Vehicle exterior equipment and manufacturing method for vehicle exterior equipment

Abstract

To provide vehicle exterior equipment capable of suppressing release of a film member.SOLUTION: A front panel 11 includes: a plate-like base material 20 formed by a resin material; a film member 30 which is superimposed on an external surface 20a of the base material and in which a plurality of films 31, 32 are layered and bonded. The first film 31 is formed by a resin material different from the second film 32. An end edge 35 of the film member 30 is provided with a coating member 40 provided separately from the base material 20 by the resin material and coating a boundary part BL of the films 31, 32 adjacent to each other.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to an exterior part for a vehicle and a method for manufacturing the exterior part for a vehicle.

Background Art

[0002] Patent Document 1 describes a lamp cover of a lighting device. This lamp cover has a film layer and a synthetic resin molding layer. The synthetic resin molding layer has a main body portion on which the film layer is laminated, and an outer edge portion that bends and extends from the edge of the main body portion and is joined to the housing.

[0003] The film layer includes a polycarbonate resin (PC) film laminated on the outer surface or the inner surface of the main body portion, and a methacrylic resin (PMMA) film laminated on the outer surface of the PC film.

[0004] Such a lamp cover is manufactured, for example, as follows. When the resin material of the synthetic resin molding layer is PC, first, a film layer formed by laminating a PMMA film on a PC film is inserted into the cavity of a mold. Then, by filling the cavity with a molten resin material, a lamp cover in which the film layer and the synthetic resin molding layer are integrally molded is obtained.

[0005] Also, when the resin material of the synthetic resin molding layer is a synthetic resin other than PC, before filling the cavity with the molten resin material in the above process, a well-known adhesive is applied to the surface of the film layer on the PC film side. Thereby, a lamp cover in which an adhesive layer is interposed between the film layer and the synthetic resin molding layer is obtained.

[0006] In such a lamp cover, the PC film and the synthetic resin molding layer are protected from ultraviolet rays by the PMMA film having excellent light resistance.

Prior Art Documents

Patent Documents

[0007] [Patent Document 1] Japanese Patent Application Laid-Open No. 2001-14915 [Summary of the Invention] [Problems to be Solved by the Invention]

[0008] By the way, in such a lamp cover, the edge of the film layer is exposed. Therefore, cracks are likely to occur at the edge due to exposure to chemical peeling factors such as detergents. As a result, peeling of the film layer from the synthetic resin molding layer starting from the crack, or peeling between the films is likely to occur.

[0009] Note that such problems are not limited to lamp covers joined to the housing, and can occur similarly in vehicle exterior parts in which a film member is laminated on the outer or inner surface of a base material made of a synthetic resin material.

[0010] Also, such problems are not limited to vehicle exterior parts formed by insert molding, and can occur similarly in vehicle exterior parts obtained by attaching a film member with an adhesive after molding the base material. [Means for Solving the Problems]

[0011] Each aspect of a vehicle exterior part and a method for manufacturing a vehicle exterior part for solving the above problems will be described. [Aspect 1] A vehicle exterior part including a plate-shaped base material formed of a resin material, and a film member that is overlapped on one end surface in the plate thickness direction of the base material and in which a plurality of films are laminated and joined in the plate thickness direction, wherein at least one of the plurality of films is formed of a resin material different from the other films, and at the edge of the film member, a covering member is provided that is provided separately from the base material by a resin material and covers the boundary portion between adjacent films.

[0012] According to the above configuration, at the edge of the film member, the boundary portion between the films adjacent to each other is covered by the covering member. Therefore, compared with the case where the edge of the film member is exposed, the boundary portion is less likely to be exposed to chemical peeling factors. As a result, cracks are less likely to occur in the boundary portion. Consequently, peeling between the films starting from the crack is less likely to occur.

[0013] Therefore, peeling of the film member can be suppressed. [Aspect 2] An exterior component for a vehicle, comprising a plate-shaped base material formed of a resin material, and a film member that is overlapped on one end surface in the plate thickness direction of the base material and in which a plurality of films are laminated and joined in the plate thickness direction, wherein at least one of the plurality of films is formed of a resin material different from the other films, and the film member has a folded portion formed by folding the edge of the film member toward the base material side.

