JP2009023278A - Vibration-welded structure of resin-molded product - Google Patents

Vibration-welded structure of resin-molded product Download PDF

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JP2009023278A
JP2009023278A JP2007190442A JP2007190442A JP2009023278A JP 2009023278 A JP2009023278 A JP 2009023278A JP 2007190442 A JP2007190442 A JP 2007190442A JP 2007190442 A JP2007190442 A JP 2007190442A JP 2009023278 A JP2009023278 A JP 2009023278A
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solid
vibration
welding
resin panel
resin
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JP4916019B2 (en
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Shuya Uetaki
修也 上瀧
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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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12441—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being a single wall
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin-molded product wherein intrusion of an end of a welded rib into a foamed layer in vibration-welding is prevented, and two resin panels are fixedly integrated. <P>SOLUTION: In vibration-welding, a first protruding solid part 17a in a center of three first and second protruding solid parts 17a and 17b on a back surface of the first resin panel 3 is positioned to confront an end face of the welded rib 19 on a back surface of the second resin panel 5. The end of the welded rib 19 is molten by pressure-contact and vibration with the first protrusion solid part 17a while melting down the first protrusion solid part 17a, and is welded only with the solid part of an outer surface of the first resin panel 3, and the first resin panel 3 and the second resin panel 5 are welded and integrated. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

この発明は、第１樹脂パネルと第２樹脂パネルとを圧接させた状態で振動させることにより溶着一体化してなる樹脂成形品の振動溶着構造の改良に関するものである。   The present invention relates to an improvement in a vibration welded structure of a resin molded product obtained by welding and integrating by vibrating a first resin panel and a second resin panel.

特許文献１には、樹脂成形品の振動溶着構造として、自動車のインストルメントパネルに装着されるグローブボックスのリッドが挙げられている。このリッドは、リッドインナパネルとリッドアウタパネルとからなり、リッドインナパネルのリッドアウタパネルとの合わせ面側に複数個の溶着リブを振動方向に延びるように一体に突設し、これら溶着リブ先端面をリッドアウタパネル裏面に圧接させた状態で振動させることにより、リッドインナパネルとリッドアウタパネルとを溶着一体化している。
特開２００４−５８４６８号公報（段落００２８欄、図１，４） Patent Document 1 discloses a lid of a glove box that is attached to an instrument panel of an automobile as a vibration welded structure of a resin molded product. This lid is composed of a lid inner panel and a lid outer panel. A plurality of welding ribs are integrally projected on the mating surface side of the lid inner panel with the lid outer panel so as to extend in the vibration direction, and the front end surfaces of these welding ribs are provided. The lid inner panel and the lid outer panel are welded and integrated by vibrating in a state of being pressed against the back surface of the lid outer panel.
JP 2004-58468 A (paragraph 0028 column, FIGS. 1 and 4)

ところで、樹脂成形品においては、外面はソリッド層で堅いが、内部を発泡層にして軽量化を図ることが行われることがある。   By the way, in the resin molded product, the outer surface is hard with a solid layer, but there are cases where the inside is a foamed layer to reduce the weight.

振動溶着により２個の樹脂パネルを一体化する際に、一方の樹脂パネルが上述の如く内部に発泡層を有している場合、他方の樹脂パネル裏面に突設された溶着リブ先端面を、上記発泡層を有する一方の樹脂パネル裏面に圧接させた状態で振動溶着させようとすると、発泡層はソリッド層に比べて剛性が低く、かつソリッド層は薄くて面剛性が十分に得られず撓み易いため、ソリッド層が振動溶着時の圧接力に抗しきれず、溶着リブ先端がソリッド層を突き抜けて発泡層に入り込んでしまうことがある。   When two resin panels are integrated by vibration welding, when one resin panel has a foam layer inside as described above, the front end surface of the welding rib projecting from the other resin panel back surface, If vibration welding is attempted in the state of being pressed against the back side of one of the resin panels having the foam layer, the foam layer has a lower rigidity than the solid layer, and the solid layer is thin and does not have sufficient surface rigidity to bend. Since it is easy, the solid layer cannot resist the pressure contact force during vibration welding, and the weld rib tip may penetrate the solid layer and enter the foam layer.

その状態を図１２に示す。図１２は後述する実施形態１の図１（ｂ）に相当し、図１２中、ａは樹脂成形品の表側を構成する第１樹脂パネルであり、該第１樹脂パネルａ外面には樹脂密度が高くて堅いソリッド層ｂが形成されるとともに、内部には該ソリッド層ｂよりも樹脂密度が低い発泡層ｃが形成されている。ｄは第１樹脂パネルａ表面に被着された不織布からなる表皮である。ｅは樹脂成形品の裏側を構成する第２樹脂パネル裏面に一体に突設された溶着リブであり、該溶着リブｅ先端は振動溶着により溶融して第１樹脂パネルａ裏面に一体に溶着され、かつソリッド層ｂを突き抜けて発泡層ｃに入り込んでいる。ｆは振動溶着時に溶着リブｅ先端及びソリッド層ｂが溶融して盛り上がった溶融樹脂部である。ｇは第１樹脂パネルａが裏面を上に向けた状態でセットされる振動溶着治具である。   The state is shown in FIG. FIG. 12 corresponds to FIG. 1B of the first embodiment to be described later. In FIG. 12, a is a first resin panel constituting the front side of the resin molded product, and the resin density is formed on the outer surface of the first resin panel a. The solid layer b is high and hard, and the foam layer c having a resin density lower than that of the solid layer b is formed inside. d is a skin made of a non-woven fabric applied to the surface of the first resin panel a. e is a welding rib integrally protruding on the back surface of the second resin panel constituting the back side of the resin molded product, and the tip of the welding rib e is melted by vibration welding and integrally welded to the back surface of the first resin panel a. And penetrates the solid layer b and enters the foam layer c. f is a molten resin portion where the tip of the welding rib e and the solid layer b are melted and raised during vibration welding. g is a vibration welding jig that is set with the first resin panel a facing the back side up.

このように、溶着リブｅ先端が発泡層ｃに入り込むと、ソリッド層ｂに比べて低剛性の発泡層ｃは溶着リブｅを十分に支えることができず、また、溶着リブｅ先端と第１樹脂パネルａとの溶着強度も低下気味になり、２個の樹脂パネルを振動溶着により強固に一体化させた樹脂成形品を得ることができなくなる。   As described above, when the tip of the weld rib e enters the foam layer c, the foam layer c having a lower rigidity than the solid layer b cannot sufficiently support the weld rib e, and the tip of the weld rib e and the first The welding strength with the resin panel a also seems to be lowered, and it becomes impossible to obtain a resin molded product in which two resin panels are firmly integrated by vibration welding.

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、溶着リブ先端が振動溶着時に発泡層に入り込まないようにして２個の樹脂パネルが強固に一体化された樹脂成形品を得ることである。   The present invention has been made in view of the above points, and an object of the present invention is to provide a resin molding in which two resin panels are firmly integrated so that the tip of the welding rib does not enter the foam layer during vibration welding. Is to get the goods.

