WO2020013118A1 - Composite molded article provided with fittings, vehicle step provided with fittings, and method for producing composite molded article provided with fittings - Google Patents

Composite molded article provided with fittings, vehicle step provided with fittings, and method for producing composite molded article provided with fittings Download PDF

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Publication number
WO2020013118A1
WO2020013118A1 PCT/JP2019/026963 JP2019026963W WO2020013118A1 WO 2020013118 A1 WO2020013118 A1 WO 2020013118A1 JP 2019026963 W JP2019026963 W JP 2019026963W WO 2020013118 A1 WO2020013118 A1 WO 2020013118A1
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WO
WIPO (PCT)
Prior art keywords
molded body
heating medium
molded article
fixture
composite molded
Prior art date
Application number
PCT/JP2019/026963
Other languages
French (fr)
Japanese (ja)
Inventor
山路　弘行
今成　大典
常盤　知生
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株式会社ジェイエスピー
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Publication date
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Publication of WO2020013118A1 publication Critical patent/WO2020013118A1/en

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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
    • 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
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • 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
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • 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
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R3/00—Arrangements of steps or ladders facilitating access to or on the vehicle, e.g. running-boards
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
    • C08J5/08—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials glass fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/228—Forming foamed products

Definitions

  • the present invention relates to a composite molded article with a fixture and a method for producing the same, and more particularly to a composite molded article with a fixture used as a vehicle step and a method for producing the same.
  • Patent Documents 1 and 2 disclose a hollow blow molded article in which a soft parison formed by extruding a resin melt of a thermoplastic resin is blow-molded in a molding die. Is formed, and a foamed particle filling tube is driven into the wall of the hollow blow-molded body to fill the hollow blow-molded body with the thermoplastic resin foamed particles.
  • the composite molded body obtained by such a manufacturing method is superior in bending rigidity to a molded body composed of only the hollow blow molded body, and even if the thickness of the skin material is reduced and the weight is reduced, only the hollow blow molded body is used. It was possible to prepare a molded article having a bending rigidity equal to or higher than that of the formed molded article. Therefore, such composite molded articles have begun to be used in various applications in recent years because of their excellent bending rigidity and light weight.
  • the above-mentioned composite molded body has a mounting strength, specifically, the composite molding of the fixture, when the fixture is attached to the composite molded body. There is a problem that the pull-out strength from the body tends to decrease.
  • the present invention has been made in view of the problems of the background art described above, and an object thereof is to provide a composite molded article with a fixture excellent in lightness and excellent in pull-out strength of the fixture, and a method of manufacturing the same. It is to propose.
  • the present invention provides a composite molded article with a fixture and a method for producing the same according to the following [1] to [8].
  • a composite molded body with a fixture A foamed particle molded body composed of a plurality of thermoplastic resin foamed particles that are heat-fused with each other, and a skin material composed of a thermoplastic resin hollow molded body, wherein the foamed particle molded body is formed inside the skin material.
  • the skin material is a plurality of heating medium supply pipe traces formed by a heating medium supply pipe that supplies a heating medium for heating and fusing the thermoplastic resin foam particles filled in the hollow portion of the thermoplastic resin hollow molded article.
  • the fixture is attached between two traces of the heating medium supply pipe, The distance between the two heating medium supply pipe traces is 400 mm or less, The distance between the attachment and one of the two heating medium supply pipe traces is 180 mm or less, Composite molded body with fittings.
  • the foamed particles thus filled are heated and fused to each other to form a foamed particle molded product, and the inner surface of the thermoplastic resin hollow molded product and the foamed particle molded product are adhered to each other.
  • a first step of obtaining a composite molded article of a skin material and a foamed particle molded article located inside the skin material The fixing member is fixed to the composite molded body by fastening the fastening member by penetrating the fastening member through the skin material and the mounting member, and the composite molded body and the fixing member fixed to the composite molded body are fixed.
  • the distance between the two heating medium supply pipes is set to 400 mm or less, and the two heating medium supply pipes are inserted across the part of the composite molded body to which the fixture is attached, and The distance between the heating medium supply pipe and one of the two heating medium supply pipes is set to 180 mm or less, and the heating medium supply pipe is inserted into the thermoplastic resin hollow molded body and heated.
  • the heating medium supply pipe is inserted across the part where the fixture for the skin material is to be attached, and A heating medium supply pipe is inserted into a close position (a position of 180 mm or less) to heat-mold the filled foamed particles. Therefore, even if the thickness of the skin material is thin, the skin around the portion where the mounting fixture is to be attached is provided. The peel strength between the material and the foamed particle molded body is improved, so that it is lightweight and the pull-out strength of the fixture attached to the site is high.
  • FIG. 2 is a perspective view showing the vehicle step shown in FIG. 1 from obliquely below.
  • FIG. 2 is an enlarged cross-sectional view of a portion along the line AA in FIG. 1 (portion where a fixture is attached). It is sectional drawing which showed a part of manufacturing apparatus of a composite molded object notionally.
  • FIG. 1 is a perspective view showing an embodiment of a vehicle step, which is a composite molded article with a fixture according to the present invention, from an obliquely upper side
  • FIG. 2 is a perspective view showing the vehicle step from an obliquely lower side.
  • FIG. 3 is an enlarged cross-sectional view of a portion along the line AA in FIG. 1 (portion where the mounting fixture is attached).
  • the vehicle step 1 includes a mounting having a composite molded body 10 and three mounting tools 50 fixed to the composite molded body 10 for attaching the composite molded body to another. It is formed in a composite molded body with a tool.
  • the upper surface of the composite molded body in a state of being attached to the vehicle body is referred to as the upper surface.
  • a lower surface a lower surface in the vertical direction of the vehicle body.
  • the composite molded body 10 includes a skin material 11 and a foamed particle molded body 12.
  • the skin material 11 is made of a thermoplastic resin and is molded as a thermoplastic resin hollow molded body having a hollow portion (hereinafter, referred to as “hollow molded body”).
  • the foamed particle molded body 12 is made up of a plurality of thermoplastic resin foamed particles (hereinafter, referred to as “foamed particles”) which are mutually heat-fused.
  • the foamed particle molded body 12 is formed in a hollow portion of the skin material 11.
  • the foamed particle molded body 12 is adhered to the inner surface of the skin material 11.
  • the foamed particle molded body 12 is formed by filling the hollow portion of the hollow molded body with foamed particles, and heating and fusing the foamed particles to each other. Heat fusion of the foamed particles is performed by inserting a heating medium supply pipe into the hollow molded body and supplying the heating medium from the heating medium supply pipe to the hollow portion. Further, by supplying a heating medium from the heating medium supply pipe to the hollow portion, the skin material 11 and the foamed particle molded body 12 are bonded to each other.
  • the attachment 50 is fixed to the composite molded body 10 by a fastening member 51. The fastening member 51 penetrates the attachment 50 and the skin material 11 to be fastened.
  • the skin material 11 has a trace 13 of a blow pipe, a trace 14 of a foamed particle filling pipe, and a trace 15 of a heating medium supply pipe.
  • the blow pipe trace 13 is formed by a blow pipe that supplies air to a hollow portion when the skin material 11 is manufactured.
  • the foam particle filling tube trace 14 is formed by a foam particle filling tube that fills the hollow particles of the skin material 11 with the foam particles.
  • the heating medium supply pipe trace 15 is formed by a heating medium supply pipe that supplies a medium for heating the filled expanded particles to the hollow portion.
  • the vehicle step 1 according to the illustrated embodiment has two traces of the blow pipe 13, one trace of the foamed particle filling pipe 14, and nine traces of the heating medium supply pipe 15.
  • the first wall 11a and the second wall 11b are fused only at their peripheral edges to form a hollow portion. That is, the hollow molded body is formed by fusing the first wall 11a and the second wall 11b only at their peripheral edges, and inside the hollow molded body, the first wall 11a, the second wall 11b, There is no rib formed by abutting and fusing at positions other than the peripheral edge.
  • the hollow molded body may have a rib structure as long as the weight can be reduced.
  • the outer shape of the hollow molded body constituting the skin material 11 is formed in a long plate-like body attached below the door opening of the vehicle body. Specifically, it is formed in a plate-like body of about 2000 ⁇ 200 ⁇ 100 mm.
  • the hollow molded body has a step portion 20 and a mounting portion 21 and is formed in a substantially L-shaped cross section.
  • the step portion 20 has a substantially flat plate shape that extends outward in a substantially horizontal direction from below the door opening when attached to the vehicle body.
  • the mounting portion 21 is formed to protrude upward in the width direction inside (the vehicle body side) of the step portion 20.
  • the first wall 11a forms an upper surface of the step portion 20.
  • an uneven slip prevention portion 22 for preventing a slip when the occupant places his / her foot extends in the length direction.
  • the second wall 11b forms a lower surface of the step portion 20.
  • a plurality of mounting portions 23 are formed, which are portions for fixing a mounting tool (metal stay) 50 to the vehicle body. In the illustrated embodiment, three concave mounting portions 23 are formed.
  • the traces of the blow tube 13, the traces of the foamed particle filling tube 14, and the traces of the heating medium supply tube 16 are preferably formed on the second wall 11 b forming the lower surface of the step portion 20 in consideration of the appearance.
  • all of the two blow pipe traces 13, one foamed particle filling pipe trace 14, and the nine heating medium supply pipe traces 15, as shown in FIG. It is formed on the two walls 11b.
  • a thermoplastic resin such as a polypropylene resin, a polyethylene resin, and a polystyrene resin can be used.
  • a polypropylene-based resin is preferred because of its excellent balance between mechanical strength and heat resistance.
  • the skin material 11 is made of a fiber-reinforced thermoplastic resin containing a reinforcing fiber in the thermoplastic resin.
  • the skin material 11 is composed of a fiber-reinforced polypropylene resin containing a reinforcing fiber in the polypropylene resin.
  • the content of the reinforcing fibers in the fiber-reinforced thermoplastic resin is preferably from 10 to 30% by weight, and more preferably from 12 to 20% by weight.
  • the content of the reinforcing fibers is 10% by weight or more, the hollow molded body as the skin material 11 is more excellent in bending rigidity.
  • the content of the reinforcing fiber is 30% by weight or less, molding of the hollow molded body becomes easy.
  • the hollow molded body as the skin material 11 may have a multilayer structure.
  • the outer layer may be made of a fiber-reinforced thermoplastic resin
  • the inner layer may be made of a fiber-reinforced thermoplastic resin containing a smaller amount of reinforcing fibers than the outer layer or a thermoplastic resin containing no reinforcing fibers. it can.
  • the outer layer may be made of a fiber-reinforced polypropylene resin
  • the inner layer may be made of a fiber-reinforced polypropylene resin containing a smaller amount of reinforcing fibers than the outer layer or a polypropylene resin containing no reinforcing fibers.
  • the expanded particles filled in the hollow portion are a polypropylene resin
  • the expanded particle molded article 12 and the hollow molded article can be firmly fused together.
  • the bending rigidity of the composite molded body can be further increased.
  • the content of the reinforcing fibers in this case may be any as long as the content of the entire multilayered reinforcing fiber is within the above range.
  • polypropylene resin examples include homopolypropylene (h-PP), random polypropylene (r-PP) such as propylene-ethylene random copolymer and propylene-ethylene-butene random copolymer, block polypropylene (b-PP) or Examples thereof include mixtures thereof.
  • the block polypropylene is not only a block copolymer such as a propylene-ethylene block copolymer, but also a polymer obtained by polymerizing propylene in the presence of an olefin-based thermoplastic elastomer or an olefin-based rubber, or a polypropylene and an olefin-based thermoplastic elastomer. And those kneaded with olefin rubber.
  • the type of the reinforcing fibers include inorganic fiber materials such as glass fiber, glass wool, and carbon fiber; and organic fiber materials such as cellulose nanofiber.
  • the thickness of the hollow molded body which is the skin material 11, is preferably 1 to 4 mm, more preferably 1.5 to 3 mm in average thickness in consideration of strength and lightness. If the average thickness is less than 1 mm, the strength is not sufficient. On the other hand, if the average thickness exceeds 4 mm, the lightness is impaired.
  • the average thickness (average thickness) of the hollow molded body is measured as follows. Cross sections perpendicular to the longitudinal direction at a total of three positions selected from the central portion in the longitudinal direction and the vicinity of both ends in the longitudinal direction of the hollow molded body are used for measuring the wall thickness.
  • the thickness (wall thickness) of six vertical cross sections in the thickness direction is measured at regular intervals along the circumferential direction of each vertical cross section.
  • the obtained thickness values at the 18 locations are arithmetically averaged, and the average value becomes the average thickness of the hollow molded body.
  • the foamed particle molded body 12 located inside the skin material 11 filled in the hollow portion of the hollow molded body as the skin material 11 includes a polypropylene resin, a polyethylene resin, a polystyrene resin, and a polyolefin resin.
  • a foam using a composite resin of a resin and a polystyrene resin, polyurethane or the like as a base resin can be used.
  • the type of the resin forming the expanded particle molded body 12 is the same as the resin of the hollow molded body that is the skin material 11.
  • a foamed particle molded body using a polypropylene resin as a base resin is preferable.
  • the fusion property between the skin material 11 and the foamed particle molded body 12 can be improved. And the composite molded body 10 having more excellent bending rigidity can be obtained.
  • the polypropylene resin constituting the expanded particles propylene homopolymer, propylene-ethylene random copolymer, propylene-butene random copolymer, and propylene-ethylene-butene random copolymer are preferable.
  • the foamed particles the surface of a foamed core layer made of a polypropylene resin, which is a foamed layer, is coated with a resin having a melting temperature or a softening temperature lower than the melting temperature of the polypropylene resin forming the core layer.
  • foamed particles having a multilayer structure as described above it is possible to use foamed particles having a multilayer structure as described above or foamed particles comprising a base resin containing a polypropylene-based resin polymerized by a metallocene-based polymerization catalyst. By using these foamed particles, the foamed particles can be fused together with a relatively low heating medium heating pressure.
  • the apparent density of the expanded bead 12 is not particularly limited, and a commonly used apparent density can be widely used. However, since the balance between light weight and mechanical strength is excellent, the apparent density is 30 to 150 kg / m2. 3 , more preferably 30 to 120 kg / m 3 , and particularly preferably 35 to 90 kg / m 3 .
  • the apparent density of the foamed particle molded body 12 means a value obtained by dividing the weight of the foam by the volume of the foam. The volume of the foam can be determined by a method of measuring from the rise in water level when the foam is submerged in water (submersion method) or the like.
  • the apparent density of the foamed particle molded body 12 located inside the skin material 11 is obtained, for example, by measuring the weight of a sample having a predetermined volume cut out from the foamed particle molded body, and dividing the weight by the volume. be able to. Further, the ratio of the weight of the foamed particle molded body 12 to the weight of the hollow molded body constituting the skin material 11 is preferably 0.2 to 0.5 in consideration of a balance between strength and lightness. More preferably, it is from 0.25 to 0.35.
  • the attachment 50 is attached to the composite molded body 10 as described above.
  • the attachment 50 may be any fitting such as a vehicle body or the like to which the composite molded body 10 can be attached, and the specific structure is not limited.
  • a metal member having strength can be widely used as the material of the attachment 50.
  • an attachment (iron stay) 50 to a vehicle body is attached to an attachment portion 23 formed on the second wall 11b by a fastening member (blind rivet) 51.
  • a rivet as the fastening member 51 from the viewpoint of increasing the pull-out strength.
  • the mounting method of the mounting tool 50 is not limited to rivets.
  • the fixture 50 can be fixed by embedding an insert nut in the composite molded body 10 in advance and fastening the insert nut and a bolt.
  • the blind rivet has a rivet body part fastened to an object and a mandrel part for fastening the rivet body part.
  • the rivet body portion is inserted into the composite molded body 10 via the fixture 50.
  • the mandrel formed integrally with the rivet body is pulled out and broken, so that a part of the rivet body is buckled, and the buckled portion is removed.
  • the rivet body portion is fastened by being hooked on the inside of the composite molded body 10 (the skin material 11 on the foamed particle molded body side). Thereby, the fixture 50 can be attached to the composite molded body 10.
