JP2009090576A - Molding member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding member which is hardly deformed even when it is heated/cooled, excellent in strength, and lightweight. <P>SOLUTION: The molding member 1 comprises a design part 10 consisting of a resin material and a core part 20 embedded in the design part 10. The design part 10 and the core part 20 are integrally molded so as to make the core part 20 cylindrical, the strength of the core part 20 larger than the strength of the design part 10 and the coefficient of linear expansion of the core part 20 smaller than the coefficient of linear expansion of the design part 10. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a molded member that can be used as a structural member, an appearance member, or the like.

Molded members made of resin materials such as polyethylene, polypropylene, and polystyrene have been conventionally used for building members. However, since these resin materials have a large coefficient of linear expansion, they are greatly expanded or contracted due to changes in temperature or the like. For reference, the linear expansion coefficient of high-density polyethylene is about 100 to 120 × 10 ⁻⁶ / ° C. For other resin materials, the linear expansion coefficient is similar. Therefore, when a molded member made of these resin materials is used in an environment with a large temperature change, the molded member is deformed, and a gap is formed between the mating member assembled with the molded member and the molded member or between adjacent molded members. Occurs, and there is a problem that it is difficult to assemble the molded member stably. In addition, when a part of the molded member is heated / cooled, the molded member warps or bends greatly. Furthermore, the molded member made of a resin material also has a problem of poor strength.

  For this reason, conventionally, a composite material obtained by kneading a material having a low linear expansion coefficient such as wood powder (hereinafter referred to as a low expansion material) into a resin material has been used as the material of the molded member. However, in this case, since the resin material and the low expansion material exist independently of each other, it is difficult to sufficiently suppress the expansion and contraction of the resin material. In this case, when the molded member is cut, the low expansion material is exposed on the cut surface. In this case, for example, when wood powder is used as the low expansion material, there is a problem that the cut surface is discolored or mold is generated.

  There is also a technique in which a plate material made of a low expansion material such as a metal plate or an FRP plate is integrally formed inside the molded member (for example, see Patent Document 1). However, even with this technique, it is difficult to sufficiently suppress the expansion and contraction of the resin material. That is, since the bonding area between the part made of a resin material (hereinafter referred to as the design part) and the plate material in the molded member is small, the expansion and contraction of the part located at the boundary with the plate material in the design part is suppressed. Although effective, it is difficult to suppress the expansion and contraction of the design portion in a portion away from the plate material. Furthermore, since plate materials, such as an aluminum plate, are inferior in bending strength and are easy to deform | transform, it is difficult to improve the intensity | strength of the whole shaping | molding member. For this reason, the molded member formed by integrally molding the plate material also has a problem that it is inferior in shape stability and difficult to assemble stably.

  Furthermore, it is necessary to fix the molded member and the other molded member (or the mating material) with an adhesive or screws, etc., because it is difficult to stably assemble the molded member made of the plate material to other molded members or the mating material. There is. FIGS. 11 to 15 are explanatory views schematically showing a state in which a forming member formed by integrally forming a plate material is assembled to a counterpart material.

  A molding member 100 shown in FIG. 11 has a design portion 101 made of a resin material and a plate material 102 made of a metal material. In general, the molded member 100 is fixed to the counterpart material 107 with a plurality of fixing screws 109a and 109b while being pressed against the counterpart material 107 to which the adhesive 108 is applied. At this time, it is necessary to reduce the interval P between the adjacent fixing screws 109a and 109b in consideration of the expansion / contraction amount of the molding member 100 according to the temperature difference of the environment in which the molding member 100 is assembled. Further, the gap between the adjacent molded members 100a and 100b also needs to be set in consideration of the amount of expansion / contraction of the molded members 100a and 100b. The gap was filled with the elastic material 110.

  However, even if the molding member 100 assembled by the method shown in FIG. 11 is heated and cooled several times, it thermally expands, and as shown in FIG. 12, the abutting portions of the adjacent molding members 100a and 100b. Comes up. This is because the plate material 102 is inferior in bending strength.

  As shown in FIG. 13, when the ends of the molded member 100 are cut out and the plate members 102a and 102b of the adjacent molded members 100a and 100b are overlapped, the butted portions of the adjacent molded members 100a and 100b can be fixed. it is conceivable that. In addition, as shown in FIG. 13, even when pressing the butted portion of the adjacent molded members 100 a and 100 b with the cover body 111 separate from the molded members 100 a and 100 b, the butted portions of the adjacent molded members 100 a and 100 b are It can be fixed.

