Functional Sheet

Abstract

To improve an appearance of a composite member.SOLUTION: First, a functional body sheet 26 including a layer made of a nonwoven fabric or a foam is set in a molding die 40. Next, the molding die 40 is closed to divide the functional body sheet 26 at a position corresponding to a frame part 18 by a shape of the die that forms the frame part 18 of a support 14, thereby forming a functional body 12. Then, the support 14 is molded in a cavity 46 defined by closing the molding die, thereby obtaining a composite member 10 in which the functional body 12 and the frame part 18 are connected.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a composite member in which a functional body is supported by a support member made of synthetic resin and having a frame portion. [Background technology]

[0002] For vehicle panels that require sound absorption, such as engine undercovers, there has been proposed a panel-shaped fibrous body made of nonwoven fabric as the main body, reinforced with a resin molding formed on the back surface of the fibrous body (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-213727 A Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, a vehicle panel is manufactured by so-called insert molding, in which a resin molded body is molded in a mold in which a fibrous body is set. In the manufacturing method of Patent Document 1, the amount of shrinkage of the resin molded body differs from the amount of shrinkage of the fibrous body, so that the resulting vehicle panel may warp.

[0005] The present invention has been proposed in view of the above-mentioned problems associated with the conventional technology, and aims to provide a manufacturing method for composite parts that can produce composite parts with good appearance. [Means for solving the problem]

[0006] In order to overcome the above problems and achieve the intended object, the method for producing a composite member according to the present invention comprises the steps of: A method for manufacturing a composite member in which a functional body is supported by a synthetic resin support having a frame portion, the method comprising the steps of: A functional sheet including a layer of nonwoven fabric or foam is set in a mold; The mold is closed to divide the functional body sheet at a position corresponding to the frame portion by a mold shape that forms the frame portion, thereby forming the functional body; The present invention relates to a method for manufacturing a mold for forming a molded product, comprising the steps of: forming a support body in a cavity defined by closing a mold; Effect of the Invention

[0007] According to the method for producing a composite material according to the present invention, a composite material with a good appearance can be obtained. [Brief description of the drawings]

[0008] [Figure 1] 1 is a perspective view of an engine undercover according to an embodiment of the present invention, as viewed obliquely from above. FIG. [Diagram 2] FIG. 2 is a perspective view of the engine undercover of the embodiment as viewed obliquely from below. [Diagram 3] FIG. 2 is a plan view showing the engine undercover of the embodiment. [Figure 4] FIG. 2 is a bottom view showing a main portion of the engine undercover of the embodiment. [Diagram 5] 4(a) is an end view taken along line AA in FIG. 3, and (b) is a cross-sectional view showing a main part of (a). [Figure 6] 4(a) is an end view taken along line BB in FIG. 3, and (b) is a cross-sectional view showing a main part of (a). [Figure 7] 4(a) is an end view taken along line CC in FIG. 3, and (b) is a cross-sectional view showing a main part of (a). [Figure 8] 4(a) is an end view taken along line DD in FIG. 3, and (b) is a cross-sectional view showing a main part of (a). [Figure 9] FIG. 1A is a plan view showing a functional sheet according to an embodiment of the present invention, and FIG. 1B is a cross-sectional view taken along line EE of FIG. [Figure 10] 4 is an explanatory diagram showing the manufacturing process of the embodiment, and shows the portion corresponding to line CC in FIG. [Figure 11] 4 is an explanatory view showing a main part of the manufacturing process of the embodiment, and shows a part corresponding to the line CC in FIG. [Figure 12] 5 is an explanatory diagram showing the manufacturing process of the embodiment, and shows the portion corresponding to the line DD in FIG. [Figure 13] 4 is an explanatory view showing a main part of the manufacturing process of the embodiment, and shows a portion corresponding to the line DD in FIG. [Figure 14] 4 is an explanatory view showing a main part of the manufacturing process of the embodiment, and shows a portion corresponding to the line DD in FIG. [Figure 15] FIG. 1 is a plan view showing a main part of a first type of embodiment, where (a) shows the state before a function sheet is set, and (b) shows the state after the function sheet is set. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Next, the manufacturing method of the composite member according to the present invention will be described below with reference to the attached drawings by way of preferred embodiments. The composite member according to the present invention can be suitably used as vehicle panels constituting a vehicle, such as vehicle exterior members such as an engine undercover, a floor undercover, and a fender liner, or vehicle interior members such as a deck portion of a trunk room, a door trim, a ceiling, and a pillar. In the embodiment, an engine undercover attached to the underside of an engine room in a vehicle will be described as an example of the composite member.

