Vehicle panel and method for manufacturing vehicle panel

Abstract

To provide a panel for a vehicle capable of enhancing the degree of freedom of design expression, and a method for manufacturing the panel for the vehicle.SOLUTION: The vehicle panel 11 includes a resin first layer 13 molded by a first mold, and a resin second layer 15 molded on a surface of the first layer 13 by a second mold. The surface of the second layer 15 has a plurality of surface regions 16 that include the region A and the region D and are continuous in the one direction X. A first grain 19 molded by a first mold is formed in a region H corresponding to the region D on the surface of the first layer 13. In the region A, the second grain 17 molded by the second mold is formed. In the region D, a third grain 18 which is constituted by a sink mark generated when the second layer 15 is molded on the first grain 19 and whose grain height is lower than that of the second grain 17 is formed.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a vehicle panel and a method for manufacturing a vehicle panel. [Background technology]

[0002] Conventionally, resin decorative articles are known as vehicle panels, for example, as shown in Patent Document 1. Such resin decorative articles have a resin base material formed by injection molding. A textured surface consisting of fine irregularities is formed on the surface of the base material. The textured surface is formed by transferring pre-formed irregularities onto the molding surface of a mold that molds the base material during molding. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-236389 Summary of the Invention [Problem to be solved by the invention]

[0004] However, if it is desired to make the textured surface of the substrate finer to increase the freedom of design expression, it is necessary to make the texture formed on the molding surface of the mold finer. However, there is a limit to how fine the texture can be formed on the molding surface of the mold by machining. Therefore, there is room for improvement in increasing the freedom of design expression of vehicle panels. [Means for solving the problem]

[0005] Hereinafter, various aspects of a vehicle panel and a method for manufacturing a vehicle panel for solving the above problems will be described. [Aspect 1] A vehicle panel comprising a first layer made of resin molded by a first mold and a second layer made of resin molded on the surface of the first layer by a second mold, wherein the surface of the second layer has a plurality of surface regions including a first region and a second region and continuing in one direction, a first embossment molded by the first mold is formed in an area on the surface of the first layer corresponding to the second region, a second embossment molded by the second mold is formed in the first region, and a third embossment formed on the first embossment by a sink mark that occurs when molding the second layer and has a embossing height that is lower than that of the second embossment is formed in the second region.

[0006] Generally, when a texture is formed using a mold that has been textured by machining, the texture height is approximately 20 μm or more, but when a texture is formed using sink marks that occur during resin molding, the texture height can be 10 μm or less. In this regard, according to the above-mentioned configuration, by continuously forming the second texture and the third texture, which have different texture height ranges, on the surface of the second layer, it is possible to express designs over a wider range of texture heights. Therefore, the degree of freedom in design expression can be increased.

[0007] [Aspect 2] The vehicle panel described in [Aspect 1] is characterized in that the second layer is visible light transmissive, the surface of the second layer has a third region as the surface region between the first region and the second region in the one direction, the second embossment is formed in the third region, the first embossment is formed in a region on the surface of the first layer corresponding to the third region, the first embossment is configured so that the embossment height is higher on the second region side than on the first region side in the one direction, and the second embossment is configured so that the embossment height is lower on the second region side than on the first region side in the one direction.

[0008] According to the above configuration, the state of light reflection on the surfaces of the first and second layers changes in different, opposite ways in one direction, so that subtle gradations can be expressed.

[0009] [Embodiment 3] A method for manufacturing a vehicle panel, comprising: a first layer molding process in which a first layer made of resin is molded using a first mold; and a second layer molding process in which a second layer made of a resin that is visible light transmissive is molded onto the surface of the first layer using a second mold, the second layer having a first region and a second region on its surface and a plurality of surface regions that are continuous in one direction; wherein in the first layer molding process, a first grain is formed using the first mold in an area on the surface of the first layer that corresponds to the second region; and in the second layer molding process, a second grain is formed in the first region using the second mold, and a sink mark that occurs in the second region is formed in the second region as a third grain that is lower in grain height than the second grain.