[0014] According to the above configuration, the edge of the film member is disposed between the portion of the film member other than the folded portion and the base material. Therefore, compared with the case where the edge of the film member is exposed, the boundary portion between the films adjacent to each other at the edge is less likely to be exposed to chemical peeling factors. As a result, cracks are less likely to occur in the boundary portion. Consequently, peeling between the films starting from the crack is less likely to occur.

[0015] Therefore, peeling of the film member can be suppressed. [Aspect 3] An exterior component for a vehicle, comprising a plate-shaped base material formed of a resin material, and a film member that is overlapped on one end surface in the plate thickness direction of the base material and in which a plurality of films are laminated and joined in the plate thickness direction, wherein at least one of the plurality of films is formed of a resin material different from the other films, and the film member has a compressed portion formed by compressing the edge of the film member.

[0016] According to the above configuration, in the compression part, adjacent films are firmly joined by the anchor effect. Therefore, even when the boundary part is exposed to chemical peeling factors, cracks are less likely to occur in the boundary part compared to the case where the edge of the film member is simply exposed. As a result, peeling between the films starting from the crack is less likely to occur.

[0017] Therefore, peeling of the film member can be suppressed. [Aspect 4] The vehicle exterior part has a recess formed by compressing the edge of the film member and the base material at a position including the boundary part between the edge of the film member and the base material, and a part of the recess formed by the film member is the compression part, the vehicle exterior part according to [Aspect 3].

[0018] According to the above configuration, in the recess, the compression part and the base material are firmly joined by the anchor effect. Therefore, even when the boundary part between the compression part and the base material is exposed to chemical peeling factors, cracks are less likely to occur in the boundary part. As a result, peeling of the film member from the base material starting from the edge of the film member is less likely to occur.

[0019] Therefore, peeling of the film member can be further suppressed. [Aspect 5] A vehicle exterior part including a plate-shaped base material formed of a resin material and a film member laminated on one end surface in the plate thickness direction of the base material, wherein the film member is composed of a single film, and a covering member provided separately from the base material and covering the boundary part between the edge and the base material is provided at the edge of the film member.

[0020] According to the above configuration, the boundary portion between the film member and the base material is covered by the covering member at the edge of the film member. Therefore, compared with the case where the edge of the film member is exposed, the boundary portion is less likely to be exposed to chemical peeling factors. As a result, cracks are less likely to occur in the boundary portion. Consequently, peeling of the film member from the base material starting from the edge of the film member is less likely to occur.

[0021] Therefore, peeling of the film member can be suppressed. [Aspect 6] A manufacturing method for manufacturing the vehicle exterior component according to [Aspect 1], comprising a preform forming step of laminating and joining a plurality of the films made of a resin material in the plate thickness direction to form a film-like preform, a shaping step of shaping the preform into a shape along the one end face of the base material, a trimming step of trimming the shaped preform to form the film member, a covering member forming step of forming the covering member at the edge of the film member, and a base material forming step of injecting and molding a molten resin with the film member having the covering member formed at the edge inserted into a molding die to mold the base material.

[0022] According to the above method, the vehicle exterior component according to [Aspect 1] can be manufactured.

Effects of the Invention

[0023] According to the present invention, peeling of the film member can be suppressed.

Brief Description of the Drawings

[0024]

Figure 1

Figure 2

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Figure 8

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Figure 10

Figure 11

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Figure 14

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Figure 16

MODE FOR CARRYING OUT THE INVENTION

[0025] Hereinafter, with reference to FIGS. 1 to 14, each embodiment of the vehicle exterior part and the manufacturing method of the vehicle exterior part will be described. <First Embodiment> First, with reference to FIGS. 1 to 6, a first embodiment of an exterior part for a vehicle will be described. In this embodiment, the present invention is embodied as the front panel 11 of the automobile 10.

[0026] As shown in FIGS. 1 to 3, the front panel 11 constitutes the front mask of the automobile 10 together with the headlight and the like, and is attached to the body of the automobile 10 through an attachment portion (not shown) at the front portion 10a of the automobile 10. The attachment portion is attached to the body by, for example, screw fastening, claw fitting, or the like. In this embodiment, the front panel 11 has a so-called grille-less design surface 11a without a ventilation opening. An emblem E for displaying, for example, the manufacturer or model of the automobile 10 is attached to the central portion of the design surface 11a.

