CN102112308B - Panel and method for producing same - Google Patents

Panel and method for producing same Download PDF

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Publication number
CN102112308B
CN102112308B CN200980130374.2A CN200980130374A CN102112308B CN 102112308 B CN102112308 B CN 102112308B CN 200980130374 A CN200980130374 A CN 200980130374A CN 102112308 B CN102112308 B CN 102112308B
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CN
China
Prior art keywords
panel
panel body
foaming
resin
nonwoven
Prior art date
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Active
Application number
CN200980130374.2A
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Chinese (zh)
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CN102112308A (en
Inventor
汤泽伊知郎
北野千
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Meiwa Corp
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Meiwa Corp
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Priority claimed from JP2008239601A external-priority patent/JP5406489B2/en
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Publication of CN102112308A publication Critical patent/CN102112308A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/22—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor using multilayered preforms or parisons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/4273—Auxiliary operations after the blow-moulding operation not otherwise provided for
    • B29C49/42808—Filling the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/067—Wood fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
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    • B32B2266/0214—Materials belonging to B32B27/00
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2607/00—Walls, panels

Abstract

Provided is a panel obtained by injecting a foaming raw material into a hollow resin panel main body and causing the foaming raw material to expand within the panel main body. The rigidity of the panel is improved by having the foam expanded within the panel main body firmly joined to the inner surface of the panel main body. As shown in fig. 2, a panel (1) comprises a resin panel main body (2) having a hollow cavity, a nonwoven fabric (3) joined to the inner surface of the panel main body (2), and a resin foam (4) filled within the panel main body (2).

Description

Panel and the method for manufacturing this panel
Technical field
A kind of method that the present invention relates to panel and manufacture this panel, this panel possesses the resin panel body of inner formation hollow and is filled in the intrinsic resin foaming body of this panel.
Background technology
For example, the panel that is laid on baseboard material in car trunk, is arranged on interior material, the interior material for building in car or is widely used as the above-mentioned form of partition wall etc. is well-known (referring to patent documentation 1) all the time.Due to the in-built foam of filling in and issuing of the panel body at above-mentioned panel, this foaming body is deposited over the inner face of panel body, and the rigidity of whole panel is improved, therefore can be by this panel for multiple object.
Above-mentioned panel is to manufacture like this: when manufacturing the resin panel body of inner hollow, in this panel body, be packed into the foaming body after type, this foaming body be deposited over to the inner face of this panel body by the heat of panel body.Described panel body for example consists of polypropylene, as foaming body, can use the material this panel body to compatibility, for example the foaming body of acrylic resin.But such foaming body produces leftover pieces when moulding, the shortcoming that the cost of inevitable panel rises thus.
So, as the method for manufacturing more at low cost panel, consider such method: in the resin panel body of inner hollow, inject liquid foaming raw material, foaming is foamed in this panel body with raw material, thereby manufacture panel.
Yet while manufacturing panel by such method, the material according to foaming with raw material and panel body, can not make the inner face of panel body engage securely with foaming body, likely can not fully improve the rigidity of made panel.For example, when using polypropylene panel body processed or polyethylene panel body processed, in this panel body, inject foaming raw material, and polyurethane foaming body is filled in the intrinsic situation of this panel, can not make the intrinsic polyurethane foaming body of this panel be engaged in securely the inner face of panel body.If such panel is applied to larger external force, between the inner face of panel body and foaming body, form gap, although therefore filled foaming body in panel body, can not as desired, improve the rigidity of panel.
So, in the past, in the situation that use foaming body and the panel body of material as poor in above-mentioned zygosity, before in panel body, injection is foamed with raw material, the leading section of nozzle is inserted in panel body, from this nozzle ejection subbing (プ ラ イ マ mono-), this subbing is applied to the inner face of panel body, and improve the zygosity of this face, and then in this panel body, inject foaming raw material, make its foaming.So just the intrinsic foaming body of this panel can be engaged in to the inner face of panel body securely by subbing, and can improve the rigidity of panel.
But if at the inner face barrier coating coating of panel body, dry this subbing needs a lot of time, so the manufacturing process of panel becomes complicated, such shortcoming that unavoidably cost of this panel rises.