[0010] For example, if the composite member is a vehicle exterior member, the side facing the outside of the vehicle is the front side, and the side facing the inside of the vehicle is the back side. For example, if the composite member is a vehicle interior member, the side facing the passenger compartment is the front side, and the side facing the vehicle body is the back side. In the engine undercover described in the following examples, the front side is the bottom, and the back side is the top side. EXAMPLES

[0011] As shown in Figures 1 to 4, engine undercover (composite member) 10 includes a functional body 12 including a layer made of nonwoven fabric or foam, and a support body 14 that supports the functional body 12. In the engine undercover 10, the functional body 12 is connected to the support body 14 made of synthetic resin. The engine undercover 10 is attached to the body of a vehicle such as an automobile by using an attachment portion 16 provided on the support body 14.

[0012] The functional body 12 exerts required functions such as sound absorption and heat insulation due to the characteristics derived from the nonwoven fabric and foam constituting the main layer of the functional body 12. The engine undercover 10 suppresses outside noise such as engine sound and running sound by the functional body 12. The nonwoven fabric constituting the functional body 12 may be made of polyester fiber, polyolefin fiber, aramid fiber, glass fiber, cellulose fiber, nylon fiber, vinylon fiber, rayon fiber, or the like. The foam constituting the functional body 12 may be made of polyurethane-based, polyolefin-based, polystyrene-based, or the like.

[0013] The functional body 12 may be composed of one layer, or may be composed of two or more layers. As shown in Fig. 6(b) and Fig. 8(b), the functional body 12 of the embodiment has a multi-layer structure composed of a first layer 12a made of nonwoven fabric and a second layer 12b made of nonwoven fabric. The second layer 12b is disposed below the first layer 12a. In the functional body 12, the first layer 12a is a layer for ensuring the main function required of the functional body 12 (sound absorption in the embodiment). The second layer 12b is a layer for ensuring an auxiliary function added to the functional body 12 (water repellency in the embodiment). In the functional body 12 of the embodiment, the second layer 12b is set to have a higher density than the first layer 12a. For example, the density of the first layer 12a is set to 165 kg / m 3 and the density of the second layer 12b is about 400 kg / m 3The second layer 12b of the embodiment has water repellency by adding a water repellent material such as silicone resin or fluororesin to the nonwoven fabric. In the engine undercover 10, the lower surface of the functional body 12 is formed of the water repellent second layer 12b, so that it is possible to prevent water from penetrating the functional body 12, and prevent snow from adhering to the functional body 12, and prevent ice from forming on the functional body 12. Therefore, the engine undercover 10 of the embodiment can prevent damage to the functional body 12 due to water on the functional body 12 freezing, etc. The engine undercover 10 is layered on the upper side of the functional body 12, and is formed of a second layer 12b having a density of, for example, 20 kg / m 3 For example, a nonwoven fabric or the like may be arranged to improve the sound absorption characteristics in the low frequency range.

[0014] The support 14 is a molded product made by injection molding of synthetic resin, etc. Examples of synthetic resin that can be used include polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyethylene terephthalate (PET), and polyamide (PA).