  • a pop rivet POP Rivets
  • a pop HC rivet POP HC Rivets manufactured by Pop Rivet Fastener Co., Ltd.
  • Pop Rivet Fastener Co., Ltd. a pop rivet
  • the buckled portion spread in a planar manner, and the rivet portion was fastened so as to be sandwiched between the surfaces, so that even a small number of the rivet portions were attached to the composite molded body 10.
  • pop HC rivets POP HC Rivets
  • the attachment 50 is attached between two adjacent traces 15 of the heating medium supply pipe.
  • the distance between the two heating medium supply pipe traces 15 is 400 mm or less.
  • the distance between the fixture 50 attached to the composite molded body 10 and the heating medium supply pipe trace 15 of one of the two heating medium supply pipe traces is 180 mm or less.
  • the two heating medium supply pipes are placed at an interval of 400 mm or less with the mounting part 23 interposed therebetween, and one of the heating medium supply pipes is positioned at a distance of 180 mm or less from the mounting part 23. Then, the heating medium supply pipe is inserted into the skin material 11.
  • two adjacent heating medium supply pipe traces 15 are located at an interval of 400 mm or less across the fixture 50, and at least one heating medium supply pipe trace 15 is 180 mm or less from the fixture 50. Will be located in the vicinity.
  • the distance between the fixture 50 and one of the two adjacent heating medium supply pipe traces 15 is more preferably 150 mm or less, and particularly preferably 130 mm or less. preferable.
  • the distance between the two adjacent heating medium supply pipe traces 15 is preferably 350 mm or less, and more preferably 300 mm or less.
  • the distance between the fixture 50 and one of the two adjacent heating medium supply pipe traces 15 is approximately 30 mm or more. Preferably, it is 50 mm or more.
  • the distance between the two heating medium supply pipe traces 15 is preferably approximately 100 mm or more, more preferably 150 mm or more, More preferably, it is 180 mm or more.
  • the fixture 50 be fixed to the composite molded body 10 by approaching one of the two traces of the heating medium supply pipe 15.
  • the distance between the fixture 50 and the other one of the two heating medium supply pipe traces 15 is preferably 200 mm or less, more preferably 180 mm or less, Particularly preferably, it is 160 mm or less.
  • the distance between the fixture 50 and the trace of the heating medium supply pipe 15 is such that the center points of the two traces of the heating medium supply pipe 15 located in the vicinity of the fixture 50 are connected by a straight line.
  • the load when the skin material 11 and the foamed particle molded body 12 are separated at the time of pulling out the attachment 50 is preferably 1.5 kN or more, more preferably 1.8 kN or more. It is particularly preferably 2.0 kN or more.
  • the load when the skin material 11 and the foamed particle molded body 12 are separated is within the above range, the pull-out strength of the fixture 50 attached to the attachment portion 23 becomes strong, and the composite molding with the fixture is highly reliable. Be a body.
  • the load at the time of peeling of the skin material 11 and the foamed particle molded body 12 at the time of pulling out the fixture 50 can be measured, for example, using a tensile tester as follows.
  • the composite molded body with the fixture is fixed to a jig for a tensile test (for measuring a load), and in a tensile test, the composite molded body is uniformly spread in a direction perpendicular to a fusion surface between the skin material 11 and the foamed particle molded body 12.
  • the fixture 50 and the tensile tester are fixed so that an appropriate load is applied.
  • a tensile test is performed by applying a tensile load at a predetermined speed by a tensile tester, and the load at the time of peeling is determined by measuring the load at the time when the skin material 11 is peeled from the foamed particle molded body 12. Can be.
  • the tensile test when the skin material 11 peels off from the foamed particle molded body 12, a temporary decrease in the load with respect to the displacement appears in the displacement-load graph. Can be obtained.
  • the step 1 for a vehicle with a fixture formed of the composite molded article with the fixture described above fills a hollow portion of the thermoplastic resin hollow molded body with thermoplastic resin foam particles, and two or more thermoplastic resin hollow molded articles are provided in the thermoplastic resin hollow molded body.
  • a heating medium supply pipe By inserting a heating medium supply pipe and supplying a heating medium from the heating medium supply pipe, the filled thermoplastic resin foam particles are heated and fused to each other to form a foamed particle molded article and a thermoplastic resin hollow molding.
  • the fastening member is fixed to the composite molded body by fastening the fastening member by penetrating the fastening member through the skin material and the fixture, and the composite molded body has a fixture fixed to the composite molded body.
  • Composite with fixture It can be made by a production method and a second step of obtaining a feature.
  • a softened cylindrical parison or two sheet barisons formed by extruding a melt of a thermoplastic resin from a die are sandwiched by a split mold (mold 60), and then inserted into the parison.
  • the blow tube 61 is driven, and a pressurized gas (hereinafter, also referred to as blow air) such as air is blown into the parison through the blow tube 61.
  • blow air a pressurized gas
  • the parison swells in the cavity of the molding die 60 and is pressed against the inner wall of the molding die 60 to shape the parison, thereby forming a hollow molded body (blow molding).
  • the parison is brought into close contact with the inner wall of the mold while the blow air is being blown, by evacuating from the mold 60 side.
  • the formed hollow molded article more easily reflects the shape of the mold.
  • the slip prevention portion 22 formed on the upper surface of the step portion 20 of the skin material 11 and the attachment portion 23 formed on the lower surface are formed with high precision.
  • a thermoplastic resin for forming the outer layer and reinforcing fibers are supplied to an extruder to be in a molten state to obtain a molten resin for forming an outer layer.
  • a thermoplastic resin for forming the inner layer is supplied to an extruder to be in a molten state to obtain a molten resin for forming the inner layer.
  • a reinforcing fiber is supplied to an extruder as needed, and it is made into a molten state.
  • thermoplastic resin molten resin
  • molten resin molten resin
  • the laminated product is extruded from a die provided in an extruder (co-extrusion method).
  • the foamed thermoplastic resin particles are filled into the hollow molded body that is the formed skin material 11.
  • a foaming particle filling tube 62 is provided in a blow molding die 60, and after the blow molding, before the hollow molded body is cooled and solidified, the foaming particle filling process is performed. It can be performed by driving the tube 62 from the outside of the hollow molded body into the inside (hollow portion), and filling the foamed particles together with the compressed air through the driven foamed particle filling tube 62.
  • the filling of the expanded particles is preferably performed at a stage where the hollow molded body is in a softened state.
  • the foamed particle molded body 12 in which the foamed particles are fused to each other by the heating medium and the inner surface of the hollow molded body serving as the skin material 11 can be more reliably formed. Can be fused.
  • a heating medium is supplied to the foamed particles filled in the hollow molded body, and the foamed particles are heated and fused to each other.
  • a heating medium supply pipe 63 provided in a mold 60 for blow molding is inserted toward the inside of the hollow molded body, and the inserted heating medium supply This can be performed by supplying a heating medium (for example, steam) into the hollow molded body through the pipe 63.
  • the foamed particles heated by the supplied heating medium are fused together to form the foamed particle molded body 12.
  • the inner surface of the hollow molded body which is the skin material 11, and the portion of the foamed particle molded body 12 that comes into contact with the inner surface are fused.
  • the two heating medium supply pipes 63 are set to have a distance between the two heating medium supply pipes of 400 mm or less, and the composite molded body to which the fixture 50 is attached. 10 (mounting part 23), and the distance between the mounting part 23 and one of the two heating medium supply pipes 63 is set to 180 mm or less.
  • the heating medium supply pipe 63 is inserted and heated. Thereby, the fusion
  • the distance between the mounting portion 23 and one of the two heating medium supply pipes 63 is preferably 150 mm or less, particularly preferably 130 mm or less. Further, in the first step, it is preferable that the distance between the two heating medium supply pipes 63 is 350 mm or less, and the heating medium supply pipe 63 is inserted into the hollow molded body to heat the hollow molded body. More preferably, the distance between the tubes 63 is 320 mm or less. In addition, from the viewpoint that the fixture 50 can be stably fixed, the distance between the attachment portion 23 and one of the two heating medium supply pipes 63 is preferably about 30 mm or more. , More preferably 50 mm or more.
  • the distance between the two heating medium supply pipes 63 is set to 100 mm or more, and the heating medium supply pipe is inserted into the hollow molded body.
  • the heating medium 63 is inserted and heated, and the distance between the two heating medium supply pipes 63 is more preferably 150 mm or more, and further preferably 180 mm or more.
  • the attachment portion 23 be provided closer to one of the two heating medium supply pipe traces 15.
  • the distance between the other heating medium supply pipe 63 of the two heating medium supply pipes 63 is set to 200 mm or less, and the heating medium supply pipe 63 is inserted into the hollow molded body and heated. Is preferred.
  • the distance between the two heating medium supply pipes 63 and the other heating medium supply pipe 63 is more preferably 180 mm or less, and particularly preferably 160 mm or less.
  • the distance between the mounting portion 23 and the heating medium supply pipe 63 is such that a straight line connects the center points of the two heating medium supply pipes 63 located near the mounting portion 23, and The midpoint of the line segment having both ends at the point where the side end of the portion 23 intersects is the center point of the mounting portion 23, and the distance between the center point of the mounting portion 23 and the center point of the heating medium supply pipe 63.
  • the apparatus for manufacturing a composite molded body includes an extruder, a die (these are not shown), and a molding die 60 for molding.
  • the molding die 60 includes a blow tube 61 for supplying blow air for blow molding a softened parison to form a hollow molded body, a foamed particle filling tube 62 for filling the formed hollow molded body with foamed particles, and filling.
  • Heating medium supply pipes 63 for supplying a heating medium for heating and fusing the expanded particles to each other are provided.
  • FIG. 4 shows the heating medium supply step described above, in which the heating medium supply pipe 63 is inserted into the hollow molded body that is the skin material 11.
  • the blow tube 61, the expanded particle filling tube 62, and the heating medium supply tube 63 are configured to be insertable into the molding die 60, respectively.
  • the blow tube 61 is configured to be capable of supplying blow air
  • the expanded particle filling tube 62 is capable of supplying expanded particles
  • the heating medium supply tube 63 is configured to be capable of supplying a heating medium (for example, steam).
  • the illustrated mold 60 is formed as a split mold, and includes a mold piece 60a for forming the first wall 11a forming the upper surface of the skin material 11, and a second wall 11b forming the lower surface. And a molding die piece 60b for molding.
  • the blow tube 61, the foamed particle filling tube 62, and the heating medium supply tube 63 are all arranged on a molding die piece 60b that forms the second wall 11b side forming the lower surface of the skin material 11.
  • a molding die piece 60b that forms the second wall 11b side forming the lower surface of the skin material 11.
  • the fixture 50 is fixed to the composite molded body 10 manufactured in the first step.
  • an attachment for example, a metal stay
  • a fastening member (blind rivet) 51 is attached to the skin material 11 and the attachment 50. Is inserted into the mounting portion 23 so as to penetrate through, and the fastening member (blind rivet) 51 is fastened and fixed.
  • a rivet is used as the fastening member 51, but the method of attaching the fixture 50 is not limited to this.
  • a bolt and a nut can be used as the fastening member 51.
  • an insert nut is embedded in the composite molded body 10 in advance, and the fixture 50 is fastened by fastening the insert nut and the bolt. 10 may be attached.
  • the vehicle step 1 with a fixture which is the above-described composite molded body with a fixture according to the present invention, can be attached to the vehicle body via the fixture 50 with a fastener such as a bolt.
  • a fastener such as a bolt.
  • the vehicle step 1 is composed of the composite molded body 10 composed of the skin material 11 made of a hollow molded body and the foamed particle molded body 12 located inside the skin material 11, It has sufficient rigidity and suppresses the occurrence of problems such as deformation and breakage.
  • the cushioning performance at the time of collision becomes a good step.
  • the hollow molded body which is the skin material 11, is reinforced by the foamed particle molded body 12 located inside thereof, so that the rib structure is eliminated, and the first wall 11a forming the upper surface and the lower wall 11a are formed. Since the second wall 11b forming the surface and the peripheral edge thereof are formed in a hollow molded body fused to each other, the weight of the vehicle step 1 can be reduced. By reducing the weight of the vehicle step 1, the labor required for mounting the vehicle step 1 can be reduced.
  • the step 1 for a vehicle which is a composite molded body with a fixture according to the present invention, includes the step of inserting the heating medium supply pipe 63 with the mounting portion 23 of the skin material 11 interposed therebetween during the production of the composite molded body 10.
  • the heating medium supply pipe 63 By inserting the heating medium supply pipe 63 into a position close to the position 23 (a position of 180 mm or less) to heat-mold the filled expanded particles, even if the skin material 11 has a small thickness, The peel strength between the skin material 11 and the foamed particle molded body 12 in the periphery is improved, and the pull-out strength of the fixture 50 attached to the attachment portion 23 is enhanced. Therefore, the vehicle step is lightweight and can be stably mounted on the vehicle body via the mounting tool 50.
  • a fixture having a shape as shown in FIG. 1 and having, as schematic dimensions, a length of the composite molded body of 2000 mm, a width of the step portion of 160 mm, a thickness of the step portion of 80 mm, and a height of the attachment portion of 120 mm.
  • a composite molded body (vehicle step) was prepared.
  • the production of the composite molded article was performed by the following method. First, a block polypropylene (MFR: 1.0 g / 10 min, density: 1.0 g / cm 3 ) obtained by adding a glass fiber (fiber length 0.8 mm) at a blending ratio of 15% by weight to an extruder having an inner diameter of 65 mm. And heated and kneaded at 210 ° C. to obtain a molten resin. Next, the molten resin was charged into an accumulator (a set temperature of 210 ° C.), and the molten resin was extruded from the accumulator into a cylindrical shape through a die to form a soft parison.
  • MFR 1.0 g / 10 min, density: 1.0 g / cm 3
  • the parison was sandwiched between split dies arranged immediately below the die.
  • the mold temperature was adjusted to 70 ° C.
  • a blow tube is driven into the parison, and at the same time, pressurized air of 0.50 MPa (G: gauge pressure) is blown from the blow tube into the parison.
  • G gauge pressure
  • a hollow molded body having an average thickness of 3.5 mm was formed.
  • a molding die having a molding cavity equivalent to the approximate dimensions of the vehicle step was used.
  • One tube with an outer diameter of 20 mm was used as a foamed particle filled tube, two tubes with an outer diameter of 4 mm were used as blow tubes, and nine tubes with an outer diameter of 8 mm were used as heating medium supply tubes.
  • Each tube was arranged in a molding die so as to have a positional relationship as shown in FIG.
  • the nine heating medium supply pipes are inserted into the softened hollow molded body from one divided mold toward the other divided mold, and the heating medium supply pipe is inserted into the hollow portion of the hollow molded body.
  • a foamed particle filled tube is inserted into the hollow molded body, and the propylene-ethylene random copolymer is passed through the foamed particle filled tube.
  • the steam of (G) was supplied for 10 seconds.
  • 0.4 MPa (G) steam was supplied from the heating medium supply pipe A group for 10 seconds while evacuating from the heating medium supply pipe B group.
  • steam of 0.4 MPa (G) is supplied from all the heating medium supply pipes A and B for 8 seconds to heat and fuse the foamed particles to each other, and to melt the inner surface of the hollow molded body and the foamed particles. I wore it. Thereafter, the compact is cooled until the pressure of the surface pressure gauge attached to the mold becomes 0.05 MPa (G), the heating medium supply pipe is extracted, the mold is opened, and the mold is released from the mold. A composite molded body was obtained.
  • the obtained composite molded article had the above-described approximate dimensions, the average thickness of the skin material was 3.5 mm, and the apparent density of the foamed particle molded article was 45 kg / m 3 .
  • a load load at the time of peeling
  • the measurement of the load at the time of peeling was performed by the following method using a tensile tester (Tensilon universal tester: manufactured by Orientec).
  • the composite molded body with the fixture attached so that the distance from the trace of the heating medium supply pipe was as shown in Table 1 was fixed to a load measuring jig such that the fixture was on the upper surface (the lower surface of the step was the upper surface).
  • the distance from the trace of one heating medium supply pipe and the distance from the trace of the other heating medium supply pipe are defined by the distance between the center points of the two traces of the heating medium supply pipe located near the fixture.
  • a straight line, the midpoint of a line segment having both ends at the point where the straight line intersects with the side end of the fixture is the center point of the fixture, and the center point of the fixture and the center of the trace of the heating medium supply pipe It means the respective distance between the points.
  • a composite molded article with a fixture that is excellent in lightness and excellent in the pull-out strength of the fixture for example, a relatively high vehicle height such as a pickup truck or some multipurpose sports cars can be provided. It can be widely used as a step in a tall vehicle.