Patent documentation 1: TOHKEMY 2006-334801 communique
Summary of the invention
The object of the present invention is to provide a kind of panel that starts described form herein of the shortcoming of having eliminated above-mentioned prior art and the method for manufacturing this panel.
The present invention proposes such panel: this panel possesses the inner resin panel body that forms hollow; Be engaged at least one material among nonwoven, fabric, fiberglass packing and the aramid fiber mat of the inner face of this panel body; Be filled in the intrinsic resin foaming body of this panel.
Equally, the present invention proposes such panel: this panel possesses resin panel body and foaming body, described resin panel body at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat, the inner hollow that forms, described foaming body makes to be injected into the intrinsic foaming of this panel and forms with raw material foaming.
Now, advantageously, above-mentioned panel body is by least blow molding method, the material after panel body substrate forming being consisted of, and described panel body base material obtains by extrusion molding.
In addition, the present invention proposes such method that is filled with the panel of resin foaming body in panel body that is manufactured on, it comprises: in resin panel body, inject foaming raw material, this foaming is foamed in this panel body with raw material, described resin panel body at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat, the inner hollow that forms.
In addition, the present invention proposes such panel: this panel possess inner form hollow, by the panel body forming with fibre-reinforced resin; Be engaged at least one material among nonwoven, fabric, fiberglass packing and the aramid fiber mat of the inner face of this panel body; Be filled in the intrinsic resin foaming body of this panel.
Equally, the present invention proposes such panel: this panel possesses panel body and foaming body, described panel body is by forming with fibre-reinforced resin, and the inner hollow that forms, at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat; Described foaming body makes to be injected into the intrinsic foaming of this panel and forms with raw material foaming.
Now, advantageously, the fiber of above-mentioned enhancing resin consists of at least one fiber among glass fibre, carbon fiber, wood fibre, aramid fibre, nylon fiber and pet fiber.
In addition, advantageously, the resin that forms above-mentioned panel body consists of polyolefin or PLA, and above-mentioned foaming body consists of polyurethane foaming body.
And, advantageously, above-mentioned panel body is by first and second panel body base material is at least consisted of the material after blow molding method moulding, and described first and second panel body base material obtains the resin extrusion molding being mixed with as the fiber of reinforcing material.
In addition, the present invention proposes the method for such panel that is manufactured on the foaming body that is filled with resin manufacture in panel body, it comprises: after in panel body, injection is foamed with raw material, this foaming is foamed in this panel body with raw material, described panel body is by forming with fibre-reinforced resin, and the inner hollow that forms, at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat.
Invention effect
According to the present invention, at the inner face of panel body, engage at least one material having among nonwoven, fabric, fiberglass packing and aramid fiber mat, therefore being filled in the intrinsic foaming body of this panel is engaged in the inner face of panel body securely by the grappling effect of at least one material among nonwoven, fabric, fiberglass packing and aramid fiber mat, can fully improve thus the rigidity of panel.
In addition, at panel body, by form with fibre-reinforced resin in the situation that, rigidity and the resistance to impact of this panel body are improved, and the rigidity of whole panel and intensity can significantly improve.When being heated to high temperature, panel still the rigidity of this panel body can be remained on to high level.
Accompanying drawing explanation
Fig. 1 is the stereoscopic figure of the panel of embodiment.
Fig. 2 is the II-II sectional view of Fig. 1 of embodiment.
Fig. 3 is the sectional view that injects the state while foaming with raw material in panel body that embodiment is shown.
Fig. 4 is the sectional view of the first manufacture method that the manufacture panel body of embodiment is shown.
Fig. 5 is the sectional view of the first manufacture method that the manufacture panel body of embodiment is shown.
Fig. 6 is the sectional view of the second manufacture method that the manufacture panel body of embodiment is shown.
Fig. 7 is the sectional view of the 4th manufacture method that the manufacture panel body of embodiment is shown.
Fig. 8 is the sectional view of the 4th manufacture method that the manufacture panel body of embodiment is shown.
The specific embodiment
Below, explain with reference to the accompanying drawings embodiments of the present invention example.
