Vehicle exterior components and vehicles

Abstract

The present invention aims to provide a vehicle exterior component that offers high ease of installation and airtightness, and can be scaled up. [Solution] The vehicle exterior member of the present invention comprises a three-dimensional resin sheet having an average thickness of 0.8 to 8.0 mm and including a polycarbonate layer, and a frame material including a groove portion having a groove width of 2.0 to 10 times the average thickness of the resin sheet, wherein the ends of the resin sheet are located in the groove portion and fixed to the frame material with fixing resin, and the ratio of the height of the resin sheet as viewed from the horizontal direction to the first length, which is the longest distance between opposing ends when viewed from the vertical direction when the resin sheet is placed on a horizontal surface, is 0.02 times or more, the first length is 500 mm or more, and the frame material is fixable to the vehicle body.

Description

Technical Field

[0001] The present invention relates to an exterior member for a vehicle and a vehicle.

Background Art

[0002] In recent years, various exterior members such as front grilles and lamps attached to vehicles have been studied from the viewpoints of improving appearance and weight reduction. For example, the replacement of metal members used in exterior members with resin members has been increasing. Resin members have a high degree of freedom in shape and are lightweight, so they contribute particularly to the weight reduction of vehicles aimed at improving fuel efficiency, and there is also a possibility of realizing a more attractive appearance in terms of design.

Summary of the Invention

Problems to be Solved by the Invention

[0003] By the way, in exterior members for vehicles, there is a tendency for them to become larger and for their designability to be more required. For example, the front grille of an automobile is one of the large exterior members. Although it is required to function as a cooling opening for cooling the internal combustion engine in an internal combustion engine vehicle, in electric vehicles that are becoming popular, since the need for cooling is low, it is considered to manufacture it using a resin member that is made larger in order to design a front grille rich in design. However, exterior members for vehicles need to be attached to the metal members of the vehicle body. Resin members tend to have a larger coefficient of thermal expansion than the metal members of the vehicle body, and when strain occurs due to the difference in the coefficient of thermal expansion, it can also be a factor causing floating or peeling. Therefore, high attachment performance of the exterior member for a vehicle to the vehicle may be required. In addition, since the flatness of the joint portion (mainly the end portion) of the resin member to the vehicle may not be sufficient as the resin member becomes larger, etc., it is also required that the exterior member for a vehicle has high sealing performance between the outside and the inside of the resin member.

[0004] Therefore, an object of the present invention is to provide an exterior member for a vehicle having high attachment performance and sealing performance and capable of being enlarged, and a vehicle including the same. [Means for solving the problem]

[0005] The present invention provides, for example, the following vehicle exterior components and a vehicle equipped therewith. [1] A three-dimensional resin sheet having an average thickness of 0.8 to 8.0 mm and containing a polycarbonate layer, A frame material including a groove section having a groove width 2.0 to 10 times the average thickness of the resin sheet, Equipped with, The end of the resin sheet is located within the groove of the groove and is fixed to the frame material with fixing resin. The aforementioned resin sheet, when placed on a horizontal surface, has a ratio of the height of the resin sheet as viewed from the horizontal direction to the first length, which is the longest distance between opposing ends when viewed from the vertical direction, to 0.02 times or more. The aforementioned first length is 500 mm or more. The frame material is characterized by being fixable to the vehicle body, and is an exterior component for a vehicle. [2] The aforementioned resin sheet further includes an acrylic resin layer, The vehicle exterior member according to [1] above, wherein the acrylic resin layer in the resin sheet is located on the opposite side from the direction that is on the vehicle body side when the vehicle exterior member is fixed to the vehicle body, relative to the polycarbonate layer. [3] The vehicle exterior component according to [2] above, wherein the average thickness of the acrylic resin layer is 10 μm to 200 μm. [4] The vehicle exterior member according to any one of [1] to [3] above, wherein the frame material has at least a metal part. [5] The vehicle exterior member according to any one of [1] to [4] above, wherein a decorative layer is formed at least partially on at least one surface of the resin sheet. [6] Vehicle exterior component for front grille as described in any of [1] to [5] above [7] An exterior vehicle component according to any of the above [1] to [5], for covering a light-emitting unit, display unit, or radar device provided on the vehicle body. [8] A vehicle exterior component, which is a lamp component, as described in any of the above [1] to [5]. [9] A vehicle equipped with any of the vehicle exterior components described in [1] to [8] above.

[10] The vehicle according to [9] above, further comprising a resin member between the exterior vehicle component and the vehicle body. [Effects of the Invention]

[0006] According to the present invention, it is possible to provide a vehicle exterior component that has high ease of installation and sealing properties, and can be enlarged, as well as a vehicle equipped therewith. [Brief explanation of the drawing]

[0007] [Figure 1] This is a schematic plan view showing a vehicle exterior component according to one embodiment of the present invention, fixed to the vehicle body. [Figure 2] This is a schematic cross-sectional view of the vehicle exterior component shown in Figure 1, along the line a-a'. [Figure 3] Figure 2 is an enlarged cross-sectional view of the frame material shown. [Figure 4] Figure 3 is a cross-sectional view showing a modified example of the frame material. [Figure 5] Figure 3 is a cross-sectional view showing a further modified example of the frame material. [Modes for carrying out the invention]

[0008] The embodiments of the present invention (hereinafter referred to as "these embodiments") will be described in detail below with reference to the drawings, but the present invention is not limited to these embodiments. In this specification, "A~B" (where A and B are numerical values) means "greater than or equal to A and less than or equal to B".

