Automobile interior parts, structures, and manufacturing method for automobile interior parts

Abstract

To provide a structure which inhibits its shape from being limited due to a manufacturing method, and to provide a manufacturing method of the structure which can inhibit limitation on the shape of the structure.SOLUTION: A structure includes a base part, a reinforcement part, and a hinge part. The reinforcement part is provided so as to reinforce the base and includes at least one of a structure (a) and a structure (b). In the structure (a), the base part and the reinforcement part are coupled through the hinge part. In the structure (b), the reinforcement part includes the hinge part.SELECTED DRAWING: Figure 1

Description

[Technical field]

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

[0002] The manufacturing method of the structure disclosed in Patent Document 1 proposes placing a foamed resin sheet that has been heated and softened into the cavity of a split mold, and then reducing the pressure in the cavity by suction to cause secondary foaming of the foamed resin sheet, thereby expanding the foamed resin sheet. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2001-310380 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the method for manufacturing a structure by injection molding, liquid molten resin is supplied at high pressure to the cavity of a split mold, so that the molten resin can easily spread throughout the cavity even if the cavity has a complex shape. Therefore, the method for manufacturing a structure by injection molding makes it easy to manufacture structures with complex shapes. However, since the method for manufacturing a structure in Patent Document 1 employs a configuration in which a single foamed resin sheet is sandwiched between split molds, the method for manufacturing a structure in Patent Document 1 may be subject to greater restrictions on the shape of the structure that can be molded compared to the method for manufacturing a structure by injection molding.

[0005] The present invention has been made in consideration of the above circumstances, and aims to provide a structure in which shape restrictions due to the manufacturing method are suppressed, and a manufacturing method for a structure that can suppress shape restrictions of the structure. [Means for solving the problem]

[0006] According to the present invention, there is provided a structure comprising a base, a reinforcing portion, and a hinge portion, the reinforcing portion being provided to reinforce the base, and comprising at least one of the following configurations (a) and (b): Configuration (a): The base and the reinforcing portion are connected via the hinge portion; Configuration (b): The reinforcing portion comprises the hinge portion.

[0007] According to the present invention, since at least one of the configuration (a) and the configuration (b) is provided, structures of various shapes can be manufactured by bending the hinge portion, and therefore, according to the present invention, restrictions on shapes due to the manufacturing method are suppressed.

[0008] Various embodiments of the present invention will be described below. The embodiments described below can be combined with each other. Preferably, the structure comprises the configuration (a). Preferably, the base portion has a base wall and a flange wall, the flange wall being formed on an edge portion of the base wall, and the hinge portion connecting the flange wall and an end portion of the reinforcing portion. Preferably, the reinforcing portion has a reinforcing rib, and the reinforcing rib supports the rear surface of the base wall. Preferably, the reinforcing rib is formed so as to protrude toward the rear surface of the base wall. Preferably, a structure is provided in which the base has a base edge, the hinge portion connects the base edge and the reinforcement portion, and the reinforcement portion is a plate-shaped member extending along the base edge, and is bent toward the base side with the hinge portion as an axis. Preferably, the structure is configured by overlaying a skin material on a resin molded body, the base has first and second base edge portions, the reinforcement portion has first and second reinforcement portions, the hinge portion has first and second hinge portions, the first hinge portion connects the first base edge portion and the first reinforcement portion, the second hinge portion connects the second base edge portion and the second reinforcement portion, the first and second reinforcement portions are plate-like members provided to extend along the first and second base edges, and the first and second reinforcement portions are bent toward the base side about the first and second hinge portions as axes so that the first reinforcement portion is sandwiched between the base and the second reinforcement portion, the first reinforcement portion and the second reinforcement portion are welded to each other, and the skin material in the first reinforcement portion is impregnated with a resin that constitutes the resin molded body in the second reinforcement portion. Preferably, the structure comprises configuration (b). Preferably, the base portion has a base wall and a flange wall, the flange wall being formed on an edge of the base wall. Preferably, the reinforcing portion has an extension portion, the hinge portion, and a reinforcing rib, the extension portion is connected to the flange wall, the extension portion and the reinforcing rib are connected via the hinge portion, and the reinforcing rib supports the rear surface of the base. Preferably, the reinforcing rib is formed in a flat plate shape. Preferably, the extension portion has a first and a second extension portion, the hinge portion has a first, a second, a third and a fourth hinge portion, one end of the reinforcing rib is connected to the first extension portion via the first hinge portion, the other end of the reinforcing rib is connected to the second extension portion via the second hinge portion, and the third and fourth hinge portions are provided in a portion of the reinforcing rib between the one end and the other end. Preferably, the reinforcing rib and the base wall are welded together. Preferably, the base portion, the reinforcing portion and the hinge portion are formed by molding a same resin sheet, and the hinge portion is formed to be thin. Preferably, the base further has an upstanding wall, the base wall having a first edge and a second edge, the flange wall being formed on the first edge and the upstanding wall being formed on the second edge. The manufacturing method of a structure according to the embodiment includes a molding process and a rotation process, in which a resin parison is molded to form a molded body having a base, a reinforcing portion, and a hinge portion, the hinge portion being configured to connect the base and the reinforcing portion, and in which the rotation process rotates all or a part of the reinforcing portion around the hinge portion as an axis. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1A is a front view of the structure 30 according to the first embodiment, FIG. 1B is a front perspective view of the structure 30 according to the first embodiment, and FIG. 1C is a rear perspective view of the structure 30 shown in FIG. 1A in an inverted state. [Diagram 2] 1B is an AA end view of the structure 30 shown in FIG. 1A. [Diagram 3] FIG. 3A is a front view of the structure 300 in a state where the hinge portion H of the structure 30 is not bent, and FIG. 3B is a front perspective view of the structure 300. FIG. [Figure 4] FIG. 4A is a BB end view of the structure 300 shown in FIG. 3A, and FIG. 4B is an enlarged view of area A shown in FIG. 4A. [Diagram 5] 1 shows a foam molding machine 1 and first and second molds 21, 22 used when manufacturing a structure 30 according to a first embodiment. [Figure 6] The figure shows a state in which a foamed resin sheet 23 is suspended between a first mold 21 and a second mold 22, and a skin material 32 is disposed between the first mold 21 and the second mold 22. [Figure 7] The foamed resin sheet 23 and the skin material 32 are shown in a state where they are shaped in the second mold 22 . [Figure 8] Figure 8A shows the state in which the first and second molds 21, 22 are closed, Figure 8B is an enlarged view of area B shown in Figure 8A, and Figure 8C shows the state in which the foamed resin sheet 23 has been foamed to expand the foamed resin sheet 23. [Figure 9] This shows the state in which the first and second molds 21 and 22, which were closed, are now open. [Figure 10] FIG. 10A is a front view of a structure 30B according to variant example 1 of the first embodiment, FIG. 10B is a rear perspective view of the structure 30B shown in FIG. 10A in an upside-down state, and FIG. 10C is an enlarged view of area C shown in FIG. 10B. [Figure 11] FIG. 11A is a front perspective view of structure 300B in which reinforcing portion 50B of structure 30B is not bent, FIG. 11B is a rear perspective view of structure 300B shown in FIG. 11A in an upside-down state, and FIG. 11C is an enlarged view of area D shown in FIG. 11B. [Figure 12] FIG. 12A is a front view of a structure 30C according to variant example 2 of the first embodiment, FIG. 12B is a rear perspective view of the structure 30C shown in FIG. 12A in an upside-down state, and FIG. 12C is an enlarged view of area E shown in FIG. 12B. [Figure 13] FIG. 13A is a rear perspective view of structure 300C in a state in which reinforcing portion 50C of structure 300C is not bent, and FIG. 13B is an enlarged view of region F shown in FIG. 13A. [Figure 14] FIG. 14A is a front view of a structure 30D according to the third modification of the first embodiment, FIG. 14B is a perspective view of the structure 30D shown in FIG. 14A, and FIG. 14C is a perspective view of the structure 30D shown in FIG. 14B as viewed from the direction of arrow Ar. [Figure 15] FIG. 14B is a cross-sectional view of the XX end shown in FIG. 14A. [Figure 16] FIG. 16A shows a structure 30E according to the second embodiment, FIG. 16B is an enlarged view of a region B shown in FIG. 16A, and FIG. 16C is an enlarged view of a region C shown in FIG. 16A. [Figure 17] FIG. 17A shows a structure 300E in a state where hinge portion H of structure 300E is not bent, and FIG. 17B is a perspective view of structure 300E shown in FIG. 17A. [Figure 18] FIG. 18A shows a partially cut away state of structure 300E shown in FIG. 17B, and FIG. 18B is an enlarged view of region B shown in FIG. 18A. [Figure 19] FIG. 16C is a cross-sectional view of the XX end shown in FIG. 16B. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, embodiments of the present invention will be described. Various features shown in the following embodiments can be combined with each other. Also, each feature can be an invention independently.

