CN108136713A - 中空构造板 - Google Patents

中空构造板 Download PDF

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Publication number
CN108136713A
CN108136713A CN201680061299.9A CN201680061299A CN108136713A CN 108136713 A CN108136713 A CN 108136713A CN 201680061299 A CN201680061299 A CN 201680061299A CN 108136713 A CN108136713 A CN 108136713A
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CN
China
Prior art keywords
protrusion
hollow structure
structure plate
hollow
present
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN201680061299.9A
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English (en)
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CN108136713B (zh
Inventor
星野秀明
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ube Exsymo Co Ltd
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Ube Exsymo Co Ltd
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Publication date
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Publication of CN108136713A publication Critical patent/CN108136713A/zh
Application granted granted Critical
Publication of CN108136713B publication Critical patent/CN108136713B/zh
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Abstract

在本技术中，主要目的在于提供一种压缩强度得到保持并且加工容易性优异的中空构造板。对此，在本技术中，提供一种中空构造板，在中空凸部成形片的至少一面层叠有表面材料和/或表皮材料，该中空凸部成形片由在至少一面形成有多个中空状的凸部的一张或两张的热塑性树脂片形成，其特征在于，所述凸部的侧壁的至少一部分的弯曲半径R为0.75mm～20mm。

Description

中空构造板
技术领域
本发明涉及一种中空构造板。更详细而言，涉及一种保持了压缩强度并且加工容易性优异的中空构造板。
背景技术
树脂制的中空构造板由于轻型，并且耐化学性、耐水性、隔热性、隔音性以及复原性优异，也容易处理，因此使用在箱材料、包装材料等物流用途以及墙壁、顶棚用的面板材料等建筑用途，此外还使用在汽车用途等广泛的领域。例如在专利文献1中公开了一种中空构造板，该中空构造板为在隔开预定的间隔地平行配置的合成树脂原料制的两张片间夹持有以预定的节距重复设有凹凸波形的合成树脂原料制的波形构件的状态。