上記の目的を達成するため、この発明は、振動溶着箇所のソリッド層を補強したことを特徴とする。   In order to achieve the above object, the present invention is characterized in that the solid layer of the vibration welded portion is reinforced.

具体的には、この発明は、第１樹脂パネルと第２樹脂パネルとを圧接させた状態で振動させることにより溶着一体化してなる樹脂成形品の振動溶着構造を前提とし、次のような解決手段を講じた。   Specifically, the present invention presupposes a vibration welded structure of a resin molded product obtained by welding and integrating the first resin panel and the second resin panel in a state where they are in pressure contact with each other. Measures were taken.

すなわち、請求項１に記載の発明は、上記第１樹脂パネルは、外面にソリッド層が形成されるとともに内部に発泡層が形成されてなり、振動溶着前の第１樹脂パネル裏面のソリッド層には、複数個の突状ソリッド部が振動方向に延びるように振動方向と交差する方向に互いに接近して一体に平行突設され、上記第２樹脂パネル裏面には、溶着リブが上記第１樹脂パネルの突状ソリッド部突設領域に対応して振動方向に延びるように一体に突設され、振動溶着時、上記複数個の突状ソリッド部のうち少なくとも１個の突状ソリッド部は上記溶着リブ先端面に対向位置し、該溶着リブ先端は、上記対向位置する突状ソリッド部との圧接振動により該突状ソリッド部を溶失させつつ自身も溶融してソリッド部分のみと溶着されていることを特徴とする。   That is, according to the first aspect of the present invention, the first resin panel has a solid layer formed on the outer surface and a foam layer formed on the inside, and the first resin panel has a solid layer on the back surface of the first resin panel before vibration welding. The plurality of projecting solid portions extend in parallel to each other in a direction intersecting the vibration direction so that the plurality of protruding solid portions extend in the vibration direction, and a welding rib is provided on the back surface of the second resin panel on the first resin. The protruding solid portion of the panel is integrally protruded so as to extend in the vibration direction corresponding to the protruding area, and at the time of vibration welding, at least one protruding solid portion of the plurality of protruding solid portions is welded. The welding rib tip is located opposite to the rib tip surface, and melts itself while being melted by the pressure contact vibration with the protruding solid part located at the opposite position, so that only the solid part is welded. It is characterized by .

請求項２に記載の発明は、請求項１に記載の発明において、突状ソリッド部は３個以上からなり、溶着リブ先端面に対向位置する突状ソリッド部の両外側方には、残りの突状ソリッド部が位置し、上記溶着リブ先端の両側面は、該溶着リブ先端及び溶着リブ先端面に対向位置する突状ソリッド部の各々の溶融樹脂部により、両外側方に位置する突状ソリッド部の対向側面と溶着一体化していることを特徴とする。   The invention according to claim 2 is the invention according to claim 1, wherein the projecting solid portion is composed of three or more, and the remaining portions on both outer sides of the projecting solid portion located opposite the front end surface of the welding rib A projecting solid portion is located, and both side surfaces of the weld rib tip are projecting shapes located on both outer sides by the molten resin portions of the projecting solid portion and the projecting solid portion facing the weld rib tip surface, respectively. It is characterized by being fused and integrated with the opposite side surface of the solid part.

請求項３に記載の発明は、上記前提において、上記第１樹脂パネルは、外面にソリッド層が形成されるとともに内部に発泡層が形成されてなり、上記第１樹脂パネル裏面のソリッド層には、突状ソリッド部が複数箇所で振動方向に間隔をあけて振動方向と交差するように一体に突設され、上記第２樹脂パネル裏面には、上記第１樹脂パネルの突状ソリッド部突設領域に対応して溶着リブが振動方向に延びるように一体に突設され、振動溶着時、上記複数個の突状ソリッド部は上記溶着リブ先端面に対向位置し、該溶着リブ先端は、上記各突状ソリッド部との圧接振動により該各突状ソリッド部の圧接箇所を溶融させつつ自身も溶融してソリッド部分のみと溶着されていることを特徴とする。   According to a third aspect of the present invention, in the above premise, the first resin panel has a solid layer formed on the outer surface and a foam layer formed on the inner surface. The projecting solid portion is integrally projected so as to intersect the vibration direction at intervals in the vibration direction at a plurality of locations, and the projecting solid portion of the first resin panel is provided on the back surface of the second resin panel. Corresponding to the region, the welding ribs are integrally protruded so as to extend in the vibration direction, and at the time of vibration welding, the plurality of protruding solid portions are positioned to face the welding rib tip surface, and the welding rib tip is It is characterized in that the pressure contact portion of each projecting solid part is melted by the pressure vibration with each projecting solid part and melts itself and is welded only to the solid part.

請求項１に係る発明によれば、第１樹脂パネル裏面のソリッド層が、振動方向に延びる複数個の突状ソリッド部により補強されて面剛性が高くなっているため、振動溶着時に溶着リブ先端面を該溶着リブ先端面に対向位置する突状ソリッド部に圧接させても、当該突状ソリッド部突設領域のソリッド層はこの圧接力に十分に抗し得て撓まず、しかも、ソリッド層は突状ソリッド部がある分だけソリッド部分が厚くなっているため、溶着リブ先端がソリッド層を突き抜けて発泡層に入り込まない。   According to the first aspect of the present invention, the solid layer on the back surface of the first resin panel is reinforced by the plurality of projecting solid portions extending in the vibration direction and has high surface rigidity. Even if the surface is brought into pressure contact with the projecting solid portion facing the front end surface of the welding rib, the solid layer in the projecting solid portion projecting region can sufficiently resist this pressure contact force and does not flex, and the solid layer Since the solid portion is thicker than the protruding solid portion, the tip of the weld rib penetrates the solid layer and does not enter the foam layer.

したがって、溶着リブを堅くて面剛性が高くなっている突状ソリッド部突設領域のソリッド層で安定支持するとともに、溶着リブと第１樹脂パネルとの溶着強度を高めて、第１樹脂パネルと第２樹脂パネルとを振動溶着により強固に一体化させた樹脂成形品を得ることができる。   Therefore, the weld rib is stably supported by the solid layer in the protruding solid portion projecting region having a hard and high surface rigidity, and the weld strength between the weld rib and the first resin panel is increased, A resin molded product in which the second resin panel is firmly integrated by vibration welding can be obtained.

請求項２に係る発明によれば、振動溶着時に溶融する溶着リブ先端及び溶着リブ先端面に対向位置する突状ソリッド部の各々の溶融樹脂部を介して溶着リブ先端の両側面が、その両外側方の突状ソリッド部の対向側面と溶着一体化しているため、溶着リブ先端とソリッド層との溶着面積が広がって十分な溶着強度を得ることができる。   According to the second aspect of the present invention, both side surfaces of the welding rib tip are disposed through the melted resin portions of the welding rib tip and the projecting solid portion positioned opposite to the welding rib tip surface which are melted during vibration welding. Since it is integrated with the opposite side surface of the protruding solid portion on the outer side, the welding area between the tip of the welding rib and the solid layer is widened, and a sufficient welding strength can be obtained.

