JPH1120014A - Manufacture of resin composite product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for manufacture of composite product of an integrated sun visor and mirror, which does not require presetting of a fitting recess, mount, etc., for assembling the mirror to the sun visor. SOLUTION: A mirror case 13 is placed on the molding surface of a molding tool 21a, and each synthetic resin composing a base layer 11 and a skin layer 12 of a sun visor 10a is fed to the molding surface of the molding tool 21a so that each synthetic resin surrounds the mirror case 13. Thereby, the sun visor 10a composed of the base layer 11 and the skin layer 12 wrapping the mirror case 13 is formed, and the mirror case 13 is caulked and fixed to the sun visor 10a.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a resin composite product, and more particularly to a method for manufacturing a first component comprising a base layer formed of a synthetic resin and a skin layer formed of a synthetic resin. The present invention also relates to a method of manufacturing a resin composite product in which a second component having a function different from that of the first component is assembled.

[0002]

2. Description of the Related Art A first part of a composite product of this type is, for example, a sun visor which is an interior part of a car, and a second part is a mirror, a microphone of a car telephone, a speaker and the like. There is a real opening 63-
Japanese Patent No. 44818 discloses a composite product in which a microphone and a speaker of a car phone are mounted on a sun visor.

[0003]

By the way, in this type of composite product, in order to assemble the second part with the first part, a fitting recess for assembling the second part with the first part is required. Place, mounting seat and the like are set in advance, and the second part is fitted and positioned in the fitting recess provided in the first part, and the positioned second part is placed in the first part. A means for screwing into a mounting seat provided in the above with screws or the like.

For this reason, a fitting recess, a mounting seat, and the like for assembling the second component must be set in the first component in advance. Is required. In addition, an operation for assembling the second component to the first component is required, and further, an attachment component for attaching the second component is required. Accordingly, it is an object of the present invention to address these issues.

[0005]

According to the present invention, there is provided a first component comprising a base layer formed of a synthetic resin and a skin layer formed of a synthetic resin and covering the base layer. The first component is a method for manufacturing a resin composite product in which a second component having a different function from the first component is assembled, and the second component is placed on a mold surface of the molding die. The synthetic resin forming the material layer and the skin layer is supplied onto the mold surface of the molding die, and the synthetic resin is wrapped around the second component to wrap the second component. Forming the first component comprising the material layer and the skin layer;
The second component is fixed to the component by caulking.

In the manufacturing method of the present invention, a composite product can be suitably manufactured by employing a sun visor as the first component and a mirror as the second component.

[0007]

According to the production method of the present invention, each synthetic resin forming the base layer and the skin layer is placed on the mold surface of the mold while the second component is placed on the mold surface of the mold. , Each of these synthetic resins wraps around the second component and wraps around the second component, and in this state, the first component consisting of the base material layer and the skin layer is formed. When the second part is fixed to the part by caulking, a composite product is formed.

Thus, according to the manufacturing method of the present invention,
When the synthetic resin forming the base material layer and the skin layer is supplied onto the mold surface of the mold while the second component is placed on the mold surface of the mold, the second component becomes the first component. Since it is attached to a set portion, it is not necessary to previously set a fitting recess, an attachment seat, and the like for assembling the second component to the first component when forming a conventional composite product of this type. Not at all
Such dimensional control in production does not require very high precision.

Further, according to the manufacturing method of the present invention, since the second component is attached to the first component when the first component is molded, the second component is assembled after the first component is molded. Work is not required, and mounting components for mounting the second component are not required.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. FIG. 1 schematically shows a composite product in which a sun visor and a mirror are integrated as an example of a composite product according to the present invention. .

The composite product 10 includes a sun visor 10a
The sun visor 10a is formed in a flat bag shape by a base layer 11 made of a synthetic resin and a skin layer 12 made of a synthetic resin. The mirror 10b is composed of a mirror case 13 and a mirror glass 14 fitted to an edge of an opening of the mirror case 13. The mirror 10b is fitted in a concave portion 15 on the front side of the sun visor 10a, and It is attached to. The composite product 10 is manufactured by the steps shown in FIGS.
It is manufactured by the vacuum mold 21.

In the first step shown in FIG. 2, the mirror case 13 shown in FIG. 6 constituting the mirror 10b is placed at a predetermined position on the surface of the lower mold 21a constituting the molding die 21, and FIG. In the second step, the synthetic resin forming the base layer 11 of the sun visor 10a and the synthetic resin forming the skin layer 12 are simultaneously melted from the dies 22 connected to the two extruders in a molten state. Is extruded on the mold surface of the lower mold 21a and the mold surface of the upper mold 21b. FIGS. 7A and 7B show a perspective view and a vertical cross-sectional view of the dice 22, respectively.
Immediately after being extruded from the die 22, the synthetic resin forming the skin layer 12 is adhered to each other to form sheet-like synthetic resin layers 11a, 12a to form both types 21a, 21b.
And on the mirror case 13.

