Manufacturing method of the storage box

Abstract

To reduce cost required for a mold device.SOLUTION: Storage boxes 10, 40 having plural types of box bodies 11, 41 having mutually-different depths are manufactured through at least a box body formation step. In the above-mentioned step, a movable mold is brought close to a stationary mold. The box bodies 11, 41 are formed by filling a resin material in cavities 75, 76 formed between inner wall surface formation parts 62, 66 and an external wall surface formation part 72. In the above-mentioned step, the one in which the external wall surface formation part 72 has a length that may form an external wall surface 17 of the box body 11 in the type with the deepest depth in a depth direction is used as the movable mold 71. In the above-mentioned step, the ones which are stationary molds 61, 65 provided for each of the plural types of box bodies 11, 41 with the different depths and in which the inner wall surface formation parts 62, 66 have a length that may form inner wall surfaces 22, 52 for each of the box bodies 11, 41 in the depth direction are used as the stationary molds.SELECTED DRAWING: Figure 15

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a storage box to be mounted in the passenger compartment of a motor vehicle. [Background technology]

[0002] There is known an automobile in which a storage box, such as a glove box, for storing items is built into the instrument panel at the front of the passenger compartment (see, for example, Patent Document 1). This storage box includes a box body having an entrance for items at one end and a bottom at the other end, and a lid for opening and closing the entrance.

[0003] The box body is resin molded by a mold device equipped with a fixed mold and a movable mold. The fixed mold has at least an inner wall surface forming portion that forms the inner wall surface of the box body. The movable mold moves toward and away from the fixed mold in the depth direction of the box body. The movable mold has an outer wall surface forming portion that forms the outer wall surface of the box body. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Utility Model Registration No. 2521757 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the same vehicle model, there may be hybrid vehicles using an engine and an electric motor as a power source, and engine vehicles using an engine as a power source. In this case, the size of the installation space of the storage box in the depth direction in the instrument panel may differ depending on the type of power source. On the other hand, there is a need to make the box body as large as possible in the depth direction. Therefore, in the same vehicle model, a storage box is required in which multiple types of box bodies are set, each with a different depth from the entrance to the bottom depending on the type of power source. Accordingly, a different mold device is required for each type of storage box. On the other hand, as the number of types of mold devices increases, the cost of the mold device and therefore the manufacturing cost of the storage box increases. [Means for solving the problem]

[0006] A method for manufacturing a storage box that solves the above problem is a method for manufacturing a storage box that is mounted in the passenger compartment of an automobile, the storage box comprising a box body having an entrance / exit for items at one end and a bottom at the other end and formed by a mold device, and a lid for opening and closing the entrance / exit, and a plurality of types of box bodies having different depths from the entrance / exit to the bottom are set, the mold device comprising a fixed mold having at least an inner wall surface forming portion that forms the inner wall surface of the box body, and a movable mold that moves in the depth direction of the box body toward and away from the fixed mold and has an outer wall surface forming portion that forms the outer wall surface of the box body, The method includes a box body forming process in which a cavity is formed between the inner wall surface forming portion and the outer wall surface forming portion by clamping the mold, and the box body is formed by filling the cavity with a resin material, and in the box body forming process, the movable mold used is one in which the outer wall surface forming portion has a length in the depth direction sufficient to form the outer wall surface of the deepest type of box body, and in the box body forming process, the fixed mold used is one which is provided for each of the multiple types of box bodies having different depths, and the inner wall surface forming portion has a length in the depth direction sufficient to form the inner wall surface of each of the box bodies.

[0007] According to the above-mentioned manufacturing method, a storage box is manufactured in which a plurality of types of box bodies having different depths from the entrance to the bottom are set. In this manufacturing method, a box body forming process is performed using a mold device equipped with a fixed mold and a movable mold, thereby forming the plurality of types of box bodies.

[0008] The movable mold is one in which the outer wall surface forming part has a length in the depth direction that allows it to form the outer wall surface of the deepest type of box body. The outer wall surface forming part of this movable mold has a length in the depth direction that allows it to form the outer wall surface of a type of box body that is shallower than the above. Therefore, by using the movable mold, it is possible to form the outer wall surfaces of multiple types of box bodies with different depths by the outer wall surface forming part.

[0009] The fixed molds are provided for each of a plurality of types of box bodies having different depths. The inner wall surface forming portion of each fixed mold has a length in the depth direction sufficient to form the inner wall surface of each box body.

[0010] When the movable mold and one type of fixed mold among the multiple types of fixed molds are clamped together, a cavity is formed between the inner wall surface forming portion and the outer wall surface forming portion. The cavity is filled with a resin material to form a box body. The fixed mold is then changed and the clamping is performed to form cavities of different depths. The cavity is filled with a resin material to form box bodies of different depths.

[0011] Therefore, it is not necessary to use the same number of types of movable dies to form multiple types of box bodies with different depths. The movable dies can be standardized. Compared to the case where a different movable die is used for each type of box body with different depths, the cost required for the mold device is reduced.