請求項３に係る発明によれば、第１樹脂パネル裏面のソリッド層が、複数箇所で振動方向に間隔をあけて振動方向と交差するように一体に突設された突状ソリッド部により補強されて面剛性が高くなっているため、振動溶着時に溶着リブ先端面を該溶着リブ先端面に対向位置する各突状ソリッド部に圧接させても、当該突状ソリッド部突設領域のソリッド層はこの圧接力に十分に抗し得て撓まず、しかも、ソリッド層は各突状ソリッド部がある分だけソリッド部分が厚くなっているため、溶着リブ先端がソリッド層を突き抜けて発泡層に入り込まない。   According to the third aspect of the invention, the solid layer on the back surface of the first resin panel is reinforced by the protruding solid portions that are integrally projected so as to intersect the vibration direction at intervals in the vibration direction at a plurality of locations. Therefore, even if the weld rib tip surface is pressed against each projecting solid part facing the weld rib tip surface during vibration welding, the solid layer in the projecting solid part projecting region is Since the solid layer is thick enough for each projecting solid part, the weld rib tip penetrates the solid layer and does not enter the foamed layer. .

したがって、溶着リブを堅くて面剛性が高くなっている突状ソリッド部突設領域のソリッド層で安定支持するとともに、溶着リブと第１樹脂パネルとの溶着強度を高めて、第１樹脂パネルと第２樹脂パネルとを振動溶着により強固に一体化させた樹脂成形品を得ることができる。   Therefore, the weld rib is stably supported by the solid layer in the protruding solid portion projecting region having a hard and high surface rigidity, and the weld strength between the weld rib and the first resin panel is increased, A resin molded product in which the second resin panel is firmly integrated by vibration welding can be obtained.

さらに、振動溶着時に溶着リブ先端が各突状ソリッド部を溶融させながら該各突状ソリッド部にくい込んで溶着一体化しているため、溶着リブ先端とソリッド層との溶着面積が広がって十分な溶着強度を得ることができる。   In addition, the welding rib tip melts each projecting solid part during vibration welding, so that each projecting solid part is inserted into the welded solid so that the welding area between the welding rib tip and the solid layer is widened. Strength can be obtained.

以下、この発明の実施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.

（実施形態１）
図２及び図３は、この発明の実施形態１に係る振動溶着構造が適用された樹脂成形品としての略矩形のパッケージトレイ１を示す。このパッケージトレイ１は、第１樹脂パネル３と第２樹脂パネル５とからなり、これら両者を圧接させた状態で振動させることにより溶着一体化して構成されている。図３中、符号Ｌを付して示す破線は溶着ラインであり、本例では、この溶着ラインＬがパッケージトレイ１の長手方向に沿うように平行に５箇所設けられている。 (Embodiment 1)
2 and 3 show a substantially rectangular package tray 1 as a resin molded product to which the vibration welding structure according to Embodiment 1 of the present invention is applied. The package tray 1 includes a first resin panel 3 and a second resin panel 5 and is configured to be welded and integrated by vibrating the two in a state in which both are pressed. In FIG. 3, broken lines indicated by reference sign L are welding lines, and in this example, five welding lines L are provided in parallel along the longitudinal direction of the package tray 1.

上記第１樹脂パネル３表面には、見栄えを良くする等の観点から不織布からなる表皮７が一体に被着されている（図２参照）とともに、一方の長辺側中央には把持用の凹部９が形成されている。上記第２樹脂パネル５の両短辺側には嵌合凹部１１が形成され、該嵌合凹部１１を例えばハッチバック車の車体後部の荷室のサイドトリムに形成された支持ピンに着脱自在に嵌合させることにより、荷室をパッケージトレイ１で上下に区分するようになっている。なお、図３では、便宜上、表皮７を図示していない。   A skin 7 made of non-woven fabric is integrally attached to the surface of the first resin panel 3 from the standpoint of improving appearance (see FIG. 2), and a holding recess is provided at the center of one long side. 9 is formed. A fitting recess 11 is formed on both short sides of the second resin panel 5, and the fitting recess 11 is detachably fitted to a support pin formed on a side trim of a cargo compartment at the rear of the hatchback vehicle body, for example. By combining them, the cargo compartment is divided into upper and lower parts by the package tray 1. In FIG. 3, the skin 7 is not shown for convenience.

上記第１樹脂パネル３は、図１（ａ）及び図４に示すように、外面に樹脂密度が高くて堅いソリッド層１３が形成されるとともに、内部に上記ソリッド層１３よりも樹脂密度が低い発泡層１５が形成されてなり、振動溶着前の第１樹脂パネル３裏面のソリッド層１３には、該ソリッド層１３と同質の３個の長尺突状ソリッド部が振動方向（パッケージトレイ１の長手方向）に延びるように振動方向と交差（直交）する方向に互いに接近して一体に平行突設されている。これにより、第１樹脂パネル３裏面のソリッド層１３がこれら３個の突状ソリッド部により補強されて面剛性が高くなっている。これら３個の突状ソリッド部が突設されている突状ソリッド部突設領域が、振動溶着後の上記溶着ラインＬに対応している。以下、中央の突状ソリッド部を第１突状ソリッド部１７ａと称呼するとともに、該第１突状ソリッド部１７ａの両外側方でその両側面に対向位置する突状ソリッド部を第２突状ソリッド部１７ｂと称呼する。上記第１突状ソリッド部１７ａは突出量が第２突状ソリッド部１７ｂよりも少なく、振動溶着後には溶失している（図１（ｂ）参照）。   As shown in FIG. 1A and FIG. 4, the first resin panel 3 is formed with a solid layer 13 having a high resin density on the outer surface and a lower resin density than the solid layer 13 inside. The foam layer 15 is formed, and the solid layer 13 on the back surface of the first resin panel 3 before vibration welding has three elongated solid portions of the same quality as the solid layer 13 in the vibration direction (on the package tray 1). The projections are integrally projected in parallel so as to approach each other in a direction intersecting (orthogonal) with the vibration direction so as to extend in the longitudinal direction). Thereby, the solid layer 13 on the back surface of the first resin panel 3 is reinforced by these three projecting solid portions, and the surface rigidity is increased. The projecting solid portion projecting region in which these three projecting solid portions are projected corresponds to the welding line L after vibration welding. Hereinafter, the projecting solid portion at the center is referred to as a first projecting solid portion 17a, and the projecting solid portions located on both outer sides of the first projecting solid portion 17a are opposed to both side surfaces. This is referred to as the solid portion 17b. The first projecting solid portion 17a has a smaller projection than the second projecting solid portion 17b, and is melted away after vibration welding (see FIG. 1B).

