JP2013001021A - Foam panel and its molding method - Google Patents

Foam panel and its molding method Download PDF

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JP2013001021A
JP2013001021A JP2011135907A JP2011135907A JP2013001021A JP 2013001021 A JP2013001021 A JP 2013001021A JP 2011135907 A JP2011135907 A JP 2011135907A JP 2011135907 A JP2011135907 A JP 2011135907A JP 2013001021 A JP2013001021 A JP 2013001021A
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thermoplastic resin
molding
mold
solid
foam
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Shingo Niimi
慎悟 新見
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DaikyoNishikawa Corp
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DaikyoNishikawa Corp
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Abstract

PROBLEM TO BE SOLVED: To make a foam panel higher in rigidity and heat insulation, and light in weight.SOLUTION: Both top and reverse surfaces of a plane part 13 are continuously composed of a solid part 19, projection streaks 17 are provided at the opposite side of the solid part 19 from an opening side, and a space 23 is formed in the solid part 19. The space 23 has bridges 21 formed of foam layers for bridging both the top and reverse surfaces of the solid part 19 according to the projection streaks 17.

Description

本発明は、平面部を有する熱可塑性樹脂製の発泡パネルに関するものである。   The present invention relates to a foam panel made of a thermoplastic resin having a flat portion.

特許文献１に開示された衝撃緩衝部材の表面は、ソリッド部で構成され、該ソリッド部の内部には、該衝撃緩衝部材の長手方向に延びる隔壁と、該隔壁により隔てられた低密度の発泡構造部とが隙間なく形成されている。この衝撃緩衝部材の発泡構造部は、該発泡構造部に対応するスライドコア型を進出させた状態でキャビティ内に溶融樹脂を充填し、成形面近傍にソリッド部が形成され、かつ内部がまだ溶融状態であるときにスライドコア型を後退させることにより成形される。   The surface of the shock-absorbing member disclosed in Patent Document 1 is composed of a solid part, and a partition extending in the longitudinal direction of the shock-absorbing member and a low-density foam separated by the partition in the solid part. The structure part is formed without a gap. The foam structure part of this shock absorbing member is filled with molten resin in the cavity with the slide core mold corresponding to the foam structure part advanced, a solid part is formed in the vicinity of the molding surface, and the inside is still molten It is formed by retreating the slide core mold when it is in a state.

特開平１１−６０７６９号公報Japanese Patent Laid-Open No. 11-60769

しかし、上記特許文献１に開示された衝撃緩衝部材の構造を、剛性・断熱性の向上、及び軽量化が求められる発泡パネルに適用すると、ソリッド部の内部に隔壁と発泡構造部とが隙間なく形成されるため、発泡パネルの十分な軽量化を実現できず、かつ十分な断熱性を得ることができない。   However, when the structure of the shock-absorbing member disclosed in Patent Document 1 is applied to a foam panel that is required to be improved in rigidity and heat insulation and reduced in weight, there is no gap between the partition wall and the foam structure part inside the solid part. Since it is formed, a sufficient weight reduction of the foam panel cannot be realized, and sufficient heat insulation cannot be obtained.

一方、軽量化のために、発泡パネルを薄くしたり、熱可塑性樹脂が存在しない空間部のみでソリッド部の内部を構成すると、発泡パネルの剛性が低下する。   On the other hand, if the foamed panel is made thin or the interior of the solid part is composed only of the space where there is no thermoplastic resin for weight reduction, the rigidity of the foamed panel is lowered.

本発明は、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、発泡パネルの剛性及び断熱性を高めるとともに、軽量化を実現することにある。   This invention is made | formed in view of this point, The place made into the objective is to implement | achieve weight reduction while improving the rigidity and heat insulation of a foam panel.

上記の目的を達成するため、本発明は、ソリッド部の内部に空間部を設けるとともに、ソリッド部の表裏両面を発泡層からなる橋絡部で橋絡したことを特徴とする。   In order to achieve the above object, the present invention is characterized in that a space portion is provided inside the solid portion, and both the front and back surfaces of the solid portion are bridged by a bridging portion made of a foam layer.

具体的には、本発明は、平面部を有する熱可塑性樹脂製の発泡パネルを対象とし、次のような解決手段を講じた。   Specifically, the present invention is directed to a thermoplastic resin foam panel having a flat portion, and the following solution has been taken.

すなわち、請求項１に記載の発明は、上記平面部は、表裏両面を連続して構成し、少なくとも表裏両面の一方の面に突部が部分的に突設されたソリッド部と、該ソリッド部の内部に設けられた空間部と、該空間部に上記突部に対応して設けられ、上記ソリッド部の表裏両面を橋絡する発泡層からなる橋絡部とを備えたことを特徴とする。   That is, in the first aspect of the present invention, the flat portion is configured so that both the front and back surfaces are continuously formed, and at least one surface of the front and back surfaces has a protruding portion that partially protrudes. And a bridging portion that is provided in the space portion corresponding to the protruding portion and that includes a foam layer that bridges both the front and back surfaces of the solid portion. .

請求項２に記載の発明は、請求項１に記載の発泡パネルにおいて、上記突部は、互いに格子状に交差する複数本の突条であることを特徴とする。   According to a second aspect of the present invention, in the foam panel according to the first aspect, the protrusions are a plurality of protrusions intersecting each other in a lattice shape.

