JP2007007941A - Resin molding - Google Patents

Resin molding Download PDF

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JP2007007941A
JP2007007941A JP2005189872A JP2005189872A JP2007007941A JP 2007007941 A JP2007007941 A JP 2007007941A JP 2005189872 A JP2005189872 A JP 2005189872A JP 2005189872 A JP2005189872 A JP 2005189872A JP 2007007941 A JP2007007941 A JP 2007007941A
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layer
molded body
standing wall
expansion
stepped portion
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JP4790332B2 (en
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Toshiki Miyaji
敏記 宮地
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DaikyoNishikawa Corp
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DaikyoNishikawa Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/58—Moulds
    • B29C44/586—Moulds with a cavity increasing in size during foaming

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  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To prevent cracking in the level difference part of the boundary between a solid layer and an expansion layer in spite of being lightweight. <P>SOLUTION: A skin layer 23 is formed on the surface of a plate main body 3 excluding a mounting seat 7 and a vertical wall base part outside edge vicinity 19 and the expansion layer 25 having numbers of voids is formed in the inside. The solid layer 27 having no expansion layer 25 is formed in the mounting seat 7 and the vertical wall base part outside edge vicinity 19. The level difference part 29 made of the skin layer 23 is formed in the plate thickness direction in the boundary between the solid layer 27 of the vertical wall base part outside edge vicinity 19 and the expansion layer 25. A plurality of reinforcing ribs 31 made of the solid layer 27 connecting the vertical wall base part outside edge vicinity 19 and the level difference part 29 are projected integrally in the circumferential direction in the level difference part 29 to prevent the occurrence of cracking by an expansion pressure in the level difference part 29 between the reinforcing ribs 31 when the expansion layer 25 is formed. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

この発明は、成形体本体の表面にスキン層が形成されるとともに多数の空隙を有する膨張層が内部に形成された樹脂成形体の改良に関するものである。   The present invention relates to an improvement of a resin molded body in which a skin layer is formed on the surface of a molded body and an expanded layer having a large number of voids is formed inside.

特許文献１では、成形面に凹部が形成された固定型と、スライド型を内蔵した可動型とを型閉じした状態で、キャビティ内に繊維入り熱可塑性樹脂を射出充填し、該キャビティ内で上記繊維入り熱可塑性樹脂が固化する過程で、上記可動型内でスライド型をキャビティ容積が拡大する方向に後退移動させて繊維入り熱可塑性樹脂を成形型で圧縮されている繊維の弾性復元力（スプリングバック現象）で膨張させることにより、空隙がなく堅いスキン層が表面全体に形成されるとともに多数の空隙を有する膨張層が内部に形成された樹脂成形体を得るようにしている。そして、この樹脂成形体では上記膨張層により軽量化を図ることができる。
特開平１１−１７９７５１号公報（第３，７頁、図１） In Patent Document 1, in a state in which a fixed mold having a recess formed on a molding surface and a movable mold incorporating a slide mold are closed, a fiber-filled thermoplastic resin is injected and filled in the cavity, In the process of solidifying the thermoplastic resin containing fibers, the elastic restoring force (spring) of the fibers compressed by the molding die by moving the slide mold backward in the direction of increasing the cavity volume in the movable mold By expanding by the back phenomenon, a rigid skin layer having no voids is formed on the entire surface, and a resin molded body having an expanded layer having a large number of voids formed therein is obtained. And in this resin molding, weight reduction can be achieved by the said expansion layer.
Japanese Patent Laid-Open No. 11-179751 (pages 3 and 7, FIG. 1)

しかし、膨張層は軽量化を図るメリットがある反面、剛性の低下を招くことも事実である。したがって、例えば、筒状取付座が成形体本体に一体に突設された樹脂成形体を上記の特許文献１のようにして成形すると、取付座の剛性が低下することになる。   However, the expanded layer has the merit of reducing the weight, but it is also a fact that the rigidity is lowered. Therefore, for example, if a resin molded body in which the cylindrical mounting seat is integrally projected on the molded body is molded as described in Patent Document 1, the rigidity of the mounting seat is reduced.

そこで、図８に示すように、取付座ａ及び取付座基部外縁近傍部ｂを空隙がなく堅いソリッド層ｃに形成して剛性を高める一方、成形体本体ｄ表面にスキン層ｅを形成するとともに、成形体本体ｄ内部に多数の空隙を有する膨張層ｆを形成して樹脂成形体ｇの軽量化を図ることが考えられるが、成形型のキャビティを拡大して膨張層ｆを形成する際に、取付座基部外縁近傍部ｂのソリッド層ｃと膨張層ｅとの境界に形成されている段差部ｈに亀裂ｉが発生して該段差部ｈの剛性が低下し、その結果、樹脂成形体ｇの強度が低下することになる。段差部ｈに亀裂ｉが発生するのは、段差部ｈを構成するスキン層ｅが膨張層ｆ形成時の膨張圧で板厚方向に引っ張られるためであると考えられる。   Therefore, as shown in FIG. 8, the mounting seat a and the mounting seat base outer edge vicinity portion b are formed in a solid layer c having no gap to increase rigidity, while a skin layer e is formed on the surface of the molded body d. It is conceivable to reduce the weight of the resin molded body g by forming an expanded layer f having a large number of voids inside the molded body d. However, when forming the expanded layer f by enlarging the cavity of the mold. In addition, a crack i occurs in the stepped portion h formed at the boundary between the solid layer c and the expansion layer e in the vicinity of the outer peripheral edge b of the mounting seat base portion, and the rigidity of the stepped portion h is lowered. The strength of g will decrease. It is considered that the crack i occurs in the stepped portion h because the skin layer e constituting the stepped portion h is pulled in the plate thickness direction by the expansion pressure when the expansion layer f is formed.

この発明はかかる点に鑑みてなされたものであり、その目的とするところは、軽量でありながらソリッド層と膨張層との境界の段差部に亀裂が発生しないようにすることである。   The present invention has been made in view of the above points, and an object of the present invention is to prevent cracks from occurring at the step portion at the boundary between the solid layer and the expanded layer while being lightweight.

上記の目的を達成するため、この発明は、ソリッド層と膨張層との境界の段差部を強化したことを特徴とし、具体的には、次のような解決手段を講じた。   In order to achieve the above object, the present invention is characterized in that the step portion at the boundary between the solid layer and the expanded layer is reinforced, and specifically, the following solution is taken.