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Abstract

A composite molded article provided with fittings, the composite molded article having exceptional lightness as well as exceptional pull-out strength of the fittings. A composite molded article (1) provided with fittings is equipped with: a composite molded article (10) having a foamed particle molded article (12) comprising a plurality of foamed thermoplastic resin particles heat-fused to each other and a skin material (11) comprising a thermoplastic resin hollow molded article, the foamed particle molded article (12) being formed inside the skin material (11) and bonded to the inner surface of the skin material (11); fittings (50) for fitting the composite molded article to another part; and fastening members (51) that penetrate the skin material and the fittings and fasten the fittings to the skin material. The skin material (11) has a plurality of heating medium supply pipe tracks (16) formed by heating medium supply pipes, and the fittings (50) are fitted between two heating medium supply pipe tracks (16). The distance between two heating medium supply pipe tracks (16) is 400 mm or less, and the distance between a fitting (50) and one heating medium supply pipe track (16) from among the two heating medium supply pipe tracks (16) is 180 mm or less.

Description

取付具付き複合成形体、取付具付き車両用ステップ及び取付具付き複合成形体の製造方法Composite molded article with fixture, vehicle step with fixture, and method of manufacturing composite molded article with fixture
　本発明は、取付具付き複合成形体及びその製造方法に関するもので、特に、車両用ステップとして使用される取付具付き複合成形体及びその製造方法に関するものである。 The present invention relates to a composite molded article with a fixture and a method for producing the same, and more particularly to a composite molded article with a fixture used as a vehicle step and a method for producing the same.
　一般にピックアップトラックや一部の多目的スポーツ車などの比較的車高の高い車両においては、フロントドアやリヤドア、バックドアなどのドアの開口部の下方に、乗降性や荷物の積み下ろし性が良好になるように、乗降用や足掛け用のステップが設けられている。
　このステップに関し、昨今、樹脂成形体が使われ始めている。樹脂成形体のステップとしては、中空部を有するブロー成形体からなるものがある。この従来のブロー成形体からなるステップにあっては、その機械的強度等を高めるために、リブ構造を有したものとするとともに肉厚の厚いものとされており、結果として製品重量は重いものとなっていた。 Generally, vehicles with relatively high heights, such as pickup trucks and some multi-purpose sports cars, have good boarding / unloading and luggage loading / unloading properties under the openings of front doors, rear doors, and back doors. As described above, steps for getting on and off and for footrest are provided.
Regarding this step, recently, resin molded articles have begun to be used. As a step of the resin molded body, there is a step formed of a blow molded body having a hollow portion. In the step of the conventional blow-molded body, in order to increase its mechanical strength, it is required to have a rib structure and a thick wall, and as a result, the product weight is heavy. It was.
　一方、中空状の樹脂製表皮材とその内部に充填された発泡粒子を成形してなる発泡粒子成形体とを備える複合成形体が知られている。
　この複合成形体を製造する方法として、例えば特許文献１、２などには、熱可塑性樹脂の樹脂溶融物を押し出して形成された軟化状態のパリソンを成形型内でブロー成形して中空ブロー成形体を形成し、この中空ブロー成形体の壁部に発泡粒子充填管を打ち込み該中空ブロー成形体内に熱可塑性樹脂発泡粒子を充填し、その後、同じく中空ブロー成形体の壁部に挿通した加熱媒体供給管を介して中空ブロー成形体内にスチームを供給して中空ブロー成形体内に充填した発泡粒子を加熱し、発泡粒子どうしを融着させて発泡粒子成形体とするとともに、発泡粒子成形体と中空ブロー成形体の内面とを融着させる方法が提案されている。ここで、製造する複合成形体の外観性を考慮し、上記した発泡粒子充填管及び加熱媒体供給管の本数が出来るだけ少なくなるように設計し、これらの跡が少ない複合成形体としている。 On the other hand, there is known a composite molded article including a hollow resin skin material and a foamed particle molded article formed by molding foamed particles filled therein.
As a method of manufacturing this composite molded article, for example, Patent Documents 1 and 2 disclose a hollow blow molded article in which a soft parison formed by extruding a resin melt of a thermoplastic resin is blow-molded in a molding die. Is formed, and a foamed particle filling tube is driven into the wall of the hollow blow-molded body to fill the hollow blow-molded body with the thermoplastic resin foamed particles. Steam is supplied into the hollow blow-molded body through a pipe to heat the foamed particles filled in the hollow blow-molded body, and the foamed particles are fused together to form a foamed particle molded body. There has been proposed a method of fusing the inner surface of a molded body with the molded body. Here, in consideration of the appearance of the composite molded article to be manufactured, the number of the above-described expanded particle filling pipe and heating medium supply pipe is designed to be as small as possible, and the composite molded article with few traces of these is obtained.
　このような製造方法で得られる複合成形体は、中空ブロー成形体のみで構成された成形体よりも曲げ剛性に優れ、表皮材の厚みを薄くして軽量化しても、中空ブロー成形体のみで構成された成形体と同等以上の曲げ剛性を有するものを調製することが可能であった。そこで、このような複合成形体は、曲げ剛性と軽量性に優れることから、近年、さまざまな用途で利用されはじめている。 The composite molded body obtained by such a manufacturing method is superior in bending rigidity to a molded body composed of only the hollow blow molded body, and even if the thickness of the skin material is reduced and the weight is reduced, only the hollow blow molded body is used. It was possible to prepare a molded article having a bending rigidity equal to or higher than that of the formed molded article. Therefore, such composite molded articles have begun to be used in various applications in recent years because of their excellent bending rigidity and light weight.
日本国特開平０６－１６６１１２号公報Japanese Patent Application Laid-Open No. 06-166112 日本国特開２００８－２７３１１７号公報Japanese Patent Application Publication No. 2008-273117
しかしながら、上述した複合成形体は、その表皮材の肉厚が薄いものである場合には、取付具を該複合成形体に取り付けた際に、その取付強度、具体的には取付具の複合成形体からの引抜強度が低下しやすくなると言う課題があった。 However, in the case where the thickness of the skin material is small, the above-mentioned composite molded body has a mounting strength, specifically, the composite molding of the fixture, when the fixture is attached to the composite molded body. There is a problem that the pull-out strength from the body tends to decrease.
本発明は、上述した背景技術が有する課題に鑑み成されたものであって、その目的は、軽量性に優れるとともに、取付具の引抜強度にも優れた取付具付き複合成形体及びその製造方法を提案することにある。 The present invention has been made in view of the problems of the background art described above, and an object thereof is to provide a composite molded article with a fixture excellent in lightness and excellent in pull-out strength of the fixture, and a method of manufacturing the same. It is to propose.
　上記した目的を達成するため、本発明は、次の〔１〕～〔８〕に記載した取付具付き複合成形体及びその製造方法とした。
　〔１〕取付具付き複合成形体であって、
　相互に加熱融着した複数の熱可塑性樹脂発泡粒子からなる発泡粒子成形体と、熱可塑性樹脂中空成形体からなる表皮材とを有し、上記発泡粒子成形体が上記表皮材の内部に形成されかつ上記表皮材の内面に接着された複合成形体と、
　上記複合成形体を他に取り付けるための取付具と、
　上記表皮材及び上記取付具を貫通して上記取付具を上記表皮材に締結する締結部材と、
を備え、
　上記表皮材は、熱可塑性樹脂中空成形体の中空部に充填された熱可塑性樹脂発泡粒子を加熱融着させるための加熱媒体を供給する加熱媒体供給管により形成された複数の加熱媒体供給管跡を有しており、
　上記取付具は、２つの加熱媒体供給管跡の間に取り付けられており、
　上記２つの加熱媒体供給管跡の間の距離が４００ｍｍ以下であり、
　上記取付具と、上記２つの加熱媒体供給管跡のうちの一方の加熱媒体供給管跡との距離が、１８０ｍｍ以下であることを特徴とする、
　取付具付き複合成形体。
　〔２〕上記取付具の引抜き時における、上記表皮材と上記発泡粒子成形体とが剥離する際の荷重が、１．５ｋＮ以上であることを特徴とする、上記〔１〕に記載の取付具付き複合成形体。
　〔３〕上記表皮材の平均肉厚が、１～４ｍｍであることを特徴とする、上記〔１〕または〔２〕に記載の取付具付き複合成形体。
　〔４〕上記表皮材が、熱可塑性樹脂中に強化繊維を含む繊維強化熱可塑性樹脂から構成される中空ブロー成形体であることを特徴とする、上記〔１〕～〔３〕のいずれかに記載の取付具付き複合成形体。
　〔５〕上記繊維強化熱可塑性樹脂中の強化繊維の含有量が、１０～３０重量％であることを特徴とする、上記〔４〕に記載の取付具付き複合成形体。
　〔６〕上記熱可塑性樹脂が、ポリプロピレン系樹脂であることを特徴とする、上記〔４〕または〔５〕に記載の取付具付き複合成形体。
　〔７〕上記発泡粒子成形体が、見掛け密度３０～１５０ｋｇ／ｍ３の熱可塑性樹脂発泡粒子成形体であることを特徴とする、上記〔１〕～〔６〕のいずれかに記載の取付具付き複合成形体。
　〔８〕上記発泡粒子成形体が、ポリプロピレン系樹脂発泡粒子成形体であることを特徴とする、上記〔７〕に記載の取付具付き複合成形体。
　〔９〕上記〔１〕～〔８〕のいずれかに記載の取付具付き複合成形体からなる、車体のドア開口部の下方に取り付けられる取付具付き車両用ステップ。
　〔１０〕複合成形体と、該複合成形体に固定された、該複合成形体を他に取り付けるための取付具とを有する取付具付き複合成形体の製造方法であって、
　熱可塑性樹脂中空成形体の中空部に熱可塑性樹脂発泡粒子を充填し、該熱可塑性樹脂中空成形体内に２つ以上の加熱媒体供給管を挿入して該加熱媒体供給管から加熱媒体を供給することにより上記充填した発泡粒子を相互に加熱融着させて発泡粒子成形体を形成するとともに熱可塑性樹脂中空成形体の内面と発泡粒子成形体とを接着させて、熱可塑性樹脂中空成形体からなる表皮材と、該表皮材の内部に位置する発泡粒子成形体との複合成形体を得る第一工程と、
　上記表皮材と取付具とに締結部材を貫通させて該締結部材を締結することにより上記複合成形体に取付具を固定し、複合成形体と、該複合成形体に固定された取付具とを有する取付具付き複合成形体を得る第二工程とを有し、
　上記第一工程において、２つの加熱媒体供給管を、２つの加熱媒体供給管の間の距離を４００ｍｍ以下として、取付具が取り付けられる複合成形体の部位を挟んで挿入するとともに、上記部位と、上記２つの加熱媒体供給管のうちの一方の加熱媒体供給管との距離を１８０ｍｍ以下として、熱可塑性樹脂中空成形体内に該加熱媒体供給管を挿入して加熱することを特徴とする、
　取付具付き複合成形体の製造方法。 In order to achieve the above object, the present invention provides a composite molded article with a fixture and a method for producing the same according to the following [1] to [8].
[1] A composite molded body with a fixture,
A foamed particle molded body composed of a plurality of thermoplastic resin foamed particles that are heat-fused with each other, and a skin material composed of a thermoplastic resin hollow molded body, wherein the foamed particle molded body is formed inside the skin material. And a composite molded body adhered to the inner surface of the skin material,
A mounting tool for mounting the composite molded body to another,
A fastening member that penetrates the skin material and the mounting tool and fastens the mounting tool to the skin material;
With
The skin material is a plurality of heating medium supply pipe traces formed by a heating medium supply pipe that supplies a heating medium for heating and fusing the thermoplastic resin foam particles filled in the hollow portion of the thermoplastic resin hollow molded article. Has,
The fixture is attached between two traces of the heating medium supply pipe,
The distance between the two heating medium supply pipe traces is 400 mm or less,
The distance between the attachment and one of the two heating medium supply pipe traces is 180 mm or less,
Composite molded body with fittings.
[2] The fitting according to [1], wherein a load when the skin material and the foamed particle molded product are separated at the time of pulling out the fitting is 1.5 kN or more. With composite molding.
[3] The composite molded article with a fitting according to [1] or [2], wherein the average thickness of the skin material is 1 to 4 mm.
[4] The method according to any one of [1] to [3], wherein the skin material is a hollow blow molded article composed of a fiber-reinforced thermoplastic resin containing reinforcing fibers in a thermoplastic resin. A composite molded article with the fitting according to the above.
[5] The composite molded article with a fitting according to [4], wherein the content of the reinforcing fibers in the fiber-reinforced thermoplastic resin is 10 to 30% by weight.
[6] The composite molded article with a fixture according to [4] or [5], wherein the thermoplastic resin is a polypropylene resin.
[7] The mounting according to any of [1] to [6], wherein the foamed particle molded article is a thermoplastic resin foamed particle molded article having an apparent density of 30 to 150 kg / m 3. With composite molding.
[8] The composite molded article with a fixture according to [7], wherein the foamed particle molded article is a polypropylene-based resin expanded particle molded article.
[9] A vehicle-equipped step mounted below the door opening of the vehicle body, the vehicle step being made of the composite molded article with the fixture according to any one of [1] to [8].
[10] A method for producing a composite molded article with a fixture having a composite molded article and a fixture fixed to the composite molded article for attaching the composite molded article to another,
The hollow portion of the thermoplastic resin hollow molded body is filled with thermoplastic resin foam particles, and two or more heating medium supply pipes are inserted into the thermoplastic resin hollow molded body to supply a heating medium from the heating medium supply pipe. The foamed particles thus filled are heated and fused to each other to form a foamed particle molded product, and the inner surface of the thermoplastic resin hollow molded product and the foamed particle molded product are adhered to each other. A first step of obtaining a composite molded article of a skin material and a foamed particle molded article located inside the skin material,
The fixing member is fixed to the composite molded body by fastening the fastening member by penetrating the fastening member through the skin material and the mounting member, and the composite molded body and the fixing member fixed to the composite molded body are fixed. Having a second step of obtaining a composite molded body with a fixture having,
In the first step, the distance between the two heating medium supply pipes is set to 400 mm or less, and the two heating medium supply pipes are inserted across the part of the composite molded body to which the fixture is attached, and The distance between the heating medium supply pipe and one of the two heating medium supply pipes is set to 180 mm or less, and the heating medium supply pipe is inserted into the thermoplastic resin hollow molded body and heated.
A method for producing a composite molded article with a fixture.
　上記した本発明に係る取付具付き複合成形体及びその製造方法によれば、複合成形体の製造時に、表皮材の取付具を取り付ける部位を挟んで加熱媒体供給管を挿入するとともに、該部位に近い位置（１８０ｍｍ以下の位置）に加熱媒体供給管を挿入して充填された発泡粒子の加熱成形を行うため、表皮材の肉厚が薄いものであっても、取付具を取り付ける部位周辺における表皮材と発泡粒子成形体との剥離強度が向上したものとなり、軽量であるとともに該部位に取り付けられた取付具の引抜強度が強いものとなる。 According to the composite molded article with a fixture and the method for manufacturing the same according to the present invention described above, during the production of the composite molded article, the heating medium supply pipe is inserted across the part where the fixture for the skin material is to be attached, and A heating medium supply pipe is inserted into a close position (a position of 180 mm or less) to heat-mold the filled foamed particles. Therefore, even if the thickness of the skin material is thin, the skin around the portion where the mounting fixture is to be attached is provided. The peel strength between the material and the foamed particle molded body is improved, so that it is lightweight and the pull-out strength of the fixture attached to the site is high.
本発明に係る取付具付き複合成形体である車両用ステップの一実施形態を斜め上方から示した斜視図である。BRIEF DESCRIPTION OF THE DRAWINGS It is the perspective view which showed one Embodiment of the vehicle step which is a composite molded object with a fixture which concerns on this invention from diagonally upper direction. 図１に示した車両用ステップを斜め下方から示した斜視図である。FIG. 2 is a perspective view showing the vehicle step shown in FIG. 1 from obliquely below. 図１のＡ－Ａ線に沿う部分（取付具が取り付けられた部分）の拡大断面図である。FIG. 2 is an enlarged cross-sectional view of a portion along the line AA in FIG. 1 (portion where a fixture is attached). 複合成形体の製造装置の一部を概念的に示した断面図である。It is sectional drawing which showed a part of manufacturing apparatus of a composite molded object notionally.