[0015] As shown in Figs. 1 to 4, the support 14 has a plurality of frame portions 18 that intersect with each other. In the support 14 of the embodiment, the frame portions 18 extending in the front-rear direction of the vehicle and the frame portions 18 extending in the left-right direction of the vehicle are arranged in a lattice pattern. The support 14 has an outer frame portion 20 connected to the frame portions 18 at its outer edge. In the support 14, a plurality of frame portions 18, or opening portions 14a surrounded by the frame portions 18 and the outer frame portion 20, are formed side by side in the front-rear and left-right directions. In the support 14, the function body 12 is connected to the frame portions 18 and the outer frame portion 20 (see Figs. 6 and 8). In the support 14, the opening portions 14a are closed by the function body 12. In the engine undercover 10, the function body 12 is divided and arranged for each opening portion 14a of the support 14. The support 14 is a molded product in which the frame portion 18 and the outer frame portion 20 are integrally formed. The support 14 has a mounting portion 16 provided on an outer frame portion 20 .

[0016] As shown in Figs. 6 and 8, the frame 18 is formed in a groove shape that opens at the bottom (one side in the front-back direction) and closes at the top (the other side in the front-back direction) except for the intersection 22 where the front, rear, left and right frame parts 18, 18 intersect with each other. As shown in Figs. 5 and 7, the intersection 22 of the frame 18 is formed in a shape that opens at the top (the other side in the front-back direction) and closes at the bottom (one side in the front-back direction). The general part of the frame 18 except for the intersection 22 has general wall parts 18b rising from both edges of the general closing part 18a. At the open end of the general wall part 18b, an extension part 18c is formed that extends outward so as to intersect with the general wall part 18b (see Figs. 6(b) and 8(b)). The intersection part 22 has cross wall parts 22b rising so as to surround all four sides of the cross closing part 22a. The intersection portion 22 is connected to the general blocking portion 18a at the open end of the cross wall portion 22b or at a vertical midpoint of the cross wall portion 22b (see Figures 5(b) and 7(b)). The intersection portion 22 in the embodiment is formed in a cylindrical shape surrounded by the annularly connected cross wall portion 22b. In the support 14, the general blocking portion 18a of the general portion and the cross blocking portion 22a of the intersection portion 22 are arranged to be offset in the vertical direction.

[0017] As shown in Fig. 6(b) and Fig. 8(b), in the frame 18, the functional body 12 is connected to the extension 18c of the general part. Specifically, the synthetic resin constituting the support 14 penetrates and mixes with the end of the functional body 12, and the extension 18c of the frame 18 and the functional body 12 are integrated. In the engine undercover 10, the open end of the general part of the frame 18 is aligned with the lower surface of the functional body 12 (see Fig. 6(b) and Fig. 8(b)). In the engine undercover 10, the general closing part 18a of the general part of the frame 18 and the upper surface of the functional body 12 are vertically shifted. In the engine undercover 10, the lower surface of the intersection closing part 22a of the intersection part 22 is aligned with the lower surface of the functional body 12.

[0018] 6 and 8, in the engine undercover 10, a plurality of openings 14a provided in a support 14 are covered by functional bodies 12 that are divided for each opening 14a. In the engine undercover 10, the functional bodies 12 that cover adjacent openings 14a are separated by a frame portion 18 between them and are independent from each other (see FIGS. 1 to 4).

[0019] As shown in Figures 6(b) and 8(b), the engine undercover 10 is provided with a compressed portion 24 at a portion of the functional body 12 that contacts the frame portion 18. The compressed portion 24 is recessed so as to open upward from the top surface of the functional body 12. The compressed portion 24 is thinner than the central portion of the functional body 12 that closes the opening portion 14a of the support body 14. The compressed portion 24 has a higher density than the central portion of the opening portion 14a of the functional body 12, making it difficult for the synthetic resin that constitutes the frame portion 18 to penetrate therein.

[0020] The engine undercover 10 of the embodiment is obtained by so-called insert molding, in which the support body 14 is molded using a mold 40 in which a functional body sheet 26 is set (see Figs. 10 to 14). In the engine undercover 10 obtained by insert molding, the functional body 12 and the support body 14 are integrated using the bonding strength of the support body 14 itself, which is formed by curing synthetic resin.