請求項３に記載の発明は、請求項１又は２に記載の発泡パネルを成形する方法であって、上記平面部の表裏両面の一方の面を成形する第１成形面を有する固定型と、上記平面部の表裏両面の他方の面を成形する第２成形面を有する可動型とを備え、上記第１成形面及び第２成形面の少なくとも一方に凹部が形成された成形型を用意し、上記成形型を型閉じして固定型と可動型との間にキャビティを形成し、この状態から、熱可塑性樹脂を上記キャビティ内に射出充填し、上記熱可塑性樹脂の成形面近傍にソリッド部が形成され始めた時点で、上記可動型を固定型から離れる方向に後退させてキャビティ容積を拡大させて上記熱可塑性樹脂を発泡させることにより、上記第１成形面近傍及び第２成形面近傍にソリッド部を形成するとともに上記凹部内に上記突部を形成し、かつ該ソリッド部が、上記凹部対応箇所では、熱可塑性樹脂の発泡膨張により形成された発泡層からなる橋絡部により橋絡される一方、上記凹部非対応箇所では、熱可塑性樹脂の過発泡により形成された空間部により分離された段階で、上記可動型の後退を止めて上記熱可塑性樹脂を固化することにより上記平面部を形成することを特徴とする。   Invention of Claim 3 is a method of shape | molding the foam panel of Claim 1 or 2, Comprising: The stationary mold | type which has a 1st shaping | molding surface which shape | molds one surface of both the front and back both surfaces of the said plane part, A movable mold having a second molding surface that molds the other surface of both the front and back surfaces of the plane portion, and preparing a molding die in which a recess is formed in at least one of the first molding surface and the second molding surface, The mold is closed and a cavity is formed between the fixed mold and the movable mold. From this state, the thermoplastic resin is injected and filled into the cavity, and a solid portion is formed in the vicinity of the molding surface of the thermoplastic resin. When the formation starts, the movable mold is retracted in a direction away from the fixed mold to expand the cavity volume and foam the thermoplastic resin, so that solids are formed in the vicinity of the first molding surface and the second molding surface. Forming part and above The protrusion is formed in a portion, and the solid portion is bridged by a bridging portion made of a foamed layer formed by foaming expansion of a thermoplastic resin in the portion corresponding to the recess, while the portion not corresponding to the recess Then, in the stage separated by the space formed by over-foaming of the thermoplastic resin, the planar portion is formed by stopping the retreat of the movable mold and solidifying the thermoplastic resin.

請求項１に記載の発明によれば、ソリッド部の内部に、熱可塑性樹脂の存在しない空間部が形成されるので、ソリッド部の内部に隙間なく発泡層を形成する場合に比べ、平面部を軽量化し、かつ平面部の断熱性を高めることができる。その結果、発泡パネル全体を軽量化し、その断熱性を高めることができる。   According to the first aspect of the present invention, since the space portion in which the thermoplastic resin does not exist is formed inside the solid portion, the plane portion is formed as compared with the case where the foamed layer is formed without any gap inside the solid portion. It is possible to reduce the weight and improve the heat insulating property of the flat portion. As a result, the entire foam panel can be reduced in weight and its heat insulation can be enhanced.

また、ソリッド部の表裏両面を発泡層からなる橋絡部により橋絡するので、大幅な重量増大や断熱性の大幅な低下を招くことなく、ソリッド部の内部を空間部のみで構成する場合に比べ、平面部の面剛性を高めることができる。   In addition, since both sides of the solid part are bridged by a bridging part made of a foam layer, when the interior of the solid part is composed only of a space part without causing a significant increase in weight or a significant decrease in heat insulation. In comparison, the surface rigidity of the flat portion can be increased.

請求項２に記載の発明によれば、同方向に延びる突条間の強度をこれと交差する突条により補って、平面部の面剛性をより高めることができる。   According to the second aspect of the invention, the strength between the ridges extending in the same direction can be supplemented by the ridges intersecting the ridges, and the surface rigidity of the flat surface portion can be further increased.

請求項３に記載の発明によれば、固定型及び可動型の少なくとも一方に凹部を設けるだけで、従来からあるコアバック法により請求項１又は２の発泡パネルを容易にかつ確実に得ることができる。   According to the third aspect of the present invention, the foamed panel of the first or second aspect can be easily and reliably obtained by a conventional core back method only by providing a recess in at least one of the fixed mold and the movable mold. it can.

本発明の実施形態に係る発泡パネルとしてのダクトパネルと、該ダクトパネルが組み付けられるインストルメントパネル本体を示す斜視図である。It is a perspective view which shows the duct panel as a foam panel which concerns on embodiment of this invention, and the instrument panel main body by which this duct panel is assembled | attached. インストルメントパネル本体に組み付けられた状態のダクトパネルを、インストルメントパネル本体の裏側から見た図１のＡ−Ａ線に相当する断面斜視図である。It is the cross-sectional perspective view equivalent to the AA line of FIG. 1 which looked at the duct panel of the state assembled | attached to the instrument panel main body from the back side of the instrument panel main body. 本発明の実施形態において、成形型のキャビティ内に熱可塑性樹脂を射出充填した状態を示す図１のダクトパネルのＡ−Ａ線に相当する断面図である。In embodiment of this invention, it is sectional drawing equivalent to the AA line of the duct panel of FIG. 1 which shows the state which injected and filled the thermoplastic resin in the cavity of the shaping | molding die. 本発明の実施形態において、図３における成形型の可動型をキャビティ容積が拡大する方向に僅かに後退させた状態を示す図３対応図である。FIG. 4 is a view corresponding to FIG. 3 showing a state in which the movable mold of the forming mold in FIG. 3 is slightly retracted in the direction in which the cavity volume is enlarged in the embodiment of the present invention. 本発明の実施形態において、図４における成形型の可動型をキャビティ容積が拡大する方向にさらに後退させた状態を示す図４対応図である。FIG. 5 is a view corresponding to FIG. 4 showing a state in which the movable mold of the forming mold in FIG. 4 is further retracted in the direction in which the cavity volume is enlarged in the embodiment of the present invention. 本発明の実施形態の変形例に係る図２のＢ部対応箇所を示す拡大断面斜視図である。It is an expanded sectional perspective view which shows the B section corresponding part of FIG. 2 which concerns on the modification of embodiment of this invention.