[0011] 1. First embodiment 1-1.Structure 30 The structure 30 according to the first embodiment is an interior part of an automobile, and the structure 30 has a front surface 43B on which an occupant of the automobile can place an article, such as a drink container. Since the front surface 43B is a portion to which the load of the article is applied, the structure 30 has a configuration (reinforcing portion 50 described later) that reinforces the region of the structure 30 where the front surface 43B is formed.

[0012] As shown in FIG. 1A to FIG. 2, the structure 30 includes a base 40, a reinforcing portion 50, and a hinge portion H. A protruding portion 35 is formed in the structure 30. The protruding portion 35 divides the concave space of the structure 30 into a first region R1 and a second region R2. As shown in FIG. 2, the structure 30 has a two-layer structure. That is, the structure 30 includes a resin molded body 31 as a first layer and a skin material 32 as a second layer. The resin molded body 31 is a molded body formed of a foamed resin. The foaming ratio of the resin molded body 31 is not particularly limited, but is, for example, 1.5 to 6 times. In the first embodiment, the resin constituting the resin molded body 31 is a foamed resin, but may not be a foamed resin. In the first embodiment, the structure 30 is a structure including a skin material 32, but may not include a skin material 32.

[0013] 1-1-1. Base 40 As shown in FIG. 1A to FIG. 2, the base 40 includes a base body 41 and a flange wall 42. The base body 41 is formed in a concave shape, and the flange wall 42 is connected to the edge of the base body 41. The base body 41 includes a base wall 43 and a standing wall 44. The base wall 43 is a plate-like member, and in the first embodiment, the base wall 43 is a flat plate. The base wall 43 may be curved. The base wall 43 is supported by the reinforcing portion 50, and when a load is applied to the base wall 43, deformation of the base wall 43 is suppressed. The base wall 43 has a first edge portion 43A, a second edge portion 43a, a front surface 43B, and a back surface 43C. The flange wall 42 is connected to the first edge portion 43A. The front surface 43B is formed on the opposite side to the back surface 43C, and the back surface 43C faces the reinforcing portion 50 with a gap therebetween. The back surface 43C is a surface supported by the reinforcing portion 50. The standing wall 44 is a plate-shaped member, and extends so as to rise from the base wall 43. In the first embodiment, the standing wall 44 is connected to the second edge portion 43a. The standing wall 44 has a protrusion 35. The flange wall 42 is connected to the edge of the standing wall 44.