另外，在专利文献2中公开了一种将突出设于两张热塑性树脂片的多个凸部以对接的状态热熔接而成的结构的所谓双锥(TWINCONE、注册商标)型的中空构造板。该双锥(注册商标)型的中空构造板使用在汽车内部装饰材料、物流材料以及建筑材料等各种各样的领域。
现有技术文献
专利文献
专利文献1：日本特开2003-170515号公报
专利文献2：日本特开2007-83407号公报
发明内容
本申请发明人对中空构造板的构造进行了潜心研究，结果发现通过着眼于凸部的侧壁的至少一部分的弯曲半径，将该弯曲半径的值控制在预定的范围内，能够获得压缩强度得到保持并且加工容易性优异的中空构造板，由此得以完成本发明。
即，在本发明中提供一种中空构造板，该中空构造板在中空凸部成形片的至少一面层叠有表面材料和/或表皮材料，该中空构造板由在至少一面形成有多个中空状的凸部的一张或两张的热塑性树脂片形成，其特征在于，
所述凸部的侧壁的至少一部分的弯曲半径R为0.75mm～20mm。
附图说明
图1是示意性地表示本实施方式的中空构造板1的第1实施方式的构造的立体图。
图2的A是示意性地表示本实施方式的中空构造板1的第1实施方式的截面构造的剖视示意图，图2的B是开口部212的放大图。
图3的A是示意性地表示本实施方式的中空构造板1的第2实施方式的构造的立体图，图3的B是从图3的A的箭头方向看到的情况的示意图。
图4是示意性地表示本实施方式的中空构造板1的第3实施方式的构造的立体图。
图5是示意性地表示本实施方式的中空构造板1的第4实施方式的构造的立体图。
图6是示意性地表示本实施方式的中空构造板1的第5实施方式的构造的立体图。
图7是示意性地表示本实施方式的中空构造板1的第6实施方式的构造的立体图。
图8是示意性地表示本实施方式的中空构造板1的第7实施方式的构造的立体图。
图9是示意性地表示本实施方式的中空构造板1的第8实施方式的截面构造的剖视示意图。
图10是表示本实施方式的中空构造板1的制造方法的一个例子的概念图。
图11是表示本实施方式的中空构造板1的与图10不同的制造方法的一个例子的概念图。
图12是表示本实施方式的中空构造板1的与图10和图11不同的制造方法的一个例子的概念图。
图13的A～图13的C是示意性地表示压溃加工的样子的示意图。
图14的A～图14的C是示意性地表示开孔加工的样子的示意图。
具体实施方式
在本发明中，能将上述凸部的开口部的长径方向的长度a1与短径方向的长度a2的比值(a1/a2)设为1.05≤a1/a2≤1.23。
另外，在本发明中，也能够是，将上述凸部的开口部的长径方向的长度a1与短径方向的长度a2的比值(a1/a2)设为1.08≤a1/a2≤1.21。
此外，在本发明中，也能够是，在上述凸部，将上述侧壁的弯曲半径R成为0.75mm～20mm的曲线部的总长度L与上述凸部的高度h的比值(L/h)设为0.05≤L/h≤0.3。
而且，在本发明中，也能够是，将上述凸部的开口部间的最短距离设为0.5mm～5mm。
另外，在本发明中，也能够是，将上述凸部的形状设为圆台形状、椭圆台形状或多棱台形状。
此外，在本发明中，也能够是，将上述凸部的开口部的形状设为椭圆形状。
而且，在本发明中，也能够采用如下构造：上述中空凸部成形片由在一面上形成有多个台体形状的上述凸部的一张热塑性树脂片形成，在上述凸部的上表面部、开口部或者上表面部和开口部这两者层叠有上述表面材料。
另外，在本发明中，也能够采用如下构造：上述中空凸部成形片由在一面上形成有多个台体形状的上述凸部的两张热塑性树脂片形成，并且在使凸部21彼此对接的状态下将上述两张热塑性树脂片熔融而构成。
这里，在以往的中空构造板中公知具有各向同性优异的物性的中空构造板。这种中空构造板由于压缩强度优异，因此广泛用作轻型高刚度板。但在另一方面，由于压缩强度高，因此在实施了压溃加工、开孔加工等加工时，在加工后的面的相反侧的面浮出按压痕迹，产生了难以进行这种加工的问题。