以下、本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.

図１は、自動車のインストルメントパネルの主体をなす樹脂製インストルメントパネル本体１、及びその裏面に組み付けられる本実施形態に係る発泡パネルとしてのダクトパネル３を示す。該ダクトパネル３は、熱可塑性樹脂製であり、図２にも示すように、断面略コ字状で車幅方向に延びる樋形状をなし、その開放側をインストルメントパネル本体１に向けた状態で、インストルメントパネル本体１の裏面に一体に振動溶着されている。また、ダクトパネル３の車幅方向中央部分には、デフロスターエア導入口４が設けられている。   FIG. 1 shows a resin instrument panel main body 1 that is a main body of an instrument panel of an automobile, and a duct panel 3 as a foam panel according to the present embodiment that is assembled to the back surface thereof. The duct panel 3 is made of a thermoplastic resin, and as shown in FIG. 2, the duct panel 3 has a substantially U-shaped cross section and extends in the vehicle width direction, and its open side faces the instrument panel body 1. Thus, it is vibration welded integrally to the back surface of the instrument panel body 1. In addition, a defroster air inlet 4 is provided at the center of the duct panel 3 in the vehicle width direction.

上記インストルメントパネル本体１の車幅方向両側には、サイドデフロスターエア吹出口５が形成され、その下方に接近してサイドベントエア吹出口７が形成されている。また、インストルメントパネル本体１の車幅方向中程には、センターベントエア吹出口９が形成されている。さらに、インストルメントパネル本体１の車体前端には、車幅方向に延びるフロントデフロスターエア吹出口１１が形成されている。   Side defroster air outlets 5 are formed on both sides of the instrument panel main body 1 in the vehicle width direction, and side vent air outlets 7 are formed close to the lower side. A center vent air outlet 9 is formed in the middle of the instrument panel body 1 in the vehicle width direction. Further, a front defroster air outlet 11 extending in the vehicle width direction is formed at the vehicle body front end of the instrument panel body 1.

上記インストルメントパネル本体１及びダクトパネル３により、車幅方向に延びる断面略矩形状のデフロスターエア通路１２が内部に形成され、図示しない空調ユニットで調整された空調エアがデフロスターエア導入口４を経てデフロスターエア通路１２に導入され、該デフロスターエア通路１２を流れる過程で上記フロントデフロスターエア吹出口１１やサイドデフロスターエア吹出口５等から車室内に吹き出すようになっている。   The instrument panel body 1 and the duct panel 3 form a defroster air passage 12 having a substantially rectangular cross section extending in the vehicle width direction, and the conditioned air adjusted by an air conditioning unit (not shown) passes through the defroster air inlet 4. The air is introduced into the defroster air passage 12 and is blown out from the front defroster air outlet 11 and the side defroster air outlet 5 into the vehicle compartment in the course of flowing through the defroster air passage 12.

上記ダクトパネル３は、表裏両面を上下方向に向けて車幅方向に延びる平面部１３と、該平面部１３の車体前後の両側縁から上方に延びる一対の側面部１５とを備えている。上記両側面部１５の間隔は、延出方向（ダクトパネル３の開放側）に向けて徐々に広がっている。   The duct panel 3 includes a plane portion 13 that extends in the vehicle width direction with both front and back surfaces facing up and down, and a pair of side portions 15 that extend upward from both side edges of the plane portion 13 at the front and rear of the vehicle body. The distance between the side surface portions 15 gradually increases in the extending direction (the opening side of the duct panel 3).

上記平面部１３は、表裏両面を連続して構成するソリッド部１９を備え、該ソリッド部１９の表裏両面の反開放側（車体下側）の面には、突部としての複数本の突条１７が互いに格子状に交差するように突設されている。また、上記ソリッド部１９の内部には、熱可塑性樹脂の存在しない空間部２３が形成されている。この空間部２３には、上記ソリッド部１９の表裏両面を橋絡する橋絡部２１が、上記突条１７に対応して格子状に設けられている。これにより、上記空間部２３が橋絡部２１で複数の独立空間部２３ａに区画されている。上記橋絡部２１は、上記ソリッド部１９よりも樹脂密度が低い発泡層からなる。なお、上記ソリッド部１９は、未発泡の樹脂、又は若干発泡した樹脂で構成される。   The flat surface portion 13 includes a solid portion 19 that continuously forms both front and back surfaces, and a plurality of protrusions serving as protrusions are provided on the surface of the solid portion 19 on the opposite side of the front and back surfaces (the vehicle body lower side). The projections 17 project so as to cross each other in a grid pattern. In addition, a space 23 in which no thermoplastic resin is present is formed inside the solid portion 19. In the space portion 23, bridging portions 21 that bridge both the front and back surfaces of the solid portion 19 are provided in a lattice shape corresponding to the protrusions 17. As a result, the space portion 23 is partitioned into a plurality of independent space portions 23 a by the bridge portion 21. The bridge portion 21 is formed of a foam layer having a resin density lower than that of the solid portion 19. The solid portion 19 is made of an unfoamed resin or a slightly foamed resin.