[0014] The flange wall 42 is a plate-like member, and in the first embodiment, the flange wall 42 is formed in an annular shape. The inner edge of the flange wall 42 is connected to the base wall 43 and the standing wall 44. A hinge portion H is formed on the outer edge of the flange wall 42, and the outer edge of the flange wall 42 is connected to the reinforcing portion 50 via the hinge portion H. An opening 42A is formed in the flange wall 42, and a fixing member (e.g., a bolt) for fixing the structure 30 to an interior part of an automobile is inserted into the opening 42A.

[0015] 1-1-2. Reinforcement part 50 and hinge part H As shown in FIG. 2, FIG. 4A, and FIG. 4B, the reinforcing portion 50 is rotatably connected to the base portion 40 via the hinge portion H. In the first embodiment, the structure 30 is provided with two reinforcing portions 50 and two hinge portions H, but the number is not limited to two, and may be one, or three or more. The hinge portion H is formed to be thin. Specifically, the thickness of the hinge portion H is thinner than the thickness of the reinforcing portion 50 and the thickness of the base portion 40. For this reason, the hinge portion H is configured so that the manufacturer or the manufacturing device can bend the reinforcing portion 50 so as to tilt the reinforcing portion 50 toward the rear surface 43C of the base wall 43.

[0016] The reinforcing portion 50 is a plate-like member formed in a concave shape. The reinforcing portion 50 has a reinforcing rib 51 and a fixing portion 52. When the reinforcing portion 50 is bent, the reinforcing rib 51 is formed so as to protrude toward the back surface 43C of the base wall 43. The reinforcing portion 50 is provided so as to reinforce the base portion 40. Specifically, in the first embodiment, the reinforcing rib 51 abuts against the back surface 43C of the base wall 43, whereby the base wall 43 is supported by the reinforcing portion 50, and as a result, the base portion 40 is reinforced by the reinforcing portion 50. Note that, in the first embodiment, the reinforcing rib 51 abuts against the base wall 43, but is not limited thereto. An intervening member may be provided between the reinforcing rib 51 and the base wall 43, and the reinforcing rib 51 may not abut against the base wall 43. The reinforcing rib 51 is welded to the back surface 43C of the base wall 43. An opening 53 is formed in the fixing portion 52, and a fixing member (for example, a bolt) for fixing the structure 30 to an interior part of an automobile is inserted into the opening 53.

[0017] 1-1-3.Skin material 32 2, the skin material 32 is provided over the entire front surface of the resin molded body 31. In one example, the skin material 32 is made of a breathable nonwoven fabric, and specific examples thereof include, but are not limited to, nylon fiber, cellulose fiber, and aramid fiber.

[0018] 1-2. Configuration of foam molding machine 1 5, the foam molding machine 1 includes a resin supplying device 2, a T-die 18, a first mold 21, and a second mold 22. The resin supplying device 2 includes a hopper 12, an extruder 13, an injector 16, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27.

[0019] 1-2-1. Hopper 12 and extruder 13 The hopper 12 is used to feed the raw resin 11 into the cylinder 13a of the extruder 13. The form of the raw resin 11 is not particularly limited, but is usually in the form of pellets. The raw resin is, for example, a thermoplastic resin such as polyolefin, and examples of polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer, and mixtures thereof. After being fed from the hopper 12 into the cylinder 13a, the raw resin 11 is heated in the cylinder 13a to melt it and become a molten resin. In addition, the raw resin 11 is conveyed toward the tip of the cylinder 13a by the rotation of a screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and conveys the molten resin while kneading it by its rotation. A gear device is provided at the base end of the screw, and the screw is rotated and driven by the gear device.

[0020] 1-2-2. Injector 16 The cylinder 13a is provided with an injector 16 for injecting a foaming agent into the cylinder 13a. The foaming agent injected from the injector 16 may be a physical foaming agent, a chemical foaming agent, or a mixture thereof, but a physical foaming agent is preferred. The physical foaming agent may be an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, or water, or an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, or dichloroethane, or a supercritical fluid thereof. The supercritical fluid is preferably made from carbon dioxide, nitrogen, or the like, and may be obtained by setting the critical temperature of nitrogen to -149.1°C and the critical pressure to 3.4 MPa or more, or the critical temperature of carbon dioxide to 31°C and the critical pressure to 7.4 MPa or more. The chemical foaming agent may be one that generates carbon dioxide gas by a chemical reaction between an acid (e.g., citric acid or a salt thereof) and a base (e.g., baking soda). The chemical foaming agent may be introduced from the hopper 12 instead of being injected from the injector 16.

[0021] 1-2-3. Accumulator 17 and T-die 18 The foamed resin obtained by melt-kneading the raw resin and the foaming agent is extruded from the resin extrusion port of the cylinder 13a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b that can slide inside the cylinder 17a, and the foamed resin can be stored in the cylinder 17a. Then, by moving the piston 17b after a predetermined amount of the foamed resin is stored in the cylinder 17a, the foamed resin is extruded through the connecting pipe 27 from a slit provided in the T-die 18 and hangs down to form a foamed resin sheet 23.

[0022] 1-2-4. First and second molds 21, 22 The foamed resin sheet 23 is introduced between the first and second molds 21 and 22. A concave cavity cv is formed in the first mold 21. A convex core cr is formed in the second mold 22. The first and second molds 21 and 22 are provided with a large number of decompression suction holes (not shown). Furthermore, the first and second molds 21 and 22 are formed with pinch-off portions 21c and 22c so as to surround the cavity cv.

[0023] 1-3. Manufacturing method of the structure 30 The method for manufacturing the structure 30 according to the first embodiment includes a positioning step, a molding step, a cutting step, a rotating step, and a welding step.

[0024] 1-3-1. Placement process 6, in the arrangement step, one foamed resin sheet 23 formed by extruding a molten foamed resin through a slit in a T-die 18 is arranged between a first mold 21 and a second mold 22. A skin material 32 is arranged between the foamed resin sheet 23 and the second mold 22.