[0010] Generally, when a texture is formed using a mold that has been textured by machining, the texture height is approximately 20 μm or more, but when a texture is formed using sink marks that occur during resin molding, the texture height can be 10 μm or less. In this regard, the above method makes it possible to continuously form the second and third textures, each having a different texture height range, on the surface of the second layer, allowing for a wider range of texture heights to be expressed in a design. This increases the degree of freedom in design expression. [Effects of the Invention]

[0011] The present invention can increase the degree of freedom in design expression. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a schematic plan view illustrating a portion of a vehicle panel according to an embodiment. [Figure 2] FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. [Figure 3] FIG. 2 is a cross-sectional view showing a state in which a first layer is molded by a first mold. [Figure 4] FIG. 10 is a cross-sectional view showing a state in which the second mold is clamped with the first layer disposed in the second mold. [Figure 5]5 is a cross-sectional view showing a state in which a thermosetting resin that will become a second layer is filled into a second cavity in a second mold in FIG. 4. FIG. [Figure 6] FIG. 6 is a cross-sectional view showing the state when the second mold is opened after the second layer is molded in FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0013] An embodiment will be described below with reference to the drawings. <Vehicle Panel 11> 1 and 2, a vehicle panel 11 is used, for example, as a vehicle interior panel such as an instrument panel or door trim, or as a vehicle exterior panel such as a bumper or back panel. The vehicle panel 11 includes a first layer 13 made of a thermoplastic resin that does not transmit visible light and is molded by a first mold 12 (see FIG. 3), and a second layer 15 made of a thermosetting resin that transmits visible light and is molded on the surface of the first layer 13 by a second mold 14 (see FIG. 4).

[0014] Examples of thermoplastic resins that can be used to form the first layer 13 include PE (polyethylene), PVC (polyvinyl chloride), PP (polypropylene), PS (polystyrene), ABS (acrylonitrile-butadiene-styrene copolymer resin), AS (acrylonitrile-styrene copolymer resin), PMMA (acrylic resin), PBT (polybutylene terephthalate), PET (polyethylene terephthalate), and PC (polycarbonate).

[0015] On the other hand, examples of the thermosetting resin that constitutes the second layer 15 include thermosetting polyurethane, polyurea, unsaturated polyester, etc. The thermosetting resin that constitutes the second layer 15 is transparent or translucent.

[0016] In the following description, the long side direction of the vehicle panel 11 is defined as one direction X, and the short side direction of the vehicle panel 11 is defined as a width direction Y.

[0017] <2nd layer 15> 1 and 2, the surface of the second layer 15 has a plurality of (four in this example) surface regions 16 that are continuous in one direction X. In this example, the four surface regions 16 are configured by region A as an example of a first region, region D as an example of a second region, region B as an example of a third region, and region C as an example of a third region.

[0018] That is, the four surface regions 16 include region A and region D. Regions A to D are continuously arranged in the order region A, region B, region C, and region D from one side to the other in the direction X. Therefore, the surface of the second layer 15 has region B and region C between region A and region D in the direction X.

[0019] Second grains 17 are formed in regions A, B, and C on the surface of the second layer 15 by a second mold 14 (see FIG. 4). As an example, the second grains 17 are formed of a plurality of irregularities that extend in the width direction Y and are arranged in one direction X and have a triangular cross-sectional shape. The grain height of the second grains 17 is set to be, for example, in the range of 20 μm to 100 μm. The length of each of the irregularities that make up the second grain 17 in one direction X is constant.

[0020] The second embossments 17 in each of the regions A, B, and C are configured so that the height of the embossment is lower on the region D side than on the region A side in one direction X. That is, the height of the second embossments 17 in the region A is higher than the height of the second embossments 17 in the region B, and the height of the second embossments 17 in the region B is higher than the height of the second embossments 17 in the region C.