[0009] <Vehicle exterior components> As shown in FIG. 1, the exterior member for a vehicle according to this embodiment is a three-dimensional resin sheet 11 that can be fixed to a vehicle body VB of a vehicle, has an average thickness of 0.8 to 8.0 mm, and includes a polycarbonate layer, and a frame member 12 including a groove portion 121 having a groove width that is 2.0 to 10 times the average thickness of the resin sheet 11. Further, an end portion 111 of the resin sheet 11 is located within the groove of the groove portion 121 and is fixed to the frame member 12 with a fixing resin 13. When the resin sheet 11 is placed on a horizontal plane, the ratio of the height of the resin sheet 11 viewed from the horizontal direction to the first length, which is the largest distance between opposite end portions when viewed from the vertical direction, is 0.02 times or more, and the first length is 500 mm or more. And the frame member 12 can be fixed to the vehicle body VB. By having such a configuration, the exterior member 10 for a vehicle according to this embodiment has high mounting property and airtightness and can be enlarged. In this specification, the vehicle refers to automobiles such as passenger cars, buses, and trucks; moving bodies that can travel on the ground such as motorcycles, electric bicycles, electric wheelchairs, and machine tools; and other moving bodies including trains, ships, airplanes, etc., but is typically an automobile.

[0010] In this specification, when the exterior member 10 for a vehicle is fixed to the vehicle body VB, the direction on the vehicle body VB side with respect to the exterior member 10 for a vehicle is referred to as the vehicle side DV, and the direction opposite to the vehicle side is referred to as the external side DO.

[0011] (Resin Sheet) The resin sheet 11 is a portion that is visible from the outside of the vehicle V when the exterior member 10 for a vehicle is fixed to the vehicle body VB. The resin sheet 11 has a three-dimensional shape. It can have a shape that is integrated with the shape of the entire vehicle V when fixed to the vehicle V, and the designability can be improved. Specifically, an end portion 111 of the resin sheet 11 is located within the groove portion 121 of the frame member 12, and a central portion 112 other than the end portion 111 becomes a portion that is mainly visible from the outside when the exterior member 10 for a vehicle is fixed to the vehicle. The specific shape of the resin sheet 11 can be arbitrarily set, but it has the following predetermined height and length. That is, when the resin sheet 11 is placed on a horizontal plane and the distance between the opposing ends when viewed from the vertical direction is the largest, if this distance is defined as the first length (mm), the first length is 500 mm or more. Also, the ratio of the height of the resin sheet 11 viewed from the horizontal direction to the first length is 0.02 times or more.

[0012] When the vehicle exterior member 10 is fixed to the vehicle body VB, for example, during a period when the outside air is hot, strain is likely to occur due to the difference in the coefficient of thermal expansion between the resin sheet 11 and the vehicle body VB. In particular, since the vehicle exterior member 10 of the present embodiment has a first length of 500 mm or more and is a relatively large member, the strain is likely to be large. However, since the resin sheet 11 of the present embodiment has the above-mentioned height, even if the strain occurs, the strain can be relaxed by deforming in the height direction of the resin sheet 11. That is, even if strain occurs in the vehicle exterior member 10, the vehicle exterior member has high mountability to the vehicle.

[0013] The first length is 500 mm or more, but it may be 700 mm or more, 1000 mm or more, or 1500 mm or more. Also, the upper limit value of the first length is not particularly limited, but for example, it can be set to 8000 mm or less, and may also be 6000 mm or less or 4000 mm or less. Note that the distance between the opposing ends when the resin sheet 11 is placed on a horizontal plane and viewed from the vertical direction and is the smallest is not particularly limited, but for example, it can be 30 mm or more, 50 mm or more, or 100 mm or more.

[0014] The ratio of the height of the resin sheet 11 viewed from the horizontal direction to the first length is 0.02 times or more, but it may be 0.04 times or more, 0.1 times or more, or 0.2 times or more. The upper limit value of the ratio is not particularly limited, but it can be set to 2.0 times or less, and may also be 1.5 times or less or 1.0 times or less. The height of the resin sheet 11 as viewed from the horizontal direction refers to the distance measured vertically from the horizontal plane to the top of the resin sheet 11 when the resin sheet 11 is placed on a horizontal surface and viewed from the horizontal direction. The top refers to the part of the resin sheet that is furthest from the horizontal plane.

[0015] The specific shape of the resin sheet 11 can be any shape, depending on the position of the vehicle body VB to which the vehicle exterior component 10 is attached, as well as from the standpoint of design. For example, when the resin sheet 11 is placed on a horizontal surface and viewed from the horizontal direction, the central portion 112 can be made into a convex shape overall, extending from the vehicle side DV to the external side DO. Alternatively, the central portion 112 may be convex in whole or in part, extending from the external side DO to the vehicle side DV (a concave shape when viewed from the vehicle side DV to the external side DO). Furthermore, as shown in Figure 2, the end portion 111 can extend in a direction substantially perpendicular to the direction from the vehicle side DV toward the external side DO, but the extension direction of the end portion 111 can be arbitrary. For example, a part of the end portion 111 can be extended in the direction from the external side DO toward the vehicle side DV.