[0025] 1-3-2. Molding process In the molding process, a resin parison is molded to form a molded body having a base portion 40, a reinforcing portion 50, and a hinge portion H. The molding process includes a suction process, a mold closing process, and an expansion process. As shown in FIG. 7, in the suction process, the foamed resin sheet 23 and the skin material 32 are sucked through the reduced pressure suction holes of the second mold 22. As a result, the foamed resin sheet 23 and the skin material 32 are shaped to fit the core cr of the second mold 22.

[0026] As shown in FIG. 8A, in the mold closing step, the first mold 21 and the second mold 22 are brought close to each other, and the first and second molds 21 and 22 are closed. In the state where the mold closing step is completed, the interval between the first mold 21 and the second mold 22 is very narrowed in the portion where the hinge portion H is to be formed, and the foamed resin sheet 23 and the skin material 32 are crushed. As a result, the thinned hinge portion H is formed in the structure 300. Also, as shown in FIG. 8B, in the state where the mold closing step is completed, the pinch-off portion 21c and the pinch-off portion 22c come into contact with each other, and an enclosed space S is formed in the first mold 21 and the second mold 22. The portions of the foamed resin sheet 23 and the skin material 32 that are outside the enclosed space S become burrs br. As shown in FIG. 8C, in the expansion step, the enclosed space S is decompressed from the decompression suction holes of the first and second molds 21 and 22. As a result, the foamed resin sheet 23 is expanded. When the sealed space S is decompressed, foaming of the foamed resin sheet 23 is promoted, and the foamed resin sheet 23 expands.

[0027] 1-3-3. Excision process 9, the first and second molds 21, 22 are opened, and the structure 300 is taken out from the first and second molds 21, 22. In the cutting step, burrs br formed on the structure 300 are cut off.

[0028] 1-3-4. Rotation process As indicated by the dashed arrow in Fig. 4A, in the rotation process, the entire reinforcement portion 50 of the structure 300 is rotated around the hinge portion H of the structure 300 as an axis. Specifically, the reinforcement portion 50 of the structure 300 is bent so as to tilt the reinforcement portion 50 of the structure 300 toward the rear surface 43C of the base wall 43. This allows the structure 300 to be transformed into the structure 30. The rotation process may be performed by the manufacturer or by a manufacturing device. As described above, in the manufacturing method of the structure 30 according to the first embodiment, the structure 30 is not manufactured in the molding step, but the structure 300 is manufactured in the molding step. That is, the structure 300 is manufactured by sandwiching one foamed resin sheet 23 between the first and second molds 21, 22, and then the structure 300 is transformed into the structure 30 in the rotation step.

[0029] 1-3-5.Welding process In the welding process, the back surface 43C of the base wall 43 of the structure 30 and the reinforcing rib 51 of the reinforcing part 50 of the structure 30 are welded together. This makes it possible to prevent the bent reinforcing part 50 from returning to its original state, i.e., the state before the bending process, due to the elastic force of the hinge part H. In the welding process, ultrasonic welding is used.

[0030] 1-4. Effects of the First Embodiment In the structure 30 according to the first embodiment, the reinforcing part 50 is disposed on the back side of the base wall 43. A structure having such a configuration can be manufactured relatively easily by a manufacturing method using injection molding. On the other hand, it is technically difficult to mold a structure having such a configuration as the structure 30 by a manufacturing method in which one foamed resin sheet 23 is sandwiched between the first and second molds 21 and 22, as in the manufacturing method of the structure 30 according to the first embodiment. Since the structure 30 according to the first embodiment has a thinned hinge part H, even if the reinforcing part 50 is tilted toward the back side 43C of the base wall 43, the manufacturer can easily transform the structure 300 from the state of the structure 300 to the state of the structure 30. In other words, since the structure 300 according to the first embodiment has a thinned hinge part H, the manufacturer can bend the reinforcing part 50 so as to tilt the reinforcing part 50 toward the back side 43C of the base wall 43 without damaging the structure 300. In this way, the configuration of the structure 30 according to the first embodiment is suppressed from being restricted in shape due to the manufacturing method. Furthermore, the manufacturing method according to the first embodiment is a method that can suppress restrictions on the shape of the structure. In particular, the manufacturing method according to the first embodiment is effective when providing a reinforcing structure on the back side of a structure having a deep-drawn shape such as structure 30.

[0031] 1-5. Modification 1 of the first embodiment In the first modification of the first embodiment, the description of the parts common to the first embodiment will be omitted as appropriate. As shown in Figs. 10A to 11C, the structure 30B according to the first modification includes a base 40 and a reinforcing portion 50B. In the first modification of the first embodiment, the reinforcing portion 50B includes a hinge portion H. Therefore, in the rotation process of the structure 30B of the first modification, a part of the reinforcing portion 50B rotates around the hinge portion H as an axis.

[0032] The reinforcing portion 50B includes a reinforcing rib 51B, a pair of extending portions 52B, and a hinge portion H. The reinforcing portion 50B also has an opening 53B, into which a fixing member (e.g., a bolt) for fixing the structure 30B to an interior component of an automobile is inserted. The openings 53B are formed in the reinforcing rib 51B and the extending portion 52B, and when the reinforcing rib 51B is folded, the opening 53B of the reinforcing rib 51B and the opening 53B of the extending portion 52B are connected to each other.