< the first embodiment >
Fig. 1 is the stereoscopic figure of panel, and Fig. 2 is the II-II line sectional view of Fig. 1.As shown in these figures, this routine panel 1 possess the inner resin panel body 2 that forms hollow, be engaged in this panel body 2 whole inner face nonwoven and be filled in the resin foaming body 4 in this panel body 2.As detailed description below, this foaming body 4 is that the foaming being injected in panel body 2 is formed with raw material foaming.
Panel body 2 forms such as the resin by the polyolefin such as polypropylene or polyethylene or PLA or other comparison hard, and foaming body 4 for example consists of polyurethane foaming body.With other resin-phase ratio, polyurethane is cheap, while therefore polyurethane foaming body being used as to foaming body 4, can reduce the cost of panel 1.But as mentioned above, in the situation that use panel body and the foaming body of this material, the intrinsic foaming body of panel can not be engaged in the inner face of panel body securely, likely can not improve thus the rigidity of panel as desired.
Yet because this inner body surface of panel joint of this routine panel 1 has nonwoven 3, thereby by the grappling effect of this nonwoven 3, foaming body 4 is engaged in nonwoven 3 securely, its result, foaming body 4 is securely fixed in panel body 2.Therefore,, when counter plate 1 applies larger external force, also there will not be between the inner face of this panel body 2 and foaming body 4 and produce the such problem in gap, and can effectively improve the rigidity of panel 1.And, needn't for foaming body 4 is engaged in securely panel body 2 inner face and at the inner face barrier coating coating of this panel body 2, therefore need to be when manufacturing panel 1 operation of dry subbing.Therefore, can simplify the manufacturing process of panel 1, and can reduce panel 1 cost.
In the panel 1 shown in Fig. 2, although have nonwoven 3 at the inner face joint of this panel body 2, even if fabric, fiberglass packing or aramid fiber mat are engaged in to the whole inner face of panel body 2, also can obtain effect same as described above.And, with other materials is engaged in to panel body 2 inner face time compare, when fiberglass packing is engaged in to the inner face of panel body 2, can improve the rigidity of panel; When aramid fiber mat is engaged in to the inner face of panel body 2, can improve the impact strength of panel 1.Also two or more material among nonwoven, fabric, fiberglass packing, aramid fiber mat can be engaged in to the inner face of panel body 2.Like this, at the inner face of panel body 2, engage at least one material having among nonwoven, fabric, fiberglass packing and aramid fiber mat.
As mentioned above, by at least one material among inner face joint nonwoven, fabric, fiberglass packing and aramid fiber mat at panel body 2, can use the original polyolefin system without zygosity or PLA panel body 2 processed and be filled in the polyurethane foaming body 4 of the inside of this panel body 2, and when using polyolefin system or PLA panel processed body 2, can also obtain and can or burn such advantage of processing by its recycling.
Next, provide the concrete example of the manufacture method of the panel 1 that is filled with as shown in Figure 2 resin foaming body 4 in panel body 2.Now, although also the inner face of counter plate body 2 joint has the situation of nonwoven 3 to describe herein, but in the situation that the inner face of panel body 2 engages, there are fabric, fiberglass packing or aramid fiber mat, also can adopt identical method to manufacture panel 1.
Fig. 3 is the sectional view of an example of method that is illustrated in the interior filling foaming body 4 (as shown in Figure 2) of panel body 2.First, prepare the resin panel body 2 that engaging at inner face as shown in Fig. 3 (a) has nonwoven 3, inside forms hollow.As mentioned above, this panel body 2 consists of the higher resin of rigidity (it is formed by for example polypropylene or polyethylene).
Then, as shown in Fig. 3 (b), in the interior formed hole of panel body 2, insert the leading section of nozzle 5, from the front end of this nozzle 5, liquid foaming is injected in panel body 2 with raw material, make this foaming with raw material in the interior foaming of panel body 2, thereby at the interior filling of this panel body 2 polyurethane foaming body for example.Carry out mixing by biliquid the chemical reaction type polyurethane foam occurring.Now, by the grappling effect of nonwoven 3, the intrinsic foaming body of panel is engaged in the inner face of panel body 2 securely by this nonwoven 3.After the interior injection foaming of panel body 2 is with raw material, extract nozzle 5, with softening resin, stop up the hole that this inserted nozzle 5 if desired.