上記のように、外面にソリッド層１３が、内部に発泡層１５がそれぞれ形成され、かつ上記ソリッド層１３に３個の第１及び第２突状ソリッド部１７ａ，１７ｂが一体に突設された第１樹脂パネル３は、例えば次のようにして成形される。   As described above, the solid layer 13 is formed on the outer surface, the foamed layer 15 is formed inside, and the three first and second projecting solid portions 17a and 17b are integrally projected on the solid layer 13. The 1st resin panel 3 is shape | molded as follows, for example.

まず、成形に際し、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（物理的発泡材）等の発泡促進物質と、ガラス繊維等の繊維とが混入された熱可塑性樹脂（例えばポリプロピレン）を用意する。   First, during molding, a foaming promoting substance such as a chemical foaming material that generates gas by a chemical reaction or an inert gas (physical foaming material) such as carbon dioxide gas and nitrogen gas, and fibers such as glass fiber are mixed. A thermoplastic resin (eg, polypropylene) is prepared.

そして、この熱可塑性樹脂を型閉じ状態の成形型のキャビティ内に射出充填する。この成形型の成形面には、第１樹脂パネル３裏面の第１及び第２突状ソリッド部１７ａ，１７ｂに対応して３個の細長い凹溝部が形成されている。キャビティ内では、熱可塑性樹脂が固化進行することにより、成形型の成形面近傍にスキン層が生成される。このスキン層は未だ完全に固化しきっていない。   Then, this thermoplastic resin is injected and filled into the cavity of the mold in the mold closed state. On the molding surface of the mold, three elongated concave grooves are formed corresponding to the first and second protruding solid portions 17a and 17b on the back surface of the first resin panel 3. In the cavity, the thermoplastic resin is solidified and a skin layer is generated in the vicinity of the molding surface of the mold. This skin layer has not yet fully solidified.

次に、熱可塑性樹脂が固化する過程で、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。この段階で、熱可塑性樹脂は、成形型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いるため、樹脂密度が高くて空隙がなく堅いソリッド層１３となって外面層を構成する。一方、熱可塑性樹脂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。   Next, in the process of solidifying the thermoplastic resin, the cavity volume is expanded by, for example, twice or more. At this stage, the portion of the thermoplastic resin that comes into contact with the molding surface of the mold is cooled early due to the influence of the mold temperature, so that the outer layer becomes a solid layer 13 having a high resin density and no voids. Constitute. On the other hand, the inner part of the thermoplastic resin is hardly affected by the mold temperature and is in a highly viscous gel state.

したがって、キャビティ容積の拡大により、それまで成形型で圧縮されている熱可塑性樹脂が成形型の成形面に引っ張られるとともに、熱可塑性樹脂中の化学反応により発生したガスや不活性ガス等により発泡膨張する。この際、熱可塑性樹脂中の繊維も上記圧縮が軽減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）によっても熱可塑性樹脂が膨張する。   Therefore, the expansion of the cavity volume causes the thermoplastic resin that has been compressed in the mold until now to be pulled to the molding surface of the mold, and expands and expands due to the gas generated by the chemical reaction in the thermoplastic resin, an inert gas, or the like. To do. At this time, the fibers in the thermoplastic resin are also elastically restored by reducing the compression, and the thermoplastic resin expands also by this elastic restoring force (spring back phenomenon).

これにより、樹脂密度が高くて空隙がなく堅いソリッド層１３が外面に形成されるとともに、内部に多数の空隙（図示せず）を有し上記ソリッド層１３に比べて樹脂密度が低い発泡層１５が形成された第１樹脂パネル３が成形される。また、この第１樹脂パネル３裏面のソリッド層１３には、３個の第１及び第２突状ソリッド部１７ａ，１７ｂが一体に突設されている。そして、この第１樹脂パネル３は、発泡層１５がなく樹脂密度が高いソリッド層１３のみからなる場合に比べて軽量化を図ることができる。なお、熱可塑性樹脂にはガラス繊維等の繊維は必ずしも混入させなくてもよい。また、熱可塑性樹脂の発泡膨張は、ガラス繊維等の繊維による弾性復元力のみで行ってもよい。   As a result, the solid layer 13 having a high resin density and no voids is formed on the outer surface, and the foamed layer 15 has a large number of voids (not shown) inside and has a lower resin density than the solid layer 13. The first resin panel 3 formed with is molded. Further, three first and second projecting solid portions 17a and 17b are integrally projected on the solid layer 13 on the back surface of the first resin panel 3. And this 1st resin panel 3 can achieve weight reduction compared with the case where it does not have the foaming layer 15 but consists only of the solid layer 13 with high resin density. It is not always necessary to mix fibers such as glass fibers in the thermoplastic resin. Moreover, you may perform foaming expansion of a thermoplastic resin only by the elastic restoring force by fibers, such as glass fiber.

一方、上記第２樹脂パネル５裏面には、５個の溶着リブ１９が上記第１樹脂パネル３の５箇所の突状ソリッド部突設領域に対応して振動方向に延びるようにそれぞれ一体に平行突設されている。該溶着リブ１９は、振動溶着時に横ブレしないように両側から複数個の補強リブ２１で安定支持されている（図２参照）。   On the other hand, on the back surface of the second resin panel 5, five welding ribs 19 are integrally parallel to each other so as to extend in the vibration direction corresponding to the five protruding solid portion projecting regions of the first resin panel 3. Projected. The welding rib 19 is stably supported by a plurality of reinforcing ribs 21 from both sides so as not to laterally shake during vibration welding (see FIG. 2).

このように構成された第１樹脂パネル３と第２樹脂パネル５とを振動溶着する。この時、図１（ａ）に示すように、第１樹脂パネル３を第１及び第２突状ソリッド部１７ａ，１７ｂが上を向くように下側の振動溶着治具２３にセットするとともに、第２樹脂パネル５を溶着リブ１９が下を向くように図示しない上側の振動溶着治具にセットし、上記第１突状ソリッド部１７ａを溶着リブ１９先端面に対向位置させるとともに、上記２個の第２突状ソリッド部１７ｂを溶着リブ１９先端の両外側方に位置させる。この状態から、上側の振動溶着治具を上方から下側の振動溶着治具２３に押し付けて第２樹脂パネル５の溶着リブ１９先端面を第１樹脂パネル３の第１突状ソリッド部１７ａに圧接させながら、上側の振動溶着治具をパッケージトレイ１の長手方向に振動させる。   The first resin panel 3 and the second resin panel 5 thus configured are vibration welded. At this time, as shown in FIG. 1 (a), the first resin panel 3 is set on the lower vibration welding jig 23 so that the first and second protruding solid portions 17a and 17b face upward, The second resin panel 5 is set on an upper vibration welding jig (not shown) so that the welding rib 19 faces downward, and the first projecting solid portion 17a is opposed to the front end surface of the welding rib 19, and the two The second projecting solid portion 17b is positioned on both outer sides of the tip of the welding rib 19. From this state, the upper vibration welding jig is pressed against the lower vibration welding jig 23 from above, and the front end surface of the welding rib 19 of the second resin panel 5 is brought into contact with the first protruding solid portion 17a of the first resin panel 3. The upper vibration welding jig is vibrated in the longitudinal direction of the package tray 1 while being pressed.