[0033] The reinforcing rib 51B is a plate-like member, and in the first modification, the reinforcing rib 51B is formed in a flat plate shape. The reinforcing rib 51B may be curved. The reinforcing rib 51B is connected to the extending portion 52B via the hinge portion H. In a state in which the reinforcing rib 51B is bent around the hinge portion H as an axis, the reinforcing rib 51B is provided on the back surface of the base portion 40, and the reinforcing rib 51B supports the back surface of the base portion 40. Specifically, the reinforcing rib 51B is fixed to the standing wall 44, and as a result, the reinforcing rib 51B supports the base wall 43 connected to the standing wall 44. In the first modification of the first embodiment, the reinforcing rib 51B abuts against the standing wall 44, but is not limited thereto. An intervening member may be provided between the reinforcing rib 51B and the standing wall 44, and the reinforcing rib 51B may not abut against the standing wall 44. Moreover, the reinforcing rib 51B is welded to the standing wall 44, whereby the reinforcing rib 51B is fixed to the standing wall 44. For example, ultrasonic welding can be used as the welding method.

[0034] The extension portion 52B is a plate-like member, one end of which is connected to the outer edge of the flange wall 42, and the other end of which is connected to the reinforcing rib 51B via a hinge portion H. The extension portion 52B is provided on the base wall 43 with a gap therebetween. Although the hinge portion H is not provided at the connection portion between the extension portion 52B and the flange wall 42, the hinge portion H may be formed at the connection portion between the extension portion 52B and the flange wall 42. In this case, the extension portion 52B will be provided parallel to the flange wall 42 immediately after molding in a mold.

[0035] The hinge portion H is formed to have a thin wall, and the thickness of the hinge portion H is thinner than the thickness of the reinforcing rib 51B, the thickness of the extension portion 52B, and the thickness of the base portion 40.

[0036] As indicated by the dashed arrow in FIG. 11C, the manufacturer can transform the structure 300B shown in FIG. 11A into the structure 30B shown in FIG. 10A by bending the reinforcing rib 51B around the hinge portion H as an axis.

[0037] 1-6. Modification 2 of the first embodiment In the second modification of the first embodiment, the description of the parts common to the first embodiment will be omitted as appropriate. As shown in Figs. 12A to 13B, the structure 30C according to the second modification includes a base 40 and a reinforcing portion 50C. As in the first modification of the first embodiment, the second modification of the first embodiment also includes the reinforcing portion 50C having a hinge portion H. Therefore, in the rotation process of the structure 30C of the second modification, a part of the reinforcing portion 50C rotates around the hinge portion H as an axis. By carrying out the rotation process, the manufacturer can transform the structure 300C into the structure 30C.

[0038] The reinforcing portion 50C includes a reinforcing rib 51C, a pair of extending portions 52C, and a hinge portion H. The reinforcing portion 50C has an opening 53C, into which a fixing member (e.g., a bolt) for fixing the structure 30C to an interior component of an automobile is inserted.

[0039] The extending portion 52C has a configuration similar to that of the extending portion 52B described in Modification 1. In Modification 2 of the first embodiment, one of the pair of extending portions 52C is referred to as a first extending portion 52C1, and the other of the pair of extending portions 52C is referred to as a second extending portion 52C2.

[0040] In the second modification of the first embodiment, the hinge portion H has a first hinge portion h1, a second hinge portion h2, a third hinge portion h3, and a fourth hinge portion h4. The first hinge portion h1, the second hinge portion h2, the third hinge portion h3, and the fourth hinge portion h4 extend in parallel. The first hinge portion h1 is provided at one end of the reinforcing rib 51C, and the second hinge portion h2 is provided at the other end of the reinforcing rib 51C. The third hinge portion h3 and the fourth hinge portion h4 are provided in a portion between one end and the other end of the reinforcing rib 51C.

[0041] The reinforcing rib 51C is a plate-like member, and has a pair of first plate-like portions c1 and a second plate-like portion c2. The first extending portion 52C1 and one of the first plate-like portions c1 are connected via a first hinge portion h1, and the second extending portion 52C2 and the other of the first plate-like portions c1 are connected via a second hinge portion h2. The one of the first plate-like portions c1 and the second plate-like portion c2 are connected via a third hinge portion h3, and the other of the first plate-like portions c1 and the second plate-like portion c2 are connected via a fourth hinge portion h4.

[0042] In a state in which the reinforcing rib 51C is bent around the hinge portion H as an axis, the reinforcing rib 51C is provided on the back surface of the base portion 40, and the reinforcing rib 51C supports the back surface of the base portion 40. Specifically, the second plate-shaped portion c2 abuts against the back surface 43C of the base wall 43, and thus the base wall 43 is supported by the reinforcing portion 50C, and as a result, the base portion 40 is reinforced by the reinforcing portion 50C. In the second modification of the first embodiment, the second plate-shaped portion c2 abuts against the base wall 43, but is not limited thereto. An intervening member may be provided between the second plate-shaped portion c2 and the base wall 43, and the second plate-shaped portion c2 may not abut against the base wall 43. The second plate-shaped portion c2 is fixed to the base wall 43 by being welded to the base wall 43. As in the first embodiment and the first modification of the first embodiment, ultrasonic welding may be used for this welding method.

[0043] The extension portion 52C is a plate-like member, and one end of the extension portion 52C is connected to the outer edge of the flange wall 42. A first hinge portion h1 is provided at an end of the first extension portion 52C1 facing the second extension portion 52C2, and a second hinge portion h2 is provided at an end of the second extension portion 52C2 facing the first extension portion 52C1. The extension portion 52C is provided on the base wall 43 at a distance. Although the hinge portion H is not provided at the connection portion between the extension portion 52C and the flange wall 42, the hinge portion H may be formed at the connection portion between the extension portion 52C and the flange wall 42. In this case, the extension portion 52C of the structure 30C immediately after molding with a mold is provided parallel to the flange wall 42.

[0044] The hinge portion H is formed to have a thin wall, and the thickness of the hinge portion H is thinner than the thickness of the reinforcing rib 51C, the thickness of the extension portion 52C, and the thickness of the base portion 40.