[0021] As shown in FIG. 9(a), the function body sheet 26 which becomes the function bodies 12 in the engine undercover 10 is a single sheet that is not divided to correspond to the openings 14a of the support body 14. When the engine undercover 10 is molded in a molding die 40, the function body sheet 26 is divided to match the individual openings 14a in the support body 14 due to the uneven shape of the cavity surface of the molding die 40 (see FIGS. 10 to 14). The molding die 40 is configured to divide the function body sheet 26 set in the molding die 40 by closing the die. In this way, the function bodies 12 are formed by dividing the function body sheet 26 by closing the die during insert molding.

[0022] As shown in FIG. 9(a), the functional body sheet 26 has a split weak portion 28 formed in a position corresponding to the formation position of the frame portion 18. In the functional body sheet 26 of the embodiment, split weak portions 28 extending in the front-rear direction and split weak portions 28 extending in the left-right direction are arranged in a lattice pattern corresponding to the frame portion 18 formed in a lattice pattern. The split weak portions 28 are made easier to break than other parts of the functional body sheet 26 by forming slits penetrating the functional body 12 in the thickness direction or by making cuts in the functional body sheet 26. The split weak portions 28 of the embodiment are formed in a perforation pattern with slits arranged intermittently (see FIG. 9(b)). In the engine undercover 10, the frame portion 18 of the support body 14 is arranged in a gap formed by breaking the split weak portions 28 of the functional body sheet 26.

[0023] As shown in Fig. 9(a), openings 30 are formed in the functional sheet 26 in correspondence with the positions at which the intersections 22 of the frame portions 18 are formed. In the functional sheet 26 of the embodiment, a plurality of openings 30 are arranged at the positions at which divided weak portions 28 extending in the front-rear and left-right directions intersect. The openings 30 penetrate the functional sheet 26 in the thickness direction (see Fig. 9(b)). In the engine undercover 10, the intersection blocking portions 22a of the intersections 22 of the frame portions 18 are arranged in the openings 30 of the functional sheet 26.

[0024] As shown in FIG. 9(a), the function body sheet 26 has a set hole 32 formed in a position corresponding to the formation position of the outer frame portion 20 of the support 14. The set hole 32 is used to pass a set pin 54 (see FIG. 15) described later when the function body sheet 26 is set in the mold 40. The function body sheet 26 also has a protective weak portion 34 formed therein, which extends from the opening edge of the set hole 32 toward the edge of the function body sheet 26. The protective weak portion 34 extends to the opposite side to the inside of the function body sheet 26 where the splitting weak portion 28 and the opening 30 are provided. The protective weak portion 34 is made easier to split than other parts of the function body sheet 26 by forming a slit penetrating the function body sheet 26 in the thickness direction or by making a cut in the function body sheet 26. The protective weak portion 34 in the embodiment is a slit that connects from the set hole 32 to the edge of the function body sheet 26.

[0025] As shown in Figures 10 to 14, the molding die 40 for manufacturing the engine undercover 10 described above includes a first die 42 which is a fixed die, and a second die 44 which is a movable die. When the molding die 40 is closed with the functional sheet 26 set in it, a cavity 46 is formed in line with the support body 14 (see Figures 10(c), 11(c), 12(c) and 14(b)).

[0026] As shown in Figs. 10 and 12, the first mold 42 has a first convex mold portion 48 for forming the lower surface side (concave side) of the general portion of the frame portion 18, and a first concave mold portion 50 for forming the lower surface side (convex side) of the intersection portion 22 of the frame portion 18. The first mold 42 has a plurality of first convex mold portions 48 arranged to intersect with each other (see Fig. 15(a)). The first convex mold portion 48 of the embodiment is a protrusion that becomes thinner from the base side toward the tip side. The first concave mold portion 50 is arranged at a position where the extension lines of the first convex mold portions 48, 48 intersect with each other. The first mold 42 has a gate 52 for injecting synthetic resin into the cavity 46, which opens at the bottom of the first concave mold portion 50 (see Figs. 10, 11, and 15). The first mold 42 has a set pin 54 for positioning and holding the function body 12 (see Fig. 15).