[0016] Furthermore, the specific shape of the resin sheet 11 (especially the central portion 112) when viewed from the vertical direction while the resin sheet 11 is placed on a horizontal surface can be arbitrary. For example, it can be a square, polygon, circle, or ellipse as shown in Figure 1, or it can have a curved outer edge, a straight outer edge, or a combination thereof.

[0017] Such a three-dimensional resin sheet 11 can be manufactured by shaping it, for example, by vacuum forming, pressure forming, or pressure vacuum forming (vacuum pressure forming), and among these methods, it is preferable to manufacture it by pressure vacuum forming.

[0018] Here, the resin sheet 11 has an average thickness of 0.8 to 8.0 mm. The average thickness of the resin sheet 11 may be 1.5 to 7.0 mm, 2.0 to 6.0 mm, or 2.5 to 5.0 mm. In this specification, the average thickness is the arithmetic mean of the thicknesses of any 10 points on the resin sheet 11, and the thickness means the length measured along the normal direction of the surface from the outer side DO surface of the resin sheet 11 to the vehicle side DV surface of the resin sheet 11.

[0019] The resin sheet 11 includes a polycarbonate layer, and the inclusion of the polycarbonate layer ensures the strength of the resin sheet 11 while maintaining transparency. The resin sheet 11 may also include an acrylic resin layer in addition to the polycarbonate layer. When an acrylic resin layer is included, the acrylic resin layer in the resin sheet 11 may be located on either the vehicle body side (vehicle side DV) or the side opposite to the direction of the vehicle side DV (external side DO), or both, but it is preferable that it be located on the external side DO. The inclusion of an acrylic resin layer improves the scratch resistance and weather resistance of the resin sheet 11.

[0020] The polycarbonate resin constituting the polycarbonate layer is not particularly limited, but may be, for example, obtained by interfacial polymerization of an aromatic dihydroxy compound or a small amount of a polyhydroxy compound and phosgene, or a branched thermoplastic polycarbonate polymer produced by a transesterification reaction of an aromatic dihydroxy compound and a diester of carbonic acid. In particular, carbonate ester polymers obtained by interfacial polymerization using bisphenol A as the main raw material are most preferred from the viewpoint of thermal stability and moldability. The molecular weight of the polycarbonate resin used is 16,000 to 33,000, preferably 21,000 to 28,000, in terms of viscosity-average molecular weight. When the viscosity-average molecular weight is less than 16,000, there is a tendency for a decrease in impact resistance. When the viscosity-average molecular weight exceeds 33,000, there is a tendency for a decrease in moldability. Other resins and various additives may be added to the polycarbonate resin to the extent that its transparency and moldability are maintained. Examples of additives include ultraviolet absorbers, antioxidants, color inhibitors, flame retardants, mold release agents, antistatic agents, and dyes and pigments.

[0021] The average thickness of the polycarbonate layer is not particularly limited, but can be in the range of 0.79 to 7.99 mm, or it may be 1.0 to 7.0 mm or 2.0 to 6.0 mm.

[0022] The acrylic resin layer may contain a thermoplastic acrylic resin and may further contain silicon dioxide particles. The average thickness of the acrylic resin layer is preferably in the range of 10 to 200 μm, more preferably 20 to 180 μm, and particularly preferably 50 to 150 μm. If the average thickness of the acrylic resin layer is too thin, scratch resistance and weather resistance tend to deteriorate. On the other hand, if the average thickness of the acrylic resin layer is too thick, impact resistance tends to decrease.

[0023] Thermoplastic acrylic resins are copolymers of methyl methacrylate and acrylic acid esters such as methyl acrylate, ethyl acrylate, or butyl acrylate. The copolymerization composition and molecular weight can be appropriately selected depending on the co-extrusion conditions. A copolymerization composition ratio of 80-99.9% methyl methacrylate and 0.1-20% acrylic acid ester such as methyl, ethyl, or butyl acrylate is preferred, but is not limited to these values. The molecular weight of the thermoplastic acrylic resin is 30,000-300,000 by weight average, but is not limited to these values. A higher load deflection temperature of the thermoplastic acrylic resin results in a higher glass transition temperature and a roll transfer temperature closer to that of polycarbonate resins, leading to excellent roll transferability and a laminate with superior appearance. Therefore, a load deflection temperature of 90°C or higher is preferable, preferably 95°C or higher, and more preferably 100°C or higher.

[0024] To impart impact resistance to thermoplastic acrylic resins, rubber-like polymers and rubber particles may be added, provided that they do not significantly reduce transparency or surface hardness. In this case, it is desirable that the Rockwell hardness (M scale) of the thermoplastic acrylic resin composition to which the rubber-like polymers and rubber particles are added is 30 or higher. If the Rockwell hardness is less than 30, transparency may decrease. This can result in a poor appearance of decorative layers (described later) that can be arbitrarily created, for example, by haze, and may also prevent the attainment of the required surface hardness.

[0025] Furthermore, thermoplastic acrylic resins may contain other resins and various additives to the extent that their transparency and moldability are maintained. Examples of additives include ultraviolet absorbers, antioxidants, color inhibitors, flame retardants, mold release agents, antistatic agents, and dyes and pigments. Adding ultraviolet absorbers is preferable because it more effectively prevents ultraviolet degradation of the polycarbonate layer and the acrylic resin layer.