[0045] As shown by the dashed arrow Ar1 in FIG. 13B, the manufacturer folds one of the first plate-shaped portions c1 from the first extending portion 52C1 around the first hinge portion h1 as an axis, and folds one of the first plate-shaped portions c1 and the second plate-shaped portion c2 around the third hinge portion h3 as an axis. Next, as shown by the dashed arrow Ar2 in FIG. 13B, the manufacturer folds the other of the first plate-shaped portions c1 from the second extending portion 52C2 around the second hinge portion h2 as an axis, and folds the other of the first plate-shaped portions c1 and the second plate-shaped portion c2 around the fourth hinge portion h4 as an axis. As a result, the reinforcing rib 51C shown in FIG. 13B is inverted and becomes in the state shown in FIG. 12C. That is, the manufacturer can transform the structure 300C shown in FIG. 13A into the structure 30C shown in FIG. 12B. The order of the operations of the dashed arrows Ar1 and Ar2 may be reversed.

[0046] 1-7. Modification 3 of the first embodiment In the third modification of the first embodiment, the description of the parts common to the first embodiment will be omitted as appropriate. As shown in Fig. 14A, a structure 30D according to the third modification includes a base 40 and a reinforcing part 50D. In the third modification, similarly to the first embodiment, the reinforcing part 50D is rotatably connected to the base 40 via a hinge part H (see arrow Br in Fig. 14B). Note that the state of the reinforcing part 50D before rotation is omitted because it is similar to the first embodiment.

[0047] Modification 3 differs from the first embodiment in that the depth dp (height) of reinforcing rib 51D of reinforcing portion 50D in modification 3 is greater than the depth (height) of reinforcing rib 51 of reinforcing portion 50 in the first embodiment. In the first embodiment, the depth (height) of each reinforcing rib 51 is the same, but in the present modified example 3, the depth (height) of each reinforcing rib 51D is different. Specifically, the depth (height) of the reinforcing rib 51D shown on the front side in Fig. 14B is greater than the depth (height) of the reinforcing rib 51D shown on the back side in Fig. 14B. In this way, even when the structure 30D has a plurality of reinforcing ribs 51D and the depths (heights) of the reinforcing ribs 51D are different, the structure 30D can be molded in the molding process described in the first embodiment, and the same effects as those of the first embodiment can be obtained.

[0048] Here, if the depth dp is set large, the portion of the foamed resin sheet that constitutes the reinforcing portion 50D is stretched in the molding process, and the reinforcing rib 51D of the reinforcing portion 50D is likely to be thin-walled. Thinning of the reinforcing rib 51D may lead to a decrease in the strength of the reinforcing portion 50D. Therefore, in the third modification, as described in 1-3-5. Welding process, the back surface 43C of the base wall 43 and the bottom portion 50D1 (see FIG. 14C) of the reinforcing rib 51D are welded together. In the third modification, ultrasonic welding can be used as the welding method, as in the first embodiment.

[0049] As shown in FIG. 15, when the back surface 43C and the bottom portion 50D1 are welded, the resin molded body 31 (foamed resin) of the back surface 43C and the resin molded body 31 (foamed resin) of the bottom portion 50D1 melt, and the melted resin molded body 31 soaks into the skin material 32 provided on the bottom portion 50D1. This makes the back surface 43C and the bottom portion 50D1 more firmly bonded, and a decrease in the strength of the reinforcement portion 50D is avoided. In other words, in the third modification, the base wall 43 (back surface 43C) and the reinforcement portion 50D (bottom portion 50D1) are welded so that the foamed resin soaks into the skin material 32 provided on the bottom portion 50D1. This avoids a decrease in the strength of the reinforcement portion 50D even if the depth dp of the reinforcement portion 50D is large.

[0050] When the manufacturer welds the back surface 43C and the bottom portion 50D1, the manufacturer does not press the tool for ultrasonic welding against the skin material 32 provided on the back surface 43C, but presses it against the skin material 32 provided on the reinforcement portion 50D. This allows the molten resin molded body 31 to soak into the skin material 32 provided on the reinforcement portion 50D. In other words, since the foamed resin constituting the resin molded body 31 is inherently difficult to soak into the skin material 32, the molten foamed resin preferentially soaks into the portion on the side where the tool for ultrasonic welding is pressed (skin material 32 of the bottom portion 50D1), while the molten foamed resin is prevented from soaking into the portion on the side where the tool for ultrasonic welding is not pressed (skin material 32 of the back surface 43C). Since the skin material 32 of the back surface 43C is a design surface, the third modification can prevent the design of the structure 30D from being impaired. That is, in the third modification, even if the depth dp is large, it is possible to avoid a decrease in the strength of the reinforcing portion 50D, and also to avoid a loss of the design of the structure 30D.

[0051] 2. Second embodiment In the second embodiment, the description of the parts common to the first embodiment will be omitted as appropriate. A structure 30E according to the second embodiment has a structure that reinforces the periphery of a base portion 40E.

[0052] 2-1.Structure 30E As shown in FIG. 16A, the structure 30E according to the second embodiment is a plate-like member. The structure 30E includes a base 40E, a reinforcing portion 50E, and a hinge portion H. The structure 30E is configured by overlaying a skin material 32 on a resin molded body 31. That is, as shown in FIG. 18A and FIG. 18B, the structure 30E includes a resin molded body 31 as a first layer and a skin material 32 as a second layer. The base 40E has a front surface 43B and a back surface 43C, and the skin material 32 of the base 40E constitutes the front surface 43B, and the back surface 43C of the base 40E constitutes the back surface 43C. The shape of the structure 30E can be appropriately changed. For example, a concave portion may be formed in the center of the base 40E, and the structure 30E may be configured in a container shape.