上記両側面部１５は、ソリッド部１９のみからなり、該両側面部１５の延出端縁には、略車幅方向に連続して延びる板状の接合フランジ部２５が車体前後方向に向けて突設されている。各接合フランジ部２５の表裏面及び突出端面は、ソリッド部１９で構成され、各接合フランジ部２５のソリッド部１９の内部には、発泡層２６が隙間なく形成されている。各接合フランジ部２５の車体上側（開放側）の面には、車幅方向に延びる振動溶着用の３本の溶着リブ２７が、車体前後方向に間隔をあけて突設されている。   The both side surface portions 15 are composed of only the solid portions 19, and plate-like joint flange portions 25 extending continuously in the vehicle width direction project from the extending end edges of the both side surface portions 15 in the vehicle longitudinal direction. Has been. The front and back surfaces and the protruding end surfaces of each joint flange portion 25 are constituted by a solid portion 19, and a foam layer 26 is formed inside the solid portion 19 of each joint flange portion 25 without a gap. Three welding ribs 27 for vibration welding extending in the vehicle width direction are provided on the surface on the vehicle body upper side (open side) of each joint flange portion 25 so as to protrude in the vehicle longitudinal direction.

上記の如きダクトパネル３は、例えば次のようにして製造される。   The duct panel 3 as described above is manufactured, for example, as follows.

製造に際し、図３に示すような成形型１０１と熱可塑性樹脂Ｒとを用意する。上記成形型１０１は、ダクトパネル３の反開放側を成形する成形面１０３’を有する固定型１０３と、該固定型１０３に対向配置され、ダクトパネル３の開放側を成形する成形面１０５’を有する可動型１０５とを備えている。詳しくは、固定型１０３の成形面１０３’は、ダクトパネル３の平面部１３の反開放側の面を成形する第１成形面としての平面部成形面１０３ａ、ダクトパネル３の両側面部１５の外側の面を成形する側面部成形面１０３ｂ、及び上記接合フランジ部２５の溶着リブ２７背面（下側の面及び突出端面）を成形するフランジ部成形面１０３ｃを有し、上記平面部成形面１０３ａには、凹部としての複数本の凹条溝１０３ｄが上記平面部１３の複数の突条１７に対応するように格子状に形成されている。一方、可動型１０５の成形面１０５’は、ダクトパネル３の平面部１３の開放側の面を成形する第２成形面としての平面部成形面１０５ａ、ダクトパネル３の両側面部１５の内側の面を成形する側面部成形面１０５ｂ、及び上記接合フランジ部２５における溶着リブ２７形成面を成形するフランジ部成形面１０５ｃを有し、上記フランジ部成形面１０５ｃには、上記３本の溶着リブ２７に対応する３本の凹条溝１０５ｄが形成されている。上記熱可塑性樹脂Ｒは、例えば化学反応によりガスを発生させる化学的発泡剤や、MuCell（ミューセル：登録商標） Processのように二酸化炭素ガス及び窒素ガス等の不活性ガス（物理的発泡剤）等が超臨界状態で混入された熱可塑性樹脂であり、ガラス繊維等の繊維が混入されていてもよいが、必ずしもこれらを混入していなくてもよい。   In manufacturing, a mold 101 and a thermoplastic resin R as shown in FIG. 3 are prepared. The molding die 101 has a fixed mold 103 having a molding surface 103 ′ for molding the non-open side of the duct panel 3, and a molding surface 105 ′ which is disposed opposite to the fixed mold 103 and molds the opening side of the duct panel 3. The movable mold 105 is provided. Specifically, the molding surface 103 ′ of the fixed mold 103 is a flat portion molding surface 103 a as a first molding surface that molds the surface on the opposite side of the flat portion 13 of the duct panel 3, and the outer sides of both side surface portions 15 of the duct panel 3. And a flange portion molding surface 103c for molding the rear surface (lower surface and protruding end surface) of the welding rib 27 of the joint flange portion 25. Are formed in a lattice shape so that a plurality of concave grooves 103 d as concave portions correspond to the plurality of protrusions 17 of the flat surface portion 13. On the other hand, the molding surface 105 ′ of the movable mold 105 is a surface inside the flat surface molding surface 105 a as a second molding surface that molds the open surface of the flat surface portion 13 of the duct panel 3 and the inner surface of the both side surface portions 15 of the duct panel 3. And a flange portion forming surface 105c for forming a weld rib 27 forming surface in the joint flange portion 25. The flange portion forming surface 105c includes the three weld ribs 27. Corresponding three concave grooves 105d are formed. The thermoplastic resin R is, for example, a chemical foaming agent that generates gas by a chemical reaction, or an inert gas (physical foaming agent) such as carbon dioxide gas or nitrogen gas, as in the MuCell (registered trademark) Process. Is a thermoplastic resin mixed in a supercritical state, and fibers such as glass fibers may be mixed, but these are not necessarily mixed.