すなわち、請求項１に記載の発明は、成形型のキャビティ内に射出充填した繊維入り熱可塑性樹脂が固化する過程で、キャビティ容積を拡大させて上記繊維入り熱可塑性樹脂を膨張させることにより、スキン層が表面に形成されるとともに多数の空隙を有する膨張層が内部に形成された成形体本体を備えたパネル状の樹脂成形体であって、上記成形体本体には、成形時にキャビティ容積を拡大せず、膨張層を有しないソリッド層が上記膨張層に隣接して形成され、上記ソリッド層と上記膨張層との境界にはスキン層からなる段差部が板厚方向に形成され、該段差部には上記ソリッド層と段差部とを連結するソリッド層からなる補強リブが複数個離間して一体に突設され、これら補強リブ間の段差部は膨張層形成時の膨張圧に抗し得て亀裂発生が回避されていることを特徴とする。   That is, the invention according to claim 1 is a method in which, in the process of solidifying the fiber-filled thermoplastic resin injected and filled into the cavity of the mold, the cavity volume is expanded and the fiber-filled thermoplastic resin is expanded, so that the skin A panel-shaped resin molded body having a molded body body in which a layer is formed on the surface and an expansion layer having a large number of voids is formed inside. The molded body body has a cavity volume enlarged at the time of molding. A solid layer having no expansion layer is formed adjacent to the expansion layer, and a stepped portion made of a skin layer is formed in the thickness direction at the boundary between the solid layer and the expansion layer. A plurality of reinforcing ribs made of a solid layer connecting the solid layer and the stepped portion are provided apart from each other so as to project integrally, and the stepped portion between the reinforcing ribs can resist the expansion pressure when the expanding layer is formed. Crack generation It is avoided, characterized in that is.

請求項２に記載の発明は、板状起立壁が成形体本体に一体に突設されたパネル状の樹脂成形体であって、上記起立壁及び起立壁基部外縁近傍部を除く成形体本体は、成形型のキャビティ内に射出充填した繊維入り熱可塑性樹脂が固化する過程で、起立壁及び起立壁基部外縁近傍部を除く成形体本体に対応するキャビティ容積を拡大させて上記繊維入り熱可塑性樹脂を膨張させることにより、スキン層が表面に形成されるとともに多数の空隙を有する膨張層が内部に形成され、上記起立壁及び起立壁基部外縁近傍部は、成形時に起立壁及び起立壁基部外縁近傍部に対応するキャビティ容積を拡大せず、膨張層を有しないソリッド層に形成され、上記起立壁基部外縁近傍部のソリッド層と上記膨張層との境界にはスキン層からなる段差部が板厚方向に形成され、該段差部には上記起立壁基部外縁近傍部と段差部とを連結するソリッド層からなる補強リブが複数個離間して一体に突設され、これら補強リブ間の段差部は膨張層形成時の膨張圧に抗し得て亀裂発生が回避されていることを特徴とする。   The invention according to claim 2 is a panel-shaped resin molded body in which a plate-like standing wall is integrally projected on the molded body, and the molded body main body excluding the standing wall and the vicinity of the standing wall base outer edge is In the process of solidifying the injection-filled fiber-filled thermoplastic resin into the mold cavity, the cavity volume corresponding to the molded body main body excluding the standing wall and the vicinity of the standing wall base outer edge is enlarged to expand the fiber-containing thermoplastic resin. By expanding the skin, a skin layer is formed on the surface and an inflated layer having a large number of voids is formed inside, and the standing wall and the standing wall base outer edge vicinity are in the vicinity of the standing wall and the standing wall base outer edge at the time of molding. The cavity volume corresponding to the portion is not enlarged and is formed as a solid layer having no expansion layer, and a stepped portion made of a skin layer is formed at the boundary between the solid layer near the outer edge of the standing wall base and the expansion layer. Direction A plurality of reinforcing ribs made of a solid layer that connect the vicinity of the outer edge of the standing wall base and the stepped portion are spaced apart and integrally formed on the stepped portion, and the stepped portion between the reinforcing ribs expands. It is characterized by being able to resist the expansion pressure during layer formation and avoiding cracks.

請求項３に記載の発明は、請求項２に記載の発明において、起立壁は筒状取付座の縦壁であることを特徴とする。   The invention according to claim 3 is the invention according to claim 2, wherein the standing wall is a vertical wall of a cylindrical mounting seat.

請求項１に係る発明によれば、成形体本体表面にスキン層が形成されるとともに、成形体本体内部に多数の空隙を有する膨張層が形成され、樹脂成形体の軽量化を図ることができる。また、ソリッド層と膨張層との境界のスキン層からなる段差部にソリッド層からなる補強リブを突設してソリッド層と段差部とを連結しているので、段差部の補強リブ対応箇所はスキン層と補強リブとが一体に連続して厚肉の堅牢層になり、膨張層形成時に、段差部を構成するスキン層が成形型のキャビティ内の膨張圧で板厚方向に引っ張られても、該膨張圧に十分に抗し得て上記補強リブ間の段差部に亀裂が発生するのを回避でき、樹脂成形体の強度を確保することができる。仮に、段差部の補強リブ間に対応する箇所に亀裂が多少発生したとしても、補強リブで段差部の剛性を補完することができる。   According to the first aspect of the present invention, the skin layer is formed on the surface of the molded body, and the expansion layer having a large number of voids is formed inside the molded body, thereby reducing the weight of the resin molded body. . In addition, since the solid layer and the stepped portion are connected by projecting the reinforcing rib made of the solid layer at the stepped portion made of the skin layer at the boundary between the solid layer and the expanded layer, the portion corresponding to the reinforcing rib of the stepped portion is Even if the skin layer and the reinforcing ribs are continuously integrated into a thick, robust layer, and the expansion layer is formed, the skin layer constituting the stepped portion is pulled in the plate thickness direction by the expansion pressure in the mold cavity. Further, it is possible to sufficiently resist the expansion pressure and to avoid the occurrence of cracks in the stepped portion between the reinforcing ribs, and to ensure the strength of the resin molded body. Even if some cracks are generated at portions corresponding to the reinforcing ribs of the stepped portion, the rigidity of the stepped portion can be supplemented by the reinforcing rib.