[0027] The front panel 11 has a base material 20, a film member 30 superposed on the base material 20, and a covering member 40 (see FIG. 3) covering the film member 30. Hereinafter, each component will be described in detail.

[0028] <Base Material 20> As shown in FIGS. 2 and 3, the base material 20 is formed in a plate shape from a resin material. As the resin material, polyolefin resins such as polyethylene (PE) and polypropylene (PP), acrylonitrile-butadiene-styrene copolymer (ABS) resin, acrylonitrile-ethylene-styrene copolymer (AES) resin, acrylonitrile-styrene-acrylate copolymer (ASA) resin, acrylic resins such as polymethyl methacrylate resin (PMMA), and thermoplastic resins such as polycarbonate (PC) can be used. Also, two or more of the above resin materials may be used in combination. In this embodiment, the base material 20 is formed of PC.

[0029] The base material 20 has a flat main body portion 21 and a frame portion 22 that bends from the edge of the main body portion 21 and extends rearward to surround the main body portion 21. <Film member 30> As shown in FIGS. 2 and 3, the film member 30 is a multilayer film formed by laminating and joining a plurality of films. At least one of the plurality of films is formed of a resin material different from that of the other films. Examples of the resin material for forming each film include polyolefin resins such as PE and PP, ABS resin, AES resin, ASA resin, acrylic resins such as PMMA, polyester resins such as polyethylene terephthalate (PET), polyvinyl chloride resin (PVC), PC, and the like.

[0030] In this embodiment, the film member 30 is formed by adhering a first film 31 formed of PC and a second film 32 formed of PMMA with an adhesive (see FIG. 3). As the adhesive, for example, a polyurethane (PU)-based adhesive can be used. In this embodiment, the first film 31 is overlapped on one end surface (hereinafter, outer surface 20a) in the plate thickness direction of the base material 20.

[0031] The film member 30 has a film main body portion 33 that is overlapped on the outer surface 21a of the main body portion 21, and a film frame portion 34 that bends from the edge of the film main body portion 33 and is overlapped on the outer surface 22a of the frame portion 22.

[0032] <Coating member 40> As shown in FIG. 3, a coating member 40 made of a resin material is provided at the edge 35 of the film frame portion 34. As the resin material, for example, an acrylic-based resin, a PU-based resin, an ABS resin, or the like can be used. In this embodiment, the coating member 40 is formed of PMMA.

[0033] The coating member 40 is formed in a thin film shape by, for example, dip coating. The coating member 40 is overlapped on an end surface 35c including a boundary portion BL between the adjacent films 31 and 32 among the edges 35, and an outer surface 35a and an inner surface 35b that extend continuously from the end surface 35c. Further, the coating member 40 is provided over the entire extending direction of the edge 35.

[0034] <Method for manufacturing the front panel 11> Next, with reference to FIGS. 4 to 6, the method for manufacturing the front panel 11 will be described. The method for manufacturing the front panel 11 includes a preform forming step, a shaping step, a trimming step, a covering member forming step, and a base material forming step.

[0035] First, a film-like preform 30A is formed by bonding a film material 31A made of PC and a film material 32A made of PMMA with a PU-based adhesive (the above is the preform forming step).

[0036] Next, as shown in FIG. 4, the preform 30A is shaped into a shape along the outer surface 20a of the base material 20 by a known method such as vacuum forming or pressure air forming (the above is the shaping step). Thereafter, an unnecessary portion 30B is trimmed by cutting a portion indicated by a one-dot chain line in FIG. 4 of the shaped preform 30A with ultrasonic waves, a hot blade, a laser, or the like (the above is the trimming step). Thereby, the film member 30 is formed.

[0037] Next, as shown in FIG. 5, the edge 35 of the film member 30 is immersed in a tank 50 containing a coating agent 40A containing PMMA as a resin material, whereby the edge 35 of the film member 30 is coated with the coating agent 40A. Thereafter, by drying and curing the coating agent 40A, a thin film-like covering member 40 covering the edge 35 is formed (the above is the covering member forming step).

