b may be formed in the second mold 17. Further, the injection port 17b may be formed in the first mold 15.

Then, in the first step, the first mold 15 and the second mold 17 are moved in the vertical direction, which is the mold clamping direction, while the first forming surface 15a and the second forming surface 17a face each other. In this way, the first mold 15 and the second mold 17 are molded. Here, in the first step, when the first mold 15 and the second mold 17 are molded, the first mold 15 and the second mold 17 are not brought into contact with each other, and both are slightly separated in the vertical direction. Make it a state.

By molding the first mold 15 and the second mold 17 in this way, the cavity C is formed by the first forming surface 15a and the second forming surface 17a. In this way, the first step is completed.

The cavity C has a shape corresponding to the roof panel 1. As a result, the cavity C forms the main body cavity C1 forming the panel main body 11, the tip portion cavity C2 forming the tip portion 13a, the side wall portion cavity C3 forming the side wall portion 13b, and the standing wall portion 13c. It has a cavity C4 for a vertical wall (see FIG. 10). Further, as shown in FIG. 7, the main body cavity C1 has a main region C11 forming the base portion 110 and a sub region C12 forming the connecting portion 111. Then, in the main body cavity C1, the main region C11 and the sub region C12 are continuous. Further, the side wall cavity C3 is continuous with the sub-region C12 and the tip cavity C2. As shown in FIG. 10, the vertical wall cavity C4 is continuous with the tip cavity C2, the side wall cavity C3, and the sub-region C12.

As shown in FIG. 8, in the main body cavity C1, in the main region C11, the vertical distance, that is, the vertical distance between the first forming surface 15a and the second forming surface 17a is the first preparation interval S1'. It has become. Then, in the sub-region C12, the vertical interval is the third preparation interval S3'. The third preparation interval S3'is narrower than the first preparation interval S1'. Further, in the tip cavity C2, the vertical interval is the second preparation interval S2'. The second preparation interval S2'is wider than the first preparation interval S1'. Although detailed illustration is omitted, the cavity C4 for the vertical wall portion also has the second preparation interval S2'. In the side wall cavity C3, the distance between the first forming surface 15a and the second forming surface 17a increases from the sub-region C12 side toward the tip cavity C2 side.

Here, as described above, in the first step, the first mold 15 and the second mold 17 are molded in a slightly separated state. Therefore, the first preparation interval S1'is wider than the first interval S1 (see FIG. 9) described later by the amount that the first type 15 and the second type 17 are separated from each other. Similarly, the second preparation interval S2'has a wider interval than the second interval S2. Further, the third preparation interval S3'is wider than the third interval S3.

Next, the second step is performed. In the second step, the molten resin 30 is injected into the cavity C from the injection machine 19 through the injection port 17b. The molten resin 30 is formed by melting a resin containing polycarbonate as a main component, that is, a resin constituting the roof panel 1. The molten resin 30 may be formed by melting a resin containing a main component other than polycarbonate.

In this second step, as shown by the white arrow in FIG. 9, in the process of injecting the molten resin 30 into the cavity C, the first mold 15 and the second mold 17 are pressed from above and below, respectively. The mold 15 and the second mold 17 are brought into contact with each other. As a result, in the cavity C, the vertical interval becomes narrower than in the first step. As a result, in the main region C11, the vertical interval is the first interval S1. Similarly, in the sub-region C12, the vertical interval is the third interval S3. Then, in the tip cavity C2, the second interval S2 is provided. The first interval S1 is an interval corresponding to the first plate thickness T1. Further, the second interval S2 is an interval corresponding to the second plate thickness T2. The third interval S3 is an interval corresponding to the third plate thickness T3.

That is, the third interval S3 is narrower than the first interval S1, and the second interval S2 is wider than the first interval S1. Further, in the side wall cavity C3, the first forming surface 15a and the second are formed from the sub-region C12 side toward the tip cavity C2 side, that is, from the main body cavity C1 side toward the tip cavity C2 side. The distance from the forming surface 17a is large.

In this way, the molten resin 30 injected into the cavity C circulates in the cavity C while spreading concentrically around the injection port 17b. Thus, as shown in FIG. 10, a part of the molten resin 30 flows from the injection port 17b toward the front end side of the cavity C. Further, a part of the molten resin 30 flows from the injection port 17b toward the rear end side of the cavity C. As described above, in the roof panel 1, where the antenna cover 13 exists, the distance from the first point P1 to the second point P2 is long. Therefore, even in the cavity C, in the place where the cavity C2 for the tip portion and the cavity C3 for the side wall portion exist, the second point P2 from the injection port 17b, and eventually the cavity C, as compared with the place consisting only of the cavity C1 for the main body. The distance to the rear end is long. Then, in the cavity C, the molten resin 30 that has flowed through the cavity C2 for the tip portion and the cavity C3 for the side wall portion joins in the cavity C4 for the vertical wall portion. Further, the molten resin 30 circulated in the cavity C4 for the vertical wall portion merges with the molten resin 30 circulated in the cavity C1 for the main body on the rear side of the cavity C4 for the vertical wall portion, and at the second point P2, and further, the cavity. It circulates toward the rear end side of C.