これにより、上記溶着リブ１９先端が、図１（ｂ）に示すように、上記第１突状ソリッド部１７ａとの圧接振動により該第１突状ソリッド部１７ａを溶失させつつ自身も溶融してソリッド部分のみと溶着され、第１樹脂パネル３と第２樹脂パネル５とが溶着一体化する。   As a result, as shown in FIG. 1B, the tip of the welding rib 19 melts itself while losing the first projecting solid portion 17a due to the pressure vibration with the first projecting solid portion 17a. Thus, only the solid portion is welded, and the first resin panel 3 and the second resin panel 5 are welded and integrated.

図１（ｂ）中、２５は、振動溶着時に溶着リブ１９先端及び第１突状ソリッド部１７ａが溶融して盛り上がった溶融樹脂部である。   In FIG. 1B, reference numeral 25 denotes a molten resin portion in which the tip of the welding rib 19 and the first protruding solid portion 17a are melted and raised during vibration welding.

このように、この実施形態１では、第１樹脂パネル３裏面のソリッド層１３を振動方向に延びる３個の第１及び第２突状ソリッド部１７ａ，１７ｂで補強して面剛性を高めているので、振動溶着時に溶着リブ１９先端面を上記第１突状ソリッド部１７ａに圧接させても、当該突状ソリッド部突設領域のソリッド層１３はこの圧接力に十分に抗し得て撓まず、しかも、ソリッド層１３は第１突状ソリッド部１７ａがある分だけソリッド部が厚くなっているので、溶着リブ１９先端がソリッド層１３を突き抜けて発泡層１５に入り込まないようにすることができる。   As described above, in the first embodiment, the solid layer 13 on the back surface of the first resin panel 3 is reinforced with the three first and second projecting solid portions 17a and 17b extending in the vibration direction to increase the surface rigidity. Therefore, even if the front end surface of the welding rib 19 is pressed against the first projecting solid portion 17a during vibration welding, the solid layer 13 in the projecting solid portion projecting region cannot sufficiently bend against this pressing force. In addition, since the solid portion of the solid layer 13 is thickened by the amount of the first projecting solid portion 17a, the tip of the welding rib 19 can be prevented from penetrating the solid layer 13 and entering the foamed layer 15. .

したがって、溶着リブ１９を堅くて面剛性が高くなっている突状ソリッド部突設領域のソリッド層１３で安定支持するとともに、溶着リブ１９と第１樹脂パネル３との溶着強度を高めて、第１樹脂パネル３と第２樹脂パネル５とを振動溶着により強固に一体化させたパッケージトレイ１を得ることができる。   Therefore, the welding rib 19 is stably supported by the solid layer 13 in the projecting solid portion protruding region, which is hard and has high surface rigidity, and the welding strength between the welding rib 19 and the first resin panel 3 is increased. The package tray 1 in which the first resin panel 3 and the second resin panel 5 are firmly integrated by vibration welding can be obtained.

（実施形態２）
図５〜図７は、この発明の実施形態２に係る振動溶着構造が適用されたパッケージトレイ１を示す。 (Embodiment 2)
5 to 7 show a package tray 1 to which a vibration welding structure according to Embodiment 2 of the present invention is applied.

この実施形態２では、パッケージトレイ１が第１樹脂パネル３と第２樹脂パネル５とを振動溶着により一体化して構成されていること、第１樹脂パネル３表面に不織布からなる表皮７が一体に被着されていること、第１樹脂パネル３外面にソリッド層１３が、内部に発泡層１５がそれぞれ形成されていること、第２樹脂パネル５裏面に溶着リブ１９が振動方向に延びるように一体に突設されていること、及び第１樹脂パネル３裏面のソリッド層１３に３個の第１及び第２突状ソリッド部１７ａ，１７ｂが振動方向に延びるように振動方向と交差（直交）する方向に間隔をあけて一体に平行突設されていること等については、実施形態１と同じであるが、第１突状ソリッド部１７ａと第２突状ソリッド部１７ｂとの間隔が実施形態１よりも若干狭く形成されている点で実施形態１と異なっている。そして、振動溶着時に溶融する溶着リブ１９先端及び第１突状ソリッド部１７ａの各々の溶融樹脂部２５により、溶着リブ１９先端の両側面をその両外側方の第２突状ソリッド部１７ｂの対向側面と溶着一体化している。なお、実施形態１と同じ構成箇所には同じ符号を付してその詳細な説明を省略する。   In the second embodiment, the package tray 1 is configured by integrating the first resin panel 3 and the second resin panel 5 by vibration welding, and the skin 7 made of nonwoven fabric is integrally formed on the surface of the first resin panel 3. It is attached so that the solid layer 13 is formed on the outer surface of the first resin panel 3 and the foamed layer 15 is formed inside, and the welding rib 19 is extended on the back surface of the second resin panel 5 in the vibration direction. And the three first and second projecting solid portions 17a and 17b cross (perpendicular to) the vibration direction so that the solid layer 13 on the back surface of the first resin panel 3 extends in the vibration direction. Although it is the same as that of the first embodiment with respect to being integrally projected in parallel with an interval in the direction, the distance between the first protruding solid portion 17a and the second protruding solid portion 17b is the first embodiment. Slightly more than It is different from the first embodiment in that it is Ku formed. Then, due to the molten resin portions 25 of the welding rib 19 and the first projecting solid portion 17a that melt at the time of vibration welding, both side surfaces of the welding rib 19 are opposed to the second projecting solid portion 17b on both outer sides. It is welded and integrated with the side. In addition, the same code | symbol is attached | subjected to the same structure location as Embodiment 1, and the detailed description is abbreviate | omitted.

したがって、この実施形態２では、実施形態１と同様に、溶着リブ１９を堅くて面剛性が高くなっている突状ソリッド部突設領域のソリッド層１３で安定支持するとともに、溶着リブ１９と第１樹脂パネル３との溶着強度を高めて、第１樹脂パネル３と第２樹脂パネル５とを振動溶着により強固に一体化させたパッケージトレイ１を得ることができる。   Therefore, in the second embodiment, similarly to the first embodiment, the welding rib 19 is stably supported by the solid layer 13 in the projecting solid portion projecting region which is hard and has high surface rigidity, and the welding rib 19 and the first rib. By increasing the welding strength with the first resin panel 3, it is possible to obtain the package tray 1 in which the first resin panel 3 and the second resin panel 5 are firmly integrated by vibration welding.

また、この実施形態２では、振動溶着時に溶融する溶着リブ１９先端及び第１突状ソリッド部１７ａの各々の溶融樹脂部２５により、溶着リブ１９先端の両側面をその両外側方の第２突状ソリッド部１７ｂの対向側面と溶着一体化しているので、溶着リブ１９とソリッド層１３との溶着面積が広がって十分な溶着強度を得ることができるというメリットを有する。   Further, in the second embodiment, the both ends of the welding rib 19 tip are made to be the second projections on both outer sides by the melted resin portions 25 of the welding rib 19 and the first projecting solid portion 17a that melt at the time of vibration welding. Since the welding is integrated with the opposite side surface of the solid part 17b, there is an advantage that the welding area of the welding rib 19 and the solid layer 13 is widened and a sufficient welding strength can be obtained.