[0038] As shown in FIG. 6, a molding die 60 is used for molding the base material 20. The molding die 60 includes a fixed die 61 and a movable die 62 provided so as to be able to approach and separate from the fixed die 61. First, the film member 30 whose edge 35 is covered with the covering member 40 is disposed in the fixed die 61 as an insert member. In this state, the molding die 60 is clamped. At this time, a space S1 is formed between the film member 30, the covering member 40, and the fixed die 61 and the movable die 62.

[0039] Next, the molten resin material (PC) is injected and filled into the space S1. When the filled resin material (PC) hardens, the base material 20 is formed (the above is the base material forming step). In this way, the front panel 11 is obtained in which the film member 30 and the covering member 40 are superposed in a state of being in close contact with the outer surface 20a of the base material 20 (see FIG. 3).

[0040] <Action of the First Embodiment> Next, the action of the first embodiment will be described. At the edge 35 of the film frame portion 34 of the film member 30, the boundary portion BL between the films 31 and 32 adjacent to each other is covered by the covering member 40. For this reason, compared with the case where the edge 35 of the film member 30 is exposed outward, the boundary portion BL is less likely to be exposed to chemical peeling factors such as detergents. As a result, cracks are less likely to occur in the boundary portion BL. As a result, peeling between the films 31 and 32 starting from the crack is less likely to occur.

[0041] <Effect of the First Embodiment> Next, the effect of the first embodiment will be described. (1-1) The front panel 11 includes a plate-shaped base material 20 formed of a resin material (PC), and a film member 30 in which a plurality of films 31 and 32 are laminated and joined while being superposed on the outer surface 20a of the base material 20. The first film 31 is formed of a resin material different from that of the second film 32. At the edge 35 of the film frame portion 34 of the film member 30, a covering member 40 that covers the boundary portion BL between the adjacent films 31 and 32 is provided.

[0042] According to such a configuration, the above-described action is exhibited. Therefore, peeling of the film member 30 can be suppressed. (1-2) The manufacturing method of the front panel 11 includes a preform forming step of laminating and bonding film materials 31A and 32A made of a resin material (PC) to form a film-like preform 30A, a shaping step of shaping the preform 30A into a shape along the outer surface 20a of the base material 20, a trimming step of trimming the unnecessary portion 30B of the shaped preform 30A to form a film member 30, a covering member forming step of forming a covering member 40 on the edge 35 of the film member 30, and a base material forming step of injecting and molding a molten resin material (PC) with the film member 30 having the covering member 40 formed on the edge 35 inserted into a mold 60 to mold the base material 20.

[0043] According to such a method, the above-mentioned front panel 11 can be manufactured. Here, in order to suppress the boundary portion BL from being exposed to chemical peeling factors, after the base material forming step, it is conceivable to form a covering member that collectively covers both the base material 20 and the edge 35 of the film member 30 by injection molding or the like. In this case, since the boundary portion between the base material 20 and the edge 35 is covered by the same covering member, the boundary portion is suppressed from being exposed to chemical peeling factors. However, in this case, the following problems occur. That is, in order to collectively cover both the base material 20 and the edge 35, the size of the covering member tends to be large. Also, when the same resin material as the base material 20 (PC in this embodiment) is adopted as the resin material of the covering member, while adhesion to the base material 20 is achieved, when the covering member is formed, a film (the second film 32 in this embodiment) formed of a resin material having a molding temperature lower than the molding temperature of PC melts due to heat. As a result, the design property of the film member 30 deteriorates.

[0044] In this regard, according to the above method, the covering member forming step is performed prior to the base material forming step. Therefore, by forming a local covering member 40 such as providing the covering member 40 only on the edge 35, it is possible to suppress the boundary portion BL from being exposed to chemical peeling factors. Therefore, compared with the above case, the size of the covering member can be reduced.

[0045] Also, by appropriately selecting the resin material for forming the covering member 40 in consideration of the adhesion to the film member 30 and the design property of the film member 30, while ensuring the design property of the film member 30, it is possible to suppress the boundary portion BL from being exposed to chemical peeling factors.

[0046] <Second Embodiment> Next, with reference to FIGS. 7 and 8, the differences between the second embodiment of the vehicle exterior part and the first embodiment will be mainly described. In the second embodiment, for the same or corresponding configurations as those in the first embodiment, the same reference numerals "**" in the first embodiment are appended with "100" to obtain reference numerals "1**", and redundant explanations are omitted.