[0012] In the above-mentioned method for manufacturing a storage box, in the box body forming process, the mold device is clamped, so that the movable mold and the fixed mold are brought into contact with each other at their mold mating surfaces set around the outer periphery of the outer wall surface forming portion, and in the box body forming process, it is preferable that the mold mating surfaces of the movable mold and the fixed mold are brought into contact at a location that forms the outer periphery of the portion that forms the entrance / exit of the cavity that forms the deepest type of box body, or at a location that is farther from the cavity in the depth direction than the above location.

[0013] According to the above manufacturing method, when the mold device is clamped in the box body forming step, the mating surface of the movable mold and the mating surface of the fixed mold come into contact with each other at a location that is the outer periphery of the portion that forms the entrance / exit of the cavity that forms the deepest type of box body, or at a location that is farther away from the cavity in the depth direction than the location.

[0014] Therefore, it is easy to form the outer wall surface forming portion capable of forming the outer wall surface of the deepest box body in a movable mold. Also, it is easy to form the inner wall surface forming portion capable of forming the inner wall surfaces of a plurality of types of box bodies having different depths for each fixed mold.

[0015] In the above-mentioned method for manufacturing a storage box, the lid body comprises a fastening portion which is placed over a covering portion which is the outer wall surface of the box body and which forms the outer periphery of the entrance / exit and is fastened to the box body, and a movable lid portion which is attached to the fastening portion so as to open and close the entrance / exit. In the box body forming process, a fixed mold is used which faces the cavity and has a rib forming portion whose length varies in the depth direction depending on the depth of the box body, so that welding ribs are formed on the outer wall surface, starting from points which are spaced the same distance from the bottom toward the entrance / exit side, and extending to the end face of the box body on the entrance / exit side. After the box body forming process, it is preferable that a welding process is performed in which the fastening portion is placed over the covering portion of the box body and the welding rib is welded to a welded portion formed on the inner surface of the fastening portion, thereby fastening the fastening portion to the box body.

[0016] According to the above manufacturing method, when the mold device is clamped in the box body forming process, the rib forming portion provided on the fixed mold faces the cavity. The length in the depth direction of the rib forming portion varies depending on the depth of the box body. The cavity is filled with resin material to form a box body having welding ribs on its outer wall surface. The welding ribs extend from the outer wall surface at positions spaced from the bottom by the same distance in the depth direction to the end face on the entrance / exit side of the box body. The length of the welding rib increases as the depth of the box body increases.

[0017] In the welding process performed after the box body forming process, the fastening portion is covered with the covering portion of the box body. The welding rib is welded to the welded portion formed on the inner surface of the fastening portion. By this welding, the fastening portion is fastened to the box body at the welded portion.

[0018] In the shallowest box body, all or a large part of the welding rib can be used for welding, and in the box body deeper than the shallowest box body, a part of the welding rib can be left unwelded.

[0019] In the above-mentioned method for manufacturing a storage box, it is preferable that in the welding process, the fastening portion is formed with a first positioning portion formed in the welded portion, and in the welding process, with the fastening portion covered over the covered portion of the box body, the first positioning portion comes into contact with the end of the welding rib on the entrance / exit side before welding, thereby positioning the fastening portion in the depth direction.

[0020] According to the above manufacturing method, in the welding step, when the fastening portion is placed on the adherend portion, the first positioning portion of the adherend portion comes into contact with the end of the weld rib on the entrance / exit side before welding. This contact determines the position of the fastening portion in the depth direction. It becomes possible to perform welding with the fastening portion positioned at the desired location in the depth direction of the adherend portion.

[0021] In the above-mentioned method for manufacturing a storage box, in the welding process, the fastening portion is formed with a second positioning portion formed in the welded portion, and in the welding process, with the fastening portion covered over the welded portion of the box body, it is preferable that the second positioning portion contacts the side of the welded rib before welding, thereby positioning the fastening portion in a direction perpendicular to the depth direction and along the inner surface.

[0022] According to the above manufacturing method, when the fastening portion is placed over the attachment portion of the box body in the welding step, the second positioning portion of the attachment portion comes into contact with the side of the welding rib before welding. This contact positions the fastening portion in a direction perpendicular to the depth direction and along the inner side surface. It becomes possible to perform welding with the fastening portion positioned at the desired location in the attachment portion in the above direction.

[0023] In the above-mentioned method for manufacturing a storage box, in the welding process, the fastening portion is formed with a groove portion extending in the depth direction and into which the welding rib engages, and when the fastening portion is placed over the attachment portion of the box body, the groove portion has an open end at an end far from the entrance / exit and a closed end at an end close to the entrance / exit, and has a pair of opposing surfaces facing each other in the groove width direction, and it is preferable that in the welding process, the closed end functions as the first positioning portion and the opposing surfaces function as the second positioning portion.

[0024] According to the above manufacturing method, in the welding step, when the fastening portion is placed over the covering portion of the box body, the welding rib engages with the groove portion from the open end to the closed end. The opposing surface of the groove portion comes into contact with the side surface of the welding rib, whereby the opposing surface functions as a second positioning portion. The fastening portion is positioned in a direction perpendicular to the depth direction and along the inner surface by the contact of the opposing surface with the side surface of the welding rib. When the end of the welding rib on the entrance / exit side comes into contact with the closed end of the groove portion, the closed end functions as a first positioning portion. The fastening portion is positioned in the depth direction by the contact of the closed end with the end of the welding rib.