于是，在本发明中，鉴于这种实际情况，主要目的在于提供一种压缩强度得到保持并且加工容易性优异的中空构造板。
采用本发明，能够提供压缩强度得到保持并且加工容易性优异的中空构造板。另外，这里记载的效果并不一定限定本发明，也可以是本公开中记载的任一种效果。
以下，参照附图详细地说明用于实施本发明的较佳的实施方式。另外，以下说明的实施方式表示了本发明的代表性的实施方式的一个例子，不由此狭隘地解释本发明的范围。
1.中空构造板1
图1是示意性地表示本实施方式的中空构造板1的第1实施方式的构造的立体图。本实施方式的中空构造板1在中空凸部成形片2的至少一面层叠有表面材料3和/或表皮材料4，该中空凸部成形片2由在至少一面形成有多个中空状的凸部21的一张或两张的热塑性树脂片形成。
中空构造板1的单位面积质量没有特别限定，但优选设为300g/m2～6000g/m2，更优选为400g/m2～4000g/m2。由此，能够实现中空构造板1的轻型化。
中空构造板1的厚度也没有特别限定，但优选设为1mm～55mm。通过将中空构造板1的厚度设为1mm以上，能够防止中空构造板1的厚度变得过薄，从而能够体现轻型化。另外，通过将中空构造板1的厚度设为55mm以下，能够控制中空凸部成形片2上的凸部21的高度，防止凸部21的侧壁部分的厚度因空气的流动(日文：ドラフト)而变得过薄，所以能够制作不易变形(压曲)的中空构造板1。
<中空凸部成形片2>
中空凸部成形片2由在至少一面形成有多个中空状的凸部21的一张或两张的热塑性树脂片形成。即，在本实施方式中，如图1等所示，既可以只在中空凸部成形片2的一面形成有凸部21，也可以如图5所示，在中空凸部成形片2的两面形成有凸部21，还可以如图8所示，由两张热塑性树脂片形成中空凸部成形片2。
图2的A是示意性地表示本实施方式的中空构造板1的第1实施方式的构造的剖视示意图。在本实施方式中，特征在于，凸部21的侧壁的至少一部分的弯曲半径R为0.75mm～20mm。
如上所述，在以往的中空构造板中，存在具有各向同性优异的物性的中空构造板，在那样的中空构造板的情况下，由于压缩强度高，因此难以进行压溃加工、开孔加工等加工。
于是，本申请发明人对中空构造板的构造进行了潜心研究，结果发现通过将弯曲半径R设为0.75mm～20mm，能够获得压缩强度得到保持并且加工容易性优异的中空构造板。
具体而言，通过将弯曲半径R设为0.75mm以上，能够防止凸部21的侧壁的倾斜变得过大，从而能在施加了载荷时避免凸部21的侧壁折断而使压缩强度降低。另外，通过将弯曲半径R设为20mm以下，能够防止压溃加工、开孔加工等的加工性的效果下降。
另外，通过将弯曲半径R控制在上述的预定的范围内，在实施了压溃加工、开孔加工等加工时，能够防止在加工后的面的相反侧的面发生按压痕迹的浮出或者产生毛边，因此加工后的中空构造板1的外观性也得到提高。
在本实施方式中，只要凸部21的侧壁的至少一部分的弯曲半径R在上述的预定的范围内即可。即，在本实施方式中，如图2的A、图9所示，当在凸部21存在多个弯曲半径R的情况下，只要至少一个弯曲半径R为0.75mm～20mm即可。
但是，如后述的实施例所示，在本实施方式中，特别优选是，在凸部21的开口部212的缘部测得的弯曲半径R在上述预定的范围内。
图2的B是开口部212的放大图。在本实施方式中，凸部21的开口部212的长径方向的长度a1与短径方向的长度a2的比值(a1/a2)没有特别限定，但优选设为1.05≤a1/a2≤1.23。
通过设为a1/a2≥1.05，能够提高长径方向的弯曲刚度，在利用热等沿短径方向进行了弯曲加工的情况下，能够避免凸部21沿任意的方向以外的方向折弯。另外，通过设为a1/a2≤1.23，能在成形时防止凸部21的侧壁的长径方向的树脂伸长而使壁厚变得过薄，因此能够避免压缩强度降低。