Then, the molten resin 30 injected into the cavity C spreads over the entire cavity C, thereby ending the injection of the molten resin 30. In this way, the second step is completed. While the molten resin 30 is being injected, the first mold 15 and the second mold 17 are continuously pressurized from above and below, respectively.

Next, the third step is performed. In the third step, the molten resin 30 is dissipated and solidified in the cavity C. As a result, as shown in FIG. 11, the roof panel 1 is formed from the molten resin 30. That is, the panel main body 11 is formed by the molten resin 30 solidified in the main body cavity C1. More specifically, the base 110 is formed by the molten resin 30 solidified in the main region C11, and the connecting portion 111 is formed by the molten resin 30 solidified in the sub region C12. At this time, the back surface 11b of the panel body 11 is formed by the first forming surface 15a, and the surface 11a of the panel body 11 is formed by the second forming surface 17a. Then, the antenna cover 13 is formed by the tip cavity C2, the side wall cavity C3, and the standing wall cavity C4. More specifically, the tip portion 13a is formed by the molten resin 30 solidified in the tip cavity C2, and each side wall portion 13b is formed by the molten resin 30 solidified in the side wall cavity C3. Further, the vertical wall portion 13c is formed by the molten resin 30 solidified in the vertical wall portion cavity C4. Following the second step, also in the third step, the first mold 15 and the second mold 17 are continuously pressed from the vertical direction until the molten resin 30 is solidified in the cavity C.

Here, since the main region C11 is the first interval S1, the base 110 is formed with the first plate thickness T1. Further, since the sub-region C12 has the third interval S3, the connecting portion 111 is formed with the third plate thickness T3. Further, since the tip cavity C2 and the standing wall cavity C4 have the second interval S2, the tip portion 13a and the standing wall portion 13c are formed by the second plate thickness T2. In the wall cavity C3, the distance between the first forming surface 15a and the second forming surface 17a increases from the sub-region C12 side toward the tip cavity C2, so that the side wall portion 13b is connected. The plate thickness is thicker than the first plate thickness T1 from the portion 111 side toward the tip portion 13a side. Since the molten resin 30 shrinks due to heat dissipation, the sizes of the first to third intervals S1 to S3 are designed in advance in anticipation of the shrinkage of the molten resin 30.

When the roof panel 1 is completed in this way, the first mold 15 and the second mold 17 are opened, and the roof panel 1 is taken out from the inside of the cavity C. This completes the third step.

As shown in FIG. 1, the roof panel 1 manufactured in this manner is arranged in the mounting space 109 with the surface 11a of the panel main body 11 facing the outside of the vehicle 100. Then, in this state, the front end of the panel main body 11 is fixed to the front side mounting portions 102a and 102b of the front pillar 102 by a plurality of mounting screws 108. Further, the rear end of the panel main body 11 is fixed to the rear side mounting portions 103a and 103b of the rear pillar 103 by a plurality of mounting screws 108. Further, the left end of the panel main body 11 is fixed to the third and fourth fixing portions 104c and 104d of the first mounting rail 104 by a plurality of mounting screws 108. Then, the right end of the panel main body 11 is fixed to the third and fourth fixing portions 105c and 105d of the second mounting rail 105 by a plurality of mounting screws 108. In this way, the roof panel 1 is fixed to the front pillar 102, the rear pillar 103, and the first and second mounting rails 104 and 105, and is fixed to the body 101. As a result, the roof panel 1 constitutes the ceiling of the vehicle 100 together with the rear end of the front pillar 102 and the front end of the rear pillar 103. Further, a seal member (not shown) is used between the roof panel 1 and the front pillar 102, between the roof panel 1 and the rear pillar 103, and between the roof panel 1 and the first and second mounting rails 104 and 105, respectively. It is sealed. The method of fixing the roof panel 1 to the body 101 is an example, and the method of fixing the roof panel 1 to the body 101 can be appropriately changed according to the shape of the body 101 and the like.