[0047] As shown in FIG. 7, in the front panel 111 of the present embodiment, the covering member 40 in the front panel 11 of the first embodiment is omitted. The film member 130 has a folding portion 136 formed by folding the edge 135 of the film frame portion 134 toward the frame portion 122 side of the base material 120.

[0048] <Manufacturing Method of Front Panel 111> Next, with reference to FIG. 8, the manufacturing method of the front panel 111 will be described. The manufacturing method of the front panel 111 is different from the manufacturing method of the front panel 11 of the first embodiment in that it has a folding step of the film member 130 instead of the covering member forming step.

[0049] In the folding step, the folding portion 136 is formed by heating and softening the folding location of the film member 130 formed through the preliminary forming step, the shaping step, and the trimming step, using heat, ultrasonic waves, or the like. Hereinafter, an example using ultrasonic waves will be described.

[0050] First, as shown in FIG. 8, vibration (ultrasonic vibration) is propagated to the edge 135 of the film member 130 through the horn 71 of the ultrasonic device 70, thereby generating frictional heat between the films 131 and 132. The edge 135 softened by this frictional heat is pressed inward by the horn 71 to be folded. As a result, a folded portion 136 is formed (the above is the folding process).

[0051] Next, with the film member 130 having the folded portion 136 as an insert member, the base material 120 is injection-molded (base material molding process). Thus, a front panel 111 is obtained in which the film member 130 is overlapped in a state of being in close contact with the outer surface 120a of the base material 120 (see FIG. 7).

[0052] <Actions and Effects of the Second Embodiment> Next, the actions and effects of the second embodiment will be described. (2-1) The film member 130 has a folded portion 136 formed by folding the edge 135 of the film frame portion 134 of the film member 130 toward the frame portion 122 side of the base material 120.

[0053] According to such a configuration, the edge 135 of the film member 130 is disposed between the portion of the film member 130 other than the folded portion 136 and the base material 120. Therefore, compared with the case where the edge 135 of the film member 130 is exposed outward, the boundary portion BL between the films 131 and 132 adjacent to each other at the edge 135 is less likely to be exposed to chemical peeling factors such as detergents. As a result, cracks are less likely to occur in the boundary portion BL. As a result, peeling between the films 131 and 132 starting from the crack is less likely to occur.

[0054] Therefore, peeling of the film member 130 can be suppressed. <Third Embodiment> Next, with reference to FIGS. 9 and 10, differences from the first embodiment in the third embodiment of the vehicle exterior component will be mainly described. In the third embodiment, for the same or corresponding configurations as those in the first embodiment, duplicate explanations are omitted by attaching reference numerals "2**" obtained by adding "200" to each reference numeral "**" in the first embodiment.

[0055] As shown in FIG. 9, in the front panel 211 of the present embodiment, the covering member 40 in the front panel 11 of the first embodiment is omitted. The film member 230 has a compression portion 236 formed by compressing the edge 235 of the film frame portion 234.

[0056] The outer surface 236a of the compression portion 236 is flush with the outer surface 232a of the second film 232. Also, the inner surface 236b of the compression portion 236 is continuous with the inner surface 231a of the first film 231 via a step. At the boundary portion BL of the compression portion 236, the first film 231 and the second film 232 are welded to each other.

[0057] <Manufacturing method of the front panel 211> Next, with reference to FIG. 10, the manufacturing method of the front panel 211 will be described. The manufacturing method of the front panel 211 is different from the manufacturing method of the front panel 11 of the first embodiment in that it has a compression step of the film member 230 instead of the covering member forming step.

[0058] In the compression step, the compression portion 236 is formed by compressing and melting the edge 235 of the film member 230 formed through a preform forming step, a shaping step, and a trimming step using a method such as thermal welding or ultrasonic welding. Hereinafter, an example using thermal welding will be described.

[0059] First, as shown in FIG. 10, the edge 235 of the film member 230 is thermally pressed from the side of the first film 231 by the heated mold 80. As a result, the first film 231 and the second film 232 are compressed and melt with each other. Then, by cooling the film member 230, a compressed portion 236 is formed in which the first film 231 and the second film 232 are compressed and welded to each other (the above is the compression step).