另外，在本实施方式中，更优选设为1.08≤a1/a2≤1.21。由此，能够提供弯曲刚度得到提高并且保持了压缩强度的中空构造板1。
凸部21只要至少具有上表面部211和开口部212即可(参照图2的A)，凸部21的形态没有特别限定，能够自由地设计。例如能够设计成图1等所示的椭圆台形状、圆台形状、三棱台形状、四棱台形状以及五棱台形状等多棱台形状，此外还能设计成椭圆柱形状、圆柱形状、多棱柱形状、多角星柱形状以及多角星台形状等各种各样的形状。另外，如图6所示，也能设计成将上述这些形状组合而成的形态。
另外，在本实施方式中，在将后述的表面材料3、表皮材料4层叠于中空凸部成形片2时，为了使起点较少而提高自表面材料3、表皮材料4的剥离强度，也能将上述的多棱台形状和多棱柱形状等的角设计为圆角。
在本实施方式中，其中，特别优选将凸部21设计为圆台形状、椭圆台形状或多棱台形状。通过将凸部21的形状设计为圆台形状、椭圆台形状或多棱台形状，能使制造工序中的设计容易进行，而且在使用模具成形凸部21的情况下，也能削减模具的制造成本。
另外，在本实施方式中，更优选将凸部21设计为圆台形状或椭圆台形状，特别优选将凸部21设计为椭圆台形状。由此，能够提高中空构造板1的弯曲刚度，并且能够保持压缩强度。
多个凸部21可以全为同一形态，也可以自由地选择两种以上的形态进行组合。另外，如图6和图9所示，也能在凸部21的中途设置台阶，或在凸部21的中途设置波形部。
在本实施方式中，凸部21的排列形态没有特别限定，例如能将凸部21排列为格子状、错列状或不规则地排列凸部21。在本实施方式中，其中，特别优选将凸部21排列为四方格子状或错列状，更优选将凸部21排列为错列状。由此，能够提高中空构造板1的弯曲刚度，并且能够保持中空构造板1的厚度方向的压缩强度。
另外，在本说明书中，将凸部21配置为错列状也包含在沿预定的基准方向观察时配置为相邻的凸部21彼此交错的状态。
另外，在将凸部21排列为错列状的情况下，连结横向的凸部21的中心彼此的线与连结倾斜方向的凸部21的中心彼此的线所构成的角度θ1(参照图3的B)没有特别限定，但特别优选设为60°。由此，能够提高中空构造板1的刚度。另外，“四方格子状”是指设为θ1＝90°的情况下的排列。
开口部212的形状没有特别限定，在设为1.05≤a1/a2≤1.23的情况下，只要是具有长径和短径的形状即可，其中特别优选设为椭圆。由此，能够提高中空构造板1的弯曲刚度，并且保持压缩强度。
上表面部211的形状没有特别限定，能够设为椭圆、正圆、三角形以及四边形等多边形等。
凸部21的开口部212间的最短距离d(参照图2的A、图3的B以及图9)也没有特别限定，但优选设为0.5mm～5mm。通过将最短距离d设为0.5mm以上，由于能够防止衬底部(是沿一定的方向观察凸部21的情况下不存在凸部21的部分；参照图3的B)的厚度变得过薄，因此能够避免压缩强度的降低。另外，通过将最短距离d设为5mm以下，能够避免凸部21间的距离变得过长而过于减少每单位面积内的凸部21的数量，因此能将中空构造板1的弯曲刚度保持为一定以上。另外，在本实施方式中，最短距离d也可以不始终恒定。
在本实施方式中，在凸部21，侧壁的弯曲半径R成为0.75mm～20mm的曲线部的总长度L与凸部21的高度h的比值(L/h)没有特别限定，但优选设为0.05≤L/h≤0.3。
通过设为L/h≥0.05，能够防止压溃加工、开孔加工等加工性的效果减轻。另外，通过设为L/h≤0.3，能够防止凸部21的侧壁的倾斜变得过大，能在施加了载荷时避免凸部21的侧壁折断而使压缩强度降低。
如图2的A所示，当在凸部21存在多个弯曲半径R的情况下，在本实施方式中，将弯曲半径R在0.75mm～20mm的范围内(在图2的A中，使任一个弯曲半径R都在此范围内)的曲线部的长度之和(L1+L2)设为总长度L。即，在本实施方式中，在总长度L的计算中不使用弯曲半径R不在此范围内的曲线部的长度。