[0025] In this way, by performing the simple task of engaging the welding rib with the groove and placing the fastening portion over the attachment portion, it is possible to position the fastening portion in the depth direction and also in a direction perpendicular to the depth direction and along the inner surface.

[0026] In the above-mentioned method for manufacturing a storage box, it is preferable that the fastening portion used in the welding step has a shape and size common to all types of box bodies having different depths.

[0027] According to the above manufacturing method, in the welding process, the fastening parts having the same shape and size are applied to the covering parts of all types of box bodies with different depths. Then, the fastening parts are welded to the covering parts at the welding ribs of each covering part. Therefore, it is possible to reduce the manufacturing cost of the fastening parts and therefore the cost of the storage box compared to the case where different fastening parts are used for each box body with different depths. Effect of the Invention

[0028] According to the above-described method for manufacturing a storage box, the cost required for a mold device can be reduced. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 is a cross-sectional view of a containment box having a deep box body in one embodiment. [Diagram 2] FIG. 2 is an enlarged cross-sectional view of part A in FIG. [Diagram 3] FIG. 2 is a cross-sectional view of a storage box having a shallow box body in the embodiment. [Figure 4] FIG. 4 is an enlarged cross-sectional view of a portion B in FIG. [Diagram 5] 2 is a cross-sectional view showing a state before a fastening portion is fastened to a box body in the storage box of FIG. 1. FIG. [Figure 6] FIG. 6 is an enlarged cross-sectional view of a portion C in FIG. 5. [Figure 7] 4 is a cross-sectional view showing a state before a fastening portion is fastened to a box body in the storage box of FIG. 3. [Figure 8] FIG. 8 is an enlarged cross-sectional view of a portion D in FIG. [Figure 9] 1A and 1B are diagrams illustrating a storage box having a deep box body in the above embodiment, where (a) is a partial cross-sectional view showing the state before the welding rib is engaged with the groove, and (b) is a partial cross-sectional view showing the engaged state. [Figure 10]1A and 1B are diagrams illustrating a storage box having a shallow box body in the above embodiment, where (a) is a partial cross-sectional view showing the state before the welding rib is engaged with the groove, and (b) is a partial cross-sectional view showing the engaged state. [Figure 11] FIG. 2 is a cross-sectional view showing a state in which a mold device for forming a deep box body is clamped in the above embodiment. [Figure 12] 12 is a cross-sectional view showing a state in which the mold apparatus of FIG. 11 is opened. FIG. [Figure 13] FIG. 11 is a cross-sectional view showing a state in which a mold device for forming a shallow box body is clamped in the embodiment. [Figure 14] 14 is a cross-sectional view showing a state in which the mold device in FIG. 13 is opened. FIG. [Figure 15] FIG. 2 is a partial cross-sectional view showing a comparison between a mold device for forming a deep box body and a mold device for forming a shallow box body in the above embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] Hereinafter, an embodiment of a method for manufacturing a storage box to be mounted in a vehicle interior will be described with reference to the drawings. A storage box is a device for storing items in the passenger compartment of an automobile. For example, a glove box built into the instrument panel at the front of the passenger compartment corresponds to this type of storage box. In addition to the glove box, a console box, an upper box, a cup holder, etc. also correspond to storage boxes.

[0031] In this embodiment, two types of storage boxes 10, 40 (see Figs. 1 and 3) are set for the same vehicle model. For example, the storage box 10 is incorporated into the instrument panel of a hybrid vehicle, and the storage box 40 is incorporated into the instrument panel of a gasoline vehicle.

[0032] <Outline of the configuration of the storage box 10> As shown in FIGS. 1 and 2, the storage box 10 includes a box body 11 and a lid body 31. As shown in FIG.

[0033] Box body 11 has an entrance 12 for entering and exiting items at one end, and a bottom 15 at the other end. Here, the direction connecting entrance 12 and bottom 15 is referred to as the depth direction of box body 11.

[0034] The box body 11 has a first storage section 14 and a second storage section 16 adjacent to each other in the depth direction. The first storage section 14 is located deeper than the second storage section 16, i.e., farther from the entrance / exit 12. The first storage section 14 has the bottom 15 at the end farther from the entrance / exit 12. The second storage section 16 has the entrance / exit 12 at the end farther from the bottom 15. The internal space of the first storage section 14 and the internal space of the second storage section 16 form a storage chamber 13, which is a space for storing items.

[0035] An outer wall surface 17 of the box body 11 that forms the outer periphery of the entrance / exit 12 serves as a covering portion 18 . The lid body 31 is for opening and closing the entrance 12 of the box body 11. The lid body 31 includes a ring-shaped fastening portion 32 and a movable lid portion 37. The fastening portion 32 and the movable lid portion 37 are formed by a general resin molding method such as injection molding. The fastening portion 32 is covered on the attachment portion 18 of the box body 11. The movable lid portion 37 is attached to the fastening portion 32 so as to open and close the entrance 12. Here, the movable lid portion 37 may open and close the entrance 12 in any manner. For example, the movable lid portion 37 may open and close the entrance 12 by rotating around an axis, or may open and close the entrance 12 by sliding.