請求項２に係る発明によれば、起立壁及び起立壁基部外縁近傍部を除く成形体本体表面にスキン層が形成されるとともに、成形体本体内部に多数の空隙を有する膨張層が形成され、樹脂成形体の軽量化を図ることができる。また、起立壁及び起立壁基部外縁近傍部が膨張層を有しないソリッド層で形成されているため、起立壁及び起立壁基部外縁近傍部の剛性を高めることができる。しかも、起立壁基部外縁近傍部のソリッド層と膨張層との境界のスキン層からなる段差部にソリッド層からなる補強リブを突設して起立壁基部外縁近傍部と段差部とを連結しているので、段差部の補強リブ対応箇所はスキン層と補強リブとが一体に連続して厚肉の堅牢層になり、膨張層形成時に、段差部を構成するスキン層が成形型のキャビティ内の膨張圧で板厚方向に引っ張られても、該膨張圧に十分に抗し得て上記補強リブ間の段差部に亀裂が発生するのを回避でき、樹脂成形体の強度を確保することができる。仮に、段差部の補強リブ間に対応する箇所に亀裂が多少発生したとしても、補強リブで段差部の剛性を補完することができる。   According to the invention of claim 2, the skin layer is formed on the surface of the molded body main body excluding the standing wall and the vicinity of the standing wall base outer edge, and the expansion layer having a large number of voids is formed inside the molded body. It is possible to reduce the weight of the resin molded body. Moreover, since the standing wall and the standing wall base outer edge vicinity portion are formed of a solid layer having no expansion layer, the rigidity of the standing wall and the standing wall base outer edge vicinity portion can be increased. In addition, a reinforcing rib made of a solid layer protrudes from the stepped portion formed by the skin layer at the boundary between the solid layer and the inflated layer near the outer edge of the standing wall base, thereby connecting the vicinity of the standing wall base outer edge and the stepped portion. As a result, the skin layer and the reinforcing rib are integrally and continuously formed into a thick, robust layer at the stepped portion corresponding to the reinforcing rib, and the skin layer constituting the stepped portion is formed in the cavity of the mold when the inflated layer is formed. Even if it is pulled in the plate thickness direction by the expansion pressure, it can sufficiently resist the expansion pressure and can avoid the occurrence of cracks in the stepped portion between the reinforcing ribs, thereby ensuring the strength of the resin molded body. . Even if some cracks are generated at portions corresponding to the reinforcing ribs of the stepped portion, the rigidity of the stepped portion can be supplemented by the reinforcing rib.

請求項３に係る発明によれば、成形体本体の取付座外周りが強化されて取付座の支持剛性を高めることができる。   According to the invention which concerns on Claim 3, the mounting seat outer periphery of a molded object main body is strengthened, and the support rigidity of a mounting seat can be improved.

以下、この発明の実施の形態について図面に基づいて説明する。   Hereinafter, embodiments of the present invention will be described with reference to the drawings.

（実施の形態１）
図３はこの発明の実施の形態１に係る樹脂成形体としての自動車のサイドドアの一部を構成する樹脂製キャリアプレート（ドアモジュール）１を車室外側から見た斜視図である。このキャリアプレート１は、図７に仮想線で示すように、ドアアウタパネル２ａとドアインナパネル２ｂとからなるドア本体２の上記ドアインナパネル２ｂに組み付けられる。 (Embodiment 1)
3 is a perspective view of a resin carrier plate (door module) 1 constituting a part of a side door of an automobile as a resin molded body according to Embodiment 1 of the present invention, as viewed from the outside of the passenger compartment. The carrier plate 1 is assembled to the door inner panel 2b of the door body 2 composed of the door outer panel 2a and the door inner panel 2b, as indicated by phantom lines in FIG.

上記キャリアプレート１は、成形体本体としてのキャリアプレート本体（以下、プレート本体という）３を備え、該プレート本体３の車室外側の面には、金属製のウインドガラス昇降用レール５を取り付けるための真円の筒状取付座７が４箇所に一体に突設されている。上記プレート本体３の車室外側の面における外周縁部には、シール溝９が全周に亘って凹設され、該シール溝９に収容されたシール材１０によりプレート本体３とドアインナパネル２ｂとの間がシールされる（図７参照）。また、上記プレート本体３のシール溝９内寄りには、キャリアプレート１をドアインナパネル２ｂに取り付けるための複数個の円筒状取付座１１が所定間隔をあけて全周に亘って突設されている。なお、図７において、プレート本体３を車室側から被うようにドアトリム（図示せず）がドアインナパネル２ｂに取り付けられる。   The carrier plate 1 includes a carrier plate main body (hereinafter referred to as a plate main body) 3 as a molded body, and a metal window glass elevating rail 5 is attached to a surface of the plate main body 3 on the outside of the passenger compartment. The round cylindrical mounting seat 7 is integrally projected at four locations. A seal groove 9 is formed in the outer peripheral edge portion of the outer surface of the plate body 3 on the outer side of the passenger compartment, and the plate body 3 and the door inner panel 2b are sealed by the sealing material 10 accommodated in the seal groove 9. Is sealed (see FIG. 7). A plurality of cylindrical mounting seats 11 for attaching the carrier plate 1 to the door inner panel 2b are provided on the inner side of the seal groove 9 of the plate body 3 so as to protrude over the entire circumference with a predetermined interval. Yes. In FIG. 7, a door trim (not shown) is attached to the door inner panel 2b so as to cover the plate body 3 from the passenger compartment side.

図１（ａ）は図３のＩ−Ｉ線断面相当図であって、かつ上述したウインドガラス昇降用レール５をキャリアプレート１に取り付けた状態の取付座７部分における図１（ｂ）のＡ−Ａ線断面図、図１（ｂ）は図１（ａ）に対応する取付座７部分の底面図である。図２（ａ）は図３のＩ−Ｉ線断面相当図であって、かつウインドガラス昇降用レール５をキャリアプレート１に取り付けた状態の取付座７部分における図２（ｂ）のＢ−Ｂ線断面図、図２（ｂ）は図２（ａ）に対応する取付座７部分の底面図である。   FIG. 1A is a cross-sectional view taken along the line I-I of FIG. 3, and A in FIG. 1B in the portion of the mounting seat 7 with the above-described window glass lifting rail 5 attached to the carrier plate 1. -A sectional view, FIG.1 (b) is a bottom view of the mounting seat 7 part corresponding to Fig.1 (a). 2 (a) is a cross-sectional view taken along the line II of FIG. 3, and is a cross-sectional view taken along the line B-B of FIG. 2 (b) in the portion of the mounting seat 7 with the window glass lifting rail 5 attached to the carrier plate 1. FIG. 2B is a bottom view of the portion of the mounting seat 7 corresponding to FIG.

上記取付座７は板状起立壁としての筒体からなる縦壁１４を備え、該縦壁１４はプレート本体３側基部に開口部１５を有し、該開口部１５と対向する先端には平坦面からなる取付面部１７が形成され、該取付面部１７にボルト挿通孔１７ａが形成されている。   The mounting seat 7 includes a vertical wall 14 made of a cylindrical body as a plate-like standing wall. The vertical wall 14 has an opening 15 at the base of the plate body 3 side, and is flat at a tip opposite to the opening 15. A mounting surface portion 17 composed of a surface is formed, and a bolt insertion hole 17 a is formed in the mounting surface portion 17.