凸部21的高度h(参照图2的A)也没有特别限定，但优选为1.5mm以上。通过将h设为1.5mm以上，能够获得刚度高的中空构造板1。另外，h优选为50mm以下。通过将h设为50mm以下，能够防止凸部21的侧壁部分变得过薄，从而能够防止中空凸部成形片2的变形。
在本实施方式中，作为中空凸部成形片2的构造，也能采用在片材的一部分存在图7所示那样的流路F的构造。在本实施方式中，流路F的形状和截面的构造等没有特别限定。另外，图7所示的箭头k表示流路F的形成方向。形成流路F的方向也没有特别限定，例如如图7所示，可以沿着从箭头g方向观察的倾斜方向形成流路F。
中空凸部成形片2的材质只要是热塑性树脂即可，没有特别限定，通常，能够使用一种能用在中空构造板中的热塑性树脂或者自由地组合使用两种以上的该热塑性树脂。
作为上述热塑性树脂，例如可以举出聚乙烯(PE)、聚丙烯(PP)、聚苯乙烯(PS)、聚氨酯、聚碳酸酯(PC)以及聚甲基丙烯酸甲酯(PMMA)等。
作为中空凸部成形片2的材质，在上述材料中，特别是从加工性、成本、重量以及物性的观点出发，优选使用低密度聚乙烯、高密度聚乙烯(HDPE)、直链低密度聚乙烯、超低密度聚乙烯、聚丙烯均聚物、聚丙烯无规共聚物以及聚丙烯嵌段共聚物等聚烯烃类树脂。另外，在本实施方式中，为了获得更高的刚度，也能使用ABS树脂和聚碳酸酯等工程塑料。
在本实施方式中，也可以在形成中空凸部成形片2、后述的表面材料3以及表皮材料4的热塑性树脂中，添加滑石、云母、碳酸钙等填料以及玻璃纤维、芳香族聚酰胺纤维、碳纤维等的短切原丝。
另外，也可以在形成中空凸部成形片2、后述的表面材料3以及表皮材料4的热塑性树脂中，添加用于提高阻燃性、导电性、浸润性、润滑性以及耐气候性等的改质剂、颜料等着色剂等。
另外，中空凸部成形片2、后述的表面材料3以及表皮材料4可以由相同的材料形成，但也可以在能够热熔接的范围内由彼此不同的材料形成。
<表面材料3(31、32)>
在本实施方式中，在上述的中空凸部成形片2的至少一面上层叠有表面材料3和/或后述的表皮材料4。即，在本实施方式中，既可以如图1～图4以及图7～图9所示，在中空构造板1上只层叠有表面材料3(31、32)或表皮材料4(41、42)，也可以如图6所示，在中空构造板1上层叠有表面材料3和表皮材料4这两者，还可以如图5所示，在中空构造板1的中空凸部成形片2的各个面上分别层叠有表面材料3和表皮材料4。
另外，在本说明书以及附图中，有时也将层叠在中空凸部成形片2上的两张表面材料分别称为第1表面材料31和第2表面材料32，但这些名称的区别是为了方便说明。因而，在作为实际的产品的中空构造板1上，没有第1表面材料31与第2表面材料32的区别。另外，如后述的实施例所示，特别是当在凸部21的上表面部211侧层叠有表面材料3的情况下，将该表面材料3方便地称为“第1表面材料31”，当在凸部21的开口部212侧层叠有表面材料3的情况下，将该表面材料3方便地称为“第2表面材料32”。
在本实施方式中，表面材料3的材质没有特别限定，通常能够使用一种能用在中空构造板中的材料或者自由地组合使用两种以上的该材料。具体而言，例如能够使用热塑性树脂和金属薄板等。另外，热塑性树脂的具体例与上述的具体例相同，因此这里省略说明。
作为表面材料3的材质，在上述材料中，特别是从加工性、成本、重量以及物性的观点出发，优选将表面材料3设为热塑性树脂，更优选设为低密度聚乙烯、高密度聚乙烯(HDPE)、直链低密度聚乙烯、超低密度聚乙烯、聚丙烯均聚物、聚丙烯无规共聚物以及聚丙烯嵌段共聚物等聚烯烃类树脂。另外，在本实施方式中，为了获得更高的刚度，也能使用ABS树脂和聚碳酸酯等工程塑料。
在本实施方式中，表面材料3的单位面积质量、厚度没有特别限定，能够设定为任意的单位面积质量、厚度。
在本实施方式中，在中空构造板1具有多张表面材料3的情况下，多张表面材料3的厚度可以相同，也可以不同。另外，既能利用相同的材质形成各表面材料，也能利用不同的材质形成各表面材料。