[0036] As shown in Fig. 5, Fig. 6, and Fig. 9(a) and (b), the fastening portion 32 covered on the covering portion 18 is fastened to the box body 11 by welding. For this welding, welding ribs 19 extending in the depth direction are formed at a plurality of locations on the outer wall surface 17. Each welding rib 19 starts at a location that is a distance D1 away from the bottom 15 in the depth direction and extends to an end face 21 on the entrance / exit 12 side of the box body 11. In other words, one end 19a of each welding rib 19 is located at a location that is a distance D1 away from the bottom 15 in the depth direction. The other end 19b of each welding rib 19 is located at the end face 21 of the box body 11.

[0037] The above-mentioned welding of the fastening portion 32 to the covering portion 18 of the box body 11 is performed at a welded portion 34 formed on an inner surface 33 of the fastening portion 32. At a location of the welded portion 34 corresponding to the welding rib 19, a groove portion 35 extending in the depth direction is formed.

[0038] Groove portion 35 has an open end 35a at the end farther from entrance / exit 12 when fastening portion 32 is placed on covering portion 18. Groove portion 35 has a closed end 35b at the end closer to entrance / exit 12 when fastening portion 32 is placed on covering portion 18. Groove portion 35 has a pair of opposing surfaces 35c facing each other in the groove width direction.

[0039] The closed end 35b constitutes a first positioning portion. The pair of opposing surfaces 35c constitute a second positioning portion. The first positioning portion positions the fastening portion 32 in the depth direction by contacting the end 19b of the welding rib 19 before welding when the fastening portion 32 is placed over the covering portion 18. The second positioning portion positions the fastening portion 32 in a direction perpendicular to the depth direction and along the inner surface 33 by contacting the side surface 19c of the welding rib 19 before welding when the fastening portion 32 is placed over the covering portion 18.

[0040] The length of the groove 35 in the depth direction is set to be approximately the same as the length of a welding rib 49, which will be described later, in the same direction. Therefore, the length of the groove 35 in the depth direction is shorter than the length of the welding rib 19.

[0041] 1, 2 and 9(b), the fastening portion 32 is fastened (joined) to the box body 11 at the attachment portion 18 by vibration welding using the welding rib 19. Note that the portion of the welding rib 19 exposed from the groove portion 35 remains unused for welding.

[0042] <Overall configuration of storage box 40> As shown in FIGS. 3 and 4, the storage box 40 includes a box body 41 and a lid 31. The box body 41 and the lid 31 are made of a plastic material.

[0043] Box body 41 has an entrance 42 for articles at one end, and a bottom 45 at the other end. Here, the direction connecting entrance 42 and bottom 45 is referred to as the depth direction of box body 41.

[0044] The box body 41 has a first storage section 44 and a second storage section 46 adjacent to each other in the depth direction. The first storage section 44 is located deeper than the second storage section 46, i.e., farther from the entrance / exit 42. The first storage section 44 has a bottom 45 at the end farther from the entrance / exit 42. The second storage section 46 has the entrance / exit 42 at the end farther from the bottom 45. The internal space of the first storage section 44 and the internal space of the second storage section 46 form a storage chamber 43, which is a space for storing items.

[0045] The first storage section 44 in the box body 41 has the same shape and size as the first storage section 14 in the box body 11. In contrast, the second storage section 46 in the box body 41 is formed shorter in the depth direction than the second storage section 16 in the box body 11. Therefore, the depth from the entrance 42 to the bottom 45 in the box body 41 is shallower than the depth from the entrance 12 to the bottom 15 in the box body 11 (see FIG. 15).

[0046] As shown in FIGS. 3 and 4, the outer wall surface 47 of the box body 41, which is a portion that forms the outer periphery of the entrance , serves as a covering portion . The lid body 31 is for opening and closing the entrance 42 of the box body 41. The lid body 31 includes a fastening portion 32 and a movable lid portion 37, similar to the lid body 31 in the storage box 10.

[0047] The fastening portion 32 has the same shape and size as the fastening portion 32 in the storage box 10, i.e., a common portion is used. The movable lid portion 37 also has the same shape and size as the movable lid portion 37 in the storage box 10, i.e., a common portion is used. Therefore, the lid body 31 in the storage box 40 and each portion thereof will be given the same reference numerals as the lid body 31 in the storage box 10 and each portion thereof.

[0048] As shown in Figs. 7, 8, and 10(a) and (b), the fastening portion 32 is covered by the covering portion 48 and is fastened to the box body 41 by welding. For this welding, welding ribs 49 extending in the depth direction are formed at a plurality of locations on the outer wall surface 47. Each welding rib 49 starts at a location that is a distance D2 away from the bottom 45 in the depth direction and extends to an end face 51 on the entrance / exit 42 side of the box body 41. In other words, one end 49a of each welding rib 49 is located at a location that is a distance D2 away from the bottom 45 in the depth direction. The other end 49b of each welding rib 49 is located at the end face 51 of the box body 41. The distance D2 is the same as the distance D1 in the box body 11.