As mentioned above, in resin panel body, inject foaming raw material, this foaming is foamed in this panel body with raw material, and can be manufactured on the panel that is filled with resin foaming body in panel body, described resin panel body at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat, the inner hollow that forms.Can obtain such panel thus: this panel possesses resin panel body and foaming body, described resin panel body at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat, the inner hollow that forms; Described foaming body makes to be injected into the intrinsic foaming of this panel and forms with raw material foaming.
Fig. 4 and Fig. 5 illustrate to manufacture at inner face joint, to have the sectional view of an example of method (the first manufacture method) of the panel body 2 of nonwoven 3 as Fig. 3 (a) as shown in.
First, by not shown extruder by thermoplastic resin extrusion molding, and the first panel body base material 2A of the sheet shown in shop drawings 4 (a).Now, at the one side joint nonwoven 3A of the first panel body base material 2A extruding from extruder, in this case, the grappling effect by between heated the first panel body base material 2A and nonwoven 3A, can engage the two securely.Also can use adhesive nonwoven 3A to be engaged in to the one side of the first panel body base material 2A.
As shown in Fig. 4 (a), the first panel body base material 2A manufacturing is like this configured on the first shaping mould 12 under thermoplastic state.Now, the mode according to nonwoven 3A towards a side contrary with the first shaping mould 12, is configured in this first panel body base material 2A on the first shaping mould 12, and wherein said nonwoven 3A is engaged in the first panel body base material 2A securely.
The first shaping mould 12 shown here within it portion has been separated to form hollow chamber 14, in the wall portion that forms this forming surface 15, has formed a plurality of SSs 16, and hollow chamber 14 is communicated with outside by this SS 16.Load the first panel body base material 2A on described the first shaping mould 12 after, by being formed on the air in the exhaust outlet 17 suction hollow chamber 14 on the first shaping mould 12, so that the air in this hollow chamber is discharged to outside.Thus, as shown in Fig. 4 (b), the first panel body base material 2A is formed as the shape along the forming surface 15 of the first shaping mould 12.The first panel body base material 2A is by vacuum forming.
Secondly, as shown in Fig. 5 (a), between the second shaping mould 18 of the first shaping mould 12 and the side of being located thereon, configure the second panel body base material 2B of sheet, its thermoplastic resin after by thermoplastic forms.This second panel body base material 2B adopts with the identical method of method of manufacturing the first panel body base material 2A to manufacture, and in its one side, engages and has nonwoven 3B securely.Mode according to described nonwoven 3B towards the first shaping mould 12, is configured in the second panel body base material 2B between the first shaping mould 12 and the second shaping mould 18.
The second shaping mould 18 is also partly separated out hollow chamber 20 within it, in the wall portion that forms this forming surface 21, has formed a plurality of SSs 22, and hollow chamber 20 is communicated with outside by this SS 22.As shown in Fig. 5 (b), described the second shaping mould 18 is declined, by two shaping mould 12,18 matched moulds, with by first and second panel body base material 2A, the edge part of 2B is engaged with each other.
Like this, by first and second shaping mould 12, after 18 matched moulds, the leading section of the air intake lever immediately tubule by hollow being formed (blow pin) 24 is inserted in first and second panel body base material 2A, space between 2B, by this air intake lever 24, air pressurized is transported to first and second panel body base material 2A, the space between 2B.Like this, to first and second panel body base material 2A, in the time of space pressurized delivered air between 2B, by being formed on the exhaust outlet 23 on the second shaping mould 18, the air in the hollow chamber 20 of suction the second shaping mould 18, to discharge this air to outside.In air in the hollow chamber 20 of suction the second shaping mould 18, to first and second panel body base material 2A, between 2B during pressurized delivered air, still proceed the suction of the air in the hollow chamber 14 of the first shaping mould 12.Like this, first and second panel body base material 2A, 2B is sealed at respectively the forming surface 15 of the first shaping mould 12 and the forming surface 21 of the second shaping mould 18, thus first and second panel body base material 2A, 2B is formed as the shape along first and second shaping mould 12,18.