　以下、本発明に係る取付具付き複合成形体及びその製造方法の実施形態を、図面に基づいて詳細に説明する。 Hereinafter, embodiments of a composite molded article with a fixture and a method for producing the same according to the present invention will be described in detail with reference to the drawings.
　図１は、本発明に係る取付具付き複合成形体である車両用ステップの一実施形態を斜め上方から示した斜視図、図２は、同車両用ステップを斜め下方から示した斜視図である。また図３は、図１のＡ－Ａ線に沿う部分（取付具が取り付けられた部分）の拡大断面図である。これらの図に示すように、該車両用ステップ１は、複合成形体１０と、該複合成形体１０に固定された、該複合成形体を他に取り付けるための３つの取付具５０とを有する取付具付き複合成形体に形成されている。
　なお、取付具付き複合成形体を車両用ステップとして用いる場合においては、車体に取り付けられた状態における、複合成形体の上部の面（車体の上下方向における上方の面）を上部面、複合成形体の下部の面（車体の上下方向における下方の面）を下部面と呼ぶ。 FIG. 1 is a perspective view showing an embodiment of a vehicle step, which is a composite molded article with a fixture according to the present invention, from an obliquely upper side, and FIG. 2 is a perspective view showing the vehicle step from an obliquely lower side. . FIG. 3 is an enlarged cross-sectional view of a portion along the line AA in FIG. 1 (portion where the mounting fixture is attached). As shown in these drawings, the vehicle step 1 includes a mounting having a composite molded body 10 and three mounting tools 50 fixed to the composite molded body 10 for attaching the composite molded body to another. It is formed in a composite molded body with a tool.
In the case where the composite molded body with the fixture is used as a vehicle step, the upper surface of the composite molded body (upper surface in the vertical direction of the vehicle body) in a state of being attached to the vehicle body is referred to as the upper surface. Is referred to as a lower surface (a lower surface in the vertical direction of the vehicle body).
　上記複合成形体１０は、表皮材１１と、発泡粒子成形体１２とからなる。
　表皮材１１は、熱可塑性樹脂からなり、中空部を有する熱可塑性樹脂中空成形体（以下、「中空成形体」という）として成形される。
　発泡粒子成形体１２は、相互に加熱融着した複数の熱可塑性樹脂発泡粒子（以下、「発泡粒子」という）からなる。発泡粒子成形体１２は、表皮材１１の中空部に形成される。発泡粒子成形体１２は表皮材１１の内面に接着されている。
　発泡粒子成形体１２は、中空成形体の中空部に発泡粒子を充填し、該発泡粒子を相互に加熱融着させることで形成される。発泡粒子の加熱融着は、該中空成形体内に加熱媒体供給管を挿入し、加熱媒体供給管から加熱媒体を中空部に供給することにより行われる。また、前記加熱媒体供給管から加熱媒体を中空部に供給することにより上記表皮材１１と上記発泡粒子成形体１２とは接着される。
　上記取付具５０は、締結部材５１により複合成形体１０に固定されている。締結部材５１は取付具５０と表皮材１１とを貫通して締結する。さらに、上記表皮材１１には、ブロー管跡１３、発泡粒子充填管跡１４、及び加熱媒体供給管跡１５を有している。ブロー管跡１３は、上記表皮材１１の製造時において中空部にエアーを供給するブロー管により形成される。発泡粒子充填管跡１４は、上記発泡粒子を表皮材１１の中空部に充填する発泡粒子充填管により形成される。加熱媒体供給管跡１５は、充填した上記発泡粒子を加熱する媒体を中空部に供給する加熱媒体供給管により形成される。図示した実施形態に係る車両用ステップ１にあっては、２つのブロー管跡１３、１つの発泡粒子充填管跡１４、そして９つの加熱媒体供給管跡１５を有している。 The composite molded body 10 includes a skin material 11 and a foamed particle molded body 12.
The skin material 11 is made of a thermoplastic resin and is molded as a thermoplastic resin hollow molded body having a hollow portion (hereinafter, referred to as “hollow molded body”).
The foamed particle molded body 12 is made up of a plurality of thermoplastic resin foamed particles (hereinafter, referred to as “foamed particles”) which are mutually heat-fused. The foamed particle molded body 12 is formed in a hollow portion of the skin material 11. The foamed particle molded body 12 is adhered to the inner surface of the skin material 11.
The foamed particle molded body 12 is formed by filling the hollow portion of the hollow molded body with foamed particles, and heating and fusing the foamed particles to each other. Heat fusion of the foamed particles is performed by inserting a heating medium supply pipe into the hollow molded body and supplying the heating medium from the heating medium supply pipe to the hollow portion. Further, by supplying a heating medium from the heating medium supply pipe to the hollow portion, the skin material 11 and the foamed particle molded body 12 are bonded to each other.
The attachment 50 is fixed to the composite molded body 10 by a fastening member 51. The fastening member 51 penetrates the attachment 50 and the skin material 11 to be fastened. Further, the skin material 11 has a trace 13 of a blow pipe, a trace 14 of a foamed particle filling pipe, and a trace 15 of a heating medium supply pipe. The blow pipe trace 13 is formed by a blow pipe that supplies air to a hollow portion when the skin material 11 is manufactured. The foam particle filling tube trace 14 is formed by a foam particle filling tube that fills the hollow particles of the skin material 11 with the foam particles. The heating medium supply pipe trace 15 is formed by a heating medium supply pipe that supplies a medium for heating the filled expanded particles to the hollow portion. The vehicle step 1 according to the illustrated embodiment has two traces of the blow pipe 13, one trace of the foamed particle filling pipe 14, and nine traces of the heating medium supply pipe 15.
　また、上記表皮材１１を構成する中空成形体においては、第一壁１１ａと、第二壁１１ｂとがそれらの周縁同士のみで融着して中空部が形成されている。即ち、中空成形体は、第一壁１１ａと第二壁１１ｂとを、周縁同士のみで融着させて形成されており、中空成形体の内部には、第一壁１１ａと第二壁１１ｂとを周縁以外の部位で突き当てて融着させて形成したリブが存在しない。なお、軽量化を達成できる範囲において、中空成形体は、リブ構造を有していてもよい。 中空 Further, in the hollow molded body constituting the skin material 11, the first wall 11a and the second wall 11b are fused only at their peripheral edges to form a hollow portion. That is, the hollow molded body is formed by fusing the first wall 11a and the second wall 11b only at their peripheral edges, and inside the hollow molded body, the first wall 11a, the second wall 11b, There is no rib formed by abutting and fusing at positions other than the peripheral edge. The hollow molded body may have a rib structure as long as the weight can be reduced.
　上記表皮材１１を構成する中空成形体の外形は、車体のドア開口部の下方に取り付けられる長尺な板状体に形成される。具体的には、２０００×２００×１００ｍｍ程度の板状体に形成される。中空成形体は、ステップ部２０と、取付部２１とを有し断面略Ｌ字状に形成されている。ステップ部２０は、車体に取り付けられた状態でドア開口部の下方から略水平方向に外方に延びる略平板状である。取付部２１は、該ステップ部２０の幅方向内側（車体側）に上方に突出して形成される。第一壁１１ａはステップ部２０の上部面を形成する。第一壁１１ａには、乗員が足を載置した際のスリップを防止する凹凸状のスリップ防止部２２が長さ方向に延設されている。第二壁１１ｂはステップ部２０の下部面を形成する。第二壁１１ｂには、車体への取付具（金属製ステー）５０を固定する部位となる取付部２３が複数カ所形成されている。図示した実施形態においては凹形状の取付部２３が３カ所形成されている。 外形 The outer shape of the hollow molded body constituting the skin material 11 is formed in a long plate-like body attached below the door opening of the vehicle body. Specifically, it is formed in a plate-like body of about 2000 × 200 × 100 mm. The hollow molded body has a step portion 20 and a mounting portion 21 and is formed in a substantially L-shaped cross section. The step portion 20 has a substantially flat plate shape that extends outward in a substantially horizontal direction from below the door opening when attached to the vehicle body. The mounting portion 21 is formed to protrude upward in the width direction inside (the vehicle body side) of the step portion 20. The first wall 11a forms an upper surface of the step portion 20. On the first wall 11a, an uneven slip prevention portion 22 for preventing a slip when the occupant places his / her foot extends in the length direction. The second wall 11b forms a lower surface of the step portion 20. At the second wall 11b, a plurality of mounting portions 23 are formed, which are portions for fixing a mounting tool (metal stay) 50 to the vehicle body. In the illustrated embodiment, three concave mounting portions 23 are formed.
　上記したブロー管跡１３、発泡粒子充填管跡１４及び加熱媒体供給管跡１６は、外観性を考慮してステップ部２０の下部面を形成する第二壁１１ｂに形成されていることが好ましい。図示した実施形態に係る車両用ステップ１においては、２つのブロー管跡１３、１つの発泡粒子充填管跡１４、そして９つの加熱媒体供給管跡１５の全てが、図２に示したように第二壁１１ｂに形成されている。 The traces of the blow tube 13, the traces of the foamed particle filling tube 14, and the traces of the heating medium supply tube 16 are preferably formed on the second wall 11 b forming the lower surface of the step portion 20 in consideration of the appearance. In the vehicle step 1 according to the illustrated embodiment, all of the two blow pipe traces 13, one foamed particle filling pipe trace 14, and the nine heating medium supply pipe traces 15, as shown in FIG. It is formed on the two walls 11b.
　上記表皮材１１である中空成形体を形成する材料としては、ポリプロピレン系樹脂、ポリエチレン系樹脂、ポリスチレン系樹脂などの熱可塑性樹脂を用いることができる。中でも、機械的強度と耐熱性とのバランスに優れることからポリプロピレン系樹脂が好ましい。
　また、強度、曲げ剛性を高める観点から、表皮材１１が熱可塑性樹脂中に強化繊維を含む繊維強化熱可塑性樹脂から構成されていることが好ましい。中でも、表皮材１１がポリプロピレン系樹脂中に強化繊維を含む繊維強化ポリプロピレン系樹脂から構成されていることがより好ましい。
　繊維強化熱可塑性樹脂中の強化繊維の含有量は、１０～３０重量％が好ましく、１２～２０重量％であることがより好ましい。強化繊維の含有量が１０重量％以上であることで、表皮材１１である中空成形体は曲げ剛性により一層優れたものとなる。強化繊維の含有量が３０重量％以下であることで、該中空成形体の成形が容易なものとなる。 As a material for forming the hollow molded body as the skin material 11, a thermoplastic resin such as a polypropylene resin, a polyethylene resin, and a polystyrene resin can be used. Above all, a polypropylene-based resin is preferred because of its excellent balance between mechanical strength and heat resistance.
Further, from the viewpoint of increasing the strength and the bending rigidity, it is preferable that the skin material 11 is made of a fiber-reinforced thermoplastic resin containing a reinforcing fiber in the thermoplastic resin. Among them, it is more preferable that the skin material 11 is composed of a fiber-reinforced polypropylene resin containing a reinforcing fiber in the polypropylene resin.
The content of the reinforcing fibers in the fiber-reinforced thermoplastic resin is preferably from 10 to 30% by weight, and more preferably from 12 to 20% by weight. When the content of the reinforcing fibers is 10% by weight or more, the hollow molded body as the skin material 11 is more excellent in bending rigidity. When the content of the reinforcing fiber is 30% by weight or less, molding of the hollow molded body becomes easy.
　また、表皮材１１である中空成形体は多層構造のものとしてもよい。例えば、外層は繊維強化熱可塑性樹脂から構成され、内層は、外層よりは少ない量の強化繊維を含む繊維強化熱可塑性樹脂又は強化繊維を含まない熱可塑性樹脂から構成されているものとすることができる。このような多層構造の中空成形体を用いる場合、中空部に充填される発泡粒子と中空成形体とに同じ種類の熱可塑性樹脂を用いることで、両者を強固に融着させることができ、複合成形体の曲げ剛性を高めることができる。
　特に、外層が繊維強化ポリプロピレン系樹脂から構成され、内層は、外層よりは少ない量の強化繊維を含む繊維強化ポリプロピレン系樹脂又は強化繊維を含まないポリプロピレン系樹脂から構成されているものとすることが好ましい。このような多層構造の中空成形体を用いることで、中空部に充填される発泡粒子がポリプロピレン系樹脂である場合に、発泡粒子成形体１２と中空成形体とを強固に融着させることができ、複合成形体の曲げ剛性をより高めることができる。なお、この場合の強化繊維の含有量は、多層とした全体の強化繊維の含有量が上記した範囲内のものであればよい。 Further, the hollow molded body as the skin material 11 may have a multilayer structure. For example, the outer layer may be made of a fiber-reinforced thermoplastic resin, and the inner layer may be made of a fiber-reinforced thermoplastic resin containing a smaller amount of reinforcing fibers than the outer layer or a thermoplastic resin containing no reinforcing fibers. it can. When using a hollow molded body having such a multilayer structure, by using the same type of thermoplastic resin for the foamed particles and the hollow molded body to be filled in the hollow portion, the two can be strongly fused together, and the composite The bending rigidity of the molded body can be increased.
In particular, the outer layer may be made of a fiber-reinforced polypropylene resin, and the inner layer may be made of a fiber-reinforced polypropylene resin containing a smaller amount of reinforcing fibers than the outer layer or a polypropylene resin containing no reinforcing fibers. preferable. By using such a multi-layered hollow molded article, when the expanded particles filled in the hollow portion are a polypropylene resin, the expanded particle molded article 12 and the hollow molded article can be firmly fused together. In addition, the bending rigidity of the composite molded body can be further increased. Note that the content of the reinforcing fibers in this case may be any as long as the content of the entire multilayered reinforcing fiber is within the above range.
　上記ポリプロピレン系樹脂としては、ホモポリプロピレン（ｈ－ＰＰ）、プロピレン－エチレンランダム共重合体やプロピレン－エチレン－ブテンランダム共重合体などのランダムポリプロピレン（ｒ－ＰＰ）、ブロックポリプロピレン（ｂ－ＰＰ）或いはそれらの混合物などを例示することができる。なお、ブロックポリプロピレンは、プロピレン－エチレンブロック共重合体などのブロック共重合体だけではなく、オレフィン系熱可塑性エラストマーやオレフィン系ゴムの存在下でプロピレンを重合したものや、ポリプロピレンとオレフィン系熱可塑性エラストマーやオレフィン系ゴムとを混錬したものも包含する。
　また、上記強化繊維の種類としては、ガラス繊維、グラスウール、炭素繊維などの無機繊維材料；セルロースナノファイバーなどの有機繊維材料が例示される。 Examples of the polypropylene resin include homopolypropylene (h-PP), random polypropylene (r-PP) such as propylene-ethylene random copolymer and propylene-ethylene-butene random copolymer, block polypropylene (b-PP) or Examples thereof include mixtures thereof. The block polypropylene is not only a block copolymer such as a propylene-ethylene block copolymer, but also a polymer obtained by polymerizing propylene in the presence of an olefin-based thermoplastic elastomer or an olefin-based rubber, or a polypropylene and an olefin-based thermoplastic elastomer. And those kneaded with olefin rubber.
Examples of the type of the reinforcing fibers include inorganic fiber materials such as glass fiber, glass wool, and carbon fiber; and organic fiber materials such as cellulose nanofiber.
　表皮材１１である中空成形体の厚みは、強度と軽量性との兼ね合いから、平均肉厚で１～４ｍｍであることが好ましく、１．５～３ｍｍであることがより好ましい。平均肉厚が１ｍｍ未満であると、強度が十分ではない。一方、平均肉厚が４ｍｍを超えると、軽量性が損なわれる。
　なお、中空成形体の平均厚み（平均肉厚）は、次のようにして測定される。中空成形体の長手方向中央部および長手方向両端部付近から選択された計３つの位置の長手方向に対する垂直断面が肉厚の測定に用いられる。それぞれの位置の垂直断面について、各垂直断面の周方向に沿って等間隔に６箇所の垂直断面の厚み方向の厚さ（壁部の肉厚）の測定が行われる。得られた１８カ所の厚みの値が算術平均され、その平均値が中空成形体の平均肉厚となる。 The thickness of the hollow molded body, which is the skin material 11, is preferably 1 to 4 mm, more preferably 1.5 to 3 mm in average thickness in consideration of strength and lightness. If the average thickness is less than 1 mm, the strength is not sufficient. On the other hand, if the average thickness exceeds 4 mm, the lightness is impaired.
The average thickness (average thickness) of the hollow molded body is measured as follows. Cross sections perpendicular to the longitudinal direction at a total of three positions selected from the central portion in the longitudinal direction and the vicinity of both ends in the longitudinal direction of the hollow molded body are used for measuring the wall thickness. With respect to the vertical cross section at each position, the thickness (wall thickness) of six vertical cross sections in the thickness direction is measured at regular intervals along the circumferential direction of each vertical cross section. The obtained thickness values at the 18 locations are arithmetically averaged, and the average value becomes the average thickness of the hollow molded body.