The third step shown in FIG. 4 is a step of performing vacuum forming. The third step is a step of forming the synthetic resin layers 11a, 12a and the upper mold 21b placed on the mold surface of the lower mold 21a and the mirror case 13. Synthetic resin layer 11a placed on the surface,
Negative pressure is applied to the mold surface 12a from the mold surface side, and the synthetic resin layers 11a and 12a on the lower mold 21a are in close contact with the mold surface of the lower mold 21a while the mirror case 13 is rolled up, and the upper mold 2
The synthetic resin layers 11a and 12a on 1b are in close contact with the mold surface of the upper mold 21b. Thereby, the synthetic resin layers 11a, 12a
Is the shape of the front and back sides of the sun visor 10a.

The fourth step shown in FIG. 5 is a step of pressing and caulking a part of the synthetic resin layers 11a and 12a which have passed through the respective through holes 13a of the mirror case 13.
As shown in (a) and (b), the cylinder 21c provided on the lower mold 21a is operated to move the pressing rod 21d upward,
The synthetic resin layers 11a and 12a that have passed through the through holes 13a of the mirror case 13 are pressed and crushed, and the mirror case 1
3 is fixed to the synthetic resin layers 11a and 12a.

After the fifth step, as shown by the arrow in FIG. 5, the upper mold 21b is inverted via the hinge 21e, and the upper mold 21b is placed on the synthetic resin layers 11a and 12a on the lower mold 21a. The synthetic resin layers 11a and 12a of 21b are integrated.
Thereby, a flat bag-shaped sun visor 10a in which the mirror case 13 is integrally assembled is formed. Sun visor 1
The mirror glass 14 is inserted into and fixed to a hook 13b provided at the edge of the opening of the mirror case 13 integrated with the mirror case 0a, thereby forming the mirror 10b.

As described above, in the manufacturing method of the present invention, each of the synthetic resins forming the base layer 11 and the skin layer 12 with the mirror case 13 placed on the mold surface of the molding die (the lower die 21a) is used. When the synthetic resin layers 11a and 12a are supplied on the mold surface of the lower mold 21a, the respective synthetic resin layers 11a and 12a are wound around the mirror case 13 and wrap the same case 13, and in this state, the sun visor 10a including the base material layer 11 and the skin layer 12 is formed. Molded,
Thereafter, the mirror case 13 is caulked and fixed to the sun visor 10a to form a composite product.

Therefore, according to the manufacturing method of the present invention, the synthetic resin forming the base layer 11 and the skin layer 12 is transferred to the lower mold 2 while the mirror case 13 is mounted on the mold surface of the lower mold 21a.
When the mirror case 13 is supplied on the mold surface of the sun visor 10a, the mirror case 13 is attached to the set portion of the sun visor 10a. Therefore, when forming such a conventional composite product, the mirror case 13 is assembled to the sun visor 10a. There is no need to previously set fitting recesses, mounting seats, and the like, and dimensional control in the production thereof does not require very high precision.

Further, according to the manufacturing method of the present invention, the mirror case 13 is attached to the sun visor 10a when the sun visor 10a is formed, so that the operation for mounting the mirror case 13 after the formation of the sun visor 10a is unnecessary. In addition, there is no need for a component for mounting the mirror case 13.

[Brief description of the drawings]

FIG. 1 is a sectional view schematically showing an example of a composite product manufactured by a manufacturing method of the present invention.

FIG. 2 is an explanatory view showing a first step constituting the manufacturing method.

FIG. 3 is an explanatory view showing a second step constituting the manufacturing method.

FIG. 4 is an explanatory view showing a third step constituting the manufacturing method.

FIG. 5 is an explanatory view showing a fourth step constituting the manufacturing method.

FIG. 6 is a perspective view of a mirror case, which is a second component of the composite product manufactured by the same manufacturing method.

FIGS. 7A and 7B are a perspective view and a longitudinal sectional view, respectively, of a die used in the manufacturing method.

FIGS. 8A and 8B are a partial longitudinal sectional view showing a state immediately before caulking of a caulked portion in a caulking step of the manufacturing method, and a partial longitudinal sectional view showing a state immediately after caulking.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Composite product, 10a ... Sun visor, 10b ... Mirror, 11 ... Base layer, 12 ... Skin layer, 11a, 12a ... Synthetic resin layer, 13 ... Mirror case, 13a ... Through-hole, 13
b: hook claw, 14: mirror glass, 15: recess, 21 ...
Vacuum forming mold, 21a ... lower mold, 21b ... upper mold, 21c ... cylinder, 21d ... pressing rod, 21e ... hinge, 22 ...
dice.

Claims (2)

[Claims] A first component comprising a base layer formed of a synthetic resin and a skin layer formed of a synthetic resin and covering the base layer has a function different from that of the first component. A method of manufacturing a resin composite product obtained by assembling a second component into the base material layer and the skin layer in a state where the second component is placed on a mold surface of a molding die. Each synthetic resin to be formed is supplied onto the mold surface of the molding die, and these synthetic resins are wrapped around the second component. From the base material layer and the skin layer surrounding the second component, Forming the first component, and fixing the second component to the first component by caulking. 2. The method according to claim 1, wherein said first component is a sun visor, and said second component is a mirror. Production method.