[0026] Examples of usable UV absorbers include benzotriazole-based, benzophenone-based, phenyl salicylate-based, benzoxazine-based, malonic acid-based, triazine-based, and high-molecular-weight UV absorbers in which these are attached as pendants. Benzotriazole-based UV absorbers include 2-(5-methyl-2-hydroxyphenyl)benzotriazole, 2-[2-hydroxy-3,5-bis(α,α-dimethylbenzyl)phenyl]-2H-benzotriazole, 2-(2'-hydroxy-5'-t-octylphenyl)benzotriazole, 2,2-methylenebis[4-(1,1,3,3-tetramethylenebutyl)-6-(2H-benzotriazole-2-yl)phenol], and 2-(2H-benzotriazole-2 Examples of benzophenone-based UV absorbers include 2-hydroxy-4-octoxybenzophenone, 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxy-4'-chlorobenzophenone, 2,2-dihydroxy-4-methoxybenzophenone, and 2,2-dihydroxy-4,4'-dimethoxybenzophenone.

[0027] Examples of phenyl salicylate-based UV absorbers include pt-butylphenyl salicylate. Examples of benzoxazine-based UV absorbers include 2,2'-(1,4-phenylene)bis[4H-3,1-benzoxazine-4-one].

[0028] Examples of malonic acid ester-based UV absorbers include [(4-methoxyphenyl)-methylene]dimethyl malonate. Examples of triazine-based UV absorbers include 2,4-diphenyl-6-(2-hydroxy-4-methoxyphenyl)-1,3,5-triazine, 2,4-diphenyl-6-(2-hydroxy-4-ethoxyphenyl)-1,3,5-triazine, 2,4-diphenyl-(2-hydroxy-4-propoxyphenyl)-1,3,5-triazine, 2,4-diphenyl-(2-hydroxy-4-butoxyphenyl)-1,3,5-triazine, 2,4-diphenyl-6-(2-hydroxy-4-butoxyphenyl)-1,3,5-triazine, and 2,6-di(4-biphenyl)-4-(2-hydroxy-4-(2-ethylhexyl)oxyphenyl)-1,3,5-triazine. Examples include azines, 2,4-diphenyl-6-(2-hydroxy-4-hexyloxyphenyl)-1,3,5-triazines, 2,4-diphenyl-6-(2-hydroxy-4-octyloxyphenyl)-1,3,5-triazines, 2,4-diphenyl-6-(2-hydroxy-4-dodecyloxyphenyl)-1,3,5-triazines, 2,4-diphenyl-6(2-hydroxy-4-benzyloxyphenyl)-1,3,5-triazines, and 2,4-diphenyl-6-(2-hydroxy-4-butoxyethoxy)-1,3,5-triazines, but are not limited to these and include commonly available UV absorbers.

[0029] High molecular weight UV absorbers are those that have a hydroxybenzophenone or hydroxybenzotriazole structure in their molecule, and some of these have hydrogen atoms substituted with alkyl groups. An example of a high molecular weight UV absorber is UVA-633L (2-hydroxy-4-(methacryloyloxyethoxy)benzophenone) methyl methacrylate copolymer, which is commercialized by BASF.

[0030] Commercially available thermoplastic acrylic resins include Asahi Kasei's 80HD, Kuraray's Parapet HR-1000L, Arkema's ALTUGLAS V020, and Mitsubishi Rayon's IRG304.

[0031] The silicon dioxide particles that may be included in the acrylic resin layer along with the thermoplastic acrylic resin preferably have an average particle size of 0.1 to 2 μm, and more preferably 0.2 to 0.6 μm. If the average particle size is small, the scratch resistance effect is insufficient, and if it is large, the number of point defects in the multilayer sheet and multilayer film tends to increase. The silicon dioxide particle content is preferably 0.1 to 1% by weight relative to the total thermoplastic acrylic resin, and more preferably 0.3 to 0.6% by weight. If the silicon dioxide particle content is low, sufficient scratch resistance tends not to be obtained, and if it is high, the haze of the resin sheet 11 tends to increase. There are no particular restrictions on the method of producing silicon dioxide particles, but they can be produced by known methods such as the VMC method, wet synthesis method, and melting method. In particular, considering the uniformity of the silicon dioxide particle size, the VMC method is preferred. The VMC method is a method of obtaining fine spherical silicon dioxide particles by introducing silicon powder (metallic silicon) into an oxygen stream and oxidizing it, and utilizing the reaction heat. Commercially available silicon dioxide particles include AdmaFine SO-C1, AdmaFine SO-C2, AdmaFine SO-C4, AdmaFine SO-C5, etc., manufactured by Admatex Co., Ltd., which can be selected and used individually or in mixtures as appropriate.

[0032] Silicon dioxide particles contained in thermoplastic acrylic resins can be identified by the following method. First, the presence of silicon dioxide particles can be confirmed by observing the surface or cross-section of the molded body using surface observation equipment such as TEM and FE-SEM. These measurements allow for confirmation of the particle dispersion state and the bleed-out state to the surface. Simultaneously, silicon dioxide particles can be identified by using surface elemental analysis equipment such as EDX, XPS, and EPMA.

[0033] The particle size and content of silicon dioxide particles contained in thermoplastic acrylic resin can be measured by the following method. As a pretreatment, the test specimen and sample solution can be prepared by the following methods. For example, the sample solution can be prepared by embedding a molded body in epoxy resin, cutting out only the acrylic resin layer from the embedded molded body using a surface cutting device such as an ultramicrotome, and dissolving it in a suitable solvent (dichloromethane, THF, etc.), or by punching out a certain area of ​​the molded product and dissolving the punched-out piece in a suitable solvent (dichloromethane, THF, etc.).