（実施形態３）
図８〜図１０は、この発明の実施形態３に係る振動溶着構造が適用されたパッケージトレイ１を示す。 (Embodiment 3)
8 to 10 show a package tray 1 to which the vibration welding structure according to Embodiment 3 of the present invention is applied.

この実施形態３では、パッケージトレイ１が第１樹脂パネル３と第２樹脂パネル５とを振動溶着により一体化して構成されていること、第１樹脂パネル３表面に不織布からなる表皮７が一体に被着されていること、第１樹脂パネル３外面にソリッド層１３が、内部に発泡層１５がそれぞれ形成されていること、及び第２樹脂パネル５裏面に溶着リブ１９が振動方向に延びるように一体に突設されていること等については、実施形態１，２と同じであるが、突状ソリッド部の形状及び向きが実施形態１，２と異なっている。   In the third embodiment, the package tray 1 is configured by integrating the first resin panel 3 and the second resin panel 5 by vibration welding, and the skin 7 made of nonwoven fabric is integrally formed on the surface of the first resin panel 3. The solid layer 13 is formed on the outer surface of the first resin panel 3 and the foamed layer 15 is formed inside the first resin panel 3, and the welding rib 19 is extended on the back surface of the second resin panel 5 in the vibration direction. Although it is the same as that in the first and second embodiments, it is different from the first and second embodiments in the shape and orientation of the protruding solid portion.

すなわち、実施形態１，２では、ソリッド層１３からなる３個の長尺の第１及び第２突状ソリッド部１７ａ，１７ｂが振動方向（パッケージトレイ１の長手方向）に延びるように振動方向と交差（直交）する方向に互いに接近して第１樹脂パネル３裏面のソリッド層１３に一体に平行突設され、かつ中央の第１突状ソリッド部１７ａが振動溶着後に溶失している。これに対し、実施形態３では、複数個の短尺の突状ソリッド部２７が複数箇所で振動方向（パッケージトレイ１の長手方向）に間隔をあけて振動方向と交差（直交）するように、かつ一直線状に整然と並ぶように第１樹脂パネル３裏面のソリッド層１３に一体に平行突設されている点、及び、振動溶着時、上記複数個の突状ソリッド部２７が第２樹脂パネル５の溶着リブ１９先端面に対向位置し、該溶着リブ１９先端が上記各突状ソリッド部２７との圧接振動により該各突状ソリッド部２７の圧接箇所を溶融させつつ自身も溶融してソリッド部分のみと溶着されている点で、実施形態１，２と異なっている。なお、図８（ｂ）及び図９では、便宜上、振動溶着時に溶融する溶着リブ１９先端及び突状ソリッド部２７の各々の溶融樹脂部は図示していない。また、実施形態１，２と同じ構成箇所には同じ符号を付してその詳細な説明を省略する。   That is, in the first and second embodiments, the three elongated first and second projecting solid portions 17a and 17b made of the solid layer 13 extend in the vibration direction so as to extend in the vibration direction (longitudinal direction of the package tray 1). Close to each other in the intersecting (orthogonal) direction, the first resin panel 3 has a solid layer 13 on the back surface of the solid layer 13 integrally projecting in parallel, and the central first projecting solid portion 17a is melted away after vibration welding. On the other hand, in the third embodiment, a plurality of short protruding solid portions 27 are crossed (orthogonal) with the vibration direction at intervals in the vibration direction (longitudinal direction of the package tray 1), and The solid resin 13 on the back surface of the first resin panel 3 is arranged so as to be aligned in a straight line, and the plurality of protruding solid portions 27 are formed on the second resin panel 5 at the time of vibration welding. The welding rib 19 is opposed to the front end surface of the welding rib 19, and the tip of the welding rib 19 melts the press contact portion of each protruding solid portion 27 by the pressure contact vibration with each protruding solid portion 27. This is different from the first and second embodiments in that it is welded. In FIG. 8B and FIG. 9, for the sake of convenience, the tip of the welding rib 19 that melts at the time of vibration welding and the molten resin portion of the protruding solid portion 27 are not shown. Further, the same components as those in the first and second embodiments are denoted by the same reference numerals, and detailed description thereof is omitted.

そして、この実施形態３では、第１樹脂パネル３裏面のソリッド層１３を、複数箇所で振動方向に間隔をあけて振動方向と交差するように一体に突設された複数個の突状ソリッド部２７で補強して面剛性を高めているので、振動溶着時に溶着リブ１９先端面を上記各突状ソリッド部２７に圧接させても、当該突状ソリッド部突設領域のソリッド層１３はこの圧接力に十分に抗し得て撓まず、しかも、ソリッド層１３は各突状ソリッド部２７がある分だけソリッド部分が厚くなっているので、溶着リブ１９先端がソリッド層１３を突き抜けて発泡層１５に入り込まないようにすることができる。   In the third embodiment, the solid layer 13 on the back surface of the first resin panel 3 has a plurality of protruding solid portions that are integrally projected so as to intersect the vibration direction at intervals in the vibration direction at a plurality of locations. 27, since the surface rigidity is enhanced by vibration welding, even if the tip end surface of the welding rib 19 is pressed against each of the protruding solid portions 27 at the time of vibration welding, the solid layer 13 in the protruding solid portion protruding region is in this pressure contact. Since the solid layer 13 is thick enough to have the protruding solid portions 27, the tip of the welding rib 19 penetrates the solid layer 13 and the foam layer 15. You can keep out.

したがって、この実施形態３では、実施形態１，２と同様に、溶着リブ１９を堅くて面剛性が高くなっている突状ソリッド部突設領域のソリッド層１３で安定支持するとともに、溶着リブ１９と第１樹脂パネル３との溶着強度を高めて、第１樹脂パネル３と第２樹脂パネル５とを振動溶着により強固に一体化させたパッケージトレイ１を得ることができる。   Therefore, in the third embodiment, as in the first and second embodiments, the welding rib 19 is stably supported by the solid layer 13 in the protruding solid portion projecting region which is hard and has high surface rigidity, and the welding rib 19. The package tray 1 in which the first resin panel 3 and the second resin panel 5 are firmly integrated by vibration welding can be obtained.

さらに、この実施形態３では、振動溶着時に溶着リブ１９先端が各突状ソリッド部２７を溶融させながら該各突状ソリッド部２７にくい込んで溶着一体化しているので、溶着リブ１９とソリッド層１３との溶着面積が広がって十分な溶着強度を得ることができる。   Further, in the third embodiment, the tip of the welding rib 19 melts each protruding solid portion 27 and is integrally welded and integrated with each other during the vibration welding, so that the welding rib 19 and the solid layer 13 are integrated. And a sufficient welding strength can be obtained.