上記取付座７（縦壁１４、取付面部１７）及び縦壁（起立壁）基部外縁近傍部１９を除くプレート本体３は、後述する成形型３９のキャビティ４１内に射出充填した繊維入り熱可塑性樹脂Ｐが固化する過程で、取付座７及び縦壁基部外縁近傍部１９を除くプレート本体３に対応するキャビティ容積を拡大させて上記繊維入り熱可塑性樹脂Ｐを繊維２１の弾性復元力（膨張力）で膨張させることにより、空隙がなく堅いスキン層２３が表面に形成されるとともに、多数の空隙（図示せず）を有する膨張層２５がプレート本体３の車内側に膨出するように内部に形成されている。これに対し、上記取付座７及び縦壁基部外縁近傍部１９は、成形時に取付座７及び縦壁基部外縁近傍部１９に対応するキャビティ容積を拡大せず、膨張層２５を有しない堅いソリッド層２７に形成されている。そして、この実施の形態１では、上記縦壁基部外縁近傍部１９は真円のリング形状であり、上記取付座７と同心円上に形成されている。このように、プレート本体３表面全体にスキン層２３が形成されるとともに、プレート本体３内部に多数の空隙を有する膨張層２５が形成されることで、キャリアプレート１の軽量化を図ることができる。また、上記取付座７及び縦壁基部外縁近傍部１９が膨張層２５を有しない堅いソリッド層２７で形成されているので、取付座７及び縦壁基部外縁近傍部１９の剛性を高めることができる。   The plate body 3 excluding the mounting seat 7 (vertical wall 14, mounting surface portion 17) and vertical wall (standing wall) base outer edge vicinity portion 19 is a fiber-filled thermoplastic resin injected and filled into a cavity 41 of a molding die 39 to be described later. In the process of solidifying P, the cavity volume corresponding to the plate body 3 excluding the mounting seat 7 and the vertical wall base outer edge vicinity portion 19 is enlarged, and the fiber-containing thermoplastic resin P is elastically restored (expanded) by the fibers 21. In this way, a hard skin layer 23 having no voids is formed on the surface, and an expansion layer 25 having a large number of voids (not shown) is formed inside so as to bulge inside the vehicle body of the plate body 3. Has been. On the other hand, the mounting seat 7 and the vertical wall base outer edge vicinity portion 19 do not expand the cavity volume corresponding to the mounting seat 7 and the vertical wall base outer edge vicinity portion 19 at the time of molding, and are solid solid layers that do not have the expansion layer 25. 27. And in this Embodiment 1, the said vertical wall base outer edge vicinity part 19 is a perfect circle ring shape, and is formed on the said mounting seat 7 and a concentric circle. As described above, the skin layer 23 is formed on the entire surface of the plate body 3, and the expansion layer 25 having a large number of voids is formed inside the plate body 3, whereby the weight of the carrier plate 1 can be reduced. . Further, since the mounting seat 7 and the vertical wall base outer edge vicinity portion 19 are formed of a solid solid layer 27 having no expansion layer 25, the rigidity of the mounting seat 7 and the vertical wall base outer edge vicinity portion 19 can be increased. .

この発明の最大の特徴として、上記縦壁基部外縁近傍部１９のソリッド層２７と上記膨張層２５との境界には、空隙がなく堅いスキン層２３からなる真円のリング形状の段差部２９が板厚方向に形成され、該段差部２９には、膨張層２５を有しない堅いソリッド層２７からなる三角形状の補強リブ３１が上記縦壁基部外縁近傍部１９と段差部２９とを連結するように周方向に複数個離間して放射状に一体に突設されている。本例では、三角形状の補強リブ３１を８個設けているが、その形状及び個数は目的及び用途により適宜決定されるものである。そして、これら補強リブ３１間の段差部２９は後述する膨張層２５形成時の膨張圧に抗し得て亀裂発生が回避されている。   As the greatest feature of the present invention, a round ring-shaped step portion 29 made of a rigid skin layer 23 without a void is formed at the boundary between the solid layer 27 and the expansion layer 25 in the vicinity of the vertical wall base outer edge 19. Formed in the plate thickness direction, the stepped portion 29 is connected to the stepped portion 29 by a triangular reinforcing rib 31 made of a solid solid layer 27 having no expansion layer 25 and connecting the vertical wall base outer edge vicinity portion 19 to the stepped portion 29. In the circumferential direction, a plurality of them are spaced apart from each other in a radial manner. In this example, eight triangular reinforcing ribs 31 are provided, but the shape and number thereof are appropriately determined depending on the purpose and application. And the level | step-difference part 29 between these reinforcement ribs 31 can resist the expansion pressure at the time of formation of the expansion layer 25 mentioned later, and generation | occurrence | production of a crack is avoided.

このような取付座７を備えたキャリアプレート１は次のようにして成形される。   The carrier plate 1 having such a mounting seat 7 is formed as follows.

成形に際し、図４に示すように、可動型としての第１金型３３と、該第１金型３３に対向配置された固定型としての第２金型３５と、上記第１金型３３の挿入孔３３ａに移動可能に挿入され上記第２金型３５側に対して突出するようにスプリング等の付勢手段（図示せず）で付勢された押さえブロック３７とからなる成形型３９を用意する。図４は図１（ｂ）のＡ−Ａ線断面対応箇所の成形型３９を示す。上記第２金型３５には、取付座７の外形に対応した円形凹部３５ａが形成され、該凹部３５ａ底面に取付座７のボルト挿通孔１７ａを形成する突起３５ｂが突設されている。一方、上記押さえブロック３７には、取付座７の内形に対応した円柱状凸部３７ａが形成されているとともに、該凸部３７ａ基部周りには補強リブ３１の形状に対応した三角形状のスリット状凹部３７ｂが複数個（８個）周方向に離間して放射状に形成されている。   At the time of molding, as shown in FIG. 4, the first mold 33 as a movable mold, the second mold 35 as a fixed mold disposed opposite to the first mold 33, and the first mold 33 A molding die 39 comprising a pressing block 37 that is movably inserted into the insertion hole 33a and is urged by an urging means (not shown) such as a spring so as to protrude toward the second mold 35 is prepared. To do. FIG. 4 shows the mold 39 corresponding to the cross section along the line AA in FIG. A circular recess 35a corresponding to the outer shape of the mounting seat 7 is formed on the second mold 35, and a protrusion 35b that forms the bolt insertion hole 17a of the mounting seat 7 protrudes from the bottom surface of the recess 35a. On the other hand, the pressing block 37 is formed with a cylindrical convex portion 37a corresponding to the inner shape of the mounting seat 7, and a triangular slit corresponding to the shape of the reinforcing rib 31 around the base portion of the convex portion 37a. A plurality of (eight) concave portions 37b are formed radially apart from each other in the circumferential direction.