Next, air intake lever 24 is from the first panel body base material 2A extracts, separated from one another by first and second shaping mould 12,18, from shaping mould, take out in type mechanograph.Then, as long as the edge part of restriking dies goods has just completed by first and second panel body base material 2A, the panel body 2 that 2B forms, face engages within it nonwoven 3, and this nonwoven 3 is by being engaged in first and second panel body base material 2A, the nonwoven 3A of 2B face, 3B forms.Like this, manufacture the panel body 2 shown in Fig. 3 (a), as mentioned above, by portion's filling foaming body 4 within it, can manufacture panel 1.About the hole of the second panel body base material 2A of chimeric air intake lever 24, can be stopped up, also can on this hole, insert above-mentioned nozzle 5.
In addition, can adopt following manufacture method (the second manufacture method) to manufacture panel body 2.
As shown in Fig. 6 (a), by first and second panel body base material 2A of sheet, under the overlapping state of 2B, make their thermoplastics, and Fig. 4 and Fig. 5 shown in same the first shaping mould 12 and the second shaping mould 18 forming of shaping mould between, according to its nonwoven 3A, the direction mode respect to one another of 3B, described first and second panel body base material 2A of configuration, 2B.Then, as shown in Fig. 6 (b), the second shaping mould 18 is declined, by two shaping mould 12,18 matched moulds, so that these base materials 2A, the edge part of 2B is engaged with each other.
As mentioned above, by after first and second shaping mould 12,18 matched moulds, immediately the leading section of air intake lever 24 is inserted in to first and second panel body base material 2A, between 2B, by this air intake lever 24, air pressurized is transported to first and second panel body base material 2A, between 2B.Meanwhile, by being formed on the exhaust outlet 17,23 on first and second shaping mould 12,18, the air in hollow chamber 14,20 is discharged to outside.Now, in the wall portion that forms the forming surface 15,21 of first and second shaping mould 12,18, also form a plurality of SSs 16,22, therefore, as shown in Fig. 6 (c), first and second panel body base material 2A, 2B carries out vacuum forming by first and second shaping mould 12,18, meanwhile carries out blow molding.Then, the identical method of the method shown in employing and Fig. 4 and Fig. 5, by first and second shaping mould 12,18 separation, takes out products formed from shaping mould.Like this, the panel body 2 shown in can shop drawings 3 (a).
According to the method shown in Fig. 6, by first and second panel body base material 2A, when carrying out vacuum forming, 2B carries out blow molding, therefore, can make first and second panel body base material 2A, 2B is sealed at first and second shaping mould 12 more accurately, 18 forming surface 15,21.In addition, at first and second panel body base material 2A of sheet, under the state that 2B overlaps each other, by these panel body base materials 2A, 2B heating, therefore, and by each panel body base material 2A, the situation that 2B heats is respectively compared, in the time of can reducing worker.Now, even by first and second panel body base material 2A, after 2B overlaps each other, can there is not first and second panel body base material 2A in heating yet, the phenomenon that 2B engages under hot effect, and this is because at these base materials 2A, has nonwoven 3A, 3B between 2B.
In addition, the second shaping mould 18 shown in Fig. 6 forms in the following manner: on the periphery of the forming surface 15 of the second shaping mould 18, project trimmer blade 25, by first and second shaping mould 12, during 18 matched moulds, by this trimmer blade 25, repair first and second panel body base material 2A, the edge part of 2B.Shaping mould shown in Fig. 4 and Fig. 5 also can form according to identical mode.
In addition, as shown in Fig. 6 (b), the front end of air intake lever 24 is inserted in to first and second panel body base material 2A, in the time of between 2B, although this air intake lever 24 can puncture the first softening panel body base material 2A, also sometimes can not puncture the nonwoven 3A being engaged on this base material 2A.In this case, nonwoven 3A, 3B also has aeration, therefore, air can be pressed and delivered to without barrier to first and second panel body base material 2A, between 2B.This when the method for implementing shown in Fig. 4 and Fig. 5 too.