まず、図３に示すように、成形型１０１を型閉じして固定型１０３と可動型１０５との間にキャビティ１０７を形成し、この状態から、上述の如き発泡促進物質が混入された溶融状態の熱可塑性樹脂Ｒを上記キャビティ１０７内に射出機（図示せず）から射出充填する。このときの上記フランジ部成形面１０３ｃ，１０５ｃの凹条溝１０５ｄ非対応箇所の間隔Ｄ１は、上記平面部成形面１０３ａ，１０５ａの凹条溝１０３ｄ非対応箇所の間隔Ｄ２よりも長く設定されている。   First, as shown in FIG. 3, the mold 101 is closed and a cavity 107 is formed between the fixed mold 103 and the movable mold 105. From this state, a molten state in which the foaming promoting substance is mixed as described above. The thermoplastic resin R is injected and filled into the cavity 107 from an injection machine (not shown). At this time, the interval D1 between the flange-shaped surfaces 103c and 105c not corresponding to the groove 105d is set longer than the interval D2 between the flat-shaped surfaces 103a and 105a not corresponding to the groove 103d. .

その後、キャビティ１０７内では、熱可塑性樹脂Ｒの成形型１０１（固定型１０３、可動型１０５）の成形面１０３’，１０５’近傍の熱可塑性樹脂Ｒが、型温の影響により早期に冷却されて固化し、樹脂密度が高いソリッド部（図示せず）が表面に形成され始める。このとき、熱可塑性樹脂Ｒの内側部分は型温の影響を受け難いため、粘度の高いゲル状態になっている。この時点で、図４に示すように、可動型１０５を固定型１０３から離れる方向（図４中、矢印Ｘで示す方向）に後退させてキャビティ１０７の容積を拡大させて上記熱可塑性樹脂Ｒを発泡させる。すると、キャビティ１０７の容積拡大により、それまで固定型１０３及び可動型１０５の間で圧縮されている熱可塑性樹脂Ｒが可動型１０５の成形面１０５’に引っ張られるとともに、熱可塑性樹脂Ｒ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。熱可塑性樹脂Ｒ中にガラス繊維等の繊維が混入されていれば、熱可塑性樹脂Ｒ中のガラス繊維等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Ｒが膨張する。このとき、平面部成形面１０３ａ，１０５ａの間のキャビティ１０７の容積拡大率は、凹条溝１０３ｄ非対応箇所で凹条溝１０３ｄ対応箇所よりも高くなるので、熱可塑性樹脂Ｒの発泡倍率は、図４に示すように、凹条溝１０３ｄ非対応箇所で凹条溝１０３ｄ対応箇所よりも高くなる。   Thereafter, in the cavity 107, the thermoplastic resin R in the vicinity of the molding surfaces 103 ′ and 105 ′ of the molding die 101 (fixed die 103, movable die 105) of the thermoplastic resin R is cooled early due to the influence of the die temperature. Solidified and a solid portion (not shown) having a high resin density starts to be formed on the surface. At this time, since the inner part of the thermoplastic resin R is hardly affected by the mold temperature, it is in a gel state having a high viscosity. At this time, as shown in FIG. 4, the movable mold 105 is moved back in the direction away from the fixed mold 103 (the direction indicated by the arrow X in FIG. 4) to enlarge the volume of the cavity 107, and the thermoplastic resin R is expanded. Foam. Then, as the volume of the cavity 107 is increased, the thermoplastic resin R that has been compressed between the fixed mold 103 and the movable mold 105 is pulled to the molding surface 105 ′ of the movable mold 105, and the chemical in the thermoplastic resin R is increased. It expands and expands due to a gas generated by the reaction, an inert gas, or the like. If fibers such as glass fibers are mixed in the thermoplastic resin R, the fibers such as glass fibers in the thermoplastic resin R are also restored elastically by reducing the compression, and this elastic restoring force (springback phenomenon) ) Also expands the thermoplastic resin R. At this time, the volume expansion rate of the cavity 107 between the flat surface molding surfaces 103a and 105a is higher in the portion not corresponding to the concave groove 103d than in the portion corresponding to the concave groove 103d. Therefore, the expansion ratio of the thermoplastic resin R is As shown in FIG. 4, the portion corresponding to the groove 103 d does not correspond to the portion corresponding to the groove 103 d.

上述のようなキャビティ１０７の容積拡大による熱可塑性樹脂Ｒの発泡膨張が進行すると、平面部成形面１０３ａ，１０５ａ近傍にソリッド部１９が形成され、ソリッド部１９の内部には、凹条溝１０３ｄ非対応箇所と凹条溝１０３ｄ対応箇所とで発泡倍率の異なる発泡層が形成されるとともに、上記凹条溝１０３ｄ内に上記突条１７が形成される。   When the expansion of the expansion of the thermoplastic resin R due to the expansion of the volume of the cavity 107 as described above proceeds, the solid portion 19 is formed in the vicinity of the flat surface molding surfaces 103a and 105a. Foam layers having different expansion ratios are formed at the corresponding portions and the corresponding portions of the groove groove 103d, and the protrusions 17 are formed in the groove groove 103d.