As described above, in the manufacturing method of the embodiment, the vertical spacing in the tip cavity C2 is wider than the vertical spacing in the main body cavity C1. Further, in the side wall portion cavity C3, the distance between the first forming surface 15a and the second forming surface 17a increases from the main body cavity C1 side toward the tip portion cavity C2 side. For these reasons, in the manufacturing method of the embodiment, a weld line is generated at a position where the molten resin 30 flowing through the cavity C2 for the tip portion and the cavity C3 for the side wall portion and the molten resin 30 flowing through the cavity C1 for the main body meet. It's getting harder. That is, in this manufacturing method, in addition to the vertical wall portion 13c of the antenna cover 13, weld lines are less likely to occur at the positions where the vertical wall portion 13c and the panel main body 11 are connected. This action will be described based on the comparison with the production method of the comparative example.

In the manufacturing method of the comparative example shown in FIG. 12, the distance between the cavity C1 for the main body and the cavity C2 for the tip portion in the vertical direction is set to be the same. Further, in the side wall portion cavity C3, the distance between the first forming surface 15a and the second forming surface 17a is constant from the main body cavity C1 side to the tip portion cavity C2 side. That is, in the roof panel manufactured by the manufacturing method of the comparative example, the panel body and the roof antenna are formed with the same plate thickness. Other configurations including each step in the manufacturing method of the comparative example are the same as those of the manufacturing method of the example.

As a result, in the manufacturing method of the comparative example, the molten resin 30 injected into the cavity C flows through the cavity C1 for the main body, the cavity C2 for the tip portion, and the cavity C3 for the side wall portion at the same speed, and the cavity is circulated. It will be toward the rear end side of C. Here, as described above, in the cavity C, the second point P2 from the injection port 17b in the place where the tip cavity C2 and the side wall cavity C3 exist, as compared with the place consisting only of the main body cavity C1. As a result, the distance to the rear end of the cavity C is long. Therefore, compared to the molten resin 30 that circulates in the cavity C1 for the main body and heads toward the rear end side of the cavity C, it circulates in the cavity C2 for the tip portion and the cavity C3 for the side wall portion and flows toward the rear end side of the cavity C. There is a delay in the molten resin 30 toward. Then, the temperature of the molten resin 30 gradually decreases in the process of flowing through the cavity C. Therefore, when the molten resin 30 circulated in the tip cavity C2 and the molten resin 30 circulated in the side wall cavity C3 merge in the vertical wall cavity C4, a weld line is likely to occur. Further, when the molten resin 30 circulated in the cavity C4 for the vertical wall and the molten resin 30 circulated in the cavity C1 for the main body merge, a weld line is likely to occur.

In particular, in the manufacturing method of the comparative example, the molten resins 30 that are branched left and right with the tip cavity C2 and the side wall cavity C3 as boundaries and circulate in the main body cavity C1 are inside the tip cavity C2 and the side wall. The molten resin 30 flowing in the portion cavity C3 merges on the rear side of the standing wall cavity C4 before merging in the standing wall cavity C4. Then, the molten resin 30 that has flowed through the cavity C1 for the main body flows into the cavity C4 for the vertical wall portion before the molten resin 30 that has flowed through the cavity C2 for the tip portion and the cavity C3 for the side wall portion. In this way, the molten resin 30 circulating in the cavity C1 for the main body and the molten resin 30 circulating in the cavity C2 for the tip portion and the cavity C3 for the side wall portion merge in the cavity C4 for the vertical wall portion. As a result, in the manufacturing method of the comparative example, a weld line is likely to occur not only at the standing wall portion of the antenna cover but also at a position where the standing wall portion and the panel main body are connected.

On the other hand, in the manufacturing method of the embodiment, the molten resin 30 injected into the cavity C is more likely to flow in the tip cavity C2 and the side wall cavity C3 than in the main body cavity C1. .. Therefore, the speed of the molten resin 30 circulating in the tip cavity C2 and the side wall cavity C3 is higher than that of the molten resin 30 circulating in the main body cavity C1. As a result, as shown in FIG. 10, when the molten resin 30 ejected from the injection port 17b into the cavity C reaches the rear end of the cavity C, the molten resin 30 flows through the cavity C2 for the tip portion and the cavity C3 for the side wall portion. The difference between the resin 30 and the molten resin 30 flowing through the cavity C1 for the main body becomes small.

Therefore, in the manufacturing method of the example, the temperature of the molten resin 30 circulated in the cavity C2 for the tip portion and the temperature of the molten resin 30 circulated in the cavity C3 for the side wall portion are higher than those in the manufacturing method of the comparative example. While being maintained, they merge in the vertical wall cavity C4. Similarly, the molten resin 30 circulated in the cavity C4 for the vertical wall and the molten resin 30 circulated in the cavity C1 for the main body also merge while maintaining a high temperature. As a result, in the manufacturing method of the embodiment, in addition to the vertical wall portion 13c of the antenna cover 13, weld lines are less likely to occur at the positions where the vertical wall portion 13c and the panel main body 11 are connected.