[0034] The silicon dioxide particle content can be measured using the following method. First, a solution containing Si particles of known concentration is impregnated into filter paper and dried. To use as a calibration curve, X-ray fluorescence measurements are performed at three different concentration levels. Next, the sample solution, which has been pre-treated and dissolved, is dropped onto filter paper and dried. The dried filter paper is then measured using an X-ray fluorescence analyzer in the same manner, thereby allowing for the quantitative determination of the Si element. Regarding particle size, the prepared solution can be measured using a particle size analyzer manufactured using principles such as laser diffraction or dynamic light scattering.

[0035] Means for forming the acrylic resin layer on at least one surface of the polycarbonate layer include co-extrusion of the acrylic resin layer and the polycarbonate layer, heat lamination of a thermoplastic acrylic resin film onto the surface of the extruded polycarbonate, and coating a solution in which silicon dioxide particles are dispersed in a thermoplastic acrylic resin solution onto a polycarbonate substrate and drying it. In particular, the co-extrusion method is most preferred because a multilayer film can be obtained in one step, there is flexibility in the thickness ratio of each layer, and sufficient scratch resistance and high transparency can be achieved simultaneously. When using the heat lamination method, the thermoplastic acrylic resin film is preferably extruded. For example, if a film obtained by injection molding is heat-laminated, sufficient scratch resistance may not be obtained. Furthermore, in order to obtain sufficient scratch resistance in multilayer sheets and multilayer films obtained by coating a solution in which silicon dioxide particles are dispersed in a thermoplastic acrylic resin solution onto a polycarbonate substrate and drying it, it is necessary to include a large amount of silicon dioxide particles, which may result in impaired transparency.

[0036] The total light transmittance of the resin sheet 11 is preferably 85% or more and less than 93%, and more preferably 90% or more and less than 93%. Furthermore, the haze value of the resin sheet 11 is preferably 0.01% or more and less than 2%, and more preferably 0.01% or more and less than 1%. If the total light transmittance is too low or the haze is too high, problems may occur such as a decrease in the visibility of the resin sheet 11 or the printed color appearing cloudy when a decorative layer is printed on it.

[0037] The scratch resistance of the resin sheet 11 can be evaluated by the steel wool hardness test shown below. Steel wool (wire diameter approximately 0.012 mm) of #0000 manufactured by Nippon Steel Wool Co., Ltd. is attached to a 33 mm x 33 mm square pad. This pad is placed on the surface of a thermoplastic acrylic resin layer of a laminate held on a stand, and rubbed back and forth 15 times under a load of 1000 g. After cleaning the rubbed surface with ethanol, the haze is measured. The haze after this abrasion resistance test is preferably 0.01% or more and less than 15%, more preferably 0.01% or more and less than 10%, and most preferably 0.01% or more and less than 5%.

[0038] Here, the resin sheet 11 may consist of only a single polycarbonate layer, or it may be a multilayer sheet composed of multiple sheets or films bonded together. In the case of a multilayer sheet, resin sheets of the same composition and thickness may be bonded together, or resin sheets of different compositions and thicknesses may be bonded together. The bonding method is not particularly limited, but bonding via an adhesive is preferred.

[0039] Furthermore, the resin sheet 11 may have a masking film laminated to at least one of its surfaces. By laminating a masking film to the surface, surface damage during storage, transportation, and processing can be suppressed.

[0040] Here, the resin sheet 11 may have a decorative layer formed at least partially on at least one surface. If the resin sheet 11 is composed of multiple sheets or films, the decorative layer may be formed on any of their surfaces. The decorative layer may be provided on the surface of the vehicle-side DV, the surface of the exterior-side DO, or both sides of the resin sheet 11, but it is preferable that it be provided on the surface of the vehicle-side DV. In particular, forming the decorative layer on the surface of the vehicle-side DV can suppress peeling of the decorative layer due to external impact, abrasion, and weather deterioration. The provision of a decorative layer can further improve the design of the vehicle exterior component 10. Methods for forming the decorative layer include, for example, directly printing various designs onto the polycarbonate resin layer surface using continuous gravure printing, silk screen printing, or screen printing; transferring transfer foil; applying a metallic plating-like decoration using vapor deposition or sputtering; and laminating another resin film that has been decorated by printing or vapor deposition.

[0041] Furthermore, if the resin sheet 11 includes a decorative layer, a thermoplastic resin sheet can be laminated to protect the decorative layer. Examples of resins that make up the thermoplastic resin sheet include polycarbonate resins, thermoplastic acrylic resins, ABS resins, polyvinyl chloride resins, polyurethane resins, polyester resins, polyolefin resins, or resin compositions obtained by kneading at least two of these.

[0042] (Frame material) As shown in Figure 2, the frame member 12 is connected to the end of the resin sheet 11 and is mainly used to fix the resin sheet 11 to the vehicle body VB. As shown in Figure 3, the frame member 12 includes a groove 121, and the end 111 of the resin sheet 11 is located in the groove 121 and is fixed to the frame member 12 with fixing resin 13.

[0043] More specifically, the frame member 12 comprises a frame member base portion 122 facing the vehicle body VB and provided with fixing means 14 for fixing the vehicle exterior member 10 to the vehicle body VB, and a groove-forming portion 123 located on the external side DO relative to the frame member base portion 122, as illustrated in Figure 3. Figure 3 is a cross-sectional view of the frame member 12 in a direction perpendicular to the longitudinal direction. As illustrated in the cross-sectional view of Figure 3, the groove-forming portion 123 extends from the frame member base portion 122 to the outer side DO and extends approximately parallel to the frame member base portion 122. The groove 121 is formed by the frame member base portion 122 and the groove-forming portion 123.