（実施形態４）
図１１は、この発明の実施形態４に係る振動溶着構造が適用されたパッケージトレイ１を構成する第１樹脂パネル３裏面の突状ソリッド部突設領域を示す斜視図である。この実施形態４では、実施形態１，２の第１及び第２突状ソリッド部１７ａ，１７ｂと、実施形態３の突状ソリッド部２７とを組み合わせて突状ソリッド部突設領域を構成している。 (Embodiment 4)
FIG. 11 is a perspective view showing a protruding solid portion protruding region on the back surface of the first resin panel 3 constituting the package tray 1 to which the vibration welding structure according to Embodiment 4 of the present invention is applied. In the fourth embodiment, the first and second projecting solid portions 17a and 17b of the first and second embodiments and the projecting solid portion 27 of the third embodiment are combined to form a projecting solid portion projecting region. Yes.

したがって、上記の実施形態１〜３に比べて第１樹脂パネル３裏面のソリッド層１３の面剛性が一段と高まり、第１樹脂パネル３と第２樹脂パネル５との一体化を頑強にすることができるとともに、溶着リブ１９とソリッド層１３との溶着面積が大幅に広くなって溶着強度を得ることができる。   Therefore, the surface rigidity of the solid layer 13 on the back surface of the first resin panel 3 is further increased as compared with the first to third embodiments, and the integration of the first resin panel 3 and the second resin panel 5 can be made robust. At the same time, the welding area between the welding rib 19 and the solid layer 13 is significantly widened, and the welding strength can be obtained.

なお、上記の実施形態１，２では、３個の第１及び第２突状ソリッド部１７ａ，１７ｂを採用したが、ソリッド層１３の堅さや厚さ如何によっては２個又は４個以上であってもよい。また、溶着リブ１９との振動溶着により溶失する突状ソリッド部の数も１個に限らない。   In the first and second embodiments, the three first and second projecting solid portions 17a and 17b are used. However, depending on the hardness and thickness of the solid layer 13, the number may be two or four or more. May be. Further, the number of protruding solid portions that are melted away by vibration welding with the welding rib 19 is not limited to one.

さらに、上記の実施形態３では、複数個の短尺の突状ソリッド部２７を、複数箇所で振動方向（パッケージトレイ１の長手方向）に間隔をあけて振動方向と交差（直交）するように、かつ一直線状に整然と並ぶように第１樹脂パネル３裏面のソリッド層１３に一体に平行突設したが、例えば隣り合う突状ソリッド部２７を振動方向と交差する方向に若干変位させて千鳥状に配置したり、あるいは連続した１個の長尺の突状ソリッド部２７を振動方向に延びるようにジグザグ状に配置してもよい。   Further, in the third embodiment, the plurality of short protruding solid portions 27 are crossed (orthogonal) with the vibration direction at intervals in the vibration direction (longitudinal direction of the package tray 1) at a plurality of locations. In addition, the solid resin 13 on the back surface of the first resin panel 3 is integrally projected in parallel so as to be aligned in a straight line. For example, the adjacent solid solid portions 27 are slightly displaced in a direction crossing the vibration direction so as to be staggered. Alternatively, one continuous long protruding solid part 27 may be arranged in a zigzag shape so as to extend in the vibration direction.

また、上記の各実施形態では、樹脂成形品が自動車用パッケージトレイ１である場合を示したが、グローブボックスのリッドやトランクボード等の他の自動車用樹脂成形品、さらには自動車以外の樹脂成形品にも適用することができるものである。   In each of the above embodiments, the case where the resin molded product is the automobile package tray 1 has been described. However, other automotive resin molded products such as a glove box lid and a trunk board, and further resin molded products other than automobiles. It can also be applied to products.

この発明は、第１樹脂パネルと第２樹脂パネルとを圧接させた状態で振動させることにより溶着一体化してなる樹脂成形品の振動溶着構造について有用である。   The present invention is useful for a vibration welded structure of a resin molded product obtained by welding and integrating by vibrating in a state where the first resin panel and the second resin panel are in pressure contact with each other.

図１（ａ）は第１樹脂パネル裏面の突状ソリッド部突設領域に第２樹脂パネルの溶着リブ先端を対応させた振動溶着前の状態を示す拡大断面図、図１（ｂ）は突状ソリッド部突設領域に溶着リブ先端を振動溶着した状態を示す拡大断面図である。FIG. 1A is an enlarged cross-sectional view showing a state before vibration welding in which the tip of the welding rib of the second resin panel is made to correspond to the projecting solid portion projecting region on the back surface of the first resin panel, and FIG. It is an expanded sectional view which shows the state which welded the welding rib front-end | tip to the shape solid part protrusion area | region. 図３のII−II線における断面図である。It is sectional drawing in the II-II line | wire of FIG. 実施形態１に係るパッケージトレイの斜視図である。3 is a perspective view of a package tray according to Embodiment 1. FIG. 実施形態１における第１樹脂パネル裏面の突状ソリッド部突設領域を示す斜視図である。It is a perspective view which shows the protruding solid part protrusion area | region of the 1st resin panel back surface in Embodiment 1. FIG. 実施形態２の図１相当図である。FIG. 3 is a diagram corresponding to FIG. 実施形態２の図２相当図である。FIG. 3 is a diagram corresponding to FIG. 2 of the second embodiment. 実施形態２の図４相当図である。FIG. 5 is a diagram corresponding to FIG. 4 of the second embodiment. 実施形態３の図１相当図である。FIG. 6 is a view corresponding to FIG. 1 of Embodiment 3. 実施形態３の図２相当図である。FIG. 6 is a view corresponding to FIG. 2 of the third embodiment. 実施形態３の図４相当図である。FIG. 5 is a diagram corresponding to FIG. 4 of the third embodiment. 実施形態４の図４相当図である。FIG. 5 is a diagram corresponding to FIG. 4 of the fourth embodiment. 従来例の図１（ｂ）相当図である。It is a figure equivalent to Drawing 1 (b) of a conventional example.