[0021] A third grain 18 is formed in region D on the surface of the second layer 15, and is constituted by sink marks that occur when molding the second layer 15. As an example, the third grain 18 is constituted by a plurality of irregularities that extend in the width direction Y and are arranged in one direction X and have a triangular cross-sectional shape. The grain height of the third grain 18 is preferably set in the range of 0.5 μm to 10 μm, and more preferably set in the range of 0.5 μm to less than 5 μm.

[0022] That is, the third grain 18 has a lower grain height than the second grain 17 in region C. The length in one direction X of each of the irregularities constituting the third grain 18 is constant. Note that the surface of the second layer 15 may have regions other than regions A to D where no grain is formed.

[0023] <1st layer 13> As shown in Fig. 2, the areas on the surface of the first layer 13 corresponding to areas A, B, C, and D of the second layer 15 are designated as areas E, F, G, and H, respectively. First grains 19 are formed in areas F, G, and H on the surface of the first layer 13 by the first mold 12 (see Fig. 3).

[0024] For example, the first grain 19 is formed of a plurality of triangular cross-sectional irregularities extending in the width direction Y and aligned in the direction X. The height of the first grain 19 is set to be, for example, in the range of 16 μm to 334 μm. The length of each of the irregularities constituting the first grain 19 in the direction X is constant.

[0025] The first grains 19 in each of the regions F, G, and H are configured so that the grain height is higher on the region D side than on the region A side in one direction X. That is, the first grains 19 in the region H are higher in height than the first grains 19 in the region G, and the first grains 19 in the region G are higher in height than the first grains 19 in the region F. No first grains 19 are formed in the region E. Note that the surface of the first layer 13 may have regions other than the regions E to H where no grains are formed.

[0026] The vertices of the triangular cross-sectional irregularities of the first grain 19 in regions F and G of the first layer 13 correspond to the vertices of the triangular cross-sectional irregularities of the second grain 17 in regions B and C of the second layer 15 in a direction perpendicular to the surface of the first layer 13. The vertices of the triangular cross-sectional irregularities of the first grain 19 in region H of the first layer 13 correspond to the vertices of the triangular cross-sectional irregularities of the third grain 18 in region D of the second layer 15 in a direction perpendicular to the surface of the first layer 13.

[0027] <Method of manufacturing the vehicle panel 11> The vehicle panel 11 is manufactured by integrally molding the second layer 15 onto the surface of the first layer 13 by in-mold painting. That is, the vehicle panel 11 is manufactured by carrying out a first layer molding process of molding the first layer 13 and a second layer molding process of molding the second layer 15 onto the surface of the first layer 13.

[0028] As shown in FIG. 3, in the first layer molding process, first, a first cavity 22 formed by clamping a first mold 12 consisting of a first movable mold 20 and a fixed mold 21 is filled with molten resin made of a melted thermoplastic resin material. When the molten resin cools and solidifies, the first layer 13 is molded within the first mold 12. At this time, as shown in FIGS. 2 and 3, first grains 19 are formed in regions F, G, and H on the surface of the first layer 13 by the grained first movable mold 20. Next, the first mold 12 is opened. Next, the first movable mold 20 is replaced with a second movable mold 23 (described later), and the second layer molding process is performed.

[0029] 4, in the second layer molding step, a second mold 14 consisting of a second movable mold 23 and a fixed mold 21 is clamped. As a result, a second cavity 24 is formed between the surface of the first layer 13 in the second mold 14 and the cavity surface of the second movable mold 23.

[0030] Next, as shown in Fig. 5, a thermosetting resin material that is transparent to visible light is filled into the second cavity 24. Then, as shown in Figs. 2 and 5, when the thermosetting resin material filled into the second cavity 24 hardens through a chemical reaction, the second layer 15 is integrally molded onto the surface of the first layer 13, and the vehicle panel 11 is formed.

[0031] 2 and 5, second grain 17 is formed by the grained second movable die 23 in regions A, B, and C on the surface of the second layer 15. In this case, the position of the second movable die 23 corresponding to region D on the surface of the second layer 15 is a flat surface 25 that is not grained.