[0044] The frame material base portion 122 and the groove-forming portion 123 of the frame material 12 can be formed integrally as shown in Figure 3, or, as shown in the modified example in Figure 4, they may be manufactured separately and then connected by a method similar to that of the fixing means 14. Furthermore, as shown in Figure 5, the groove width at the opening of the groove 121 and the groove width inside the groove 121 may be different. If the groove width at the opening of the groove 121 is smaller than the groove width inside the groove 121, when the end portion 111 of the resin sheet 11 is fixed inside the groove with the fixing resin 13, the end portion 111 and the fixing resin 13 will be less likely to come out of the groove. Furthermore, as shown in Figure 1, the longitudinal lengths of the frame base portion 122 and the groove forming portion 123 can be made approximately the same.

[0045] The groove 121 of the frame material 12 can have substantially the same groove width along the longitudinal direction of the frame material 12, and the groove width is 2.0 to 10 times the average thickness of the resin sheet 11. In the vehicle exterior member 10, the end portion 111 of the resin sheet 11 is located within the groove 121, but even if there is an uneven portion (for example, a wavy portion) on the end portion 111 of the resin sheet 11, the end portion 111 can still be positioned within the groove 121. The groove width of the groove 121 may be 1.8 to 8 times the average thickness of the resin sheet 11, or it may be 2 to 7 times. The groove width of the groove 121 is the width measured at the opening of the groove 121.

[0046] The groove width of the groove portion 121 (the groove width at the opening of the groove portion 121) can be, for example, 1.6 to 25 mm or 2 to 20 mm. Furthermore, the width of the frame member 12 in a cross-section perpendicular to the longitudinal direction of the frame member 12 can be, for example, 3 to 150 mm or 10 to 100 mm.

[0047] The material of the frame material 12 is not particularly limited as long as it can fix the resin sheet 11 to the vehicle body VB, but it may be made of metal, for example. More specifically, iron, copper, aluminum, stainless steel, tin, nickel, and alloys thereof can be used, but stainless steel is preferred because it is resistant to corrosion and durable.

[0048] When fixing the vehicle exterior member 10 to the vehicle body VB, the fixing means 14 between the frame member base portion 122 and the vehicle body VB is not particularly limited and any known method can be used. For example, the frame member base portion 122 can be fixed to the vehicle body VB by screwing (connection with members such as screws, screw nails, bolts, etc.), welding, locking, riveting, clamp connection, pin connection, key connection, adhesive connection, etc. Among these, in this embodiment, screwing is preferred from the viewpoint that screwing is easy and reliable after forming screw holes in the frame member base portion 122 and the vehicle body VB. Adhesive connection is also preferred from the viewpoint of maintaining internal airtightness, and a combination of screwing and adhesive connection is more preferred.

[0049] As shown in Figure 2, the end portion 111 of the resin sheet 11 located within the groove 121 is fixed to the frame material 12 with fixing resin 13. The fixing resin 13 is not particularly limited as long as it can fix the resin sheet 11 and the frame material 12, but examples of curable resins include epoxy resins, urea resins, urethane resins, and unsaturated polyester resins. Among these, urethane resins are preferred.

[0050] Preferably, the entire circumference of the end portion 111 of the resin sheet 11 is positioned within the groove of the frame material 12 and fixed to the frame material 12 with fixing resin 13; however, only a portion of the circumference of the end portion 111 may be positioned within the groove of the frame material 12.

[0051] (Application) The vehicle exterior member 10 of this embodiment can be used in any part of a vehicle, and its use is not particularly limited, but for example, in the case of an automobile in particular, it can be used for the front grille (front panel), rear panel; and glazing parts such as rear side windows, sunroofs, and rear windows. Furthermore, the vehicle exterior member 10 of this embodiment can be used as a lamp component that covers a lamp installed in a vehicle. Furthermore, the vehicle exterior member 10 of this embodiment can be used as a component that covers a light-emitting unit, display unit, or radar device, etc., provided on the vehicle. More specifically, these light-emitting units, display units, and radar devices can be provided, for example, on a metal member of the vehicle body VB to which the vehicle exterior member 10 is fixed, so that the vehicle exterior member 10 can function as a vehicle cover member. Alternatively, an opening can be formed in the metal member of the vehicle body VB to which the vehicle exterior member 10 is fixed, such that the inside of the frame material 12 is open, and the light-emitting unit, display unit, radar device, etc., can be placed on the vehicle body VB inside the opening, thereby allowing the vehicle exterior member 10 to function as a vehicle cover member.

[0052] <Method for manufacturing vehicle exterior components> The manufacturing method for vehicle exterior components of this embodiment (hereinafter also referred to as the "manufacturing method") is the method for manufacturing vehicle exterior components as described above. The manufacturing method of this embodiment will be described below in an illustrative manner, but explanations of the same components as those of the aforementioned vehicle exterior components will be omitted as appropriate. The manufacturing method of this embodiment includes the steps of: shaping a resin sheet for molding (a resin sheet before molding) by hot press molding, vacuum molding, pressure molding, or pressure vacuum molding (vacuum pressure molding) to obtain a resin sheet in a three-dimensional shape (also referred to as the molding step); and fixing the ends of the resin sheet in the grooves of the frame material using fixing resin to connect the resin sheet and the frame material (also referred to as the connecting step).