　上記した表皮材１１である中空成形体の中空部に充満されている、表皮材１１の内部に位置する上記発泡粒子成形体１２としては、ポリプロピレン系樹脂、ポリエチレン系樹脂、ポリスチレン系樹脂、ポリオレフィン系樹脂とポリスチレン系樹脂との複合樹脂、ポリウレタンなどを基材樹脂とする発泡体とすることができる。発泡粒子成形体１２を構成する樹脂の種類を、表皮材１１である中空成形体の樹脂と同じ種類とすることが好ましい。例えば、中空成形体がポリプロピレン系樹脂から形成されている場合には、ポリプロピレン系樹脂を基材樹脂とした発泡粒子成形体が好ましい。発泡粒子成形体１２を構成する樹脂の種類を、表皮材１１である上記中空成形体の樹脂の種類と同じ種類の樹脂とすることで、表皮材１１と発泡粒子成形体１２との融着性を高めることができ、より曲げ剛性に優れた複合成形体１０が得られるようになる。 The foamed particle molded body 12 located inside the skin material 11 filled in the hollow portion of the hollow molded body as the skin material 11 includes a polypropylene resin, a polyethylene resin, a polystyrene resin, and a polyolefin resin. A foam using a composite resin of a resin and a polystyrene resin, polyurethane or the like as a base resin can be used. It is preferable that the type of the resin forming the expanded particle molded body 12 is the same as the resin of the hollow molded body that is the skin material 11. For example, when the hollow molded body is formed from a polypropylene resin, a foamed particle molded body using a polypropylene resin as a base resin is preferable. By using the same kind of resin as that of the skin material 11 as the resin of the above-mentioned hollow molded body, the fusion property between the skin material 11 and the foamed particle molded body 12 can be improved. And the composite molded body 10 having more excellent bending rigidity can be obtained.
　発泡粒子を構成するポリプロピレン系樹脂としては、プロピレン単独重合体、プロピレン－エチレンランダム共重合、プロピレン－ブテンランダム共重合、プロピレン－エチレン－ブテンランダム共重合が好ましい。また、発泡粒子としては、発泡層であるポリプロピレン系樹脂からなる発泡状態の芯層の表面を、該芯層を形成するポリプロピレン系樹脂の融解温度よりも低い融解温度又は軟化温度を示す樹脂により被覆した多層構造の発泡粒子や、メタロセン系重合触媒により重合されてなるポリプロピレン系樹脂を含む基材樹脂からなる発泡粒子を使用することができる。これらの発泡粒子を使用することにより比較的低い加熱媒体加熱圧力で発泡粒子同士を融着させることができる。 ポ リ プ ロ ピ レ ン As the polypropylene resin constituting the expanded particles, propylene homopolymer, propylene-ethylene random copolymer, propylene-butene random copolymer, and propylene-ethylene-butene random copolymer are preferable. Further, as the foamed particles, the surface of a foamed core layer made of a polypropylene resin, which is a foamed layer, is coated with a resin having a melting temperature or a softening temperature lower than the melting temperature of the polypropylene resin forming the core layer. It is possible to use foamed particles having a multilayer structure as described above or foamed particles comprising a base resin containing a polypropylene-based resin polymerized by a metallocene-based polymerization catalyst. By using these foamed particles, the foamed particles can be fused together with a relatively low heating medium heating pressure.
　発泡粒子成形体１２の見掛け密度には特に制限はなく、一般に使用されている見掛け密度のものを広く用いることができるが、軽量性と機械的強度のバランスに優れることから、３０～１５０ｋｇ／ｍ３であることが好ましく、３０～１２０ｋｇ／ｍ３であることがより好ましく、３５～９０ｋｇ／ｍ３であることが特に好ましい。
　なお、発泡粒子成形体１２の見掛け密度は、発泡体の重量を発泡体の体積で割算した値を意味する。発泡体の体積は、発泡体を水中に沈めた際の水位の上昇分から測定する方法（水没法）などにより求めることができる。表皮材１１の内部に位置する発泡粒子成形体１２の見掛け密度は、例えば、発泡粒子成形体から切り出した、所定の体積を有する試料の重量を測定し、該重量を、該体積で割って求めることができる。
　また、表皮材１１を構成する上記中空成形体の重量に対する上記発泡粒子成形体１２の重量の比は、強度と軽量性との兼ね合いから、０．２～０．５であることが好ましく、０．２５～０．３５であることがより好ましい。 The apparent density of the expanded bead 12 is not particularly limited, and a commonly used apparent density can be widely used. However, since the balance between light weight and mechanical strength is excellent, the apparent density is 30 to 150 kg / m2. 3 , more preferably 30 to 120 kg / m 3 , and particularly preferably 35 to 90 kg / m 3 .
In addition, the apparent density of the foamed particle molded body 12 means a value obtained by dividing the weight of the foam by the volume of the foam. The volume of the foam can be determined by a method of measuring from the rise in water level when the foam is submerged in water (submersion method) or the like. The apparent density of the foamed particle molded body 12 located inside the skin material 11 is obtained, for example, by measuring the weight of a sample having a predetermined volume cut out from the foamed particle molded body, and dividing the weight by the volume. be able to.
Further, the ratio of the weight of the foamed particle molded body 12 to the weight of the hollow molded body constituting the skin material 11 is preferably 0.2 to 0.5 in consideration of a balance between strength and lightness. More preferably, it is from 0.25 to 0.35.
　複合成形体１０には、上記したように取付具５０が取り付けられている。取付具５０としては、車体等、他に複合成形体１０を取り付けることが可能な金具等であればよく、具体的な構造を限定するものではない。また取付具５０の材質も、強度を有する金属製のものを広く用いることができる。図示した実施形態に係る車両用ステップ１にあっては、第二壁１１ｂに形成された取付部２３に、車体への取付具（鉄製ステー）５０が締結部材（ブラインドリベット）５１によって取り付けられている。
　取付具５０の複合成形体１０への固定においては、引抜強度を強いものとできる観点から、締結部材５１として、リベットを用いることが好ましい。取付具５０の取り付け方法はリベットに限らない。例えば、締結部材５１としてボルトとナットを用いることができる。この場合には、インサートナットを予め複合成形体１０に埋め込んでおき、該インサートナットとボルトを締結することで取付具５０を固定することができる。
　なお、ブラインドリベットは、対象物に締結されるリベットボディ部と、リベットボディ部を締結するためのマンドレル部とを有している。ブラインドリベットを用いた取り付けにおいては、まず、リベットボディ部を取付具５０を介して複合成形体１０に挿入する。次に、リベットボディ部を固定した状態で、リベットボディ部と一体となって形成されているマンドレル部を引き抜き、破断させることにより、リベットボディ部の一部を座屈させ、座屈した部分が複合成形体１０の内側（発泡粒子成形体側の表皮材１１）に引っ掛かるようにすることで、リベットボディ部が締結される。これにより、取付具５０を複合成形体１０に取り付けることができる。ブラインドリベットとしては、ポップリベット・ファスナー株式会社製のポップリベット（ＰＯＰ Ｒｉｖｅｔｓ）や、ポップＨＣリベット（ＰＯＰ ＨＣ Ｒｉｖｅｔｓ）を好適に用いることができる。特に、リベット部の一部を座屈させた際に、座屈部が面状に広がることで、面で挟むようにしてリベット部が締結されることにより、少ない個数でも複合成形体１０に取り付けられた取付具５０の引抜強度を強いものとできることから、ポップＨＣリベット（ＰＯＰ ＨＣ Ｒｉｖｅｔｓ）を用いることが好ましい。 The attachment 50 is attached to the composite molded body 10 as described above. The attachment 50 may be any fitting such as a vehicle body or the like to which the composite molded body 10 can be attached, and the specific structure is not limited. In addition, as the material of the attachment 50, a metal member having strength can be widely used. In the vehicle step 1 according to the illustrated embodiment, an attachment (iron stay) 50 to a vehicle body is attached to an attachment portion 23 formed on the second wall 11b by a fastening member (blind rivet) 51. I have.
In fixing the fixture 50 to the composite molded body 10, it is preferable to use a rivet as the fastening member 51 from the viewpoint of increasing the pull-out strength. The mounting method of the mounting tool 50 is not limited to rivets. For example, a bolt and a nut can be used as the fastening member 51. In this case, the fixture 50 can be fixed by embedding an insert nut in the composite molded body 10 in advance and fastening the insert nut and a bolt.
In addition, the blind rivet has a rivet body part fastened to an object and a mandrel part for fastening the rivet body part. In the installation using the blind rivet, first, the rivet body portion is inserted into the composite molded body 10 via the fixture 50. Next, with the rivet body fixed, the mandrel formed integrally with the rivet body is pulled out and broken, so that a part of the rivet body is buckled, and the buckled portion is removed. The rivet body portion is fastened by being hooked on the inside of the composite molded body 10 (the skin material 11 on the foamed particle molded body side). Thereby, the fixture 50 can be attached to the composite molded body 10. As the blind rivet, a pop rivet (POP Rivets) or a pop HC rivet (POP HC Rivets) manufactured by Pop Rivet Fastener Co., Ltd. can be preferably used. In particular, when a part of the rivet portion was buckled, the buckled portion spread in a planar manner, and the rivet portion was fastened so as to be sandwiched between the surfaces, so that even a small number of the rivet portions were attached to the composite molded body 10. It is preferable to use pop HC rivets (POP HC Rivets) because the pull-out strength of the fixture 50 can be increased.
　上記取付具５０は、隣接する２つの加熱媒体供給管跡１５の間に取り付けられている。上記２つの加熱媒体供給管跡１５の間の距離が４００ｍｍ以下である。上記複合成形体１０に取り付けられた取付具５０と、上記２つの加熱媒体供給管跡のうちの一方の上記加熱媒体供給管跡１５との距離は、１８０ｍｍ以下である。
　複合成形体１０の製造時において、取付部２３を挟んで２本の加熱媒体供給管を４００ｍｍ以下の間隔、かつ、一方の加熱媒体供給管を取付部２３からの距離が１８０ｍｍ以下となる位置において、表皮材１１に加熱媒体供給管を挿入する。このように製造することで、隣接する２つの加熱媒体供給管跡１５が取付具５０を挟んで４００ｍｍ以下の間隔で位置するとともに、少なくとも一方の加熱媒体供給管跡１５が取付具５０から１８０ｍｍ以下の近傍に位置することになる。取付部２３に近い位置（１８０ｍｍ以下の位置）に加熱媒体供給管を挿入して充填された発泡粒子を加熱成形することにより、取付部２３周辺における表皮材１１と発泡粒子成形体１２との融着状態が良化し剥離強度が向上する。このため、取付部２３に取り付けられた取付具５０の引抜強度が強いものとなる。
　かかる観点から、取付具５０と、上記隣接する２つの加熱媒体供給管跡のうちの一方の加熱媒体供給管跡１５との距離は１５０ｍｍ以下であることがより好ましく、１３０ｍｍ以下であることが特に好ましい。また同様の観点から、上記隣接する２つの加熱媒体供給管跡１５の間の距離が、３５０ｍｍ以下であることが好ましく、さらに好ましくは３００ｍｍ以下である。
　また、取付具５０を安定して固定できる観点から、取付具５０と、上記隣接する２つの加熱媒体供給管跡１５のうちの一方の加熱媒体供給管跡１５との距離は、概ね３０ｍｍ以上であることが好ましく、より好ましくは５０ｍｍ以上である。また、表面状態が良好な複合成形体が得られやすいという観点から、上記２つの加熱媒体供給管跡１５の間の距離は、概ね１００ｍｍ以上であることが好ましく、より好ましくは１５０ｍｍ以上であり、さらに好ましくは１８０ｍｍ以上である。
　なお、取付具５０の引抜強度をより高める観点から、取付具５０は、上記２つの加熱媒体供給管跡１５のうちのいずれか一方側に近づけて、複合成形体１０に固定することが好ましい。
　また、上記取付具５０と、上記２つの加熱媒体供給管跡１５のうちの他方の加熱媒体供給管跡１５との距離が、２００ｍｍ以下であることが好ましく、１８０ｍｍ以下であることがより好ましく、１６０ｍｍ以下であることが特に好ましい。なお、上記取付具５０と、上記加熱媒体供給管跡１５との距離は、上記取付具５０の近傍に位置する２つの加熱媒体供給管跡１５の中心点同士の間を直線で結び、該直線と上記取付具５０の側端とが交わる点を両端とした線分の中点を取付具５０の中心点とし、該取付具５０の中心点と、上記加熱媒体供給管跡１５の中心点との間の距離を意味する。図示した実施形態に係る車両用ステップ１にあっては、図２に示したａの距離は１２０ｍｍ、ｂの距離は１６０ｍｍ、ｃの距離は６０ｍｍ、ｄの距離は１４０ｍｍ、ｅの距離は１２０ｍｍ、ｆの距離は１８０ｍｍである。 The attachment 50 is attached between two adjacent traces 15 of the heating medium supply pipe. The distance between the two heating medium supply pipe traces 15 is 400 mm or less. The distance between the fixture 50 attached to the composite molded body 10 and the heating medium supply pipe trace 15 of one of the two heating medium supply pipe traces is 180 mm or less.
At the time of manufacturing the composite molded body 10, the two heating medium supply pipes are placed at an interval of 400 mm or less with the mounting part 23 interposed therebetween, and one of the heating medium supply pipes is positioned at a distance of 180 mm or less from the mounting part 23. Then, the heating medium supply pipe is inserted into the skin material 11. By manufacturing in this way, two adjacent heating medium supply pipe traces 15 are located at an interval of 400 mm or less across the fixture 50, and at least one heating medium supply pipe trace 15 is 180 mm or less from the fixture 50. Will be located in the vicinity. By inserting a heating medium supply pipe at a position close to the mounting portion 23 (at a position of 180 mm or less) to heat-mold the filled foamed particles, the fusion of the skin material 11 and the foamed particle molded body 12 around the mounting portion 23 is achieved. The adhesion state is improved and the peel strength is improved. For this reason, the pull-out strength of the attachment 50 attached to the attachment portion 23 becomes strong.
From this viewpoint, the distance between the fixture 50 and one of the two adjacent heating medium supply pipe traces 15 is more preferably 150 mm or less, and particularly preferably 130 mm or less. preferable. In addition, from the same viewpoint, the distance between the two adjacent heating medium supply pipe traces 15 is preferably 350 mm or less, and more preferably 300 mm or less.
In addition, from the viewpoint that the fixture 50 can be stably fixed, the distance between the fixture 50 and one of the two adjacent heating medium supply pipe traces 15 is approximately 30 mm or more. Preferably, it is 50 mm or more. In addition, from the viewpoint that a composite molded body having a favorable surface state is easily obtained, the distance between the two heating medium supply pipe traces 15 is preferably approximately 100 mm or more, more preferably 150 mm or more, More preferably, it is 180 mm or more.
In addition, from the viewpoint of further increasing the pull-out strength of the fixture 50, it is preferable that the fixture 50 be fixed to the composite molded body 10 by approaching one of the two traces of the heating medium supply pipe 15.
Further, the distance between the fixture 50 and the other one of the two heating medium supply pipe traces 15 is preferably 200 mm or less, more preferably 180 mm or less, Particularly preferably, it is 160 mm or less. The distance between the fixture 50 and the trace of the heating medium supply pipe 15 is such that the center points of the two traces of the heating medium supply pipe 15 located in the vicinity of the fixture 50 are connected by a straight line. The midpoint of a line segment having a point where both ends intersect with the side end of the fixture 50 is defined as the center point of the fixture 50, and the center point of the fixture 50 and the center point of the heating medium supply pipe trace 15 Means the distance between In the vehicle step 1 according to the illustrated embodiment, the distance a shown in FIG. 2 is 120 mm, the distance b is 160 mm, the distance c is 60 mm, the distance d is 140 mm, the distance e is 120 mm, The distance of f is 180 mm.
　また、上記取付具５０の引抜き時における、上記表皮材１１と上記発泡粒子成形体１２とが剥離する際の荷重は、１．５ｋＮ以上であることが好ましく、１．８ｋＮ以上であることがより好ましく、２．０ｋＮ以上であることが特に好ましい。表皮材１１と発泡粒子成形体１２とが剥離する際の荷重が前記範囲であると、取付部２３に取り付けられた取付具５０の引抜強度が強いものとなり、信頼性の高い取付具付き複合成形体となる。
　なお、取付具５０の引抜き時における、上記表皮材１１と発泡粒子成形体１２とが剥離する際の荷重は、例えば、引張試験機を用いて次のように測定することができる。
　まず、取付具付き複合成形体を引張試験用（荷重測定用）の冶具に固定するとともに、引張試験において、表皮材１１と発泡粒子成形体１２との融着面に対して垂直な方向に均等な荷重が加わるように、取付具５０と引張試験機とを固定する。次に、引張試験機により所定の速度で引張荷重をかけて引張試験を行い、表皮材１１が発泡粒子成形体１２から剥離した際の荷重を測定することで、剥離する際の荷重を求めることができる。
　なお、引張試験において、表皮材１１が発泡粒子成形体１２から剥離した際には、変位に対する荷重の一時的な低下が変位－荷重のグラフに現れるため、この荷重の低下部分を目安にして剥離する際の荷重を求めることができる。 Further, the load when the skin material 11 and the foamed particle molded body 12 are separated at the time of pulling out the attachment 50 is preferably 1.5 kN or more, more preferably 1.8 kN or more. It is particularly preferably 2.0 kN or more. When the load when the skin material 11 and the foamed particle molded body 12 are separated is within the above range, the pull-out strength of the fixture 50 attached to the attachment portion 23 becomes strong, and the composite molding with the fixture is highly reliable. Be a body.
In addition, the load at the time of peeling of the skin material 11 and the foamed particle molded body 12 at the time of pulling out the fixture 50 can be measured, for example, using a tensile tester as follows.