[0049] As described above, the dimension of the second accommodating portion 46 in the depth direction is smaller than the dimension of the second accommodating portion 16. Therefore, the length of the welding rib 49 in the depth direction is shorter than the length of the welding rib 19.

[0050] The above welding of the fastening portion 32 to the covering portion 48 of the box body 41 is performed in the same manner as the above welding of the fastening portion 32 to the covering portion 18 of the box body 11. That is, the welding rib 49 is engaged with the groove portion 35 of the fastening portion 32. The closed end 35b (first positioning portion) of the groove portion 35 contacts the end portion 49b of the welding rib 49, thereby positioning the fastening portion 32 in the depth direction. The opposite faces 35c (second positioning portions) of the groove portion 35 contact the corresponding side faces 49c of the welding rib 49, thereby positioning the fastening portion 32 in the direction perpendicular to the depth direction and along the inner side surface 33. The fastening portion 32 is joined and fastened to the box body 41 by vibration welding using the welding rib 49. The entire welding rib 49 is engaged with the groove portion 35 and used for welding.

[0051] <Molding device 60> As shown in Figures 11, 13 and 15, two types of box bodies 11 and 41 having different depths are formed by a mold device 60. The mold device 60 includes a fixed mold and a movable mold 71 that moves toward and away from the fixed mold by moving in the depth direction.

[0052] The fixed mold comprises a fixed mold 61 for forming the deep box body 11 and a fixed mold 65 for forming the shallow box body 41. The fixed mold 61 includes an inner wall surface forming portion 62 that forms the inner wall surface 22 of the box body 11, and a rib forming portion 63 that forms the welding rib 19. The inner wall surface forming portion 62 has a length capable of forming the inner wall surface 22 of the box body 11, and has a length in the depth direction longer than an inner wall surface forming portion 66, which will be described later. The rib forming portion 63 has a length capable of forming the long welding rib 19 in the box body 11, and has a length in the depth direction longer than a rib forming portion 67, which will be described later.

[0053] The fixed mold 65 includes an inner wall surface forming portion 66 that forms the inner wall surface 52 of the box body 41, and a rib forming portion 67 that forms the welding rib 49. The inner wall surface forming portion 66 has a length capable of forming the inner wall surface 52 of the box body 41, and a length in the depth direction that is shorter than the inner wall surface forming portion 62. The rib forming portion 67 has a length capable of forming the short welding rib 49 in the box body 41, and a length in the depth direction that is shorter than the rib forming portion 63.

[0054] In this way, the inner wall surface forming portions 62, 66 of each fixed mold 61, 65 have a length in the depth direction sufficient to form the inner wall surfaces 22, 52 of each box body 11, 41. The length in the depth direction of the rib forming portions 63, 67 of each fixed mold 61, 65 differs depending on the depth of the box body 11, 41.

[0055] The movable mold 71 is equipped with an outer wall surface forming portion 72 that forms the outer wall surface 17 of the box body 11 and the outer wall surface 47 of the box body 41. The outer wall surface forming portion 72 has a length in the depth direction that is sufficient to form the outer wall surface 17 of the deep box body 11. Unlike the fixed molds 61, 65, this movable mold 71 is a common one that is used regardless of the depth of the box bodies 11, 41.

[0056] In the movable mold 71, a mold mating surface 73 is formed on the outer periphery of the outer wall surface forming portion 72. In the fixed mold 61, a mold mating surface 64 is formed on the outer periphery of the outer wall surface forming portion 72 when the mold device 60 is closed. Similarly, in the fixed mold 65, a mold mating surface 68 is formed on the outer periphery of the outer wall surface forming portion 72 when the mold device 60 is closed. The mold mating surface 73 and the mold mating surfaces 64, 68 are all formed of flat surfaces perpendicular to the depth direction.

[0057] 11 and 15, the mold mating surfaces 64, 73 come into contact with each other when a mold device 60 including a fixed mold 61 and a movable mold 71 is clamped. At this time, a cavity 75 for forming the box body 11 having the welding rib 19 is formed between the inner wall surface forming portion 62 and the outer wall surface forming portion 72 and rib forming portion 63.

[0058] 13 to 15, the mold mating surfaces 68, 73 come into contact with each other when a mold device 60 including a fixed mold 65 and a movable mold 71 is clamped. At this time, a cavity 76 for forming a box body 41 having a welding rib 49 is formed between the inner wall surface forming portion 66 and the outer wall surface forming portion 72 and the rib forming portion 67.

[0059] The above-mentioned mold mating surfaces 64, 73 and mold mating surfaces 68, 73 are formed at locations that satisfy the following conditions. Condition: A location that is the outer periphery of the part that forms the entrance / exit 12 in the cavity 75 that forms the deepest type of box body 11, or a location that is further away in the depth direction from the cavity 75 than the above-mentioned location.