In Fig. 4 to Fig. 6, illustrate panel body base material 2A, 2B manufactures the example of panel body 2 by vacuum forming and blow molding method moulding, but as the 3rd manufacture method, only uses blow molding method, also can manufacture panel body 2.To pressurized delivered air between first and second panel body base material after extrusion molding, so that this first and second panel body base material is shaped to respectively to the shape along the forming surface of first and second shaping mould.Like this, panel body 2 by least by blow molding method by first and second panel body base material 2A, material after 2B moulding forms, described panel body base material 2A, 2B obtains by extrusion molding.
In addition, vacuum forming is share in replacement and blow molding method is manufactured the panel body 2 that joint has nonwoven, as the 4th manufacture method, by injection moulding, also can manufacture panel body 2.In this case, first, as shown in Fig. 7 (a), nonwoven 3C is set in the forming surface of the first shaping mould 30, secondly, as shown in Fig. 7 (b), by the first shaping mould 30 and the second shaping mould 31 matched moulds, to the thermoplastic resin of cavity 32 injection meltings.Mold thus the first panel body base material 2C shown in Fig. 7 (c), and engage and have nonwoven 3C securely in its one side.
As shown in Fig. 8 (a), adopt and above-mentioned identical method, moulding the second panel body base material 2D, has engaged nonwoven 3D securely in the one side of the second panel body base material 2D, then, as shown in Fig. 8 (b), as long as by first and second panel body base material 2C, 2D is combined, and this docking section (prominent I closes せ portion) 33 is deposited, just can manufacture by first and second panel body base material 2C the panel body 2 that 2D forms.Face has engaged securely by nonwoven 3C within it, the nonwoven 3 that 3D forms.As mentioned above, by the interior filling foaming body at described panel body 2, the panel 1 shown in shop drawings 2.
Hereinbefore, although be illustrated in the Production Example that inner face engages the panel body that has nonwoven,, as above explanation, also can adopt method same as described above to be manufactured on inner face and engage the panel body that has fabric, fiberglass packing or aramid fiber mat.
< the second embodiment >
Because the outward appearance of present embodiment is similar with manufacturing process to the outward appearance of the first embodiment with manufacturing process, therefore adopt the figure using in the explanation of the first embodiment, mainly difference is described, as for identical formation manufacture method etc., suitably description thereof is omitted.
Identical with the formation shown in Fig. 1 and Fig. 2, the panel 1 of present embodiment has panel body 2, nonwoven 3 and foaming body 4.
Different from the first embodiment, the panel body 2 of present embodiment is by forming with fibre-reinforced resin.Herein, with fibre-reinforced resin, broadly refer to and use fibre-reinforced plastics, except fibre reinforced plastics (FRP) (it forms with fiber reinforced thermosetting resin), it also comprises fiber-reinforced thermoplastic resin, and the fiber that it is 1mm to 15mm that this fiber-reinforced thermoplastic resin mixes for example length in thermoplastic resin, be preferably 4mm to 12mm forms as reinforcing material.In addition, as described fortifying fibre, can enumerate, wood fibre, aramid fibre, nylon fiber and pet fibers such as glass fibre, carbon fiber, mestha or bamboo, can be used at least one fiber among these fibers.
In addition, the resin that forms panel body 2 and foaming body 4 also can be selected from the material of suitable material, but as the resin with fibre-reinforced panel body 2, if use polyolefin or the PLAs such as polypropylene, polyethylene, when processing this panel body 2, can obtain can be easily by its recycling or such advantage of burning.In addition, same with the first embodiment, as foaming body 4, if use polyurethane foaming body, can obtain the such advantage of cost that reduces panel 1, this is because with other resin-phase ratio, polyurethane is cheap.Like this, if consisted of polyolefin or PLA with the resin of fibre-reinforced panel body 2, foaming body 4 consists of polyurethane foaming body, can be advantageous particularly.Yet as mentioned above, in existing panel, while using the panel body of this material and foaming body, the intrinsic foaming body of panel can not be engaged in the inner face of panel body securely, likely can not improve thus the rigidity of panel as desired.Therefore, in the past, in panel body, inject foaming with raw material before, need to be at the inner face barrier coating coating of panel body, the cost of inevitable panel such shortcoming that rises thus.