[0053] Here, the hot press molding method that can be used in the molding process involves heating and softening a molding resin sheet, and then molding it by sandwiching it between a convex mold and a concave mold corresponding to the desired shape. Vacuum forming is a method in which a molding resin sheet is heated and softened, a mold of the desired shape (e.g., a convex mold, a concave mold, etc.) is covered with the molding resin sheet, and the mold is sealed tightly to the mold by vacuum suction. Compression molding is similar to vacuum forming except that compressed air is used to seal the molding resin sheet to the mold instead of vacuum suction. Furthermore, vacuum compression forming is similar to vacuum forming except that vacuum suction and compressed air sealing are performed simultaneously or with a time delay to seal the molding resin sheet to the mold.

[0054] In this manufacturing method, a three-dimensional resin sheet can be manufactured by hot press molding, vacuum forming, pressure forming, or pressure vacuum forming, thereby obtaining a vehicle exterior component that is low-cost and has a good yield. Furthermore, in the manufacturing method of this embodiment, it is preferable to manufacture by pressure vacuum forming among hot press forming, vacuum forming, pressure forming, and pressure vacuum forming. Specifically, conventionally, resin components for vehicle exteriors were manufactured by injection molding. However, this method required larger molds and injection molding machines to produce larger resin components, resulting in high manufacturing costs for vehicle exterior components. In addition, injection molding of large, transparent components such as sunroofs was difficult, leading to problems such as poor yield. However, compressed air vacuum forming requires smaller molding machines and molds compared to injection molding, enabling lower-cost molding. Furthermore, it eliminates the appearance defects such as silver streaks, burning during stagnation, insufficient filling, and sink marks that are problematic when manufacturing large injection-molded products, thus improving product yield. Furthermore, this method eliminates the need for a printing process on the three-dimensional shape by pre-applying decorative printing to the molding resin sheet and then performing pressure vacuum forming. In addition, by forming a decorative layer on the vehicle-side DV of the transparent resin sheet, a deep appearance can be obtained when viewed from the exterior DO side. When manufactured by pressure vacuum forming, the edges of the molded resin sheet can be used to fix the resulting resin sheet to the vehicle body. However, when manufacturing resin sheets by pressure vacuum forming, there is a possibility that the edges of the resin sheet may not be sufficiently flat, for example, due to warping. However, even in such cases, by using a frame material that includes a groove section with a groove width 2.0 to 10 times the average thickness of the resin sheet, the edges of the resin sheet can be positioned in the groove section of the frame material, and by using process resin, airtightness can be effectively ensured. Furthermore, if the edges of the resin sheet do not have sufficient flatness, the adhesion between the edges and the fixing resin in the groove section can be improved by the anchoring effect, thereby improving airtightness.

[0055] Furthermore, hot press molding, like pressure vacuum forming, can potentially achieve low-cost molding, improved product yield, and a deep, rich appearance. However, pressure vacuum forming has a shorter molding cycle time compared to hot press, thus improving manufacturing efficiency. In addition, while hot press requires two molds—a convex mold and a concave mold—pressure vacuum forming can be done with just one mold, resulting in lower costs. Moreover, the surface of the resin sheet that does not come into contact with the mold does not transfer the fine irregularities of the mold surface, potentially resulting in a superior appearance.

[0056] The heating temperature (or molding temperature) used to soften the molding resin sheet is preferably above the glass transition temperature of the polycarbonate layer constituting the molding resin sheet. The heating temperature (or molding temperature) is preferably 145 to 220°C, more preferably 150 to 200°C, and particularly preferably 160 to 190°C.

[0057] When performing heat press molding or vacuum pressure molding of a resin sheet for molding, the masking film protecting the surface may be applied during heat molding, or it may be applied after removing the masking film. Heat molding with the masking film applied can suppress the transfer of fine irregularities and debris from the mold surface. Also, if the heat resistance of the masking film is low, removing the masking film before heat molding can result in a resin sheet with a good appearance.

[0058] In the joining process, fixing resin is poured into the grooves of the frame material, and then the ends of the resin sheets obtained in the molding process are inserted into the grooves of the frame material into which the fixing resin has been poured, and the frames can be joined by hardening the fixing resin. Alternatively, the fixing resin may be poured and hardened after the resin sheets have been inserted into the grooves of the frame material.

[0059] <Vehicle> The vehicle of this embodiment is equipped with the vehicle exterior components described above. The manufacturing method of this embodiment will be described below illustratively, but the explanation of components that are the same as those of the vehicle exterior components described above will be omitted as appropriate. The vehicle of this embodiment includes a vehicle body and exterior vehicle components fixed to the vehicle body. More specifically, the vehicle can be connected to the exterior vehicle components by fixing the frame base portion of the frame material of the exterior vehicle components to a metal member of a predetermined portion of the vehicle body using fixing means.

[0060] Furthermore, the vehicle may be equipped with a resin member between the vehicle exterior member and the vehicle body. Specifically, when connecting the vehicle body and the vehicle exterior member, a resin member, such as a thermoplastic resin member or a curable resin member, can be provided between the surface of the frame base portion facing the vehicle body and the vehicle body. The resin member can be, for example, a resin member with a thickness of 0.1 to 2.0 mm, and as for the material of the resin member, polyurethane resin or silicone rubber can be used as a thermoplastic resin, and epoxy resin, urea resin, urethane resin, unsaturated polyester resin, acrylic resin, etc. can be used as a curable resin. By providing a resin member, distortion between the vehicle exterior member and the vehicle body can be mitigated, and the internal airtightness can be improved.