[0060] In this embodiment, the mold mating surfaces 64, 73 and the mold mating surfaces 68, 73 are formed in the cavity 75 at locations that form the outer periphery of the portion that forms the entrance / exit 12. Next, the operation of the present embodiment configured as described above will be described, along with the effects that accompany the operation.

[0061] Storage box 10 (see FIG. 1) having a deep box body 11 and storage box 40 (see FIG. 3) having a shallow box body 41 are each manufactured through at least a box body forming process and a welding process.

[0062] <(1) Box body forming process> (1-1) The box body forming process is a process for forming the box bodies 11, 41 using the fixed molds 61, 65 and the movable mold 71.

[0063] 11, 12 and 15, in the box body forming process for forming the box body 11, the movable mold 71 is brought close to the fixed mold 61 and the mold device 60 is clamped (see FIG. 11). A cavity 75 is formed between the inner wall surface forming portion 62 and the rib forming portion 63 of the fixed mold 61 and the outer wall surface forming portion 72 of the movable mold 71. The box body 11 having the welding ribs 19 is formed by filling this cavity 75 with a resin material.

[0064] 13 to 15, in the box body forming process for forming the box body 41, the movable mold 71 is brought close to the fixed mold 65 and the mold device 60 is clamped (see FIG. 13). A cavity 76 is formed between the inner wall surface forming portion 66 and the rib forming portion 67 of the fixed mold 65 and the outer wall surface forming portion 72 of the movable mold 71. The box body 41 having the welding ribs 49 is formed by filling this cavity 76 with a resin material.

[0065] As shown in Fig. 15, a movable mold 71 is used in which the outer wall surface forming portion 72 has a length in the depth direction sufficient to form the outer wall surface 17 of the deep box body 11. The outer wall surface forming portion 72 of this movable mold 71 has a length in the depth direction sufficient to form the outer wall surface 47 of the box body 41, which has a shallower depth than the above. Therefore, by using the movable mold 71, the outer wall surfaces 17, 47 of two types of box bodies 11, 41 having different depths can be formed by the outer wall surface forming portion 72.

[0066] As the fixed molds, fixed molds 61, 65 are used, each provided for two types of box bodies 11, 41 having different depths. The inner wall surface forming parts 62, 66 of each fixed mold 61, 65 have a length in the depth direction that can form the inner wall surfaces 22, 52 of each box body 11, 41. Therefore, by using the fixed molds 61, 65, the inner wall surfaces 22, 52 of the two types of box bodies 11, 41 having different depths can be formed by the inner wall surface forming parts 62, 66.

[0067] The movable die 71 is moved away from the fixed die 61, whereby the die device 60 is opened (see FIG. 12), and the box body 11 is removed from between the fixed die 61 and the movable die 71. The movable die 71 is moved away from the fixed die 65, whereby the die device 60 is opened (see FIG. 14), and the box body 41 is removed from between the fixed die 65 and the movable die 71.

[0068] Therefore, it is not necessary to use two types of movable molds 71 ​​to form two types of box bodies 11, 41 with different depths. It is possible to share the movable mold 71. Compared to the case where a different movable mold 71 is used for each of the two types of box bodies 11, 41 with different depths, the cost required for the mold device 60 can be reduced.

[0069] (1-2) In particular, as shown in Fig. 15, in the box body forming process for forming the box body 11, when the mold device 60 is clamped, the mold mating surface 73 of the movable mold 71 and the mold mating surface 64 of the fixed mold 65 come into contact with each other. In the box body forming process for forming the box body 41, when the mold device 60 is clamped, the mold mating surface 73 of the movable mold 71 and the mold mating surface 68 of the fixed mold 65 come into contact with each other.

[0070] The contact between the mold mating surfaces 64, 73 and the contact between the mold mating surfaces 68, 73 are both made at the outer periphery of the portion forming the entrance / exit 12 in the cavity 75 that forms the deep box body 11.

[0071] Therefore, it is easy to form the outer wall surface forming portion 72 capable of forming the outer wall surface 17 of the deep box body 11 in the movable mold 71. Moreover, it is easy to form the inner wall surface forming portions 62, 66 capable of forming the inner wall surfaces 22, 52 of the two types of box bodies 11, 41 having different depths for each fixed mold 61, 65.

[0072] (1-3) As described above, when the mold device 60 is clamped in the box body forming process, the rib forming portions 63, 67 provided on the fixed molds 61, 65 face the cavities 75, 76. The length in the depth direction of the rib forming portions 63, 67 varies depending on the depth of the box bodies 11, 41. The rib forming portion 63 of the fixed mold 61 forming the deep box body 11 is longer in the depth direction than the rib forming portion 67 of the fixed mold 65 forming the shallow box body 41. The cavities 75, 76 are filled with resin material to form the box bodies 11, 41 having the welding ribs 19, 49 on the outer wall surfaces 17, 47. The welding ribs 19, 49 start from the outer wall surfaces 17, 47 at positions separated by the same distances D1, D2 from the bottoms 15, 45 in the depth direction and extend to the end faces 21, 51 on the entrance / exit sides 12, 42 of the box main body 11, 41. The length of the welding ribs 19, 49 increases as the depth of the box main body 11, 41 increases.