如上所述，本实施方式的中空构造板1的构造虽然没有特别限定，但如图1～图4所示，能够形成为如下构造，即，中空凸部成形片2由在一面上形成有多个锥台形状的凸部21的一张热塑性树脂片形成，并在凸部21的上表面部211、开口部212或上表面部211和开口部212这两者层叠有表面材料3(31、32)的构造。通过采用该构造，能够提供平面压缩强度得到保持并且加工性也优异的中空构造板1。另外，例如能够利用后述的图10和图11所示的制造方法等来制造该构造的中空构造板。
另外，如图8所示，能将本实施方式的中空构造板1的构造形成为如下构造，即，中空凸部成形片2为由在一面上层叠有多个台体形状的凸部21的两张热塑性树脂片形成，并且在使凸部21彼此对接的状态下将上述两张热塑性树脂片熔融而构成的构造。通过采用该构造，能够提供翘曲得到抑制并且弯曲刚度也优异的中空构造板1。另外，例如能够利用后述的图12所示的制造方法等来制造该构造的中空构造板。
<表皮材料4(41、42)>
在本实施方式中，在上述的中空凸部成形片2的至少一面上层叠有上述的表面材料3和/或表皮材料4。通过使本实施方式的中空构造板1具有表皮材料4，能够赋予中空构造板1外观性、吸声特性以及隔热性等与用途对应的特性。
另外，在本说明书以及附图中，有时也将层叠在中空凸部成形片2上的两张表皮材料分别称为第1表皮材料41和第2表皮材料42，但这些名称的区别是为了方便说明。因而，在作为实际的产品的中空构造板1上，没有第1表皮材料41与第2表皮材料42的区别。另外，如后述的实施例所示，特别是当在凸部21的上表面部211侧层叠有表皮材料4的情况下，将该表皮材料4方便地称为“第1表皮材料41”，当在凸部21的开口部212侧层叠有表皮材料4的情况下，将该表皮材料4方便地称为“第2表皮材料42”。
表皮材料4的材质没有特别限定，通常能够根据目标的用途等，自由地选择使用能用作中空构造板的表皮材料的材料。例如可以举出热塑性树脂片、树脂制的织布、无纺布、网格布(日文：組布)、编织物、由不锈钢、铝以及铜等形成的金属片、有机类或无机类多孔质片等。另外，也能将层叠有多张同种或不同种的片的层叠片等用作表皮材料。
在本实施方式中，在中空构造板1具有多张表皮材料4的情况下，多张表皮材料4的厚度可以相同，也可以不同。另外，既能利用相同的材质形成各表皮材料，也能利用不同的材质形成各表皮材料。
2.中空构造板1的制造方法
本实施方式的中空构造板1在其构造上具有特征，因此其制造方法没有特别限定。即，在本实施方式的中空构造板1的制造中，通常能够自由地选择使用一种或两种以上的在制造中空构造板时能够采用的方法。另外，在图10～图12中，箭头j表示中空构造板1的输送方向。
图10是表示本实施方式的中空构造板1的制造方法的一个例子的概念图。在图10所示的制造方法中，首先利用模具D1、D2从两侧对熔融状态的热塑性树脂P进行压制，从而制造图1中所示的构造的中空凸部成形片2。接着，使用设有加热部件的辊R1通过热熔接将表面材料3层叠于中空凸部成形片2，从而制造本实施方式的中空构造板1，上述表面材料3是通过自在顶端设有T型模101的挤出机102挤出热塑性树脂，并将该热塑性树脂形成为片状而成的。
图11是表示本实施方式的中空构造板1的与图10不同的制造方法的一个例子的概念图。图11所示的制造方法首先使用在表面突设有多个凸状的销的成形辊R2，将熔融状态的热塑性树脂片注入该成形辊R2的槽，从而形成中空凸部成形片2。接着，使用表面平坦的平面轧辊R3将第2表面材料32通过热熔接层叠于该中空凸部成形片2的一面，随后使用设有加热部件的辊R1将第1表面材料31通过热熔接层叠于中空凸部成形片2的另一面，从而制造本实施方式的中空构造板1。