更に可動型１０５を固定型１０３から離れる方向に後退させてキャビティ１０７の容積拡大による熱可塑性樹脂Ｒの発泡膨張を進行させると、図５に示すように、平面部成形面１０３ａ，１０５ａの間の凹条溝１０３ｄ非対応箇所には、熱可塑性樹脂Ｒの過発泡により発泡層の発泡セル膜が切れて空間部２３が形成され、平面部成形面１０３ａ，１０５ａ近傍に形成されたソリッド部１９を分離する。一方、平面部成形面１０３ａ，１０５ａの間の凹条溝１０３ｄ対応箇所では、凹条溝１０３ｄ内に熱可塑性樹脂Ｒが充填されていた分、凹条溝１０３ｄ非対応箇所よりも発泡倍率が低くなるので、熱可塑性樹脂Ｒの発泡層が途切れず、熱可塑性樹脂Ｒの発泡膨張により形成された発泡層からなる橋絡部２１が形成される。この段階で、上記可動型１０５の後退を止めて上記熱可塑性樹脂Ｒを固化することにより上記平面部１３が形成される。なお、可動型１０５の後退量は、固定型１０３及び可動型１０５の平面部成形面１０３ａ，１０５ａの凹条溝１０３ｄ非対応箇所の間隔Ｄ２が例えば２倍になるように設定される。また、上記フランジ部成形面１０３ｃ，１０５ｃ近傍に形成されたソリッド部１９の間には、発泡層２６が隙間なく形成され、上記凹条溝１０５ｄ内には、上記溶着リブ２７が形成される。上記熱可塑性樹脂Ｒの充填時において、上記フランジ部成形面１０３ｃ，１０５ｃの凹条溝１０５ｄ非対応箇所の間隔Ｄ１を上記平面部成形面１０３ａ，１０５ａの凹条溝１０３ｄ非対応箇所の間隔Ｄ２よりも長く設定したため、フランジ部成形面１０３ｃ，１０５ｃの間の凹条溝１０５ｄ非対応箇所における熱可塑性樹脂Ｒの発泡倍率は、上記平面部成形面１０３ａ，１０５ａの間における空間部２３形成箇所よりも低くなる。したがって、上記フランジ部成形面１０３ｃ，１０５ｃの間には、空間部２３が形成されない。   Further, when the movable mold 105 is retracted in the direction away from the fixed mold 103 and the expansion of the thermoplastic resin R is expanded by expanding the volume of the cavity 107, as shown in FIG. 5, the space between the flat surface molding surfaces 103a and 105a is increased. In the portion not corresponding to the groove 103d, the foamed cell film of the foam layer is cut by excessive foaming of the thermoplastic resin R, and the space portion 23 is formed, and the solid portion 19 formed in the vicinity of the flat surface molding surfaces 103a and 105a is formed. To separate. On the other hand, in the portion corresponding to the concave groove 103d between the flat surface forming surfaces 103a and 105a, the expansion ratio is lower than the portion not corresponding to the concave groove 103d because the thermoplastic resin R is filled in the concave groove 103d. Therefore, the foamed layer of the thermoplastic resin R is not interrupted, and the bridging portion 21 made of the foamed layer formed by the foam expansion of the thermoplastic resin R is formed. At this stage, the planar portion 13 is formed by stopping the retraction of the movable mold 105 and solidifying the thermoplastic resin R. The retraction amount of the movable mold 105 is set such that the distance D2 between the fixed mold 103 and the flat surface molding surfaces 103a, 105a of the movable mold 105 that do not correspond to the concave groove 103d is doubled. Further, a foam layer 26 is formed between the solid portions 19 formed in the vicinity of the flange portion forming surfaces 103c and 105c without any gap, and the welding rib 27 is formed in the concave groove 105d. At the time of filling with the thermoplastic resin R, the distance D1 between the non-corresponding portions of the flange-shaped molding surfaces 103c and 105c corresponding to the concave groove 105d is greater than the distance D2 between the non-corresponding portions of the flat-surface molding surfaces 103a and 105a Therefore, the expansion ratio of the thermoplastic resin R in the portion not corresponding to the concave groove 105d between the flange portion forming surfaces 103c and 105c is larger than that in the space portion 23 forming portion between the flat portion forming surfaces 103a and 105a. Lower. Therefore, the space portion 23 is not formed between the flange portion molding surfaces 103c and 105c.

このようにして得られたダクトパネル３の溶着リブ２７をインストルメントパネル本体１の裏面に当接させて振動溶着により接合することにより、ダクトパネル３とインストルメントパネル本体１とが組み合わされて内部に断面略矩形状のデフロスターエア通路１２が形成される。   The welding rib 27 of the duct panel 3 obtained in this way is brought into contact with the back surface of the instrument panel main body 1 and joined by vibration welding, whereby the duct panel 3 and the instrument panel main body 1 are combined to form an interior. A defroster air passage 12 having a substantially rectangular cross section is formed.

したがって、本実施形態によれば、ソリッド部１９の内部に、熱可塑性樹脂Ｒの存在しない空間部２３が形成されるので、ソリッド部１９の内部に隙間なく発泡層を形成する場合に比べ、平面部１３を軽量化し、かつ平面部１３の断熱性を高めることができる。その結果、ダクトパネル３全体を軽量化し、その断熱性を高めることができる。   Therefore, according to the present embodiment, since the space portion 23 in which the thermoplastic resin R does not exist is formed inside the solid portion 19, compared with the case where the foamed layer is formed without gaps inside the solid portion 19, The part 13 can be reduced in weight, and the heat insulation of the plane part 13 can be improved. As a result, the entire duct panel 3 can be reduced in weight and its heat insulation can be enhanced.