First, the composite molded body with the fixture is fixed to a jig for a tensile test (for measuring a load), and in a tensile test, the composite molded body is uniformly spread in a direction perpendicular to a fusion surface between the skin material 11 and the foamed particle molded body 12. The fixture 50 and the tensile tester are fixed so that an appropriate load is applied. Next, a tensile test is performed by applying a tensile load at a predetermined speed by a tensile tester, and the load at the time of peeling is determined by measuring the load at the time when the skin material 11 is peeled from the foamed particle molded body 12. Can be.
In the tensile test, when the skin material 11 peels off from the foamed particle molded body 12, a temporary decrease in the load with respect to the displacement appears in the displacement-load graph. Can be obtained.
　上記した取付具付き複合成形体からなる取付具付き車両用ステップ１は、熱可塑性樹脂中空成形体の中空部に熱可塑性樹脂発泡粒子を充填し、該熱可塑性樹脂中空成形体内に２つ以上の加熱媒体供給管を挿入して該加熱媒体供給管から加熱媒体を供給することにより上記充填した熱可塑性樹脂発泡粒子を相互に加熱融着させて発泡粒子成形体を形成するとともに熱可塑性樹脂中空成形体内面と発泡粒子成形体とを接着させて、熱可塑性樹脂中空成形体からなる表皮材と、該表皮材の内部に位置する発泡粒子成形体との複合成形体を得る第一工程と、上記表皮材と取付具とに締結部材を貫通させて該締結部材を締結することにより上記複合成形体に取付具を固定し、複合成形体と、該複合成形体に固定された取付具とを有する取付具付き複合成形体を得る第二工程とを有する製造方法により作ることができる。 The step 1 for a vehicle with a fixture formed of the composite molded article with the fixture described above fills a hollow portion of the thermoplastic resin hollow molded body with thermoplastic resin foam particles, and two or more thermoplastic resin hollow molded articles are provided in the thermoplastic resin hollow molded body. By inserting a heating medium supply pipe and supplying a heating medium from the heating medium supply pipe, the filled thermoplastic resin foam particles are heated and fused to each other to form a foamed particle molded article and a thermoplastic resin hollow molding. A first step of bonding a body surface and a foamed particle molded body to obtain a composite molded body of a skin material formed of a thermoplastic resin hollow molded body and a foamed particle molded body located inside the skin material, The fastening member is fixed to the composite molded body by fastening the fastening member by penetrating the fastening member through the skin material and the fixture, and the composite molded body has a fixture fixed to the composite molded body. Composite with fixture It can be made by a production method and a second step of obtaining a feature.
　第一工程においては、先ず、熱可塑性樹脂の溶融物をダイから押し出して形成された軟化状態の円筒状のパリソン又は２枚のシートバリソンを分割成形型（成形型６０）で挟み込み、それからパリソンにブロー管６１を打ち込み、該ブロー管６１を介してパリソン内にエアーなどの加圧気体（以下、ブローエアとも言う）を吹き込む。これにより、成形型６０のキャビティ内でパリソンが膨らみ、成形型６０の内壁に押し当てられることでパリソンが賦形され、中空成形体が形成される（ブロー成形）。このブロー成形工程において、ブローエアを吹き込んでいる間、成形型６０側から真空引きして、パリソンを成形型の内壁に密着させることが好ましい。この場合、より容易に、形成される中空成形体が成形型の形状を忠実に反映したものとなる。例えば、表皮材１１のステップ部２０の上部面に形成されるスリップ防止部２２、また下部面に形成される取付部２３を精度よく形成したものとなる。 In the first step, first, a softened cylindrical parison or two sheet barisons formed by extruding a melt of a thermoplastic resin from a die are sandwiched by a split mold (mold 60), and then inserted into the parison. The blow tube 61 is driven, and a pressurized gas (hereinafter, also referred to as blow air) such as air is blown into the parison through the blow tube 61. As a result, the parison swells in the cavity of the molding die 60 and is pressed against the inner wall of the molding die 60 to shape the parison, thereby forming a hollow molded body (blow molding). In the blow molding step, it is preferable that the parison is brought into close contact with the inner wall of the mold while the blow air is being blown, by evacuating from the mold 60 side. In this case, the formed hollow molded article more easily reflects the shape of the mold. For example, the slip prevention portion 22 formed on the upper surface of the step portion 20 of the skin material 11 and the attachment portion 23 formed on the lower surface are formed with high precision.
　ここで、多層構造の中空成形体からなる表皮材１１とする場合は、例えば、外層を形成する熱可塑性樹脂及び強化繊維を押出機に供給して溶融状態となして外層形成用溶融樹脂を得る。内層については内層を形成する熱可塑性樹脂を押出機に供給して溶融状態となして内層形成用溶融樹脂を得る。なお、外層および内層については必要に応じて熱可塑性樹脂だけでなく強化繊維を押出機に供給して溶融状態とする。そして、内層、外層それぞれの層を形成する溶融状態の熱可塑性樹脂（溶融樹脂）をダイ内で合流積層させ、この積層物を押出機に備えられたダイから押し出しする方法（共押出法）を実施することで多層構造のパリソンが得られ、これを上記した成形型６０を用いて賦形すればよい。 In the case where the skin material 11 is formed of a hollow molded body having a multilayer structure, for example, a thermoplastic resin for forming the outer layer and reinforcing fibers are supplied to an extruder to be in a molten state to obtain a molten resin for forming an outer layer. . As for the inner layer, a thermoplastic resin for forming the inner layer is supplied to an extruder to be in a molten state to obtain a molten resin for forming the inner layer. In addition, about an outer layer and an inner layer, not only a thermoplastic resin but also a reinforcing fiber is supplied to an extruder as needed, and it is made into a molten state. Then, a thermoplastic resin (molten resin) in a molten state for forming each of the inner layer and the outer layer is merged and laminated in a die, and the laminated product is extruded from a die provided in an extruder (co-extrusion method). By carrying out, a parison having a multilayer structure is obtained, and the parison may be shaped using the above-described mold 60.
　続いて、成形型６０内において、形成した表皮材１１である中空成形体内に熱可塑性樹脂発泡粒子を充填する。この発泡粒子の充填工程は、例えば図４に示すように、ブロー成形用の成形型６０に発泡粒子充填管６２を設け、ブロー成形後、中空成形体が冷却固化する前に、該発泡粒子充填管６２を中空成形体の外部から内部（中空部）に打ち込み、この打ち込んだ発泡粒子充填管６２を介して圧送空気とともに発泡粒子を充填することにより行うことができる。この発泡粒子の充填は、中空成形体が軟化状態となっている段階において行うことが好ましい。このように中空成形体内に発泡粒子が充填されることにより、加熱媒体により発泡粒子が相互に融着してなる発泡粒子成形体１２と、表皮材１１となる中空成形体の内面とをより確実に融着させることができる。 Next, in the molding die 60, the foamed thermoplastic resin particles are filled into the hollow molded body that is the formed skin material 11. As shown in FIG. 4, for example, as shown in FIG. 4, a foaming particle filling tube 62 is provided in a blow molding die 60, and after the blow molding, before the hollow molded body is cooled and solidified, the foaming particle filling process is performed. It can be performed by driving the tube 62 from the outside of the hollow molded body into the inside (hollow portion), and filling the foamed particles together with the compressed air through the driven foamed particle filling tube 62. The filling of the expanded particles is preferably performed at a stage where the hollow molded body is in a softened state. By filling the foamed particles into the hollow molded body in this way, the foamed particle molded body 12 in which the foamed particles are fused to each other by the heating medium and the inner surface of the hollow molded body serving as the skin material 11 can be more reliably formed. Can be fused.
　続いて、中空成形体内に充填された発泡粒子に対して加熱媒体を供給し、発泡粒子同士を加熱融着させる。この加熱媒体の供給工程は、例えば図４に示すように、ブロー成形用の成形型６０に設けられた加熱媒体供給管６３を中空成形体の内部に向かって挿入し、該挿入した加熱媒体供給管６３を介して加熱媒体（例えばスチーム）を中空成形体内に供給することにより行うことができる。この加熱媒体の供給工程では、供給された加熱媒体で加熱された発泡粒子どうしが融着し、発泡粒子成形体１２が形成される。さらに、発泡粒子成形体１２の形成が進行するとともに、表皮材１１である中空成形体の内面とその内面に接触する発泡粒子成形体１２の部分とが融着されることとなる。 Subsequently, a heating medium is supplied to the foamed particles filled in the hollow molded body, and the foamed particles are heated and fused to each other. In the heating medium supply step, for example, as shown in FIG. 4, a heating medium supply pipe 63 provided in a mold 60 for blow molding is inserted toward the inside of the hollow molded body, and the inserted heating medium supply This can be performed by supplying a heating medium (for example, steam) into the hollow molded body through the pipe 63. In the heating medium supply step, the foamed particles heated by the supplied heating medium are fused together to form the foamed particle molded body 12. Further, as the formation of the foamed particle molded body 12 proceeds, the inner surface of the hollow molded body, which is the skin material 11, and the portion of the foamed particle molded body 12 that comes into contact with the inner surface are fused.
　上記第一工程における、上記加熱媒体の供給工程において、本発明では２つの加熱媒体供給管６３を、２つの加熱媒体供給管の間の距離を４００ｍｍ以下として、取付具５０が取り付けられる複合成形体１０の部位（取付部２３）を挟んで挿入するとともに、取付部２３と、上記２つの加熱媒体供給管のうちの一方の加熱媒体供給管６３との距離を１８０ｍｍ以下として、中空成形体内に該加熱媒体供給管６３を挿入して加熱する。これにより、取付部２３周辺における表皮材１１と発泡粒子成形体１２との融着状態が良好となり剥離強度が向上したものとなり、取付部２３に取り付けられた取付具５０の引抜強度が強いものとなる。
　かかる観点から、取付部２３と、上記２つの加熱媒体供給管６３のうちの一方の加熱媒体供給管６３との距離は、１５０ｍｍ以下であることがより好ましく、１３０ｍｍ以下であることが特に好ましい。また、上記第一工程において、上記２つの加熱媒体供給管６３の間の距離を３５０ｍｍ以下として、中空成形体内に該加熱媒体供給管６３を挿入して加熱することが好ましく、２つの加熱媒体供給管６３の間の距離は３２０ｍｍ以下であることがより好ましい。
　また、取付具５０を安定して固定できる観点から、取付部２３と、上記２つの加熱媒体供給管６３のうちの一方の加熱媒体供給管６３との距離は、概ね３０ｍｍ以上であることが好ましく、より好ましくは５０ｍｍ以上である。また、表面状態が良好な複合成形体が得られやすいという観点から、上記第一工程において、上記２つの加熱媒体供給管６３の間の距離を１００ｍｍ以上として、中空成形体内に該加熱媒体供給管６３を挿入して加熱することが好ましく、２つの加熱媒体供給管６３の間の距離は１５０ｍｍ以上であることがより好ましく、さらに好ましくは１８０ｍｍ以上である。
　なお、取付具５０の引抜強度をより高める観点から、取付部２３は、上記２つの加熱媒体供給管跡１５のうちのいずれか一方側に近づけて設けることが好ましい。
　また、上記第一工程において、上記２つの加熱媒体供給管６３のうちの他方の加熱媒体供給管６３との距離を２００ｍｍ以下として、中空成形体内に該加熱媒体供給管６３を挿入して加熱することが好ましい。上記２つの加熱媒体供給管６３のうちの他方の加熱媒体供給管６３との距離は、１８０ｍｍ以下であることがより好ましく、１６０ｍｍ以下であることが特に好ましい。
　なお、取付部２３と、上記加熱媒体供給管６３との距離は、該取付部２３の近傍に位置する２つの加熱媒体供給管６３の中心点同士の間を直線で結び、該直線と上記取付部２３の側端とが交わる点を両端とした線分の中点を取付部２３の中心点とし、該取付部２３の中心点と、上記加熱媒体供給管６３の中心点との間の距離を意味する。 In the heating medium supply step in the first step, in the present invention, the two heating medium supply pipes 63 are set to have a distance between the two heating medium supply pipes of 400 mm or less, and the composite molded body to which the fixture 50 is attached. 10 (mounting part 23), and the distance between the mounting part 23 and one of the two heating medium supply pipes 63 is set to 180 mm or less. The heating medium supply pipe 63 is inserted and heated. Thereby, the fusion | melting state of the skin material 11 and the foamed-particle molded body 12 in the periphery of the attachment part 23 becomes favorable, and the peel strength is improved, and the pull-out strength of the attachment 50 attached to the attachment part 23 is strong. Become.
From such a viewpoint, the distance between the mounting portion 23 and one of the two heating medium supply pipes 63 is preferably 150 mm or less, particularly preferably 130 mm or less. Further, in the first step, it is preferable that the distance between the two heating medium supply pipes 63 is 350 mm or less, and the heating medium supply pipe 63 is inserted into the hollow molded body to heat the hollow molded body. More preferably, the distance between the tubes 63 is 320 mm or less.
In addition, from the viewpoint that the fixture 50 can be stably fixed, the distance between the attachment portion 23 and one of the two heating medium supply pipes 63 is preferably about 30 mm or more. , More preferably 50 mm or more. In addition, from the viewpoint that a composite molded body having a good surface condition is easily obtained, in the first step, the distance between the two heating medium supply pipes 63 is set to 100 mm or more, and the heating medium supply pipe is inserted into the hollow molded body. Preferably, the heating medium 63 is inserted and heated, and the distance between the two heating medium supply pipes 63 is more preferably 150 mm or more, and further preferably 180 mm or more.
In addition, from the viewpoint of further increasing the pull-out strength of the attachment 50, it is preferable that the attachment portion 23 be provided closer to one of the two heating medium supply pipe traces 15.
Further, in the first step, the distance between the other heating medium supply pipe 63 of the two heating medium supply pipes 63 is set to 200 mm or less, and the heating medium supply pipe 63 is inserted into the hollow molded body and heated. Is preferred. The distance between the two heating medium supply pipes 63 and the other heating medium supply pipe 63 is more preferably 180 mm or less, and particularly preferably 160 mm or less.
The distance between the mounting portion 23 and the heating medium supply pipe 63 is such that a straight line connects the center points of the two heating medium supply pipes 63 located near the mounting portion 23, and The midpoint of the line segment having both ends at the point where the side end of the portion 23 intersects is the center point of the mounting portion 23, and the distance between the center point of the mounting portion 23 and the center point of the heating medium supply pipe 63. Means
　複合成形体の製造装置は、図４に示したように、押出機、ダイ（これらは図示しない）及び成形用の成形型６０を備える。成形型６０には、軟化状態のパリソンをブロー成形して中空成形体を形成するためのブローエアを供給するブロー管６１、形成した中空成形体内に発泡粒子を充填する発泡粒子充填管６２、及び充填した発泡粒子を相互に加熱融着させる加熱媒体を供給する加熱媒体供給管６３がそれぞれ設けられている。なお、この図４は、上記した加熱媒体の供給工程を示しており、加熱媒体供給管６３を表皮材１１である中空成形体内に挿入させている。これらのブロー管６１、発泡粒子充填管６２、そして加熱媒体供給管６３は、成形型６０内部に対して挿入可能にそれぞれ構成される。ブロー管６１はブローエアを、発泡粒子充填管６２は発泡粒子を、そして加熱媒体供給管６３は加熱媒体（例えばスチーム）をそれぞれ供給可能に構成されている。また、図示した成形型６０は分割成形型に形成されており、表皮材１１の上部面を形成する第一壁１１ａ側を成形する成形型片６０ａと、下部面を形成する第二壁１１ｂ側を成形する成形型片６０ｂとからなる。上記したブロー管６１、発泡粒子充填管６２、そして加熱媒体供給管６３は、その全てが表皮材１１の下部面を形成する第二壁１１ｂ側を成形する成形型片６０ｂに配置されている。これにより、複合成形体１０は、ブロー管跡１３、発泡粒子充填管跡１４、及び加熱媒体供給管跡１５の全てが、外方から見え難い下部面に存在するものとなり、外観性の良好な複合成形体１０を製造することができる。 (4) As shown in FIG. 4, the apparatus for manufacturing a composite molded body includes an extruder, a die (these are not shown), and a molding die 60 for molding. The molding die 60 includes a blow tube 61 for supplying blow air for blow molding a softened parison to form a hollow molded body, a foamed particle filling tube 62 for filling the formed hollow molded body with foamed particles, and filling. Heating medium supply pipes 63 for supplying a heating medium for heating and fusing the expanded particles to each other are provided. FIG. 4 shows the heating medium supply step described above, in which the heating medium supply pipe 63 is inserted into the hollow molded body that is the skin material 11. The blow tube 61, the expanded particle filling tube 62, and the heating medium supply tube 63 are configured to be insertable into the molding die 60, respectively. The blow tube 61 is configured to be capable of supplying blow air, the expanded particle filling tube 62 is capable of supplying expanded particles, and the heating medium supply tube 63 is configured to be capable of supplying a heating medium (for example, steam). The illustrated mold 60 is formed as a split mold, and includes a mold piece 60a for forming the first wall 11a forming the upper surface of the skin material 11, and a second wall 11b forming the lower surface. And a molding die piece 60b for molding. The blow tube 61, the foamed particle filling tube 62, and the heating medium supply tube 63 are all arranged on a molding die piece 60b that forms the second wall 11b side forming the lower surface of the skin material 11. As a result, in the composite molded body 10, all of the traces of the blow pipe 13, the traces of the foamed particle filling pipe 14, and the traces of the heating medium supply pipe 15 are present on the lower surface that is difficult to see from the outside, and the appearance is good. The composite molded body 10 can be manufactured.