[0073] <(2) Welding process> (2-1) The welding process performed after the box body forming process is a process of fastening the fastening portion 32 to the box body 11, 41 by welding. In the welding process, as shown in Fig. 5 and Fig. 7, the fastening portion 32 is covered on the covering portion 18, 48 of the box body 11, 41. At this time, as shown in Fig. 9(a), (b) and Fig. 10(a), (b), the welding rib 19, 49 is engaged with the groove portion 35 from the open end 35a toward the closed end 35b. The opposing surface 35c of the groove portion 35 contacts the side surface 19c, 49c of the welding rib 19, 49 before welding, so that the opposing surface 35c functions as a second positioning portion. The contact of the opposing surface 35c with the side surface 19c, 49c of the welding rib 19, 49 positions the fastening portion 32 in a direction perpendicular to the depth direction and along the inner surface 33.

[0074] When the ends 19b, 49b of the welding ribs 19, 49 come into contact with the closed end 35b of the groove 35, the closed end 35b functions as a first positioning portion. The contact of the closed end 35b with the ends 19b, 49b of the welding ribs 19, 49 determines the position of the fastening portion 32 in the depth direction.

[0075] In this way, the fastening portion 32 can be positioned at a desired location in the depth direction by performing the simple operation of covering the fastening portion 32 with the covering portion 18, 48 while engaging the welding ribs 19, 49 with the groove portion 35. Also, the fastening portion 32 can be positioned at a desired location in the direction perpendicular to the depth direction and along the inner surface 33.

[0076] The length of the welding rib 19 in the depth direction is longer than the length of the groove portion 35. Therefore, a part of the welding rib 19 is engaged with the groove portion 35 as described above, but the other part is exposed from the groove portion 35 (see FIGS. 1, 2, and 9(b)).

[0077] In contrast, the welding rib 49 has a length approximately equal to the depth of the groove portion 35. Therefore, the entire welding rib 49 is engaged with the groove portion 35 as described above. In this case, no part of the welding rib 49 is exposed from the groove portion 35 (see FIGS. 3, 4, and 10(b)).

[0078] Next, the welding ribs 19, 49 are joined to the welded portion 34 of the fastening portion 32 by vibration welding. That is, pressure and vibration due to reciprocating motion are applied to the intended joining surfaces of two resin parts, in this case the fastening portion 32 having the groove portion 35 in the welded portion 18, 48 and the box body 11, 41 having the welding ribs 19, 49, to generate frictional heat. This frictional heat melts and joins the welding ribs 19, 49 and the parts of the welded portion 34 where the welding ribs 19, 49 come into contact. This joining causes the fastening portion 32 to be fastened to the box body 11, 41 at the welded portion 34.

[0079] In the shallow box body 41, all or a large portion of the welding rib 49 is used for welding. In the deep box body 11, a portion of the welding rib 19 remains unwelded.

[0080] <(3) Actions and effects other than those mentioned above> (3-1) In this embodiment, as described above, a portion of the welding rib 19 in the deep box body 11 remains unused for welding.

[0081] Therefore, the remaining portion of the welding rib 19 that is not used for welding can increase the rigidity of the box body 11 and, ultimately, the storage box 10. (3-2) In this embodiment, as shown in Fig. 1 and Fig. 3, the fastening portion 32 has a common shape and size for all types of box bodies 11, 41. That is, a common fastening portion 32 is used regardless of the depth of the box bodies 11, 41. Therefore, the manufacturing cost of the fastening portion 32 can be reduced compared to the case where a different fastening portion 32 is used for each box body 11, 41.

[0082] The above embodiment can also be implemented as modified examples as follows: The above embodiment and the following modified examples can be implemented in combination with each other within a range that does not cause technical contradiction.

[0083] The above-mentioned method for manufacturing a storage box can also be applied to the case of manufacturing storage boxes having three or more types of box bodies with different depths. The mold mating surfaces 64, 73 and the mold mating surfaces 68, 73 may be set in a position that is farther in the depth direction from the cavity 75 than the outer periphery of the portion that forms the entrance / exit 12 in the cavity 75 that forms the deepest type of box body 11. In this case, the same actions and effects as those of the above embodiment can be obtained.

[0084] The above-described method for manufacturing the storage box can also be applied to the case of manufacturing a storage box in which the fastening portion 32 is fastened to the box body 11, 41 at the attachment portion 18, 48 by a means other than welding.

[0085] A plurality of types of fastening portions 32 may be provided, and different types of fastening portions 32 may be fitted onto the attachment portions 18, 48 for each box main body 11, 41. One or both of the first positioning portion and the second positioning portion may be omitted.