そして、まず、図４に示すように、上記成形型３９を型閉じした状態でキャビティ４１内に射出機（図示せず）からガラス繊維等の繊維入り熱可塑性樹脂Ｐ（例えば繊維入りポリプロピレン樹脂）を射出充填する。その後、成形型３９のキャビティ４１内で繊維入り熱可塑性樹脂Ｐが固化する過程で、図５に示すように、第１金型３３をキャビティ容積が拡大する方向Ｃに後退移動させる。つまり、第１金型３３を第２金型３５から僅かに離れさせ、押さえブロック３７（取付座７及び縦壁基部外縁近傍部１９対応箇所）を除くプレート本体３に対応するキャビティ容積を例えば２倍もしくはそれ以上に拡大させる。繊維入り熱可塑性樹脂Ｐは、成形型３９の成形面と接触する部分が型温の影響により早期に冷却されて樹脂密度の高いスキン層２３となって表面層を構成する。一方、繊維入り熱可塑性樹脂Ｐの内側部分は型温の影響を受け難く、粘度の高いゲル状態になっている。したがって、キャビティ容積の拡大により、それまで第１金型３３及び第２金型３５で圧縮されている繊維２１が該圧縮から解放されて弾性的に復元し、この弾性復元力（スプリングバック現象）すなわち膨張圧で上記繊維入り熱可塑性樹脂Ｐが膨張する。このことにより、空隙がなく堅いスキン層２３が表面に形成されるとともに、上記取付座７及び縦壁基部外縁近傍部１９を除くプレート本体３の内部に多数の空隙を有する膨張層２５が形成されたキャリアプレート１となる。これにより、プレート本体３が膨張層２５を有しないソリッド層２７のみからなりかつ本実施形態のプレート本体３と同一肉厚である場合に比べて、キャリアプレート１の軽量化を図ることができる。   First, as shown in FIG. 4, a thermoplastic resin P containing fibers such as glass fibers (for example, polypropylene resin containing fibers) from an injection machine (not shown) into the cavity 41 with the mold 39 closed. The injection filling. Thereafter, in the process in which the fiber-containing thermoplastic resin P is solidified in the cavity 41 of the mold 39, the first mold 33 is moved backward in the direction C in which the cavity volume increases, as shown in FIG. That is, the cavity volume corresponding to the plate body 3 excluding the holding block 37 (corresponding to the mounting seat 7 and the vertical wall base outer edge vicinity portion 19) is slightly separated from the second mold 35 by, for example, 2 Make it double or larger. The thermoplastic resin P containing fibers forms a surface layer as a skin layer 23 having a high resin density by quickly cooling a portion of the mold 39 that comes into contact with the molding surface under the influence of mold temperature. On the other hand, the inner part of the fiber-containing thermoplastic resin P is hardly affected by the mold temperature and is in a highly viscous gel state. Therefore, by increasing the cavity volume, the fibers 21 compressed so far by the first mold 33 and the second mold 35 are released from the compression and elastically restored, and this elastic restoring force (springback phenomenon). That is, the fiber-containing thermoplastic resin P expands due to the expansion pressure. As a result, a rigid skin layer 23 having no voids is formed on the surface, and an expansion layer 25 having a large number of voids is formed inside the plate body 3 excluding the mounting seat 7 and the vertical wall base outer edge vicinity portion 19. Carrier plate 1 is obtained. Thereby, the weight reduction of the carrier plate 1 can be achieved as compared with the case where the plate body 3 is composed only of the solid layer 27 having no expansion layer 25 and has the same thickness as the plate body 3 of the present embodiment.

一方、第１金型３３の上記後退移動時には上記押さえブロック３７は第２金型３５側に付勢されて後退しないので、成形時に上記取付座７及び縦壁基部外縁近傍部１９に対応するキャビティ容積が拡大せず、繊維入り熱可塑性樹脂Ｐ中の繊維２１は弾性復元が抑制されて、成形された取付座７及び縦壁基部外縁近傍部１９は、膨張層２５を有しない堅いソリッド層２７になって成形され、取付座７及び縦壁基部外縁近傍部１９の剛性を高めることができる。さらに、縦壁基部外縁近傍部１９のソリッド層２７と膨張層２５との境界には、空隙がなく堅いスキン層２３からなる真円のリング形状の段差部２９が板厚方向に形成され、該段差部２９には、膨張層２５を有しない堅いソリッド層２７からなる三角形状の補強リブ３１が上記縦壁基部外縁近傍部１９と段差部２９とを連結するように複数個（８個）周方向に離間して放射状に一体に突設されている。これにより、段差部２９の補強リブ対応箇所はスキン層２３と補強リブ３１とが一体に連続して厚肉の堅牢層になり、膨張層２５形成時に、段差部２９を構成するスキン層２３が膨張層２５の膨張圧で板厚方向に引っ張られてもすなわち伸張されても、該膨張圧に十分に抗し得て補強リブ３１間の上記段差部２９に亀裂が発生するのを回避でき、プレート本体３の取付座７外周りが強化されて取付座７の支持剛性を高めることができるとともに、キャリアプレート１の強度を確保することができる。仮に、段差部２９の補強リブ３１間に対応する箇所に亀裂が多少発生したとしても、補強リブ３１で段差部２９の剛性を補完することができる。   On the other hand, when the first mold 33 is moved backward, the holding block 37 is urged toward the second mold 35 and does not move backward, so that the cavity corresponding to the mounting seat 7 and the vertical wall base outer edge vicinity 19 is formed during molding. The volume of the fiber 21 in the fiber-containing thermoplastic resin P is not elastically restored, and the molded mounting seat 7 and the vertical wall base outer edge vicinity portion 19 have a solid solid layer 27 having no expansion layer 25. Thus, the rigidity of the mounting seat 7 and the vertical wall base outer edge vicinity portion 19 can be increased. Further, at the boundary between the solid layer 27 and the expansion layer 25 in the vicinity of the vertical wall base outer edge portion 19, a perfect ring-shaped step portion 29 made of a hard skin layer 23 without a void is formed in the plate thickness direction. The stepped portion 29 has a plurality of (eight) round reinforcing ribs 31 made of a hard solid layer 27 having no expansion layer 25 so as to connect the vertical wall base outer edge vicinity portion 19 and the stepped portion 29. Projecting integrally in a radial manner spaced apart in the direction. Accordingly, the skin layer 23 and the reinforcing rib 31 are integrally and continuously formed into a thick, robust layer at the portion corresponding to the reinforcing rib of the stepped portion 29, and the skin layer 23 constituting the stepped portion 29 is formed when the expanded layer 25 is formed. Even if the expansion layer 25 is pulled in the plate thickness direction by the expansion pressure, that is, the expansion layer 25 can sufficiently resist the expansion pressure and can prevent the stepped portion 29 between the reinforcing ribs 31 from cracking, The outer periphery of the mounting seat 7 of the plate body 3 can be strengthened to increase the support rigidity of the mounting seat 7, and the strength of the carrier plate 1 can be ensured. Even if some cracks are generated at portions corresponding to the space between the reinforcing ribs 31 of the stepped portion 29, the rigidity of the stepped portion 29 can be supplemented by the reinforcing rib 31.