Yet, same with the first embodiment, at this inner body surface of panel of the panel 1 of present embodiment, engage and have nonwoven 3, thereby by the grappling effect of this nonwoven 3, foaming body 4 is securely fixed in panel body 2, and can effectively improve the rigidity of panel 1.And, needn't be at the inner face barrier coating coating of this panel body 2, the operation of the dry subbing while therefore not needing to manufacture.As a result, can realize the simplification of manufacturing process and the reduction of cost of panel 1.
In addition, same with the first embodiment, the nonwoven 3 that replacement is bonded on the inner face of panel body 2, also can be used fabric, fiberglass packing or aramid fiber mat.Can realize thus the reduction of the tractability of panel body 2 and the cost of panel 1.
In addition, as mentioned above, because panel body 2 is by forming with fibre-reinforced resin, so its rigidity and resistance to impact be improved, thereby the rigidity of panel body during high temperature is also improved.Particularly, as the fiber that strengthens resin, if use glass fibre, carbon fiber or wood fibre, can increase substantially the rigidity of panel body 2, therefore can make panel body 2 thin-walled properties and lightweight.In addition, particularly, as the fiber that strengthens this resin, if use aramid fibre, nylon fiber or pet fiber, can improve the impact strength of panel body 2.
Next, provide the concrete example of the manufacture method of the panel 1 that is filled with resin foaming body 4 in panel body 2.Can adopt the first～four manufacture method described in the first embodiment.In the first manufacture method, first, prepare the resin panel body 2 that engaging at inner face as shown in Fig. 3 (a) has nonwoven 3, inside forms hollow.Herein, different from the first embodiment, as mentioned above, panel body 2 is by forming with the high resin of fibre-reinforced rigidity.
Then,, as shown in Fig. 3 (b), for example, carry out mixing by biliquid the chemical reaction type polyurethane foam occurring, at the interior filled polyurethane foaming body of this panel body 2.Carry out mixing by biliquid the chemical reaction type polyurethane foam occurring.Now, by the grappling effect of nonwoven 3, the foaming body 4 in panel body 2 is engaged in the inner face of panel body 2 securely.After the interior injection foaming of panel body 2 is with raw material, extract nozzle 5, with softening resin, stop up the hole that this inserted nozzle 5 if desired.
Adopt above-mentioned method, in panel body, inject foaming raw material, this foaming is foamed in this panel body with raw material, and can manufacture the panel that is filled with resin foaming body in panel body, wherein said panel body is by forming with fibre-reinforced resin, and the inner hollow that forms, at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat.Can obtain such panel thus: this panel possesses panel body and foaming body, described panel body is by forming with fibre-reinforced resin, and the inner hollow that forms, at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat; Described foaming body forms with raw material foaming being injected in the intrinsic foaming of this panel.
In addition, as manufacturing, as Fig. 3 (a) as shown in, at inner face joint, there is the method for 3 panel body 2 of nonwoven, can similarly adopt the first～four manufacture method described in the first embodiment with the first embodiment, can obtain same effect.Be with the first embodiment difference, in thermoplastic resin, mix the fiber as reinforcing material.Therefore, for example, when adopting the first manufacture method, the fiber that by the thermoplastic resin of extruder moulding, to mix for example length be 1mm to 15mm, be preferably 4mm to 12mm is as reinforcing material.In addition, in the operation shown in Fig. 5 (a), the second panel body base material 2B configuring also consists of the thermoplastic resin that is mixed with fortifying fibre, and the length of described fortifying fibre is for example 1mm to 15mm, is preferably 4mm to 12mm.And then, in the situation that adopting the 3rd manufacture method (the method is only manufactured panel body 2 with blow molding method), as mentioned above, panel body 2 is by first and second panel body base material 2A, 2B are at least consisted of the material after blow molding method moulding, and described first and second panel body base material obtains the resin extrusion molding being mixed with as the fiber of reinforcing material.In addition, if will be mixed with the resin extrusion molding of fiber like this, form first and second panel body, when extrusion molding, the fiber in resin is orientated along extruding direction.Therefore, the in the situation that of forming integral hinge (イ Application テ グ ラ Le ヒ Application ジ) on panel, by being the direction parallel with extruding direction by this hinge arrangement, at hinge fraction panel body base material 2A, the fiber being orientated in 2B can not ruptured, and can improve thus the durability of integral hinge.Conventionally, when when integral hinge being set on fibre-reinforced naval stores, this hinge fraction is easily ruptured, but as mentioned above, by by being filled with the resin forming of fiber, integral hinge can be arranged on panel without barrier.And, for example, in the situation that adopting the 4th manufacture method (the method is manufactured panel body 2 with injection moulding), in the operation shown in Fig. 7 (b), after the first shaping mould 30 and the second shaping mould 31 matched moulds, to the thermoplastic resin of cavity 32 injection molten conditions, in this thermoplastic resin, to be mixed with for example length be 1mm to 8mm, be preferably the fiber of 4mm to 8mm.