[0053] 2-1-1. Base 40E As shown in FIG. 16A and FIG. 17A, the base 40E is a trapezoidal plate-like member. The base 40E has four base edges 40E1, and each base edge 40E1 is provided with a hinge H. The hinge H is provided so as to extend along each base edge 40E1 of the base 40E. Here, as shown in FIG. 18B, similarly to the first embodiment, the hinge H is formed thin. That is, the thickness of the hinge H is thinner than the thickness of the reinforcing portion 50E and the thickness of the base 40E. For this reason, the hinge H is configured so that the manufacturer or manufacturing device can bend the reinforcing portion 50E so as to tilt the reinforcing portion 50E toward the back surface 43C of the base 40E.

[0054] 2-1-2. Reinforcement part 50E and hinge part H As shown in FIG. 18A and FIG. 18B, the reinforcing portion 50E is rotatably connected to the base portion 40E via the hinge portion H. In the second embodiment, the structure 30E has four reinforcing portions 50E, and the reinforcing portions 50E are plate-like members extending along the base edge portion 40E1. As shown in FIG. 18B, each hinge portion H connects each base edge portion 40E1 to each reinforcing portion 50E. The hinge portion H is formed to be thin, and specifically, the thickness of the hinge portion H is thinner than the thickness of the reinforcing portion 50E and the thickness of the base portion 40E. For this reason, the hinge portion H is configured so that the manufacturer or the manufacturing device can bend the reinforcing portion 50E so that the reinforcing portion 50E is tilted toward the back surface 43C of the base portion 40E.

[0055] 16B, 16C, and 19, a pair of adjacent reinforcing parts 50E are bent toward the base part 40E around each hinge part H as an axis so that one reinforcing part 50E is sandwiched between the base part 40E and the other reinforcing part 50E. Here, the pair of adjacent reinforcing parts 50E refers to two reinforcing parts 50E adjacent to each other in the circumferential direction of the base part 40E. Therefore, one reinforcing part 50E and the other reinforcing part 50E overlap at the longitudinal end of the pair of adjacent reinforcing parts 50E.

[0056] Of a pair of adjacent reinforcing parts 50E, one reinforcing part 50E corresponds to the first reinforcing part, and the other reinforcing part 50E corresponds to the second reinforcing part. The hinge part H and base edge part 40E1 provided on the one reinforcing part 50E correspond to the first hinge and the first base edge, and the hinge part H and base edge part 40E1 provided on the other reinforcing part 50E correspond to the second hinge and the second base edge.

[0057] 2-1-3.Skin material 32 The skin material 32 (see FIG. 18B) is provided over the entire front surface of the resin molded body 31. As in the first embodiment, in the second embodiment, the skin material 32 is made of, for example, a breathable nonwoven fabric, specific examples of which include, but are not limited to, nylon fiber, cellulose fiber, aramid fiber, and the like.

[0058] 2-2. Manufacturing method of the structure 30E The method for manufacturing the structure 30E according to the second embodiment includes a positioning step, a molding step, a cutting step, a rotating step, and a welding step. The positioning step, the molding step, and the cutting step of the second embodiment are similar to the positioning step, the molding step, and the cutting step of the first embodiment, and therefore the description thereof will be omitted.

[0059] 2-2-1. Rotation process In the rotation process, the reinforcing portion 50E of the structure 300E is rotated around the hinge portion H of the structure 300E. Specifically, the reinforcing portion 50E of the structure 300E is bent so as to bend the reinforcing portion 50E of the structure 300E toward the back surface 43C of the base 40E. Here, as shown in (1) of FIG. 17B, the manufacturer or manufacturing device first bends the reinforcing portion 50E provided on the upper edge of the base 40E, then as shown in (2), the manufacturer or manufacturing device bends the reinforcing portion 50E provided on the left and right edges of the base 40E, and as shown in (3), the manufacturer or manufacturing device bends the reinforcing portion 50E provided on the lower edge of the base 40E. In this way, each reinforcing portion 50E is bent toward the base 40E. As a result, the base 40E is reinforced by the reinforcing portion 50E, and the manufacturer or manufacturing device can transform the structure 300E into the structure 30E. By folding the reinforcing portion 50E in the order of (1) to (3) described here, the strength of the structure 30E is effectively improved in the welding step described below.

[0060] 2-2-2. Welding process In the welding process, the reinforcing parts 50E are welded together. In the second embodiment, the reinforcing parts 50E are welded together at each of the four corners of the base 40E. Here, as shown in Figs. 16B, 16C, and 19, a longitudinal end of one reinforcing part 50E (lower reinforcing part 50E) of the pair of reinforcing parts 50E is overlapped with a longitudinal end of the other reinforcing part 50E (upper reinforcing part 50E). These overlapping ends are welded together. In FIG. 19, the manufacturer presses an ultrasonic welding tool against the other reinforcement part 50E (upper reinforcement part 50E) to weld one reinforcement part 50E (lower reinforcement part 50E) and the other reinforcement part 50E (upper reinforcement part 50E). Here, in FIG. 19, the resin molded body 31 of the other reinforcement part 50E (upper reinforcement part 50E) is disposed on the skin material 32 of the one reinforcement part 50E (lower reinforcement part 50E). Therefore, the foam molded body (foamed resin) of the other reinforcement part 50E (upper reinforcement part 50E) permeates the skin material 32 of the one reinforcement part 50E (lower reinforcement part 50E). As a result, the one reinforcement part 50E (lower reinforcement part 50E) and the other reinforcement part 50E (upper reinforcement part 50E) are firmly bonded to each other, and the base part 40E is further firmly reinforced by the reinforcement part 50E.