[0027] As shown in Figs. 10 and 12, the second mold 44 has a second concave mold portion 56 which forms the upper surface side (convex surface side) of the general portion of the frame portion 18, and a second convex mold portion 58 which forms the upper surface side (concave surface side) of the intersection portion 22 of the frame portion 18. The second mold 44 has a plurality of second concave mold portions 56 which correspond to the first convex mold portions 48 of the first mold 42. The second concave mold portions 56 are formed in a groove shape. The second convex mold portions 58 are provided between the second concave mold portions 56 so as to correspond to the first concave mold portions 50 of the first mold 42. The second mold 44 has a pressing mold portion 60 which protrudes toward the first mold 42 side from the mold surface facing the upper surface of the functional body 12 at the opening edge of the second concave mold portion 56 (see Figs. 13 and 14).

[0028] Next, a method for manufacturing the engine undercover 10 using the above-mentioned molding die 40 will be described.

[0029] First, a functional sheet 26 is prepared in which the split weak parts 28, the openings 30, the set hole parts 32, and the protective weak parts 34 are formed (see FIG. 9). The functional sheet 26 can be formed by punching a sheet material of a required thickness, for example, with a Thompson blade. When the functional sheet 26 is cut to fit the outer shape of the engine undercover 10, the split weak parts 28, the openings 30, the set hole parts 32, and the protective weak parts 34 may be formed at the same time.

[0030] The set pins 54 of the first mold 42 are passed through the set holes 32 to set the functional sheet 26 in the first mold 42 (see Figures 10(a) and (b), Figures 11(a) and (b), Figures 12(a) and (b), Figures 13(a), and Figure 15(b)). The functional sheet 26 is positioned in the unfolded state relative to the first mold 42 by the set pins 54 engaging with the set holes 32. At this time, the first convex portion 48 and the split fragile portion 28 overlap (see Figure 13(b)), and the first concave portion 50 and the opening 30 overlap (see Figure 11(b)).

[0031] The second die 44 is moved toward the first die 42, and the forming die 40 is closed. At this time, the function body sheet 26 comes into contact with the tip surface of the first convex portion 48 of the first die 42 (see FIG. 13(b)). As the closing of the forming die 40 progresses, both sides of the portion of the function body sheet 26 that comes into contact with the first convex portion 48 are pressed by the pressing die portions 60, 60 of the second die 44, and the portion of the function body sheet 26 where the frame portion 18 is to be formed is separated (see FIG. 13(c)). Here, since the split fragile portion 28 was formed at the position of the function body sheet 26 where the frame portion 18 is to be formed before the sheet was set in the forming die 40, the function body sheet 26 breaks from the split fragile portion 28. As the molding die 40 continues to close, the first convex portion 48 is inserted into the function body sheet 26 pressed by the pressing die portions 60, 60 of the second die 44, and the breaking progresses (see FIG. 13(d)). The function body sheet 26 is then divided at the location where the frame portion 18 is to be formed, and function bodies 12 are formed that fit the individual opening portions 14a in the support 14. In this way, by closing the molding die 40, the mold shape that forms the frame portion 18 divides the formation position of the frame portion 18 in the function body sheet 26, forming the function bodies 12.

[0032] As the molding die 40 closes, the vicinity of the divided portion of the functional body sheet 26 (the edge portion of the functional body 12) is sandwiched and compressed between the mold surface of the first die 42 and the pressing die portion 60 of the second die 44 (see FIG. 14(a)). As a result, a compressed portion 24 that is more compressed than the central portion of the functional body 12 is formed at the edge portion of the functional body 12 before the synthetic resin that will become the support 14 is injected (see FIG. 14(b)). In addition, the edge of the functional body 12 is positioned in the space in the cavity 46 where the frame portion 18 and outer frame portion 20 are molded.