　続いて、第二工程において、上記第一工程で製造した上記複合成形体１０に取付具５０を固定する。この取付具５０の取り付けは、複合成形体１０に形成された取付部２３に、取付具（例えば金属製ステー）５０を配置し、締結部材（ブラインドリベット）５１を上記表皮材１１と取付具５０とを貫通するようにして取付部２３に挿入し、締結部材（ブラインドリベット）５１を締結して固定することによって行うことができる。締結部材５１として、リベットを用いることが好ましいが、取付具５０の取り付け方法はこれに限らない。例えば、締結部材５１としてボルトとナットを用いることができ、この場合には、インサートナットを予め複合成形体１０に埋め込んでおき、該インサートナットとボルトを締結することで取付具５０を複合成形体１０に取り付けてもよい。 Subsequently, in a second step, the fixture 50 is fixed to the composite molded body 10 manufactured in the first step. To attach the attachment 50, an attachment (for example, a metal stay) 50 is disposed on the attachment portion 23 formed on the composite molded body 10, and a fastening member (blind rivet) 51 is attached to the skin material 11 and the attachment 50. Is inserted into the mounting portion 23 so as to penetrate through, and the fastening member (blind rivet) 51 is fastened and fixed. It is preferable to use a rivet as the fastening member 51, but the method of attaching the fixture 50 is not limited to this. For example, a bolt and a nut can be used as the fastening member 51. In this case, an insert nut is embedded in the composite molded body 10 in advance, and the fixture 50 is fastened by fastening the insert nut and the bolt. 10 may be attached.
　以上、説明した本発明に係る取付具付き複合成形体である取付具付き車両用ステップ１は、取付具５０を介してボルトなどの締結具により車体に取り付けることができる。そして、かかる車両用ステップ１を車体に取り付けた状態では、乗員が表皮材１１である中空成形体のステップ部２０に足を載置することにより車内への乗降が容易となる。このとき、本発明に係る車両用ステップ１は中空成形体からなる表皮材１１と、該表皮材１１の内部に位置する発泡粒子成形体１２とからなる複合成形体１０から構成されているので、十分な剛性を有し、変形して破損したりするなどの不具合の発生が抑制される。また、車両用ステップ１の内部に位置する発泡粒子成形体１２の持つエネルギー吸収性能により衝突時の緩衝性能が良好なステップとなる。また、表皮材１１である中空成形体は、その内部に位置する発泡粒子成形体１２によってその補強が図られているためにリブ構造が無くされ、上部面を形成する第一壁１１ａと、下部面を形成する第二壁１１ｂとがそれらの周縁同士で融着された中空成形体に形成されているので、車両用ステップ１の軽量化を実現できる。車両用ステップ１の軽量化により車両用ステップ１の取付作業時の労力も軽減することができる。 ス テ ッ プ The vehicle step 1 with a fixture, which is the above-described composite molded body with a fixture according to the present invention, can be attached to the vehicle body via the fixture 50 with a fastener such as a bolt. When the vehicle step 1 is attached to the vehicle body, the occupant can easily get on and off the vehicle by placing his feet on the step portion 20 of the hollow molded body as the skin material 11. At this time, the vehicle step 1 according to the present invention is composed of the composite molded body 10 composed of the skin material 11 made of a hollow molded body and the foamed particle molded body 12 located inside the skin material 11, It has sufficient rigidity and suppresses the occurrence of problems such as deformation and breakage. In addition, due to the energy absorbing performance of the foamed particle molded body 12 located inside the vehicle step 1, the cushioning performance at the time of collision becomes a good step. Further, the hollow molded body, which is the skin material 11, is reinforced by the foamed particle molded body 12 located inside thereof, so that the rib structure is eliminated, and the first wall 11a forming the upper surface and the lower wall 11a are formed. Since the second wall 11b forming the surface and the peripheral edge thereof are formed in a hollow molded body fused to each other, the weight of the vehicle step 1 can be reduced. By reducing the weight of the vehicle step 1, the labor required for mounting the vehicle step 1 can be reduced.
　特に、本発明に係る取付具付き複合成形体である車両用ステップ１は、複合成形体１０の製造時に、表皮材１１の取付部２３を挟んで加熱媒体供給管６３を挿入するとともに、取付部２３に近い位置（１８０ｍｍ以下の位置）に加熱媒体供給管６３を挿入して充填された発泡粒子の加熱成形を行うことで、表皮材１１の肉厚が薄いものであっても、取付部２３周辺における表皮材１１と発泡粒子成形体１２との剥離強度が向上したものとなり、取付部２３に取り付けられた取付具５０の引抜強度が強いものとなる。そのため、軽量であるとともに該取付具５０を介して車体に安定的に装着できる車両用ステップとなる。 In particular, the step 1 for a vehicle, which is a composite molded body with a fixture according to the present invention, includes the step of inserting the heating medium supply pipe 63 with the mounting portion 23 of the skin material 11 interposed therebetween during the production of the composite molded body 10. By inserting the heating medium supply pipe 63 into a position close to the position 23 (a position of 180 mm or less) to heat-mold the filled expanded particles, even if the skin material 11 has a small thickness, The peel strength between the skin material 11 and the foamed particle molded body 12 in the periphery is improved, and the pull-out strength of the fixture 50 attached to the attachment portion 23 is enhanced. Therefore, the vehicle step is lightweight and can be stably mounted on the vehicle body via the mounting tool 50.
　次に、本発明について、実施例及び比較例を示してさらに詳細に説明する。但し、本発明は、何らこの実施例によって限定されるものでない。 Next, the present invention will be described in more detail with reference to examples and comparative examples. However, the present invention is not limited by this embodiment.
　図１に示すような形状を有し、概略寸法として、複合成形体の長さが２０００ｍｍ、ステップ部の幅が１６０ｍｍ、ステップ部の厚さが８０ｍｍ、取付部の高さが１２０ｍｍである取付具付き複合成形体（車両用ステップ）を作製した。 A fixture having a shape as shown in FIG. 1 and having, as schematic dimensions, a length of the composite molded body of 2000 mm, a width of the step portion of 160 mm, a thickness of the step portion of 80 mm, and a height of the attachment portion of 120 mm. A composite molded body (vehicle step) was prepared.
　上記複合成形体（車両用ステップ）の作製は、次の方法により行った。
　先ず、内径６５ｍｍの押出機に、ガラス繊維（繊維長さ０．８ｍｍ）を１５重量％の配合割合で添加したブロックポリプロピレン（ＭＦＲ：１．０ｇ/１０分、密度：１．０g/ｃｍ3）を供給し、２１０℃で加熱、混練して溶融樹脂とした。
　次に、該溶融樹脂をアキュムレータ（設定温度２１０℃）に充填し、アキュムレータから溶融樹脂をダイを通して筒状に押出して軟化状態のパリソンとした。該パリソンをダイ直下に配置された分割金型で挟み込んだ。なお、金型温度は７０℃に調整した。その後、ブロー管を打ち込みブロー管から０．５０ＭＰａ（Ｇ：ゲージ圧）の加圧空気をパリソン内に吹き込むと同時にパリソン外面と金型内面との間を減圧して、前記金型のキャビティ形状を賦形し、平均厚み３．５ｍｍの中空成形体を形成した。
　なお、中空成形体の成形においては、上記車両用ステップの概略寸法と同等の成形キャビティを有する成形金型を用いた。発泡粒子充填管としては外径２０ｍｍのものを１本使用し、ブロー管としては外径４ｍｍのものを２本使用し、加熱媒体供給管としては外径８ｍｍのものを９本使用した。また、図２に示すような位置関係となるように各管を成形金型に配置した。 The production of the composite molded article (vehicle step) was performed by the following method.
First, a block polypropylene (MFR: 1.0 g / 10 min, density: 1.0 g / cm 3 ) obtained by adding a glass fiber (fiber length 0.8 mm) at a blending ratio of 15% by weight to an extruder having an inner diameter of 65 mm. And heated and kneaded at 210 ° C. to obtain a molten resin.
Next, the molten resin was charged into an accumulator (a set temperature of 210 ° C.), and the molten resin was extruded from the accumulator into a cylindrical shape through a die to form a soft parison. The parison was sandwiched between split dies arranged immediately below the die. The mold temperature was adjusted to 70 ° C. Thereafter, a blow tube is driven into the parison, and at the same time, pressurized air of 0.50 MPa (G: gauge pressure) is blown from the blow tube into the parison. By shaping, a hollow molded body having an average thickness of 3.5 mm was formed.
In the molding of the hollow molded body, a molding die having a molding cavity equivalent to the approximate dimensions of the vehicle step was used. One tube with an outer diameter of 20 mm was used as a foamed particle filled tube, two tubes with an outer diameter of 4 mm were used as blow tubes, and nine tubes with an outer diameter of 8 mm were used as heating medium supply tubes. Each tube was arranged in a molding die so as to have a positional relationship as shown in FIG.
　次に、軟化状態の中空成形体内に、一方の分割金型から他方の分割金型に向けて前記９本の加熱媒体供給管を挿入し、該加熱媒体供給管から中空成形体の中空部内の気体を排気することにより中空成形体の中空部の圧力を０．１８ＭＰａ（Ｇ）に調整しながら、中空成形体内に発泡粒子充填管を挿入し、発泡粒子充填管を通してプロピレン―エチレンランダム共重合体を基材樹脂とするポリプロピレン系樹脂発泡粒子（見掛け密度６０ｋｇ/ｍ３）を充填した。
　発泡粒子充填後、中空成形体内に挿入された９本の加熱媒体供給管のうち４本の加熱媒体供給管Ａ群から排気しながら、残りの５本の加熱媒体供給管Ｂ群から０．４ＭＰａ（Ｇ）のスチームを１０秒間供給した。次に加熱媒体供給管Ｂ群から排気しながら、加熱媒体供給管Ａ群から０．４ＭＰａ（Ｇ）のスチームを１０秒時間供給した。最後に、全ての加熱媒体供給管Ａ群及びＢ群から０．４ＭＰａ（Ｇ）のスチームを８秒間供給して発泡粒子相互を加熱融着させると共に、中空成形体の内面と発泡粒子とを融着させた。
　その後、金型に取り付けられた面圧計の圧力が０．０５ＭＰａ（Ｇ）となるまで成形体を冷却し、加熱媒体供給管を抜き取ったのち、金型を開き、金型から離型することにより複合成形体を得た。 Next, the nine heating medium supply pipes are inserted into the softened hollow molded body from one divided mold toward the other divided mold, and the heating medium supply pipe is inserted into the hollow portion of the hollow molded body. While adjusting the pressure of the hollow portion of the hollow molded body to 0.18 MPa (G) by exhausting gas, a foamed particle filled tube is inserted into the hollow molded body, and the propylene-ethylene random copolymer is passed through the foamed particle filled tube. Was filled with expanded polypropylene resin particles having an apparent density of 60 kg / m 3 .
After filling the expanded particles, 0.4 MPa was discharged from the remaining five heating medium supply pipes B while exhausting from four heating medium supply pipes A among the nine heating medium supply pipes inserted into the hollow molded body. The steam of (G) was supplied for 10 seconds. Next, 0.4 MPa (G) steam was supplied from the heating medium supply pipe A group for 10 seconds while evacuating from the heating medium supply pipe B group. Finally, steam of 0.4 MPa (G) is supplied from all the heating medium supply pipes A and B for 8 seconds to heat and fuse the foamed particles to each other, and to melt the inner surface of the hollow molded body and the foamed particles. I wore it.
Thereafter, the compact is cooled until the pressure of the surface pressure gauge attached to the mold becomes 0.05 MPa (G), the heating medium supply pipe is extracted, the mold is opened, and the mold is released from the mold. A composite molded body was obtained.
　得られた複合成形体は、上記概略寸法を有しており、表皮材の平均厚みは３．５ｍｍであり、発泡粒子成形体の見掛け密度は４５ｋｇ／ｍ３であった。 The obtained composite molded article had the above-described approximate dimensions, the average thickness of the skin material was 3.5 mm, and the apparent density of the foamed particle molded article was 45 kg / m 3 .
　加熱媒体供給管跡からの距離が表１に示す値となるように、上記製造した複合成形体に取付具（鉄製ステー）をポップリベットを用いて取り付けた。なお、実施例１～４、比較例１においては、一つの取付具に対して、６個のポップリベット（ＰＯＰ Ｒｉｖｅｔｓ）：ポップリベット・ファスナー株式会社製ＡＤ-６４-ＴＬ Ａ-３０-Ｍ-Ｃを用いて取り付けを行った。また、実施例５においては、一つの取付具に対して、２個のポップＨＣリベット（ＰＯＰ ＨＣ Ｒｉｖｅｔｓ）：ポップリベット・ファスナー株式会社製ＳＨＣ-５２Ｍ７６を用いて取り付けを行った。 (4) An attachment (iron stay) was attached to the above-described composite molded body using a pop rivet so that the distance from the trace of the heating medium supply pipe became a value shown in Table 1. In Examples 1 to 4 and Comparative Example 1, six rivets (POP @ Rivets): AD-64-TL @ A-30-M- manufactured by Pop Rivets Fastener Co., Ltd. for one fixture. Mounting was performed using C. In Example 5, two POP HC rivets (POP @ HC \ Rivets) were attached to one fixture using SHC-52M76 manufactured by POP Rivet Fastener Co., Ltd.
　上記製造した取付具付き複合成形体について、各取付具の引抜き時における表皮材と発泡粒子成形体とが剥離する際の荷重（剥離時の荷重）を測定した。
　なお、剥離時の荷重の測定は引張試験機（テンシロン万能試験機：オリエンテック社製）を用いて次の方法により行った。
　加熱媒体供給管跡からの距離が表１となるように取り付けた取付具付き複合成形体を、取付具が上面（ステップの下部面が上面）となるようにして荷重測定用冶具に固定した。取付具の四隅部にあらかじめ設けられた穴のそれぞれに、引張試験機に取り付けられた四本のワイヤーロープをそれぞれ連結し、引張試験において、表皮材と発泡粒子成形体との融着面に対して垂直な方向に均等な荷重が加わるように、取付具と引張試験機とを固定した。次に、引張試験機により２０ｍｍ／分の速度で引張荷重をかけて引張試験を行った。この引張試験（ｎ＝３）において、表皮材が発泡粒子成形体から剥離した際の荷重の算術平均値を求め、これを引抜き時における剥離時の荷重とした。 With respect to the composite molded article with a fixture manufactured as described above, a load (load at the time of peeling) when the skin material and the foamed particle molded article were peeled when each fixture was pulled out was measured.
In addition, the measurement of the load at the time of peeling was performed by the following method using a tensile tester (Tensilon universal tester: manufactured by Orientec).
The composite molded body with the fixture attached so that the distance from the trace of the heating medium supply pipe was as shown in Table 1 was fixed to a load measuring jig such that the fixture was on the upper surface (the lower surface of the step was the upper surface). Attach the four wire ropes attached to the tensile tester to each of the holes provided in advance at the four corners of the mounting fixture, and in the tensile test, apply the The fixture and the tensile tester were fixed so that a uniform load was applied in the vertical direction. Next, a tensile test was performed by applying a tensile load at a speed of 20 mm / min using a tensile tester. In this tensile test (n = 3), the arithmetic mean value of the load when the skin material was peeled off from the foamed particle molded body was determined, and this was defined as the load at the time of peeling at the time of drawing.
　結果を表１に示す。なお、表１中、一方の加熱媒体供給管跡からの距離及び他方の加熱媒体供給管跡からの距離は、上記取付具の近傍に位置する２つの加熱媒体供給管跡の中心点同士間を直線で結び、該直線と上記取付具の側端とが交わる点を両端とした線分の中点を取付具の中心点とし、該取付具の中心点と、上記加熱媒体供給管跡の中心点との間のそれぞれの距離を意味する。 The results are shown in Table 1. In Table 1, the distance from the trace of one heating medium supply pipe and the distance from the trace of the other heating medium supply pipe are defined by the distance between the center points of the two traces of the heating medium supply pipe located near the fixture. A straight line, the midpoint of a line segment having both ends at the point where the straight line intersects with the side end of the fixture is the center point of the fixture, and the center point of the fixture and the center of the trace of the heating medium supply pipe It means the respective distance between the points.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　本発明によれば、軽量性に優れるとともに、取付具の引抜強度にも優れた取付具付き複合成形体を提供できるため、例えば、ピックアップトラックや一部の多目的スポーツ車などの比較的車高の高い車両におけるステップとして広く使用することができるものとなる。 According to the present invention, since it is possible to provide a composite molded article with a fixture that is excellent in lightness and excellent in the pull-out strength of the fixture, for example, a relatively high vehicle height such as a pickup truck or some multipurpose sports cars can be provided. It can be widely used as a step in a tall vehicle.