Claims (6)

1. a panel, is characterized in that,
This panel possesses resin panel body and foaming body, described resin panel body at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat, the inner hollow that forms; Described foaming body makes to be injected into the intrinsic foaming of this panel and forms with raw material foaming,
Wherein, described panel body be overlapping 2 panel body base materials that obtain by extrusion molding and make edge part each other matched moulds engage, and at least by blow molding method moulding,
Described nonwoven and described foaming body engage by grappling effect,
Wherein, the resin that forms described panel body consists of polyolefin or PLA, and described foaming body consists of polyurethane foaming body.
2. a method of manufacturing panel, is characterized in that,
Overlapping 2 panel body base materials also make edge part matched moulds and engaging each other, and at least by the ducted body of blow molding method moulding, in at least one side during described panel body base material extrusion molding under heated condition, engaging at least one material have among nonwoven, fabric, fiberglass packing and aramid fiber mat forms
In the resin panel body of described ducted body, inject foaming raw material, this foaming is foamed in this panel body with raw material, thereby potting resin foaming body processed in panel body, the resin panel body of described ducted body is the state of at least one material among having nonwoven, fabric, fiberglass packing and aramid fiber mat at inner face joint
Described nonwoven and described foaming body are engaged by grappling effect,
Wherein, the resin that forms described panel body consists of polyolefin or PLA, and described foaming body consists of polyurethane foaming body.
3. a panel, is characterized in that,
This panel possesses panel body and foaming body, and described panel body is by forming with fibre-reinforced resin, and the inner hollow that forms, at least one material among inner face joint has nonwoven, fabric, fiberglass packing and aramid fiber mat; Described foaming body makes to be injected into the intrinsic foaming of this panel and forms with raw material foaming,
Wherein, described panel body be overlapping 2 panel body base materials that obtain by extrusion molding and make edge part each other matched moulds engage, and at least by blow molding method moulding,
Described nonwoven and described foaming body engage by grappling effect,
Wherein, the resin that forms described panel body consists of polyolefin or PLA, and described foaming body consists of polyurethane foaming body.
4. panel as claimed in claim 3, wherein, the fiber of described enhancing resin consists of at least one fiber among glass fibre, carbon fiber, wood fibre, aramid fibre, nylon fiber and pet fiber.
5. a method of manufacturing panel, is characterized in that,
Overlapping 2 panel body base materials also make edge part matched moulds and engaging each other, and at least by the ducted body of blow molding method moulding, in at least one side during described panel body base material extrusion molding under heated condition, engaging at least one material have among nonwoven, fabric, fiberglass packing and aramid fiber mat forms, and strengthen with fiber
In the resin panel body of ducted body, inject foaming raw material, this foaming is foamed in this panel body with raw material, thereby potting resin foaming body processed in panel body, the resin panel body of described ducted body is the state of at least one material among having nonwoven, fabric, fiberglass packing and aramid fiber mat at inner face joint
Described nonwoven and described foaming body are engaged by grappling effect,
Wherein, the resin that forms described panel body consists of polyolefin or PLA, and described foaming body consists of polyurethane foaming body.
6. the manufacture method of panel as claimed in claim 5, wherein, the fiber of described enhancing panel body consists of at least one fiber among glass fibre, carbon fiber, wood fibre, aramid fibre, nylon fiber and pet fiber.
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