[0033] Before being set in the mold 40, the functional sheet 26 is formed with an opening 30 at a position corresponding to the intersection 22 between the frame parts 18, 18. This makes it easy to cut the functional sheet 26 at the portion corresponding to the intersection 22 when the mold 40 is closed. When the mold 40 is closed, a space corresponding to the general portion of the frame part 18 in the cavity 46 is formed between the first convex part 48 of the first mold 42 and the second concave part 56 of the second mold 44 (see FIG. 14(b)). Also, a space corresponding to the intersection part 22 of the frame part 18 in the cavity 46 is formed between the first concave part 50 of the first mold 42 and the second convex part 58 of the second mold 44 (see FIG. 11(c)). At this time, a gate 52 provided in the first mold 42 faces the space corresponding to the intersection part 22 of the frame part 18 in the cavity 46 through the opening 30 of the functional sheet 26 (see FIG. 11(c)).

[0034] Next, synthetic resin is injected into the cavity 46 through the gate 52 (see FIG. 11(c)) to form the support 14. At this time, the synthetic resin penetrates into the end of the functional body 12 arranged in the space in the cavity 46 corresponding to the frame portion 18 and the outer frame portion 20. Note that the compressed portion 24 compressed by the pressing mold portion 60 is formed at the edge portion of the functional body 12, so that the synthetic resin is prevented from penetrating beyond the compressed portion 24. By forming the support 14 in this state, the frame portion 18 or the outer frame portion 20 and the functional body 12 are connected, and the opening portion 14a of the formed support 14 is blocked by the functional body 12 (see FIG. 12(c)).

[0035] When the second die 44 is moved away from the first die 42 to open the molding die 40, the engine undercover 10 follows the second die 44 and is removed from the first die 42 (see Figures 10(d), 11(d), 12(d) and 14(c)). The engine undercover 10 is removed from the second die 44 by an ejection mechanism (not shown) provided on the second convex portion 58 of the second die 44, thereby obtaining the engine undercover 10 in which the functional body 12 is supported by the support body 14.

[0036] In the above-mentioned manufacturing method, by closing the mold 40, the intended position of the frame 18 in the function body sheet 26 is divided by the mold shape that forms the frame 18, and the function bodies 12 corresponding to the openings 14a of the support 14 can be easily formed. Therefore, it is not necessary to prepare the number and shapes of the function bodies 12 corresponding to the multiple openings 14a in the support 14, and it is only necessary to prepare one function body sheet 26. In addition, it is only necessary to set one function body sheet 26 in the mold 40, and it is not necessary to take the time and effort of setting multiple function bodies 12 corresponding to the multiple openings 14a in the support 14 in the mold 40. In this way, according to the above-mentioned manufacturing method, it is possible to easily obtain the engine undercover 10 in which the function bodies 12 divided for each opening 14a of the support 14 and the frame 18 of the support 14 are connected.

[0037] For example, it is possible to insert-mold a composite member by changing the shape of a single sheet material to match the uneven shape of the support 14. In this case, the difference between the amount of shrinkage of the support 14 and the amount of shrinkage of the sheet material causes the sheet material to shrink toward the frame 18, resulting in problems such as deformation such as warping of the composite member. In particular, if the frame 18 in the embodiment has a groove shape, and the sheet material is arranged along the groove shape of the frame 18, it is significantly affected by the difference in the amount of shrinkage between the frame 18 and the sheet material. According to the above-mentioned manufacturing method, the function body sheet 26 is divided at the formation position of the frame 18 to form the function bodies 12 corresponding to the individual openings 14a, so that the function bodies 12 are less susceptible to the molding shrinkage of the frame 18. Therefore, the engine undercover 10 obtained by the above-mentioned manufacturing method can prevent deformation such as warping caused by the difference in the amount of shrinkage of the function body 12 and the support 14, and can improve the appearance.

[0038] Even if the groove is deep like the frame portion 18 in the embodiment, the function body sheet 26 is divided at the position where the frame portion 18 is formed, so the function body sheet 26 (function body 12) is not forced to follow the shape of the frame portion 18. Therefore, the shape of the frame portion 18 is less likely to be restricted by the thickness, hardness, etc. of the function body 12, improving the degree of freedom of shape. Furthermore, the function body 12 is less likely to be restricted by the shape of the frame portion 18. And according to the manufacturing method described above, the amount of wrapping of the terminal of the function body 12 into the frame portion 18 can be reduced, thereby reducing costs.