[0060] Next, the film member 230 in which the compressed portion 236 is formed is used as an insert member, and the base material 220 is injection molded (base material molding step). In this way, the front panel 211 in which the film member 230 is overlapped in a state of being in close contact with the outer surface 220a of the base material 220 is obtained (see FIG. 9).

[0061] <Operation and Effect of the Third Embodiment> Next, the operation and effect of the third embodiment will be described. (3-1) The film member 230 has a compressed portion 236 formed by compressing the edge 235 of the film frame portion 234 of the film member 230.

[0062] According to such a configuration, in the compressed portion 236, the films 231 and 232 adjacent to each other are firmly joined by the anchor effect. Therefore, even when the boundary portion BL is exposed to chemical peeling factors such as detergents compared to the case where the edge 235 of the film member 230 is simply exposed outward, cracks are less likely to occur in the boundary portion BL. As a result, peeling between the films 231 and 232 starting from the crack is less likely to occur.

[0063] Therefore, peeling of the film member 230 can be suppressed. <Fourth Embodiment> Next, with reference to FIGS. 11 to 13, the differences between the fourth embodiment of the vehicle exterior component and the third embodiment will be mainly described. In the fourth embodiment, for the same or corresponding configurations as those in the third embodiment, the same reference numerals “**” in the third embodiment are added with “100” to form reference numerals “3**”, and duplicate descriptions will be omitted.

[0064] The front panel 311 has a recess 337 formed by compressing the edge 335 of the film member 330 and the base material 320 at a position including the boundary portion BL between the edge 335 and the base material 320.

[0065] The portion of the recess 337 formed by the film member 330 is a compressed portion 336 formed by compressing the edge 335 of the film frame portion 334 of the film member 330. The outer surface 336a of the compressed portion 336 is continuous with the outer surface 332a of the second film 332 via a step. Also, the inner surface 336b of the compressed portion 336 is flush with the inner surface 331a of the first film 331.

[0066] <Manufacturing method of the front panel 311> With reference to FIGS. 12 and 13, the manufacturing method of the front panel 311 will be described. The manufacturing method of the front panel 311 is different from the manufacturing method of the front panel 211 of the third embodiment in that a compression process is performed after the base material forming process.

[0067] First, as shown in FIG. 12, the film member 330 formed through a preliminary forming process, a shaping process, and a trimming process is disposed in the fixed mold 61 as an insert member. In this state, the molding die 60 is clamped. At this time, a space S2 is formed between the film member 330 and the fixed mold 61 and the movable mold 62. The base material 320 is molded by curing the resin material (PC) injected and filled into the space S2 (the above is the base material forming process).

[0068] Next, as shown in FIG. 13, the base material 320 integrated with the film member 330 is fixed to the jig 90. Then, the portion including the boundary portion BL between the edge 335 and the base material 320 is hot-pressed from the second film 332 side by the heated mold 91. As a result, the edge 335 and the base material 320 are compressed and melt with each other. Then, by cooling the film member 230 and the base material 320, the recess 337 is formed. Also, the compressed portion 336 and the base material 320 are welded to each other at the boundary portion BL (the above is the compression process).

[0069] <Actions and Effects of the Fourth Embodiment> Next, the actions and effects of the fourth embodiment will be described. According to this embodiment, in addition to the actions and effects (3-1) of the third embodiment, the following new actions and effects (4-1) can be achieved.

[0070] (4-1) The front panel 311 has a recess 337 formed by compressing the edge 335 of the film member 330 and the base material 320 at a position including the boundary portion BL between the edge 335 and the base material 320. The portion of the recess 337 formed by the film member 330 is the compression portion 336.

[0071] According to such a configuration, in the recess 337, the compression portion 336 and the base material 320 are firmly joined by the anchor effect. Therefore, even when the boundary portion BL between the compression portion 336 and the base material 320 is exposed to chemical peeling factors such as detergents, cracks are less likely to occur at the boundary portion BL. As a result, peeling of the film member 330 from the base material 320 starting from the edge 335 of the film member 330 is less likely to occur.

[0072] Therefore, peeling of the film member 330 can be further suppressed. <Fifth Embodiment> Next, with reference to FIG. 14, differences between the fifth embodiment of the vehicle exterior component and the first embodiment will be mainly described. In the fifth embodiment, for the same or corresponding configurations as those in the first embodiment, duplicate explanations are omitted by attaching reference numerals "4**" obtained by adding "400" to each reference numeral "**" in the first embodiment.