[0061] When fixing exterior components to the vehicle body, devices such as light-emitting units, display units, and / or radar devices may be installed at the mounting points of the exterior components before fixing them. Alternatively, after fixing the exterior components to the vehicle body, the devices may be positioned from the inside of the vehicle body so as to be covered by the exterior components.

[0062] Although embodiments of the present invention have been described above with reference to the drawings, the present invention is not limited to the above examples, and modifications can be made to the present invention as appropriate. [Examples]

[0063] The present invention will be described in more detail below with reference to examples, but the present invention is not limited in any way to the following examples.

[0064] The vehicle exterior components of the embodiment were manufactured as follows. <Resin sheet for molding> The following sheets were used as resin sheets for molding. • Polycarbonate / Acrylic multilayer sheet D02PU (manufactured by Mitsubishi Gas Chemical Co., Ltd.) Dimensions: 1420mm x 670mm x 3.0mm A co-extruded multilayer sheet made of two types of materials: polycarbonate and acrylic (polymethyl methacrylate), in two layers. Acrylic thickness: 60 μm

[0065] <Vacuum pressure forming> Vacuum pressure forming of resin sheets for molding was performed using a molding machine (TFH-1211-UD-Q) manufactured by Asano Research Institute. The molding machine is divided into upper and lower boxes, and the air pressure in each can be controlled independently. A molding resin sheet was placed inside the molding machine, and the pressure in the upper and lower boxes inside the molding machine was reduced to 0.1 kPa. Then, the molding resin sheet was brought into contact with a hot plate heated to 170°C to preheat the sheet. After that, the upper box opened, and a radiant heater entered between the upper and lower boxes. Next, the opposite side of the hot plate was heated with the radiant heater, and when the opposite side of the sheet's hot plate reached 190°C, the radiant heater was retracted. The upper box descended, sandwiching the molding resin sheet between the upper and lower boxes. Compressed air at 0.6 MPa was introduced only into the upper box inside the molding machine and brought into contact with the mold installed in the lower box inside the molding machine to obtain a molded body (resin sheet).

[0066] <Frame material> Before fixing the ends of the molded body (resin sheet) manufactured using the above method to a frame material having a groove with a width of 5.5 mm, adhesive (3M Scotch-Wel two-component polyurethane adhesive DP6310NS) was poured into the groove. Next, the ends of the molded body (resin sheet) were inserted into the grooves of the frame material and allowed to cure at room temperature for 24 hours. The same procedure was performed on the ends of all four sides of the molded body.

[0067] As described above, it was found that by manufacturing the vehicle exterior components of the embodiment by vacuum pressure forming, the molding machine and molds can be made smaller and the molding can be done at a lower cost compared to injection molding. Furthermore, since the vehicle exterior components of the embodiment did not exhibit the appearance defects that can be a problem when manufacturing large injection molded products, it was found that the product yield can be improved. [Industrial applicability]

[0068] According to the present invention, it is possible to provide a vehicle exterior component that has high ease of installation and sealing properties, and can be enlarged, as well as a vehicle equipped therewith. [Explanation of symbols]

[0069] 10. Vehicle exterior components 11 Resin sheet 111 End 112 Central part 12 Frame material 121 Groove 122 Frame material base part 123 Groove formation part 13 Fixing resin 14 Fixing means VB Vehicle Body

Claims

1. A three-dimensional resin sheet having an average thickness of 0.8 to 8.0 mm and containing a polycarbonate layer, A frame material including a groove section having a groove width 2.0 to 10 times the average thickness of the resin sheet, Equipped with, The end of the resin sheet is located within the groove of the groove and is fixed to the frame material with fixing resin. The aforementioned resin sheet, when placed on a horizontal surface, has a ratio of the height of the resin sheet as viewed from the horizontal direction to the first length, which is the longest distance between opposing ends when viewed from the vertical direction, to 0.02 times or more. The first length is 500 mm or more. The frame material is characterized by being fixable to the vehicle body, and is an exterior component for a vehicle.

2. The aforementioned resin sheet further includes an acrylic resin layer, The vehicle exterior member according to claim 1, wherein the acrylic resin layer in the resin sheet is located on the opposite side from the direction that would be the vehicle body side when the vehicle exterior member is fixed to the vehicle body, relative to the polycarbonate layer.

3. The vehicle exterior member according to claim 2, wherein the average thickness of the acrylic resin layer is 10 μm to 200 μm.

4. The vehicle exterior member according to claim 1, wherein the frame material has at least a metal portion.

5. The vehicle exterior member according to claim 1, wherein a decorative layer is formed at least partially on at least one surface of the resin sheet.

6. The vehicle exterior component according to claim 1, which is for use as a front grille.

7. An exterior vehicle component according to claim 1, for covering a light-emitting unit, display unit, or radar device provided on the vehicle body.

8. A vehicle exterior component according to claim 1, which is a lamp component.

9. A vehicle comprising a vehicle exterior member according to any one of claims 1 to 8.

10. The vehicle according to claim 9, further comprising a resin member between the vehicle exterior member and the vehicle body.

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