In particular, in the manufacturing method of the embodiment, the values of the second and third plate thicknesses T1 and T3, and by extension, the values of the second and third intervals S2 and S3 are set so as to satisfy the above formula, and the side wall portion 13b. The value of the length L1 of the longest portion in the vertical direction is set. Therefore, in the manufacturing method of the embodiment, the molten resin 30 is used in the tip cavity C2 or for the side wall while suppressing the plate thickness of the tip 13a of the antenna cover 13 and each side wall 13b from becoming excessively thick. It is possible to facilitate circulation in the cavity C3. As a result, in the manufacturing method of the embodiment, the molten resin 30 injected into the cavity C from the injection port 17b reaches the rear end of the cavity C, and the tip portion of the molten resin 30 is more than the molten resin 30 flowing through the cavity C1 for the main body. The molten resin 30 flowing through the cavity C2 for the side wall and the cavity C3 for the side wall is in the preceding state. Therefore, the molten resin 30 that has circulated in the cavity C1 for the main body before the molten resin 30 that has flowed in the cavity C2 for the tip portion and the cavity C3 for the side wall portion merges in the cavity C4 for the standing wall portion has a standing wall. It is possible to suitably prevent the inflow into the portion cavity C4. In this respect as well, the production method of the examples can suitably suppress the generation of weld lines.

In this way, according to the manufacturing method of the embodiment, the aesthetic appearance of the manufactured roof panel 1 can be enhanced. Further, in the roof panel 1 manufactured by the manufacturing method of the embodiment, cracks and the like caused by the weld line are less likely to occur, so that the durability is also high.

Further, according to the manufacturing method of the embodiment, it is possible to prevent the plate thickness of the tip portion 13a of the antenna cover 13 and the side wall portions 13b from becoming excessively thick. Therefore, it is possible to suitably secure a space for accommodating the antenna device in the antenna cover 13 while suppressing the increase in size of the antenna cover 13.

Further, in the manufacturing method of the embodiment, it is not necessary to separately heat the molten resin 30 injected into the cavity C in order to suppress the generation of weld lines. Therefore, it is possible to increase the manufacturing efficiency by shortening the time until the molten resin 30 solidifies in the cavity C. Further, in the manufacturing method of the embodiment, a heating device such as a high frequency induction heating device and the first and second types 15 and 17 that can be heated by the heating device are also unnecessary.

Therefore, according to the manufacturing method of the embodiment, it is possible to manufacture the roof panel 1 which has high quality and can realize low manufacturing cost.

Further, the main body cavity C1 has a main region C11 forming the base portion 110 and a sub region C12 forming the connecting portion C111. The sub-region C12 has a third interval S3 that is narrower than the first interval S1 of the main region C11.

Therefore, in this manufacturing method, the distance between the first forming surface 15a and the second forming surface 17a is appropriately adjusted for the side wall cavity C3, and as the distance from the main body cavity C1 side toward the tip cavity C2 , It is possible to suitably increase the distance between the first forming surface 15a and the second forming surface 17a. Therefore, in this manufacturing method, the molten resin 30 can be suitably distributed in the side wall cavity C3. As a result, in this manufacturing method, it is possible to suitably form each side wall portion 13b, and thus the antenna cover 13, while appropriately suppressing the generation of weld lines.

Further, in the main body cavity C1, the sub-region C12 becomes the third interval S3, so that the molten resin 30 is less likely to flow in the sub-region C12 than in the main region C11. Therefore, in this manufacturing method, the molten resin 30 flowing in the cavity C2 for the tip portion and the cavity C3 for the side wall portion merges in the cavity C4 for the vertical wall portion before merging in the sub-region C12, and thus for the main body. It is possible to prevent the molten resin 30 flowing through the cavity C1 from flowing into the cavity C4 for the vertical wall portion with high certainty.

Here, since the main region C11 becomes the first interval S1 and the sub-region C12 becomes the third interval S3, a step is generated at the connection point between the main region C11 and the sub-region C12. In this respect, in this manufacturing method, the shape of the first forming surface 15a is designed so that a step is generated at the connection point between the main region C11 and the sub region C12. Therefore, in the roof panel 1 manufactured by this manufacturing method, the back surface 11b of the panel main body 11 has a step at the connection point between the connection portion 111 and the base portion 110, but the roof panel 1 is connected to the front surface 11a of the panel main body 11. There is no step at the connection point between the portion 111 and the base 110. In this respect as well, this manufacturing method can enhance the aesthetic appearance of the manufactured roof panel 1.