このようにして成形されたキャリアプレート１では、プレート本体３の車室外側の面の４箇所に真円の筒状取付座７が一体に突設されている。そして、図３に仮想線で示すように、左右両側で上下に並ぶ２個の取付座７の取付面部１７にウインドガラス昇降用レール５をそれぞれ載せる。この際、ウインドガラス昇降用レール５に形成されたボルト挿通孔５ａを取付面部１７のボルト挿通孔１７ａに対応させる。さらに、図１に示すように、ウインドガラス昇降用ワイヤ（図示せず）を案内するローラ４３を上記ウインドガラス昇降用レール５上に載せてボルト４５をローラ４３の軸孔（図示せず）及び上記ボルト挿通孔５ａ，１７ａに挿通し、取付座７のパネル本体３側の開口部１５側からナット４７を上記ボルト４５に螺合締結し、ウインドガラス昇降用レール５を取付座７に取り付ける。   In the carrier plate 1 formed in this way, a circular cylindrical mounting seat 7 is integrally projected at four locations on the surface of the plate body 3 on the outer side of the passenger compartment. Then, as shown by phantom lines in FIG. 3, the window glass elevating rails 5 are respectively placed on the mounting surface portions 17 of the two mounting seats 7 arranged vertically on the left and right sides. At this time, the bolt insertion holes 5 a formed in the window glass elevating rail 5 are made to correspond to the bolt insertion holes 17 a of the mounting surface portion 17. Further, as shown in FIG. 1, a roller 43 for guiding a window glass raising / lowering wire (not shown) is placed on the window glass raising / lowering rail 5, and a bolt 45 is attached to a shaft hole (not shown) of the roller 43 and The nut 47 is inserted into the bolt insertion holes 5 a and 17 a and the nut 47 is screwed and fastened to the bolt 45 from the opening 15 side of the mounting seat 7 on the panel body 3 side, and the window glass lifting rail 5 is attached to the mounting seat 7.

（実施の形態２）
図６は樹脂成形体としてのキャリアプレート１の実施の形態２を示す図１相当図である。この実施の形態２では、上記の実施の形態１とは逆に、膨張層２５がプレート本体３の車室外側に膨出するようにプレート本体３内部に形成されているものである。補強リブ３１もプレート本体３の車室外側の面に突設されている。したがって、図示しないが、成形型３９の型構造も上記の実施の形態１とは逆に、プレート本体３の車室内側の面を形成する第１金型３３を固定型にするとともに、プレート本体３の膨張層２５を有する車室外側の面を形成する第２金型３５を可動型にし、かつ該第２金型３５側に取付座７及び縦壁基部外縁近傍部１９を形成する押さえブロック３７を設けることになる。そのほかは上記の実施の形態１と同様に構成すればよい。 (Embodiment 2)
FIG. 6 is a view corresponding to FIG. 1 showing Embodiment 2 of a carrier plate 1 as a resin molded body. In the second embodiment, contrary to the first embodiment, the expansion layer 25 is formed inside the plate body 3 so as to bulge outside the vehicle interior of the plate body 3. The reinforcing ribs 31 are also provided on the surface of the plate body 3 on the outer side of the passenger compartment. Therefore, although not shown, the mold structure of the molding die 39 is a fixed mold as the first mold 33 that forms the surface of the plate body 3 on the vehicle interior side, as opposed to the first embodiment. A holding block for forming a mounting die 7 and a vertical wall base outer edge vicinity portion 19 on the side of the second die 35 so that the second die 35 forming the outer surface of the passenger compartment having the three expansion layers 25 is movable. 37 will be provided. Others may be configured in the same manner as in the first embodiment.

したがって、この実施の形態２では、上記の実施の形態１と同様の作用効果を奏することができるものである。   Therefore, in the second embodiment, the same operational effects as in the first embodiment can be obtained.

（実施の形態３）
図７は樹脂成形体としてのキャリアプレート１の実施の形態３を示す図３のII−II線における断面図である。この実施の形態３では、上記の実施の形態２と同様に、膨張層２５がプレート本体３の車室外側に膨出するようにパネル本体３内部に形成されているものである。また、プレート本体３の車室外側の面における外周縁部３ａ（シール溝９形成箇所）及びその内側近傍部３ｂには、成形時にキャビティ容積を拡大せず、膨張層２５を有しないソリッド層２７が上記膨張層２５に隣接して形成されている。さらに、上記シール溝９形成箇所の内側近傍部３ｂのソリッド層２７と上記膨張層２５との境界にはスキン層からなる段差部２９が板厚方向に形成され、該段差部２９には、上記シール溝９形成箇所及びその内側近傍部３ｂのソリッド層２７と段差部２９とを連結するソリッド層２７からなる補強リブ３１がプレート本体３の全周に亘って複数個離間して一体に突設され、これら補強リブ３１間の段差部２９は膨張層２５形成時の膨張圧に抗し得て亀裂発生が回避されている。そして、上記補強リブ３１の外端は、上記シール溝９の内側壁９ａと一体に連結されている。なお、図示しないが、成形型３９の型構造は上記の実施の形態２と同様に、プレート本体３の車室内側の面を形成する第１金型３３を固定型にするとともに、プレート本体３の膨張層２５を有する車室外側の面を形成する第２金型３５を可動型にし、かつ該第２金型３５側に上記外周縁部３ａ及びその内側近傍部３ｂを形成する押さえブロック３７を設ける。また、第１金型３３、第２金型３５及び押さえブロック３７の成形面形状をキャリアプレート１の形状に対応させる。 (Embodiment 3)
FIG. 7 is a cross-sectional view taken along the line II-II in FIG. 3, showing Embodiment 3 of the carrier plate 1 as a resin molded body. In the third embodiment, as in the second embodiment, the expansion layer 25 is formed inside the panel main body 3 so as to bulge outside the vehicle interior of the plate main body 3. Further, in the outer peripheral edge portion 3a (where the seal groove 9 is formed) and the inner vicinity portion 3b on the outer surface of the plate body 3 on the outer side of the casing, the solid volume 27 that does not expand the cavity volume and does not have the expansion layer 25 at the time of molding. Is formed adjacent to the expansion layer 25. Further, a step portion 29 made of a skin layer is formed in the thickness direction at the boundary between the solid layer 27 and the expansion layer 25 in the inner vicinity portion 3b of the seal groove 9 formation portion. A plurality of reinforcing ribs 31 made of the solid layer 27 connecting the solid layer 27 and the stepped portion 29 in the portion where the seal groove 9 is formed and the inner vicinity 3b of the seal groove 9 are spaced apart from each other over the entire circumference of the plate body 3 and integrally project. In addition, the stepped portion 29 between the reinforcing ribs 31 can resist the expansion pressure when the expansion layer 25 is formed, and the generation of cracks is avoided. The outer end of the reinforcing rib 31 is connected to the inner wall 9a of the seal groove 9 integrally. Although not shown, the mold structure of the molding die 39 is the same as that of the second embodiment, and the first mold 33 that forms the interior surface of the plate body 3 is a fixed mold, and the plate body 3 A pressing block 37 that forms a movable mold in the second mold 35 that forms the outer surface of the passenger compartment having the expansion layer 25 and that forms the outer peripheral edge portion 3a and the inner peripheral portion 3b on the second mold 35 side. Is provided. Further, the molding surface shapes of the first mold 33, the second mold 35 and the holding block 37 are made to correspond to the shape of the carrier plate 1.