符号の説明Explanation of symbols

１ パッケージトレイ（樹脂成形品）
３ 第１樹脂パネル
５ 第２樹脂パネル
１３ ソリッド層
１５ 発泡層
１７ａ 第１突状ソリッド部
１７ｂ 第２突状ソリッド部
１９ 溶着リブ
２５ 溶融樹脂部
２７ 突状ソリッド部 1 Package tray (resin molded product)
3 First resin panel 5 Second resin panel 13 Solid layer 15 Foam layer 17a First projecting solid part 17b Second projecting solid part 19 Welding rib 25 Molten resin part 27 Projecting solid part

Claims (3)

第１樹脂パネルと第２樹脂パネルとを圧接させた状態で振動させることにより溶着一体化してなる樹脂成形品の振動溶着構造であって、
上記第１樹脂パネルは、外面にソリッド層が形成されるとともに内部に発泡層が形成されてなり、
振動溶着前の第１樹脂パネル裏面のソリッド層には、複数個の突状ソリッド部が振動方向に延びるように振動方向と交差する方向に互いに接近して一体に平行突設され、
上記第２樹脂パネル裏面には、溶着リブが上記第１樹脂パネルの突状ソリッド部突設領域に対応して振動方向に延びるように一体に突設され、
振動溶着時、上記複数個の突状ソリッド部のうち少なくとも１個の突状ソリッド部は上記溶着リブ先端面に対向位置し、該溶着リブ先端は、上記対向位置する突状ソリッド部との圧接振動により該突状ソリッド部を溶失させつつ自身も溶融してソリッド部分のみと溶着されていることを特徴とする樹脂成形品の振動溶着構造。 A vibration welded structure of a resin molded product obtained by welding and integrating by vibrating in a state where the first resin panel and the second resin panel are in pressure contact with each other,
The first resin panel has a solid layer formed on the outer surface and a foam layer formed on the inside.
In the solid layer on the back surface of the first resin panel before vibration welding, a plurality of protruding solid portions are provided in parallel and projecting in close proximity to each other in a direction intersecting the vibration direction so as to extend in the vibration direction,
On the back surface of the second resin panel, a welding rib is integrally projected so as to extend in the vibration direction corresponding to the projecting solid portion projecting region of the first resin panel,
At the time of vibration welding, at least one of the plurality of projecting solid portions is located opposite to the tip end surface of the welding rib, and the tip of the welding rib is pressed against the projecting solid portion located at the opposite position. A vibration welding structure for a resin molded product, wherein the protruding solid portion is melted by vibration and melts itself to be welded only to the solid portion. 請求項１に記載の樹脂パネルの振動溶着構造において、
突状ソリッド部は３個以上からなり、
溶着リブ先端面に対向位置する突状ソリッド部の両外側方には、残りの突状ソリッド部が位置し、
上記溶着リブ先端の両側面は、該溶着リブ先端及び溶着リブ先端面に対向位置する突状ソリッド部の各々の溶融樹脂部により、両外側方に位置する突状ソリッド部の対向側面と溶着一体化していることを特徴とする樹脂成形品の振動溶着構造。 In the vibration welding structure of the resin panel according to claim 1,
Protruding solid part consists of 3 or more,
The remaining protruding solid parts are located on both outer sides of the protruding solid part facing the welding rib tip surface,
Both side surfaces of the weld rib tip are welded integrally with opposing side surfaces of the projecting solid portion located on both outer sides by the molten resin portions of the weld rib tip and the projecting solid portion located facing the weld rib tip surface. Vibration welded structure of resin molded products, characterized in that 第１樹脂パネルと第２樹脂パネルとを圧接させた状態で振動させることにより溶着一体化してなる樹脂成形品の振動溶着構造であって、
上記第１樹脂パネルは、外面にソリッド層が形成されるとともに内部に発泡層が形成されてなり、
上記第１樹脂パネル裏面のソリッド層には、突状ソリッド部が複数箇所で振動方向に間隔をあけて振動方向と交差するように一体に突設され、
上記第２樹脂パネル裏面には、上記第１樹脂パネルの突状ソリッド部突設領域に対応して溶着リブが振動方向に延びるように一体に突設され、
振動溶着時、上記複数個の突状ソリッド部は上記溶着リブ先端面に対向位置し、該溶着リブ先端は、上記各突状ソリッド部との圧接振動により該各突状ソリッド部の圧接箇所を溶融させつつ自身も溶融してソリッド部分のみと溶着されていることを特徴とする樹脂成形品の振動溶着構造。 A vibration welded structure of a resin molded product obtained by welding and integrating by vibrating in a state where the first resin panel and the second resin panel are in pressure contact with each other,
The first resin panel has a solid layer formed on the outer surface and a foam layer formed on the inside.
In the solid layer on the back surface of the first resin panel, protruding solid portions are integrally projected so as to intersect the vibration direction at intervals in the vibration direction at a plurality of locations.
On the back surface of the second resin panel, a welding rib is integrally projected so as to extend in the vibration direction corresponding to the projecting solid portion projecting region of the first resin panel,
At the time of vibration welding, the plurality of projecting solid portions are positioned opposite to the front end surface of the welding rib, and the front end of the welding rib is pressed against each of the projecting solid portions by pressure vibration. A vibration welded structure of a resin molded product characterized in that it melts itself while being melted and is welded only to a solid part.
JP2007190442A 2007-07-23 2007-07-23 Vibration welding structure of resin molded products Expired - Fee Related JP4916019B2 (en)

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010201855A (en) * 2009-03-05 2010-09-16 Kojima Press Industry Co Ltd Joining method for foamed sheet
JP2011214651A (en) * 2010-03-31 2011-10-27 Ts Tech Co Ltd Fixing structure of member
JP2012177343A (en) * 2011-02-25 2012-09-13 Daihatsu Motor Co Ltd Head cover structure
JP2015094226A (en) * 2013-11-08 2015-05-18 トヨタ紡織株式会社 Resin cylinder head cover

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JPH0473129A (en) * 1990-05-01 1992-03-09 Toyoda Gosei Co Ltd Production of article having foam layer
JPH04208436A (en) * 1990-11-30 1992-07-30 Toyoda Gosei Co Ltd Vibration fusion joining method
JP2002364471A (en) * 2001-06-04 2002-12-18 Keihin Corp Producing method of vehicular intake manifold and resin structure body
JP2004058468A (en) * 2002-07-29 2004-02-26 Nippon Plast Co Ltd Resin structure
JP2006167918A (en) * 2004-12-10 2006-06-29 Jsp Corp Composite and its manufacturing method
JP2007091024A (en) * 2005-09-28 2007-04-12 Daikyoo Nishikawa Kk Interior article for vehicle having air bag door section

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Publication number Priority date Publication date Assignee Title
JPH0473129A (en) * 1990-05-01 1992-03-09 Toyoda Gosei Co Ltd Production of article having foam layer
JPH04208436A (en) * 1990-11-30 1992-07-30 Toyoda Gosei Co Ltd Vibration fusion joining method
JP2002364471A (en) * 2001-06-04 2002-12-18 Keihin Corp Producing method of vehicular intake manifold and resin structure body
JP2004058468A (en) * 2002-07-29 2004-02-26 Nippon Plast Co Ltd Resin structure
JP2006167918A (en) * 2004-12-10 2006-06-29 Jsp Corp Composite and its manufacturing method
JP2007091024A (en) * 2005-09-28 2007-04-12 Daikyoo Nishikawa Kk Interior article for vehicle having air bag door section

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010201855A (en) * 2009-03-05 2010-09-16 Kojima Press Industry Co Ltd Joining method for foamed sheet
JP2011214651A (en) * 2010-03-31 2011-10-27 Ts Tech Co Ltd Fixing structure of member
JP2012177343A (en) * 2011-02-25 2012-09-13 Daihatsu Motor Co Ltd Head cover structure
JP2015094226A (en) * 2013-11-08 2015-05-18 トヨタ紡織株式会社 Resin cylinder head cover

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