在图11所示的制造方法中，利用真空形成装置进行中空凸部成形片2的制造，该真空形成装置将在表面突设有多个凸状的销的成形辊R2和表面平坦的平面轧辊R3配置为旋转轴相互平行。成形辊R2设置在减压腔103a内，平面轧辊R3设置在减压腔103b内。另外，如图11所示，也能在减压腔103a设有用于吸引保持中空凸部成形片2、表面材料31、32的吸引孔104a，也能在减压腔103b设有用于吸引保持中空凸部成形片2、表面材料31、32的吸引孔104b。
图12是表示本实施方式的中空构造板1的与图10和图11不同的制造方法的一个例子的概念图。图12所示的制造方法首先使用两台成形辊R2，将熔融状态的热塑性树脂片注入该成形辊R2的槽，形成图8中所示的构造的中空凸部成形片2。接着，使用设有加热部件的辊R1将第一表面材料31和第二表面材料32通过热熔接层叠于该中空凸部成形片2的两面，从而制造本实施方式的中空构造板1。另外，在图12所示的制造方法中，利用真空形成装置形成中空凸部成形片2，真空形成装置与图12所示的制造方法的真空形成装置相同，因此这里省略说明。
另外，虽然未图示，但在将表皮材料4层叠于中空构造板1的情况下，在上述的图10～图12所示的制造方法中，能采用将表皮材料4(41、42)代替表面材料3(31、32)层叠于中空凸部成形片2的制造方法、利用设有加热部件的辊R1和表面平坦的平面轧辊R3等进一步在表面材料3上层叠表皮材料4的制造方法等。
实施例
以下，基于实施例进一步详细说明本实施方式。另外，以下说明的实施例表示本实施方式的代表性的实施例的一个例子，不会由此狭隘地解释本发明的范围。
1.试验方法和试验结果
首先，制作了以下的表1和表2所示的实施例1～实施例19以及比较例1～比较例6的中空构造板。
实施例1～实施例15以及比较例1～比较例6的中空构造板利用图10所示的制造方法制作了图1所示的构造。实施例16的中空构造板利用图10所示的制造方法制作了图3所示的构造。实施例17的中空构造板利用图10所示的制造方法制作了图8所示的构造。实施例18的中空构造板利用图10所示的制造方法制作了图7所示的构造。实施例19的中空构造板利用图10所示的制造方法制作了图4所示的构造。
[表1]
[表2]
另外，在表1和表2中，PP表示聚丙烯嵌段共聚物，ABS表示ABS树脂。另外，表1和表2中的各数值(a1、a2以及开口部间的距离d)是使用显微镜自中空构造板的截面测得的。另外，弯曲半径R是在凸部的开口部缘测得的。
接着，对各中空构造板评价了“压缩强度”、“压溃加工性”、“开孔加工性”以及“裂纹、毛边的产生”。
[压缩强度的评价方法]
将中空构造板切割为70mm×70mm，测量了在以5mm/min的条件进行了压缩的情况下的屈服点处的载荷。用获得的数值除以平面面积，从而算出了每1cm2的中空构造板的强度。另外，表1和表2中的各测量值记载的是以N＝5的条件进行测量而获得的平均值。该压缩强度的值越高，能将厚度方向的压缩强度评价为越高。
[压溃加工性的评价方法]
如图13的A～C所示，在压制机以任意的半圆柱(半径：1cm)的圆角曲面与中空构造板接触的方式设置半圆柱棒，从第一表面材料或第二表面材料侧在任意的温度(50℃)下进行了压制加工。关于不良的判断，相对于所设计的任意的厚度，在±0.1mm的误差范围内获得加工后的中空构造板，并且将在除加工后的部分以外的部分不存在压溃等的情况评价为“○”，将发生了上述的不良情况的情况评价为“×”。
[开孔加工性的评价方法]
如图14的A～C所示，利用公知的方法在压制机设置汤姆逊刀具(株式会社中山公司制造，new cutter；刀片的厚度为1mm)，从第一表面材料或第二表面材料侧在任意的温度(50℃)下进行了压制加工。关于不良的判断，将在除加工部以外的部分不存在压溃等的情况评价为“○”，将发生了上述等的不良情况的情况评价为“×”。
[裂纹、毛边的产生]