[0039] In the above-mentioned manufacturing method, the functional body sheet 26 is divided at the position where the frame portion 18 is to be formed, and the end of the functional body 12 faces the space corresponding to the extension portion 18c in the cavity 46. In this way, since only a part of the functional body 12 faces the cavity 46, the space corresponding to most of the frame portion 18 in the cavity 46 and the part other than the frame portion 18 can be defined by the mold surface of the molding die 40. Therefore, the fluidity of the synthetic resin in the cavity 46 can be improved. And, since the fluidity of the synthetic resin in the cavity 46 can be ensured, it is possible to reduce the plate thickness of the frame portion 18, and the weight of the engine undercover 10 can be reduced.

[0040] Before being set in the mold 40, the split fragile parts 28 are formed in the functional body sheet 26 at the positions where the frame parts 18 are to be formed, so that the functional body sheet 26 can be smoothly broken at the split fragile parts 28 when the mold 40 is closed. Furthermore, by forming the split fragile parts 28, the split position of the functional body sheet 26 can be stabilized, and the edges of the functional bodies 12 can be aligned.

[0041] Before being set in the mold 40, the function body sheet 26 has openings 30 formed in positions corresponding to the intersections 22 between the frames 18, 18. The portions of the function body sheet 26 that will become the corners of the function bodies 12 are separated in advance, so that the function body sheet 26 can be smoothly torn as the mold 40 is closed. Furthermore, by forming the openings 30, the dividing position of the function body sheet 26 can be stabilized.

[0042] In the above-mentioned manufacturing method, the synthetic resin is injected into the cavity 46 through the opening 30 formed in the functional body sheet 26. In the cavity 46, the synthetic resin can be made to flow from the space corresponding to the intersection 22 of the frame portion 18 to the space corresponding to the general portion of the frame portion 18. This makes it possible to make it difficult for the flow of the synthetic resin in the cavity 46 to be obstructed by the functional body 12. Also, it is possible to prevent the synthetic resin from entering the functional body 12 beyond the space in the cavity 46 corresponding to the extension portion 18c.

[0043] When the function body sheet 26 is three-dimensionally changed in shape in the closed molding die 40 by dividing the function body sheet 26, forming irregularities in the function body sheet 26, curving the function body sheet 26, or the like, a force is applied to pull the function body sheet 26 inward. During insert molding, the function body sheet 26 is held in the first die 42 by passing the set pins 54 through the set holes 32 (see FIG. 15(b)). Therefore, the function body sheet 26 is pulled by the shape of the molding die 40 when the die is closed.

[0044] Before being set in the mold 40, the function body sheet 26 is formed with a protective fragile portion 34 extending from the opening edge of the set hole portion 32 toward the edge of the function body sheet 26. If the function body sheet 26 is pulled with excessive force when the function body sheet 26 is divided by the mold shape of the mold 40 as the mold is closed, the protective fragile portion 34 breaks and the set pin 54 can be removed from the set hole portion 32. Therefore, when an unintended excessive force is applied to the function body sheet 26, the function body sheet 26 is removed from the set pin 54, so that the breakage of the set pin 54 which is used repeatedly can be prevented. Therefore, according to the above-mentioned manufacturing method, the mold 40 can be protected. Here, by forming the dividing fragile portion 28 in the function body sheet 26, the load on the set pin 54 during insert molding can be further reduced.

[0045] If the protective fragile portion 34 is a slit extending from the set hole portion 32 to the edge of the function body sheet 26, the set pin 54 can be easily removed from the set hole portion 32, and the load on the set pin 54 during insert molding can be further reduced. In this way, by adjusting the ease of separation of the protective fragile portion 34, the degree to which the set pin 54 holds the function body sheet 26 can be easily set.