Claims (10)

  1. 　取付具付き複合成形体であって、
    　相互に加熱融着した複数の熱可塑性樹脂発泡粒子からなる発泡粒子成形体と、熱可塑性樹脂中空成形体からなる表皮材とを有し、上記発泡粒子成形体が上記表皮材の内部に形成されかつ上記表皮材の内面に接着された複合成形体と、
    　上記複合成形体を他に取り付けるための取付具と、
    　上記表皮材及び上記取付具を貫通して上記取付具を上記表皮材に締結する締結部材と、を備え
    　上記表皮材は、熱可塑性樹脂中空成形体の中空部に充填された熱可塑性樹脂発泡粒子を加熱融着させるための加熱媒体を供給する加熱媒体供給管により形成された複数の加熱媒体供給管跡を有しており、
    　上記取付具は、２つの加熱媒体供給管跡の間に取り付けられており、
    　上記２つの加熱媒体供給管跡の間の距離が４００ｍｍ以下であり、
    　上記取付具と、上記２つの加熱媒体供給管跡のうちの一方の加熱媒体供給管跡との距離が、１８０ｍｍ以下であることを特徴とする、
    　取付具付き複合成形体。     A composite molded body with a fixture,
    A foamed particle molded body composed of a plurality of thermoplastic resin foamed particles that are heat-fused with each other, and a skin material composed of a thermoplastic resin hollow molded body, wherein the foamed particle molded body is formed inside the skin material. And a composite molded body adhered to the inner surface of the skin material,
    A mounting tool for mounting the composite molded body to another,
    A fastening member that penetrates the skin material and the fixture to fasten the fixture to the skin material, wherein the skin material is a thermoplastic resin foam particle filled in a hollow portion of a thermoplastic resin hollow molded body. Has a plurality of heating medium supply pipe traces formed by a heating medium supply pipe that supplies a heating medium for heating and fusing,
    The fixture is attached between two traces of the heating medium supply pipe,
    The distance between the two heating medium supply pipe traces is 400 mm or less,
    The distance between the attachment and one of the two heating medium supply pipe traces is 180 mm or less,
    Composite molded body with fittings.
  2. 　上記取付具の引抜き時における、上記表皮材と上記発泡粒子成形体とが剥離する際の荷重が、１．５ｋＮ以上であることを特徴とする、請求項１に記載の取付具付き複合成形体。 2. The composite molded article with a fixture according to claim 1, wherein a load at which the skin material and the foamed particle molded article are separated when the fixture is pulled out is 1.5 kN or more. 3. .
  3. 　上記表皮材の平均肉厚が、１～４ｍｍであることを特徴とする、請求項１または２に記載の取付具付き複合成形体。 (4) The composite molded article with a fixture according to (1) or (2), wherein the average thickness of the skin material is 1 to 4 mm.
  4. 　上記表皮材が、熱可塑性樹脂中に強化繊維を含む繊維強化熱可塑性樹脂から構成される中空ブロー成形体であることを特徴とする、請求項１～３のいずれかに記載の取付具付き複合成形体。 The composite with a fixture according to any one of claims 1 to 3, wherein the skin material is a hollow blow molded article made of a fiber-reinforced thermoplastic resin containing reinforcing fibers in the thermoplastic resin. Molded body.
  5. 　上記繊維強化熱可塑性樹脂中の強化繊維の含有量が、１０～３０重量％であることを特徴とする、請求項４に記載の取付具付き複合成形体。 The composite molded article with a fixture according to claim 4, wherein the content of the reinforcing fibers in the fiber-reinforced thermoplastic resin is 10 to 30% by weight.
  6. 　上記熱可塑性樹脂が、ポリプロピレン系樹脂であることを特徴とする、請求項４又は５に記載の取付具付き複合成形体。 The composite molded article with the fixture according to claim 4 or 5, wherein the thermoplastic resin is a polypropylene-based resin.
  7. 　上記発泡粒子成形体が、見掛け密度３０～１５０ｋｇ／ｍ３の熱可塑性樹脂発泡粒子成形体であることを特徴とする、請求項１～６のいずれかに記載の取付具付き複合成形体。 The foamed bead molded article is characterized in that it is a thermoplastic resin foamed bead molded article of apparent density 30 ~ 150kg / m 3, the fixture with composite molded body according to any one of claims 1 to 6.
  8. 　上記発泡粒子成形体が、ポリプロピレン系樹脂発泡粒子成形体であることを特徴とする、請求項７に記載の取付具付き複合成形体。 The composite molded article with the fixture according to claim 7, wherein the foamed particle molded article is a polypropylene resin foamed particle molded article.
  9. 　請求項１～８のいずれかに記載の取付具付き複合成形体からなる、車体のドア開口部の下方に取り付けられる取付具付き車両用ステップ。 A vehicle step with a fixture, which is formed below the door opening of the vehicle body and is made of the composite molded article with the fixture according to any one of claims 1 to 8.
  10. 　複合成形体と、該複合成形体に固定された、該複合成形体を他に取り付けるための取付具とを有する取付具付き複合成形体の製造方法であって、
    　熱可塑性樹脂中空成形体の中空部に熱可塑性樹脂発泡粒子を充填し、該熱可塑性樹脂中空成形体内に２つ以上の加熱媒体供給管を挿入して該加熱媒体供給管から加熱媒体を供給することにより上記充填した熱可塑性樹脂発泡粒子を相互に加熱融着させて発泡粒子成形体を形成するとともに熱可塑性樹脂中空成形体内面と発泡粒子成形体とを接着させて、熱可塑性樹脂中空成形体からなる表皮材と、該表皮材の内部に位置する発泡粒子成形体との複合成形体を得る第一工程と、
    　上記表皮材と取付具とに締結部材を貫通させて該締結部材を締結することにより上記複合成形体に取付具を固定し、複合成形体と、該複合成形体に固定された取付具とを有する取付具付き複合成形体を得る第二工程とを有し、
    　上記第一工程において、２つの加熱媒体供給管を、２つの加熱媒体供給管の間の距離を４００ｍｍ以下として、取付具が取り付けられる複合成形体の部位を挟んで挿入するとともに、上記部位と、上記２つの加熱媒体供給管のうちの一方の加熱媒体供給管との距離を１８０ｍｍ以下として、熱可塑性樹脂中空成形体内に該加熱媒体供給管を挿入して加熱することを特徴とする、
    　取付具付き複合成形体の製造方法。     A composite molded article, fixed to the composite molded article, a method of manufacturing a composite molded article with a fixture having a fixture for attaching the composite molded article to another,
    The hollow portion of the thermoplastic resin hollow molded body is filled with thermoplastic resin foam particles, and two or more heating medium supply pipes are inserted into the thermoplastic resin hollow molded body to supply a heating medium from the heating medium supply pipe. By heating and fusing the filled thermoplastic resin foam particles to each other to form a foamed particle molded body, the thermoplastic resin hollow molded body inner surface and the foamed particle molded body are bonded to each other to form a thermoplastic resin hollow molded body. And a first step of obtaining a composite molded article of a foamed particle molded article located inside the skin material,
    The fixing member is fixed to the composite molded body by fastening the fastening member by penetrating the fastening member through the skin material and the mounting member, and the composite molded body and the fixing member fixed to the composite molded body are fixed. Having a second step of obtaining a composite molded body with a fixture having,
    In the first step, the distance between the two heating medium supply pipes is set to 400 mm or less, and the two heating medium supply pipes are inserted across the part of the composite molded body to which the fixture is attached, and The distance between the heating medium supply pipe and one of the two heating medium supply pipes is set to 180 mm or less, and the heating medium supply pipe is inserted into the thermoplastic resin hollow molded body and heated.
    A method for producing a composite molded article with a fixture.
PCT/JP2019/026963 2018-07-11 2019-07-08 Composite molded article provided with fittings, vehicle step provided with fittings, and method for producing composite molded article provided with fittings WO2020013118A1 (en)

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Citations (4)

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JP2002512144A (en) * 1998-04-21 2002-04-23 エアロクイップ コーポレーション Car running board
JP2015085516A (en) * 2013-10-28 2015-05-07 ダイハツ工業株式会社 Blow molding
JP2016078292A (en) * 2014-10-15 2016-05-16 株式会社ジェイエスピー Skin material coated foam particle molded article
JP2017071179A (en) * 2015-10-09 2017-04-13 株式会社ジェイエスピー Production method of skin material-coated expanded particle molding

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002512144A (en) * 1998-04-21 2002-04-23 エアロクイップ コーポレーション Car running board
JP2015085516A (en) * 2013-10-28 2015-05-07 ダイハツ工業株式会社 Blow molding
JP2016078292A (en) * 2014-10-15 2016-05-16 株式会社ジェイエスピー Skin material coated foam particle molded article
JP2017071179A (en) * 2015-10-09 2017-04-13 株式会社ジェイエスピー Production method of skin material-coated expanded particle molding

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