また、ソリッド部１９の表裏両面を発泡層からなる橋絡部２１により橋絡するので、大幅な重量増大や断熱性の大幅な低下を招くことなく、ソリッド部１９の内部を空間部２３のみで構成する場合に比べ、平面部１３の面剛性を高めることができる。   Further, since both the front and back surfaces of the solid portion 19 are bridged by the bridging portion 21 made of a foam layer, the interior of the solid portion 19 is formed only by the space portion 23 without causing a significant increase in weight or a significant decrease in heat insulation. Compared with the case where it comprises, the surface rigidity of the plane part 13 can be improved.

また、橋絡部２１が格子状に形成されるので、同方向に延びる突条１７間の強度をこれと交差する突条１７により補って、平面部１３の面剛性をより高めることができる。   Moreover, since the bridging portion 21 is formed in a lattice shape, the strength between the ridges 17 extending in the same direction can be supplemented by the ridges 17 intersecting with the ridges 17, and the plane rigidity of the flat portion 13 can be further increased.

また、上述のように、固定型１０３及び可動型１０５の少なくとも一方に凹条溝１０３ｄを設けるだけで、従来からあるコアバック法によりダクトパネル３を容易にかつ確実に得ることができる。   Further, as described above, the duct panel 3 can be easily and reliably obtained by the conventional core back method only by providing the concave groove 103d in at least one of the fixed mold 103 and the movable mold 105.

なお、本実施形態では、格子状に交差する複数本の突条１７を上記ソリッド部１９に突設するとともに、橋絡部２１を格子状に形成した。しかし、突部及び橋絡部２１の形状はこれに限らず、突部は、ソリッド部１９の表裏両面の一方の面に部分的に突設されたものであればよい。例えば、図６に示すように、上記複数本の突条１７に代えて、複数個の平面視円形状の突部２９が上記ソリッド部１９に突設され、上記橋絡部２１が上記突部２９に対応して互いに間隔を空けて円形短柱状に形成されるようにしてもよい。したがって、図６では、空間部２３は平面部１３全体に亘って連続している。また、この場合、凹条溝１０３ｄに代えて、突部２９に対応する凹部を固定型１０３の平面部成形面１０３ａに設けることにより、本実施形態と同様に、ダクトパネル３を成形することができる。   In the present embodiment, a plurality of protrusions 17 intersecting in a lattice shape are provided on the solid portion 19 and the bridging portion 21 is formed in a lattice shape. However, the shape of the protrusion and the bridging portion 21 is not limited to this, and the protrusion may be a portion that protrudes partially on one of the front and back surfaces of the solid portion 19. For example, as shown in FIG. 6, instead of the plurality of protrusions 17, a plurality of circular protrusions 29 in plan view are provided on the solid part 19, and the bridging part 21 is the protrusion. It may be formed in the shape of a circular short column with a space from each other corresponding to 29. Therefore, in FIG. 6, the space portion 23 is continuous over the entire plane portion 13. In this case, the duct panel 3 can be molded in the same manner as in the present embodiment by providing a concave portion corresponding to the projection 29 on the flat surface molding surface 103a of the fixed mold 103 instead of the concave groove 103d. it can.

また、本実施形態及び図６の例では、突条１７や突部２９を上記ソリッド部１９の反開放側の面に突設し、凹条溝１０３ｄや凹部を固定型１０３の平面部成形面１０３ａに設けたが、反対に、突条１７や突部２９を上記ソリッド部１９の開放側の面に突設し、凹条溝１０３ｄや凹部を可動型１０５の平面部成形面１０５ａに設けてもよい。また、突条１７や突部２９を上記ソリッド部１９の表裏両面に突設し、凹条溝１０３ｄや凹部を固定型１０３及び可動型１０５の平面部成形面１０３ａ，１０５ａに設けてもよい。   Further, in the present embodiment and the example of FIG. 6, the protrusions 17 and the protrusions 29 are provided on the surface of the solid part 19 on the side opposite to the open side, and the grooves 103 d and the recesses are formed on the flat surface forming surface of the fixed mold 103. On the contrary, the protrusion 17 and the protrusion 29 are provided on the open side surface of the solid part 19, and the groove 103 d and the recess are provided on the flat surface molding surface 105 a of the movable mold 105. Also good. Further, the protrusions 17 and the protrusions 29 may be provided on both the front and back surfaces of the solid part 19, and the groove 103 d and the recess may be provided on the flat surface molding surfaces 103 a and 105 a of the fixed mold 103 and the movable mold 105.

また、上記実施形態では、ダクトパネル３に本発明を適用した例を示したが、本発明は、インストルメントパネル本体、ドアトリム、トランクボード等の軽量化や断熱性向上が求められる他の用途の発泡パネルにも適用できる。   Moreover, in the said embodiment, although the example which applied this invention to the duct panel 3 was shown, this invention is the other use for which weight reduction and heat insulation improvement of an instrument panel main body, a door trim, a trunk board, etc. are calculated | required. It can also be applied to foam panels.