したがって、この実施の形態３においても、上記の実施の形態１と同様の作用効果を奏することができるものである。特に、プレート本体３外周縁部を強化することができる。   Therefore, also in the third embodiment, the same operational effects as those of the first embodiment can be obtained. In particular, the outer peripheral edge of the plate body 3 can be strengthened.

なお、上記の実施の形態１，２では、真円の筒状取付座７を例示したが、これに限らず、楕円又は矩形の筒状取付座７であってもよい。また、縦壁基部外縁近傍部１９も上記実施の形態１，２のように真円形状に限定されることなく、楕円形状その他の形状であってもよい。   In addition, in said Embodiment 1, 2, although the perfect cylindrical mounting seat 7 was illustrated, not only this but the elliptical or rectangular cylindrical mounting seat 7 may be sufficient. Further, the vertical wall base outer edge vicinity portion 19 is not limited to a perfect circle shape as in the first and second embodiments, but may be an elliptical shape or other shapes.

さらに、上記の実施の形態１，２では、起立壁が筒状取付座７の筒体からなる縦壁１４である場合を示したが、これに限らず、例えば突状部を構成する側壁等であってもよい。   Further, in the first and second embodiments, the case where the upright wall is the vertical wall 14 made of the cylindrical body of the cylindrical mounting seat 7 has been shown. It may be.

また、上記の実施の形態１〜３では、繊維２１のスプリングバック現象を利用してパネル本体３の内部に空隙を形成したが、繊維入り熱可塑性樹脂Ｐに発泡材を含有させれば、可動型（実施の形態１では第１金型３３、実施の形態２，３では第２金型３５）の後退移動を大きくしてプレート本体３の可動型後退方向の肉厚を厚くした場合、スプリングバック現象における繊維２１の復元力（膨張圧）が不足しても、発泡材の発泡力（膨張圧）が繊維２１の復元力を補完して空隙を確実に形成することができて好ましい。この場合、発泡材としては、化学反応によりガスを発生させる化学的発泡材や、二酸化炭素ガス及び窒素ガス等の不活性ガスを用いる物理的発泡材等がある。   Moreover, in said Embodiment 1-3, although the space | gap was formed in the inside of the panel main body 3 using the spring back phenomenon of the fiber 21, if a foaming material is contained in the thermoplastic resin P containing a fiber, it will move. When the back movement of the mold (first mold 33 in the first embodiment, second mold 35 in the second and third embodiments) is increased to increase the thickness of the plate body 3 in the movable mold retraction direction, the spring Even if the restoring force (expansion pressure) of the fiber 21 in the back phenomenon is insufficient, the foaming force (expansion pressure) of the foamed material can complement the restoring force of the fiber 21 and form a void reliably. In this case, examples of the foam material include a chemical foam material that generates gas by a chemical reaction, and a physical foam material that uses an inert gas such as carbon dioxide gas and nitrogen gas.

さらにまた、上記の実施の形態１〜３では、樹脂成形体が自動車のサイドドアのキャリアプレート１である場合を示したが、インストルメントパネル、ドアトリム、トランクボード等の他の自動車用パネルや自動車以外の荷電製品、住宅用パネル等にも適用することができるものである。   Furthermore, in the first to third embodiments, the case where the resin molded body is the carrier plate 1 of the side door of the automobile is shown. However, other automobile panels such as instrument panels, door trims, trunk boards, etc. It can be applied to other charged products, residential panels, and the like.

この発明は、成形体本体の表面にスキン層が形成されるとともに多数の空隙を有する膨張層が内部に形成された樹脂成形体について有用である。   The present invention is useful for a resin molded body in which a skin layer is formed on the surface of a molded body and an expanded layer having a large number of voids is formed inside.