[0061] 2-4. Effects of the second embodiment In the structure 30E according to the second embodiment, the reinforcing portion 50E, which is a plate-like member, is bent toward the base portion 40E around the hinge portion H as an axis, so that the base portion 40E is strongly reinforced by the reinforcing portion 50E. Also, as shown by the arrow Ar in Fig. 19, the skin material 32 is disposed on the edge portion of the structure 30E, so that the design of the structure 30E is improved. In other words, the foam molded body (foamed resin) is prevented from being exposed on the edge portion of the structure 30E, so that the design of the structure 30E is improved.

[0062] In the structure 30E according to the second embodiment, the foamed molded body (foamed resin) of the other reinforcing part 50E (upper reinforcing part 50E) permeates into the skin material 32 of one reinforcing part 50E (lower reinforcing part 50E). Therefore, the one reinforcing part 50E (lower reinforcing part 50E) and the other reinforcing part 50E (upper reinforcing part 50E) are firmly bonded to each other, and as a result, the base part 40E is further strongly reinforced by the reinforcing part 50E. [Explanation of symbols]

[0063] 1: Foam molding machine 2:Resin supply device 11: Raw resin 12: Hopper 13: Extruder 13a: Cylinder 16: Injector 17: Accumulator 17a: Cylinder 17b: Piston 18: T-die 21: First mold 21c: Pinch-off section 22: Second mold 22c: Pinch-off section 23: Foam resin sheet 25: Connecting pipe 27: Connecting pipe 30 :Structure 30B: Structure 30C: Structure 30D: Structure 30E :Structure 31: Resin molding 32:Skin material 35:Protrusion 40: Base 40E: Base 40E1: Base edge 41: Base body 42: Flange wall 42A: Opening 43: Base wall 43A: First edge 43B: Front 43C: Back side 43a: Second edge 44: Vertical wall 50: Reinforcement 50B: Reinforcement part 50C: Reinforcement 50D: Reinforcement 50D1: Bottom 50E: Reinforcement 51: Reinforcement rib 51B: Reinforcement rib 51C: Reinforcement rib 51D: Reinforcement rib 52:Fixed part 52B: Extension part 52C: Extension part 52C1: 1st extension part 52C2: 2nd extension part 53: Opening 53B: Opening 53C: Opening 300 :Structure 300B: Structure 300C: Structure 300E :Structure H: Hinge part R1: 1st area R2: 2nd area S: Closed space br : Bali c1: First plate-shaped portion c2: Second plate-shaped portion cr :Core cv: cavity h1: First hinge part h2: Second hinge part h3: Third hinge part h4: 4th hinge part

Claims

1. The device includes a base portion, a reinforcing portion, and a hinge portion, The base portion has a flat base wall, The base wall has a front surface on which a skin material is provided and a back surface, The front surface is a surface that receives the load of an article placed on the front surface, The reinforcing portion is a plate-like member formed in a concave shape, the concave shape forms a reinforcing rib, the reinforcing rib protrudes toward the back surface and contacts the back surface, The base portion and the reinforcing portion are connected via the hinge portion, An interior part for an automobile, wherein a contact area between the reinforcing rib and the back surface is smaller than the entire back surface.

2. 2. The interior part of an automobile according to claim 1, An interior part for an automobile, wherein the reinforcing rib and the back surface are welded to each other at the contact area.

3. 3. The interior part of an automobile according to claim 2, The base portion, the reinforcing portion and the hinge portion are formed by molding a same foamed resin sheet.

4. 4. The interior part of an automobile according to claim 3, The reinforcing rib includes a first reinforcing rib and a second reinforcing rib spaced apart from each other, the contact area includes a first contact area and a second contact area; the first and second contact regions are spaced apart from one another on the back surface; An interior part for an automobile, wherein the back surface and the first reinforcing rib are welded to each other at the first contact area, and the back surface and the second reinforcing rib are welded to each other at the second contact area.

5. A structure comprising a base portion, a reinforcing portion, and a hinge portion, The reinforcing portion is provided to reinforce the base portion, The base portion and the reinforcing portion are connected via the hinge portion, the base has a base edge; The hinge portion connects the base edge portion and the reinforcing portion, The reinforcing portion is a plate-like member provided so as to extend along an edge portion of the base portion, and is bent toward the base portion around the hinge portion as an axis, The structure is configured by laminating a skin material onto a resin molded body, the base having first and second base edges; The reinforcing portion includes a first reinforcing portion and a second reinforcing portion, The hinge portion includes a first hinge portion and a second hinge portion. the first hinge portion connects the first base edge portion and the first reinforcement portion, the second hinge portion connects the second base edge portion and the second reinforcement portion, the first and second reinforcing portions are plate-like members provided so as to extend along the first and second base edge portions, and the first and second reinforcing portions are bent toward the base portion about the first and second hinge portions so that the first reinforcing portion is sandwiched between the base portion and the second reinforcing portion; the first reinforcing portion and the second reinforcing portion are welded together, and the skin material of the first reinforcing portion is permeated with a resin constituting the resin molded body of the second reinforcing portion; A structure in which the base portion, the reinforcing portion, and the hinge portion are formed by molding a same foamed resin sheet.

6. An interior part for an automobile according to any one of claims 1 to 4, The hinge portion is an interior part of an automobile, the interior part being formed with a thin wall.

7. A method for manufacturing an interior part of an automobile, comprising a molding process and a rotating process, In the molding step, a molded body having a base portion, a reinforcing portion, and a hinge portion is formed by molding a resin parison, and the hinge portion is configured to connect the base portion and the reinforcing portion, The base portion has a flat base wall, The base wall has a front surface on which a skin material is provided and a back surface, The front surface is a surface that receives the load of an article placed on the front surface, The reinforcing portion is a plate-like member formed in a concave shape, and the concave shape constitutes a reinforcing rib, In the rotating step, the reinforcing portion is rotated around the hinge portion as an axis, The reinforcing rib comes into contact with the back surface by the rotating process, A method, wherein the contact area between the reinforcing rib and the back surface is less than the entire back surface.

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