本発明は、平面部を有する熱可塑性樹脂製の発泡パネルとして有用である。   The present invention is useful as a foam panel made of a thermoplastic resin having a flat portion.

３ ダクトパネル（発泡パネル）
１３ 平面部
１７ 突条（突部）
１９ ソリッド部
２１ 橋絡部
２３ 空間部
２９ 突部
１０１ 成形型
１０３ 固定型
１０３’ 成形面
１０３ａ 平面部成形面（第１成形面）
１０３ｄ 凹条溝（凹部）
１０５ 可動型
１０５’ 成形面
１０５ａ 平面部成形面（第２成形面）
１０７ キャビティ
Ｒ 熱可塑性樹脂 3 Duct panel (foam panel)
13 Plane section
17 Projections (projections)
19 Solid part 21 Bridging part 23 Space part 29 Projection part 101 Mold 103 Fixed mold 103 'Molding surface 103a Flat part molding surface (first molding surface)
103d concave groove (concave)
105 movable mold 105 ′ molding surface 105a flat surface molding surface (second molding surface)
107 Cavity R Thermoplastic resin

Claims (3)

平面部(13)を有する熱可塑性樹脂製の発泡パネルであって、
上記平面部(13)は、表裏両面を連続して構成し、少なくとも表裏両面の一方の面に突部(17,29)が部分的に突設されたソリッド部(19)と、
該ソリッド部(19)の内部に設けられた空間部(23)と、
該空間部(23)に上記突部(17,29)に対応して設けられ、上記ソリッド部(19)の表裏両面を橋絡する発泡層からなる橋絡部(21)とを備えたことを特徴とする発泡パネル。 A foam panel made of a thermoplastic resin having a flat portion (13),
The flat surface portion (13) is configured by continuously forming both front and back surfaces, and at least one surface of the front and back surfaces has a protrusion (17, 29) partially protruding thereon, and a solid portion (19),
A space part (23) provided inside the solid part (19);
Provided in the space portion (23) corresponding to the protrusions (17, 29), and a bridging portion (21) made of a foam layer bridging both the front and back surfaces of the solid portion (19). Foam panel characterized by. 請求項１に記載の発泡パネルにおいて、
上記突部(17,29)は、互いに格子状に交差する複数本の突条であることを特徴とする発泡パネル。 The foam panel according to claim 1,
The foamed panel, wherein the protrusions (17, 29) are a plurality of protrusions intersecting each other in a lattice shape. 請求項１又は２に記載の発泡パネルを成形する方法であって、
上記平面部(13)の表裏両面の一方の面を成形する第１成形面(103a)を有する固定型(103)と、上記平面部(13)の表裏両面の他方の面を成形する第２成形面(105a)を有する可動型(105)とを備え、上記第１成形面(103a)及び第２成形面(105a)の少なくとも一方に凹部(103d)が形成された成形型(101)を用意し、
上記成形型(101)を型閉じして固定型(103)と可動型(105)との間にキャビティ(107)を形成し、この状態から、熱可塑性樹脂(R)を上記キャビティ(107)内に射出充填し、上記熱可塑性樹脂(R)の成形面(103',105')近傍にソリッド部(19)が形成され始めた時点で、上記可動型(105)を固定型(103)から離れる方向に後退させてキャビティ(107)容積を拡大させて上記熱可塑性樹脂(R)を発泡させることにより、上記第１成形面(103a)近傍及び第２成形面(105a)近傍にソリッド部(19)を形成するとともに上記凹部(103d)内に上記突部(17,29)を形成し、かつ該ソリッド部(19)が、上記凹部(103d)対応箇所では、熱可塑性樹脂(R)の発泡膨張により形成された発泡層からなる橋絡部(21)により橋絡される一方、上記凹部(103d)非対応箇所では、熱可塑性樹脂(R)の過発泡により形成された空間部(23)により分離された段階で、上記可動型(105)の後退を止めて上記熱可塑性樹脂(R)を固化することにより上記平面部(13)を形成することを特徴とする発泡パネルの成形方法。 A method for molding a foam panel according to claim 1 or 2,
A fixed mold (103) having a first molding surface (103a) for molding one surface of both surfaces of the flat surface portion (13), and a second mold for forming the other surface of the front and back surfaces of the flat surface portion (13). A movable mold (105) having a molding surface (105a), and a molding die (101) having a recess (103d) formed on at least one of the first molding surface (103a) and the second molding surface (105a). Prepare
The mold (101) is closed to form a cavity (107) between the fixed mold (103) and the movable mold (105) .From this state, the thermoplastic resin (R) is removed from the cavity (107). When the solid part (19) starts to be formed near the molding surface (103 ′, 105 ′) of the thermoplastic resin (R), the movable mold (105) is fixed to the fixed mold (103). The thermoplastic resin (R) is expanded by retreating in a direction away from the cavity (107) to expand the volume of the cavity (107), so that a solid part is formed in the vicinity of the first molding surface (103a) and the second molding surface (105a). (19) and the protrusion (17, 29) is formed in the recess (103d), and the solid portion (19) is the thermoplastic resin (R) in the corresponding portion of the recess (103d). On the other hand, in the portion not corresponding to the recess (103d), a space formed by over-foaming of the thermoplastic resin (R) ( 23) In separate steps, the molding method of the foam panel, and forming the planar portion (13) by solidifying the movable mold (105) the thermoplastic resin stop retraction of (R).
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