実施の形態１を示し、図１（ａ）は図３のＩ−Ｉ線断面相当図であって、かつウインドガラス昇降用レールをキャリアプレートに取り付けた状態の取付座部分における図１（ｂ）のＡ−Ａ線断面図、図１（ｂ）は図１（ａ）に対応する取付座部分の底面図である。FIG. 1 (a) shows the first embodiment, and FIG. 1 (a) is a cross-sectional view taken along the line II of FIG. 3, and FIG. 1 (b) shows a mounting seat portion in a state where the window glass lifting rail is attached to the carrier plate. FIG. 1B is a bottom view of the mounting seat portion corresponding to FIG. 1A. 実施の形態１を示し、図２（ａ）は図３のＩ−Ｉ線断面相当図であって、かつウインドガラス昇降用レールをキャリアプレートに取り付けた状態の取付座部分における図２（ｂ）のＢ−Ｂ線断面図、図２（ｂ）は図２（ａ）に対応する取付座部分の底面図である。FIG. 2 (a) shows the first embodiment, and FIG. 2 (a) is a cross-sectional view taken along the line II of FIG. 3, and FIG. 2 (b) shows a mounting seat portion in a state where the window glass lifting rail is attached to the carrier plate. FIG. 2B is a bottom view of the mounting seat portion corresponding to FIG. 2A. 実施の形態１に係るキャリアプレートを車室外側から見た斜視図である。It is the perspective view which looked at the carrier plate which concerns on Embodiment 1 from the vehicle interior outer side. 実施の形態１において、成形型のキャビティ内に繊維入り熱可塑性樹脂を射出充填した状態を示す図１（ｂ）のＡ−Ａ線断面対応箇所の成形工程図である。In Embodiment 1, it is a shaping | molding process figure of the AA cross section corresponding | compatible part of FIG.1 (b) which shows the state which injected and filled the thermoplastic resin containing a fiber in the cavity of a shaping | molding die. 実施の形態１において、第１金型をキャビティ容積が拡大する方向に僅かに後退移動させてキャリアプレートが成形された状態を示す図１（ｂ）のＡ−Ａ線断面対応箇所の成形工程図である。FIG. 1B shows a molding process diagram corresponding to the AA line cross-section in FIG. 1B showing a state in which the carrier plate is molded by slightly moving the first mold in the direction in which the cavity volume is increased in the first embodiment. It is. 実施の形態２の図１相当図である。FIG. 3 is a diagram corresponding to FIG. 実施の形態３において、図３のII−II線における断面図である。In Embodiment 3, it is sectional drawing in the II-II line | wire of FIG. 従来例において、取付座部分における図１（ｂ）のＡ−Ａ線断面相当図である。In a prior art example, it is an AA sectional view equivalent figure of Drawing 1 (b) in an attachment seat part.

符号の説明Explanation of symbols

１ キャリアプレート（樹脂成形体）
３ プレート本体（成形体本体）
７ 取付座
１４ 縦壁（起立壁）
１９ 縦壁基部外縁近傍部（起立壁基部外縁近傍部）
２１ 繊維
２３ スキン層
２５ 膨張層
２７ ソリッド層
２９ 段差部
３１ 補強リブ
Ｐ 繊維入り熱可塑性樹脂 1 Carrier plate (resin molding)
3 Plate body (molded body)
7 Mounting seat 14 Vertical wall (standing wall)
19 Vertical wall base outer edge vicinity part (standing wall base outer edge vicinity part)
21 Fiber 23 Skin layer 25 Expansion layer 27 Solid layer 29 Stepped portion 31 Reinforcement rib P Fiber-containing thermoplastic resin

Claims (3)

成形型のキャビティ内に射出充填した繊維入り熱可塑性樹脂が固化する過程で、キャビティ容積を拡大させて上記繊維入り熱可塑性樹脂を膨張させることにより、スキン層が表面に形成されるとともに多数の空隙を有する膨張層が内部に形成された成形体本体を備えたパネル状の樹脂成形体であって、
上記成形体本体には、成形時にキャビティ容積を拡大せず、膨張層を有しないソリッド層が上記膨張層に隣接して形成され、
上記ソリッド層と上記膨張層との境界にはスキン層からなる段差部が板厚方向に形成され、該段差部には上記ソリッド層と段差部とを連結するソリッド層からなる補強リブが複数個離間して一体に突設され、これら補強リブ間の段差部は膨張層形成時の膨張圧に抗し得て亀裂発生が回避されていることを特徴とする樹脂成形体。 In the process of solidifying the fiber-filled thermoplastic resin injected into the mold cavity, the cavity volume is expanded to expand the fiber-filled thermoplastic resin, thereby forming a skin layer on the surface and a large number of voids. A panel-shaped resin molded body provided with a molded body body in which an expanded layer is formed,
The molded body does not expand the cavity volume at the time of molding, a solid layer having no expansion layer is formed adjacent to the expansion layer,
A stepped portion made of a skin layer is formed in the thickness direction at the boundary between the solid layer and the expanded layer, and the stepped portion has a plurality of reinforcing ribs made of a solid layer connecting the solid layer and the stepped portion. A resin molded body characterized in that it is spaced apart and integrally protruded, and the stepped portion between these reinforcing ribs can resist the expansion pressure at the time of forming the expansion layer and the occurrence of cracks is avoided. 板状起立壁が成形体本体に一体に突設されたパネル状の樹脂成形体であって、
上記起立壁及び起立壁基部外縁近傍部を除く成形体本体は、成形型のキャビティ内に射出充填した繊維入り熱可塑性樹脂が固化する過程で、起立壁及び起立壁基部外縁近傍部を除く成形体本体に対応するキャビティ容積を拡大させて上記繊維入り熱可塑性樹脂を膨張させることにより、スキン層が表面に形成されるとともに多数の空隙を有する膨張層が内部に形成され、
上記起立壁及び起立壁基部外縁近傍部は、成形時に起立壁及び起立壁基部外縁近傍部に対応するキャビティ容積を拡大せず、膨張層を有しないソリッド層に形成され、
上記起立壁基部外縁近傍部のソリッド層と上記膨張層との境界にはスキン層からなる段差部が板厚方向に形成され、該段差部には上記起立壁基部外縁近傍部と段差部とを連結するソリッド層からなる補強リブが複数個離間して一体に突設され、これら補強リブ間の段差部は膨張層形成時の膨張圧に抗し得て亀裂発生が回避されていることを特徴とする樹脂成形体。 A plate-like upright wall is a panel-shaped resin molded body integrally projecting from the molded body,
The molded body main body excluding the standing wall and the vicinity of the standing wall base outer edge is a molded body excluding the standing wall and the standing wall base outer edge vicinity in the process of solidifying the fiber-filled thermoplastic resin injected into the cavity of the mold. By enlarging the cavity volume corresponding to the main body and expanding the thermoplastic resin containing fibers, a skin layer is formed on the surface and an expanded layer having a large number of voids is formed inside,
The standing wall and the standing wall base outer edge vicinity portion are formed into a solid layer that does not have an expansion layer without expanding the cavity volume corresponding to the standing wall and the standing wall base outer edge vicinity portion at the time of molding,
A stepped portion made of a skin layer is formed in the thickness direction at the boundary between the solid layer near the outer edge of the standing wall base and the expansion layer, and the stepped portion includes the vicinity of the rising edge of the standing wall base and the stepped portion. A plurality of reinforcing ribs made of solid layers to be connected are protruded integrally with each other, and the step portion between the reinforcing ribs can resist the expansion pressure during the formation of the expansion layer, thereby preventing the occurrence of cracks. Resin molded body. 請求項２に記載の樹脂成形体において、
起立壁は筒状取付座の縦壁であることを特徴とする樹脂成形体。 In the resin molded product according to claim 2,
A resin molded body characterized in that the standing wall is a vertical wall of a cylindrical mounting seat.
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