[0032] Furthermore, at this time, in region D on the surface of the second layer 15, sink marks (irregularities) appear as third grains 18 following the first grains 19 in region H on the surface of the first layer 13 located below region D. That is, the sink marks that appear in region D on the surface of the second layer 15 located above region H on the surface of the first layer 13 are formed in region D as third grains 18 whose grain height is lower than that of the second grains 17.

[0033] Thereafter, as shown in FIG. 6, the second mold 14 is opened and the vehicle panel 11 is taken out, thereby obtaining the vehicle panel 11. <Operation of the embodiment> 1 and 2, in the vehicle panel 11, the height of the grain on the surface of the second layer 15 gradually decreases from region A to region D, while the height of the grain on the surface of the first layer 13 gradually decreases from region H to region F, with no grain remaining in region E. Therefore, when the vehicle panel 11 is viewed from the surface side of the second layer 15, the light reflection states on the surfaces of the first layer 13 and the second layer 15 change in different, opposite ways in one direction X. Therefore, the vehicle panel 11 expresses a subtle gradation in appearance.

[0034] In this case, the vehicle panel 11 incorporates, as part of the design, sink marks that are formed on the surface of the second layer 15 and that constitute the third grain 18. That is, in the vehicle panel 11, sink marks, which generally cause poor appearance, are used to their advantage as part of the design, thereby reducing poor appearance caused by sink marks.

[0035] Furthermore, in the vehicle panel 11, for example, in a place where the light from the light source is weak, such as indoor lighting, the light that passes through the second layer 15 and is reflected on the surface of the first layer 13 easily enters the eye, making the gradation created by the first grain 19 more visible. On the other hand, in the vehicle panel 11, for example, in a place where the light from the light source is strong, such as outdoors in the sun, the light that passes through the first layer 13 and is reflected on the surface of the second layer 15 easily enters the eye, making the gradation created by the second grain 17 and the third grain 18 more visible. In other words, the appearance of the vehicle panel 11 changes depending on the intensity of the light from the surrounding light sources, making it possible to express multiple designs with a single vehicle panel 11.

[0036] <Effects of the embodiment> According to the embodiment described above in detail, the following effects are achieved. (1) The vehicle panel 11 includes a first layer 13 made of resin molded by a first mold 12, and a second layer 15 made of resin molded by a second mold 14 on the surface of the first layer 13. The surface of the second layer 15 has a plurality of surface regions 16 that include regions A and D and are continuous in one direction X.

[0037] In an area H corresponding to the area D on the surface of the first layer 13, a first grain 19 is formed by the first mold 12. In the area A, a second grain 17 is formed by the second mold 14. In the area D, a third grain 18 is formed on the first grain 19 by a sink mark that occurs when the second layer 15 is molded, and the third grain 18 has a grain height lower than that of the second grain 17.

[0038] Generally, when a grain is formed using a mold that has been textured by machining, the grain height is approximately 20 μm or more, but when a grain is formed using sink marks that occur during resin molding, the grain height can be 10 μm or less. In this regard, according to the above-mentioned configuration, by continuously forming the second grain 17 and the third grain 18 having different grain height ranges on the surface of the second layer 15, it is possible to express designs over a wider range of grain heights. Therefore, the degree of freedom in design expression can be increased.

[0039] (2) In the vehicle panel 11, the second layer 15 is visible light transmissive. The surface of the second layer 15 has regions B and C as a surface region 16 between regions A and D in one direction X. Second embossments 17 are formed in regions B and C. First embossments 19 are formed in regions F and G corresponding to regions B and C on the surface of the first layer 13. The first embossments 19 are configured so that the embossment height is higher on the region D side than on the region A side in the one direction X. The second embossments 17 are configured so that the embossment height is lower on the region D side than on the region A side in the one direction X.