在此项目中，在使用市面上出售的PET薄膜25μm层压于中空构造板的表面材料侧时，评价了裂纹、毛边(实施了薄膜加工时的破损)的产生情况。另外，以N＝20的条件进行了评价。关于不良的判断，通过目视(薄膜的破损的有无)确认了在对中空构造板进行了加工时是否没有裂纹、毛边。并且，将存在裂纹、毛边的中空构造板(薄膜有破损)判断为不良，算出了裂纹、毛边的产生率(％)。将产生率为10％以下的情况评价为“◎”，将产生率超过10％且为15％以下的情况评价为“○”，将产生率超过了15％或者无法评价的情况评价为“×”。
2.考察
实施例1～实施例19的中空构造板能将压缩强度保持为一定值以上(具体而言为0.80以上)，并且能够容易地进行压溃加工、开孔加工。另外，也基本看不到加工后的裂纹、毛边。因而，压缩强度得到保持，并且加工容易性优异。而比较例1～比较例6的中空构造板难以进行压溃加工、开孔加工，加工后的裂纹、毛边也较多(比较例5的中空构造板为成形不良，因此无法进行各种评价)。
因而，根据本试验结果可知，通过将凸部的侧壁的至少一部分的弯曲半径设为0.75mm～20mm，能够获得压缩强度得到保持，并且加工容易性优异的中空构造板。
产业上的可利用性
采用本发明，能够提供压缩强度得到保持，并且加工容易性优异的中空构造板。因此，本发明的中空构造板能够较佳地用在箱材料、包装材料等物流用途、墙壁、顶棚用的面板材料等建筑用途以及汽车的内部装饰等广泛的领域。
附图标记说明
1、中空构造板；2、中空凸部成形片；21、凸部；211、上表面部；212、开口部；3、表面材料；31、第1表面材料；32、第2表面材料；4、表皮材料；41、第1表皮材料；42、第2表皮材料；101、T型模；102、挤出机；103a、103b、减压腔；104a、104b、吸引孔；R1、设有加热部件的辊；R2、成形辊；R3、平面轧辊；D1、D2、模具；P、熔融状态的热塑性树脂；θ1、连结横向的凸部21的中心彼此的线与连结倾斜方向的凸部21的中心彼此的线所成的角度；h、凸部21的高度；d、凸部21的开口部212间的最短距离；F、流路；g、箭头；k、流路F的形成方向；j、中空构造板1的输送方向。

Claims (9)

1.一种中空构造板，该中空构造板在中空凸部成形片的至少一面层叠有表面材料和/或表皮材料，该中空凸部成形片由在至少一面形成有多个中空状的凸部的一张或两张的热塑性树脂片形成，其特征在于，
所述凸部的侧壁的至少一部分的弯曲半径R为0.75mm～20mm。
2.根据权利要求1所述的中空构造板，其中，
所述凸部的开口部的长径方向的长度a1与短径方向的长度a2的比值a1/a2为1.05≤a1/a2≤1.23。
3.根据权利要求1所述的中空构造板，其中，
所述凸部的开口部的长径方向的长度a1与短径方向的长度a2的比值a1/a2为1.08≤a1/a2≤1.21。
4.根据权利要求1所述的中空构造板，其中，
在所述凸部，所述侧壁的弯曲半径R成为0.75mm～20mm的曲线部的总长度L与所述凸部的高度h的比值L/h为0.05≤L/h≤0.3。
5.根据权利要求1所述的中空构造板，其中，
所述凸部的开口部间的最短距离为0.5mm～5mm。
6.根据权利要求1所述的中空构造板，其中，
所述凸部的形状为圆台形状、椭圆台形状或多棱台形状。
7.根据权利要求1所述的中空构造板，其中，
所述凸部的开口部的形状为椭圆形。
8.根据权利要求1所述的中空构造板，其中，
所述中空构造板为如下构造：所述中空凸部成形片由在一面上形成有多个台体形状的所述凸部的一张热塑性树脂片形成，在所述凸部的上表面部、开口部或者上表面部和开口部这两者层叠有所述表面材料。
9.根据权利要求1所述的中空构造板，其中，
所述中空构造板为如下构造：所述中空凸部成形片由在一面上形成有多个台体形状的所述凸部的两张热塑性树脂片形成，并且在使凸部(21)彼此对接的状态下将所述两张热塑性树脂片熔融而构成。
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