[0046] In the engine undercover 10, the general portion of the frame portion 18 in the support body 14 is formed in a groove shape that is open at the bottom and closed at the top. In the engine undercover 10, the crossing portion 22 of the frame portion 18 in the support body 14 is formed in a shape that is closed at the bottom and open at the top. In this way, the frame portion 18 is formed in a cross section of a "C" shape having the closed portions 18a, 22a and the wall portions 18b, 22b rising from the closed portions 18a, 22a, so that the rigidity of the support body 14 can be improved. Moreover, in the support body 14, the general closed portion 18a of the general portion of the frame portion 18 and the cross closed portion 22a of the crossing portion 22 of the frame portion 18 are arranged to be shifted up and down, so that the rigidity can be increased. In this way, the engine undercover 10 is provided with the support body 14 having excellent rigidity, so that deformation such as warping, bending, and twisting can be suppressed. Moreover, since the rigidity of the engine undercover 10 is ensured by the shape of the frame portion 18, it can be made lightweight. The engine undercover 10 is resistant to deformation and lightweight, which makes it easy to handle when attaching it to the vehicle body, etc.

[0047] The functional body 12 is connected to the open end side of the general portion of the frame portion 18, and is also connected to the cross closing portion 22a side of the intersection portion 22 of the frame portion 18. The support body 14 can restrict deformation of the opposing general wall portions 18b, 18b in the general portion of the frame portion 18 such that they move away from each other by the cross closing portion 22a of the intersection portion 22. Therefore, the engine undercover 10 can appropriately support the functional body 12 even if the functional body 12 is connected to the open end side of the general portion of the frame portion 18.

[0048] In the engine undercover 10, the openings 14a defined by the frame portion 18 in the support body 14 are closed by the functional bodies 12 divided for each opening 14a. In the engine undercover 10, the support body 14 does not support a single sheet material, but the functional bodies 12 are independent of each other for each opening 14a of the support body 14. This makes it possible to prevent deformation such as warping of the engine undercover 10 caused by the difference in material between the support body 14 and the functional bodies 12. Therefore, the appearance of the engine undercover 10 can be improved.

[0049] The support 14 has a general portion of the frame 18 formed in a groove shape by a general blocking portion 18a and general wall portions 18b, 18b rising from both edges of the general blocking portion 18a. In the engine undercover 10, adjacent functional bodies 12, 12 are connected to different general wall portions 18b in the general portion of the frame 18. In this manner, in the engine undercover 10, the adjacent functional bodies 12 are divided by the frame 18, so that the influence of each other can be minimized. Moreover, in the engine undercover 10, the functional body 12 is connected to the general wall portion 18b, and is not disposed so that the functional body 12 blocks the opening of the general portion of the frame 18 or the functional body 12 extends up to the general blocking portion 18a. This makes it possible to suppress deformation such as warping of the engine undercover 10 due to the difference in material between the support 14 and the functional body 12. Therefore, the appearance of the engine undercover 10 can be improved.

[0050] The engine undercover 10 is an insert molded product in which a synthetic resin support 14 is molded using a functional body sheet 26, which becomes the functional body 12, as an insert material. In the engine undercover 10, the functional bodies 12 are arranged corresponding to the individual openings 14a in the support 14, so that the functional bodies 12 are less susceptible to the effects of molding shrinkage of the frame portion 18. In this way, the engine undercover 10 can prevent deformation such as warping caused by the difference in the amount of shrinkage between the functional bodies 12 and the support 14. Therefore, the appearance of the engine undercover 10 can be improved. [Explanation of symbols]

[0051] 12 Function body, 14 Support body, 14a Opening part, 18 Frame part, 18a general occlusion section (occlusion section), 22 intersection section, 22a intersection occlusion section (occlusion section), 26 functional sheet, 28 split weak part, 30 opening, 32 set hole part, 34 Protective fragile part, 40 Molding mold, 46 Cavity

Claims

1. A functional sheet that closes a plurality of openings formed by a lattice-shaped frame portion of a vehicle panel when the frame portion is molded, comprising: A functional sheet in which split weak parts are arranged in a lattice pattern.

2. A setting hole portion formed on an outer edge portion of the functional sheet; The functional sheet according to claim 1 , further comprising a protective fragile portion extending from an opening edge of the setting hole toward an edge of the functional sheet.

Images