[0040] According to the above configuration, the state of light reflection on the surfaces of the first layer 13 and the second layer 15 changes in mutually opposite manners in one direction X, so that a subtle gradation in appearance can be expressed.

[0041] <Example of change> The above embodiment can be modified as follows: Furthermore, the above embodiment and the following modifications can be combined with each other within the scope of technical compatibility.

[0042] Region B on the surface of the second layer 15 and region F on the surface of the first layer 13 may be omitted. The region C on the surface of the second layer 15 and the region G on the surface of the first layer 13 may be omitted.

[0043] Regions B and C on the surface of the second layer 15 and regions F and G on the surface of the first layer 13 may be omitted. The surface of the second layer 15 may be provided with three or more regions as a third region, including region B and region C. In this case, the surface of the first layer 13 is provided with three or more regions, including region F and region G, that correspond to the three or more regions on the surface of the second layer 15.

[0044] The first embossments 19 may be provided in region E on the surface of the first layer 13. In this case, the height of the first embossments 19 in region E is preferably lower than the height of the first embossments 19 in region F.

[0045] The length in one direction X of each of the concaves and convexes constituting at least one of the first grain 19, the second grain 17, and the third grain 18 does not have to be constant. The cross-sectional shape of each of the projections and recesses that make up the first grain 19, the second grain 17, and the third grain 18 may be changed as appropriate, for example, to a rectangular shape, a semicircular shape, or the like.

[0046] The first layer 13 may be made of a resin material that is transparent to visible light. This allows the vehicle panel 11 to be transparent to visible light. Therefore, the vehicle panel 11 can be used as, for example, resin glass.

[0047] The second layer 15 may be made of a resin material that does not transmit visible light. On the surface of the second layer 15, flat portions without grain may be appropriately provided in the region between region A and region B, the region between region B and region C, and the region between region C and region D. [Explanation of symbols]

[0048] 11...Vehicle panel 12...First mold 13…1st layer 14...Second mold 15…Second layer 16…Surface area 17...2nd grain 18...3rd grain 19...1st grain 20...1st movable type 21…Fixed type 22...First cavity 23…Second movable type 24...Second cavity 25...Flat surface A...Area as an example of the first area B...Area as an example of the third area C...Area as an example of the third area D...Area as an example of the second area E…Area F…Area G…Area H…area X…One direction Y: Width direction

Claims

1. A vehicle panel comprising a first layer made of resin molded by a first mold and a second layer made of resin molded on a surface of the first layer by a second mold, the surface of the second layer has a plurality of surface regions including a first region and a second region and continuing in one direction; a first grain formed by the first mold is formed in an area of ​​the surface of the first layer corresponding to the second area; a second grain formed by the second mold is formed in the first region; A vehicle panel characterized in that a third embossment is formed in the second region, which is formed by a sink mark that occurs when molding the second layer on the first embossment and has a embossment height that is lower than that of the second embossment.

2. the second layer is visible light transmissive; the surface of the second layer has a third region as the surface region between the first region and the second region in the one direction, The second grain is formed in the third region, the first grain is formed in an area of ​​the surface of the first layer corresponding to the third area; The first grain is configured such that the grain height is higher on the second region side than on the first region side in the one direction, 2. The vehicle panel according to claim 1, wherein the second embossment is configured so that the height of the embossment is lower on the second region side than on the first region side in the one direction.

3. a first layer molding step of molding a first layer made of resin using a first mold; a second layer molding step of molding a second layer made of a resin having visible light transparency, the second layer including a first region and a second region on the surface of the first layer, and having a plurality of surface regions that are continuous in one direction, using a second mold; A method for manufacturing a vehicle panel, comprising: In the first layer molding step, a first grain is formed by the first mold in a region on the surface of the first layer corresponding to the second region; A method for manufacturing a vehicle panel, characterized in that in the second layer molding process, a second embossment is formed in the first region using the second mold, and a sink mark that occurs in the second region is formed in the second region as a third embossment having a embossing height that is lower than that of the second embossment.

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