[0073] As shown in FIG. 14, the front panel 411 of this embodiment is different from the front panel 11 of the first embodiment in that the film member 430 is composed of a single film. In this embodiment, the film member 430 is composed of a second film 432 formed of PMMA.

[0074] The covering member 440 that covers the edge 435 is interposed between the edge 435 and the base material 420 and covers the boundary portion between the edge 435 and the base material 420. <Operation and Effect of the Fifth Embodiment> Next, the operation and effect of the fifth embodiment will be described.

[0075] (5-1) The front panel 411 includes a plate-shaped base material 420 formed of a resin material and a film member 430 superposed on the outer surface 420a of the base material 420. The film member 430 is composed of a single film 432. At the edge 435 of the film member 430, a covering member 440 is provided separately from the base material 420 and covers the boundary portion between the edge 435 and the base material 420.

[0076] According to such a configuration, the boundary portion between the film member 430 and the base material 420 at the edge 435 of the film member 430 is covered by the covering member 440. Therefore, compared with the case where the edge 435 is exposed outward, the boundary portion is less likely to be exposed to chemical peeling factors such as detergents. As a result, cracks are less likely to occur in the boundary portion. As a result, peeling of the film member 430 from the base material 420 starting from the edge 435 of the film member 430 is less likely to occur.

[0077] Therefore, peeling of the film member 430 can be suppressed. <Modification Example> The above embodiment can be implemented with the following modifications. The above embodiment and the following modification examples can be implemented in combination with each other within a technically non-conflicting range.

[0078] · The coating member according to the present invention is not limited to being formed into a thin film by dip coating, like the coating member 40 exemplified in the first embodiment. For example, it may be formed by hot melt molding in which the edge 35 of the film frame portion 34 is inserted into a mold and hot melt adhesive is injected into the mold, or by insert molding in which a molten resin material is injected into the mold. In this case, as shown in FIG. 15, a coating member 40a thicker than the coating member 40 is formed.

[0079] · The front panel 11 is not limited to having a coating member 40 that collectively covers the outer surface 35a, the inner surface 35b, and the end surface 35c of the edge 35, as exemplified in the first embodiment. As shown in FIG. 16, the front panel 11 may, for example, have a coating member 40b formed only on the end surface 35c using a dispenser or the like and covering only the end surface 35c.

[0080] · The combination of resin materials for forming each of the base material 20, the first film 31, and the second film 32 is not limited to that exemplified in the first embodiment (base material: PC, first film: PC, second film: PMMA), and may be appropriately changed according to the compatibility with the resin material for forming the base material 20. For example, it may be changed to a combination such as base material: PC, first film: ASA resin, second film: PMMA, or a combination such as base material: ABS resin or ASA resin, first film: ASA resin, second film: PMMA, or base material: PMMA, first film: ASA resin, second film: PMMA.

[0081] · The first film 31 and the second film 32 are not limited to being composed only of a resin material. As long as it is mainly composed of a resin material, for example, it may be a mixture appropriately mixed with colorants such as pigments and dyes, extender pigments, solvents, stabilizers, plasticizers, catalysts, curing agents, etc., or by adding various additives, it may have functions such as scratch resistance, anti-fogging, anti-fouling, and ultraviolet shielding. Further, it may be a vapor deposition film formed by vapor depositing a metal or the like on a film formed of a resin material.

[0082] · The film member according to the present invention is not limited to being composed of two films as exemplified in the above embodiment. The film member may be formed by laminating and joining three or more films.

[0083] · The film member according to the present invention is not limited to being superimposed on the outer surface of the base material as exemplified in the above embodiment, and may be superimposed on the inner surface on the opposite side of the outer surface in the plate thickness direction of the base material. In this case, the inner surface corresponds to one end surface according to the present invention.

[0084] · The front panel 11 is not limited to being formed by injection molding the base material 20 with the film member 30 as an insert member as exemplified in the first embodiment. For example, the front panel 11 may be formed by adhering the film member 30 to the base material 20 with an adhesive after injection molding the base material 20.

[0085] · The front panel 11 may be arranged in front of a radar device that transmits and receives electromagnetic waves such as millimeter waves. In this case, the base material 20 and the film member 30 may be configured to have electromagnetic wave transmissibility.