Further, in this manufacturing method, in the second step, the molten resin 30 is injected into the cavity C, and the first mold 15 and the second mold 17 are pressed in the vertical direction while the first mold 15 and the second mold are pressed. It is brought into contact with 17. Therefore, the molten resin 30 injected into the cavity C can be suitably spread over the entire cavity C. Further, also in the third step, the first mold 15 and the second mold 17 are continuously pressed in the vertical direction until the molten resin 30 is solidified in the cavity C. For these reasons, molding defects are less likely to occur in this manufacturing method.

Although the present invention has been described above with reference to the examples, it is needless to say that the present invention is not limited to the above-mentioned embodiments and can be appropriately modified and applied without departing from the spirit of the present invention.

For example, instead of the antenna cover 13, a straightening vane extending upward from the surface 11a of the panel main body 11 in a plate shape, and a convex portion protruding upward from the surface 11a of the panel main body 11 in a hemispherical shape are provided in the "structure" of the present invention. It may be a "body".

Further, the "structure" in the present invention is not limited to the case where it extends above the surface 11a of the panel body 11, and may be a recess or the like extending downward from the surface 11a of the panel body 11.

Further, instead of the roof panel 1, a side panel provided on the side surface of the body 101, an interior panel provided in the vehicle interior CR, or the like may be used as the "resin panel for a vehicle" in the present invention.

The present invention can be used for resin panels used in vehicles and the like.

1 ... Roof panel (resin panel for vehicles)
11 ... Panel body 11a ... Surface 13 ... Antenna cover (structure)
13a ... Tip 13b ... Side wall 15 ... First type 15a ... First forming surface 17 ... Second type 17a ... Second forming surface 30 ... Molten resin 110 ... Base 111 ... Connection part C ... Cavity C1 ... Cavity for main body C2 Cavity for tip C3 ... Cavity for side wall C11 ... Main area C12 ... Sub area S1 ... 1st interval S2 ... 2nd interval S3 ... 3rd interval T1 ... 1st plate thickness T2 ... 2nd plate thickness T3 ... 3rd Plate thickness

Claims (5)

A panel body formed of a resin in a plate shape and extending in a first direction and a second direction orthogonal to the first direction.
A structure integrally formed with the panel body by the resin and extending from the surface of the panel body in the first direction and a third direction orthogonal to the second direction is provided.
The structure is a method for manufacturing a resin panel for a vehicle having a tip portion located at the tip end in the third direction and a side wall portion connecting the tip portion and the panel main body.
A first type having a first forming surface and a second type having a second forming surface facing the first forming surface are prepared, and a cavity is formed by the first forming surface and the second forming surface. 1 process and
A second step of injecting the molten resin in which the resin is melted into the cavity is provided.
The cavity is a side wall portion that is connected to a main body cavity that forms the panel main body, a tip portion cavity that forms the tip portion, and the main body cavity and the tip portion cavity to form the side wall portion. Has a cavity and
The main body cavity has a main region forming a first interval in the third direction.
The tip cavity has a second spacing wider than the first spacing in the third direction.
The vehicle resin in the side wall portion cavity is characterized in that the distance between the first forming surface and the second forming surface is increased toward the tip portion cavity side from the main body cavity side. How to manufacture the panel. The panel body has a base and a connection portion connecting the base portion and the side wall portion.
The main body cavity has a main region forming the base portion and a sub-region forming the connecting portion having a third interval narrower than the first interval in the third direction. 1. The method for manufacturing a resin panel for a vehicle according to 1. The vehicle resin panel according to claim 1 or 2, wherein in the second step, the first mold and the second mold are pressed in the mold clamping direction, and the first mold and the second mold are brought into contact with each other. Manufacturing method. A panel body formed of a resin in a plate shape and extending in a first direction and a second direction orthogonal to the first direction.
A structure integrally formed with the panel body by the resin and extending from the surface of the panel body in the first direction and a third direction orthogonal to the second direction is provided.
The panel body has a base having a first plate thickness in the third direction.
The structure is located at the tip in the third direction, has a tip portion having a second plate thickness thicker than the first plate thickness in the third direction, and a side wall connecting the tip portion and the panel main body. Has a part and
The resin panel for a vehicle is characterized in that the side wall portion is thicker than the first plate thickness toward the tip end portion side from the panel main body side. The panel body has a connection portion that connects the base portion and the side wall portion.
The vehicle resin panel according to claim 4, wherein the connecting portion has a third plate thickness thinner than the first plate thickness in the third direction.

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