[0086] In addition, the technical ideas that can be understood from each of the above embodiments will be described together with their effects. (A) A box body having an entrance for articles at one end and a bottom at the other end, and a lid for opening and closing the entrance; The lid body includes a fastening portion that is fitted over a covering portion that is an outer wall surface of the box body and that is a portion that forms the outer periphery of the entrance and is fastened to the box body, and a movable lid portion that is attached to the fastening portion so as to open and close the entrance, A welding rib extending in the depth direction of the box body is formed on the outer wall surface, The fastening portion is covered with the covering portion, and the welding rib is welded to a welded portion formed on an inner surface of the fastening portion, thereby fastening the fastening portion to the box main body, A storage box in which a portion of the welding rib in the depth direction remains unused for welding.

[0087] According to the above configuration, the portion of the welding rib that is not used for welding and remains can increase the rigidity of the box body, and ultimately the storage box. [Explanation of symbols]

[0088] 10,40…Storage box 11,41…Box body 12,42…Entrance / exit 15,45…Bottom 17,47…Exterior wall surface 18,48...Adhesive part 19,49…Welded rib 19b, 49b...End 19c,49c…side 21,51...end face 22,52…Inner wall surface 31...Cover body 32… Fastening part 33…Inner surface 34...Part to be welded 35…Groove 35a...Open end 35b...Closed end (first positioning portion) 35c...opposing surface (second positioning portion) 37…Movable lid part 60...Molding equipment 61,65…Fixed type 62,66…Inner wall surface forming part 63, 67…Rib forming section 64, 68, 73…Molding surface 71…Movable type 72...Outer wall surface forming part 75,76…Cavity D1,D2…distance

Claims

1. A method for manufacturing a storage box which is mounted in a passenger compartment of an automobile, the storage box having a box body having an entrance / exit for articles at one end and a bottom at the other end, the box body being formed by a mold device, and a lid body for opening and closing the entrance / exit, the storage box having a plurality of types of box bodies each having a different depth from the entrance / exit to the bottom, comprising: The mold device includes a fixed mold having at least an inner wall surface forming portion that forms an inner wall surface of the box body, and a movable mold that moves in a depth direction of the box body to approach and move away from the fixed mold and has an outer wall surface forming portion that forms an outer wall surface of the box body, a box body forming step of forming a cavity between the inner wall surface forming portion and the outer wall surface forming portion by clamping the mold device, and filling the cavity with a resin material to form the box body; In the box body forming step, a movable mold is used in which the outer wall surface forming portion has a length in the depth direction capable of forming the outer wall surface of the deepest type of box body, In the box body forming process, a fixed mold is used which is provided for each of a plurality of types of box bodies having different depths, and the inner wall surface forming portion has a length in the depth direction sufficient to form the inner wall surface for each box body.

2. In the box body forming process, the mold device is clamped, so that the movable mold and the fixed mold are brought into contact with each other at mold mating surfaces respectively set on the outer periphery of the outer wall surface forming portion, The method for manufacturing a storage box as described in claim 1, wherein in the box body forming process, the mating surfaces of the movable mold and the fixed mold are brought into contact at a location that is the outer periphery of the portion that forms the entrance / exit of the cavity that forms the deepest type of box body, or at a location that is farther from the cavity in the depth direction than the location.

3. The lid body includes a fastening portion that is fastened to the box body by covering a covering portion that is an outer wall surface of the box body and that is a portion that is an outer periphery of the entrance, and a movable lid portion that is attached to the fastening portion so as to open and close the entrance, In the box body forming process, a fixed mold is used that faces the cavity and has a rib forming portion whose length varies in the depth direction according to the depth of the box body, so that welding ribs are formed on the outer wall surface, starting from points that are spaced from the bottom toward the entrance / exit side by the same distance, and extending to the end face of the entrance / exit side of the box body, A method for manufacturing a storage box as described in claim 2, wherein after the box body forming process, a welding process is performed in which the fastening portion is covered with the attachment portion of the box body and the welding rib is welded to the welded portion formed on the inner surface of the fastening portion, thereby fastening the fastening portion to the box body.

4. In the welding step, a fastening portion having a first positioning portion formed in the welded portion is used, A method for manufacturing a storage box as described in claim 3, wherein in the welding process, with the fastening portion covered by the covering portion of the box body, the first positioning portion contacts the end of the welding rib on the entrance / exit side before welding, thereby positioning the fastening portion in the depth direction.

5. In the welding step, a fastening portion having a second positioning portion formed in the welded portion is used, A method for manufacturing a storage box as described in claim 4, wherein in the welding process, with the fastening portion covered by the covering portion of the box body, the second positioning portion contacts the side of the welding rib before welding, thereby positioning the fastening portion in a direction perpendicular to the depth direction and along the inner surface.

6. In the welding step, the fastening portion is formed with a groove portion that extends in the depth direction and into which the welding rib is engaged, and The groove portion has an open end at an end far from the entrance / exit and a closed end at an end close to the entrance when the fastening portion is placed over the attachment portion of the box body, and has a pair of opposing surfaces opposed to each other in a groove width direction, The method for manufacturing a storage box according to claim 5 , wherein in the welding step, the closed end functions as the first positioning portion, and the opposing surface functions as the second positioning portion.

7. The method for manufacturing a storage box according to any one of claims 3 to 6, wherein in the welding process, a fastening portion having a shape and size common to all types of box bodies having different depths is used.

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