[0086] · The vehicle exterior component according to the present invention is not limited to the front panel 11 having a grille-less design surface 11a as exemplified in the first embodiment, and can also be embodied as a front grille having a ventilation opening.

[0087] · The vehicle exterior component according to the present invention is not limited to the front panel or the front grille, and can also be embodied as a front bumper or an emblem that constitutes the front portion 10a of the automobile 10. Further, the present invention can also be applied to a rear bumper or a back door garnish that constitutes the outer shell of the rear portion of the automobile 10, a side door garnish or a pillar garnish that constitutes the outer shell of the side portion of the automobile 10, and the like.

[0088] · The vehicle exterior parts according to the present invention are not limited to those applied to the automobile 10, and can be appropriately applied as long as they constitute the outer shell of the vehicle.

Explanation of Reference Numerals

[0089] BL... Boundary portion E... Emblem S1, S2... Spaces 10... Automobile 10a... Front part 11, 111, 211, 311, 411... Front panel 11a... Design surface 20, 120, 220, 320, 420... Base material 20a, 120a, 220a, 420a... Outer surface 21... Main body part 21a... Outer surface 22, 122... Frame part 22a... Outer surface 30, 130, 230, 330, 430... Film member 30A... Preform 30B... Unnecessary part 31, 131, 231, 331... First film 31A... Film material 32, 132, 232, 332, 432... Second film 32A... Film material 33... Film main body part 34, 134, 234, 334... Film frame part 35, 135, 235, 335, 435... Edge 35a... Outer surface 35b... Inner surface 35c... End face 40, 40a, 40b, 340, 440... Coating member 40A... Coating agent 50... Tank 60... Molding die 61... Fixing die 62... Movable die 70... Ultrasonic device 71... Horn 80... Mold 90... Fixture 91... Mold 136…Folding part 231a, 331a…Inner surface 232a, 332a…Outer surface 236, 336…Compression part 236a, 336a…Outer surface 236b, 336b…Inner surface 337…Recessed part

Claims

1. A vehicle exterior part comprising a plate-shaped base material formed of a resin material, and a film member that is superposed on one end surface of the base material in the plate thickness direction and in which a plurality of films are laminated and joined in the plate thickness direction, at least one of the plurality of films is formed of a resin material different from the other films, at the edge of the film member, a covering member is provided that is provided separately from the base material by a resin material and covers the boundary portion between adjacent films, Vehicle exterior part.

2. A vehicle exterior part comprising a plate-shaped base material formed of a resin material, and a film member that is superposed on one end surface of the base material in the plate thickness direction and in which a plurality of films are laminated and joined in the plate thickness direction, at least one of the plurality of films is formed of a resin material different from the other films, the film member has a folded portion in which the edge of the film member is folded toward the base material side, Vehicle exterior part.

3. A vehicle exterior part comprising a plate-shaped base material formed of a resin material, and a film member that is superposed on one end surface of the base material in the plate thickness direction and in which a plurality of films are laminated and joined in the plate thickness direction, at least one of the plurality of films is formed of a resin material different from the other films, the film member has a compressed portion in which the edge of the film member is compressed, Vehicle exterior part.

4. The vehicle exterior part has a recess formed by compressing the edge and the base material at a position including the boundary portion between the edge of the film member and the base material, The portion of the recess formed by the film member is the compressed portion, The vehicle exterior part according to claim 3.

5. A vehicle exterior part comprising a plate-shaped base material formed of a resin material and a film member superposed on one end surface in the plate thickness direction of the base material, The film member is composed of a single film, At the edge of the film member, a covering member is provided separately from the base material and covers the boundary portion between the edge and the base material. Vehicle exterior part.

6. A manufacturing method for manufacturing the vehicle exterior part according to claim 1, A preliminary preform forming step of laminating and joining a plurality of the films made of a resin material in the plate thickness direction to form a film-shaped preliminary preform; A shaping step of shaping the preliminary preform into a shape along the one end surface of the base material; A trimming step of trimming the shaped preliminary preform to form the film member; A covering member forming step of forming the covering member at the edge of the film member; A base material forming step of injecting and molding molten resin with the film member having the covering member formed at the edge inserted into a molding die to mold the base material, Manufacturing method for vehicle exterior parts.

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