  However, even in these cases, when the plate member 102 or the design portion 101 is thermally expanded, the molded members 100a and 100b are deformed and are not firmly fixed to the mating member 107 in the molded members 100a and 100b as shown in FIG. The portion 105 is lifted from the counterpart material 107.

  The same applies to the case where the molded member 100a is assembled to another molded member 100b. For example, as shown in FIG. 15, the plate members 102a and 102b of the two molded members 100a and 100b are exposed, and the two plate members 102a and 102b are overlapped and fixed with a fixing screw 109, thereby fixing the two molded members 100a and 100b. Can be assembled. However, even in this case, due to the thermal expansion of the plate members 102a and 102b or the design portion 101, a large stress may act on the joint portion between the molding member 100a and the molding member 100b, and the joint portion may be deformed. In this case, since the plate materials 102a and 102b are exposed to the outside of the design portion 101, a cover 120 for covering the plate materials 102a and 102b is necessary. Therefore, there is a problem that the number of parts of the molded members 100a and 100b is increased and the number of assembling steps is increased. Furthermore, in this case, since the unity feeling of the two molded members 100a and 100b is damaged by the cover 120, there is a problem that the design of the molded members 100a and 100b deteriorates.

  Further, depending on the shape of the molded member or the counterpart material, bonding or screwing may not be possible. In addition, the adhesive is expensive, and there is a problem that the cost required for the bonding process is high.

If the plate material is thick, the strength of the molded member can be improved, but the weight of the molded member increases and the material cost of the molded member increases. If the thickness of the plate material is reduced, the molded member becomes lighter, but the strength of the molded member is reduced and the volume of the plate material is small, so that the resin material that is the material of the design portion cannot be reduced so much. For this reason, the material cost of the molded member in this case is substantially the same as the sum of the material cost of the conventional molded member having no plate material and the material cost required for the plate material. That is, in this case, there is a problem that the material cost of the molded member becomes high and it is difficult to manufacture the molded member at a low cost. Further, in this case, there is a problem that the manufacturing cost of the molded member increases because the process of inserting the plate material into the molded member is necessary, and it is difficult to manufacture the molded member at low cost. Further, particularly when the thickness of the molded member is large, the amount of thermal expansion greatly differs between the surface exposed to sunlight or the like in the design portion and the other surface. In this case, since the design portion is greatly deformed, it is difficult to sufficiently suppress the deformation of the design portion by the plate material. For this reason, there also existed a problem which a molded member deform | transforms large.
JP 2007-196545 A

  This invention is made | formed in view of the said situation, and it aims at providing the shaping | molding member which is hard to deform | transform even if heated and cooled, is excellent in intensity | strength, and is lightweight.

  The molded member of the present invention that solves the above problems has a design portion made of a resin material and a core portion embedded in the design portion, the core portion has a cylindrical shape, and the strength of the core portion is the design. The linear expansion coefficient of the core portion is smaller than the linear expansion coefficient of the design portion, and the design portion and the core portion are integrally formed.

The molded member of the present invention preferably includes one of the following (1) to (4), more preferably two or more.
(1) The design part is made of a foamed resin material.
(2) The core is made of a metal material.
(3) The said core part consists of fiber reinforced resin materials.
(4) The linear expansion coefficient of the core is 25 × 10 ⁻⁶ / ° C. or less.

  The molded member of the present invention has a design portion and a core portion embedded in the design portion. Since the core portion has a smaller linear expansion coefficient than the design portion, it is difficult to deform even when heated and cooled. Further, the core portion is not a mere flat plate shape but a cylindrical shape (hollow shape). For this reason, the surface area of the core is large. Therefore, the joint area between the design portion and the core portion is large, and the design portion is firmly fixed to the core portion. For this reason, the design part fixed to the core part is not easily deformed even when heated and cooled. Therefore, the molded member of the present invention hardly deforms even when heated and cooled.

  Furthermore, since the core part is cylindrical, it is lightweight. For this reason, the molded member of the present invention is lightweight. Furthermore, the strength of the core is greater than the strength of the design portion. That is, the core part is excellent in strength. For this reason, the molded member of the present invention is also excellent in strength. Furthermore, since the core portion has a cylindrical shape (hollow shape), the material cost required for the core portion can be reduced.

  Furthermore, since the core portion has a cylindrical shape, the load can be distributed and received in the circumferential direction. For this reason, the cylindrical core has an advantage that it is particularly difficult to bend and deform. Moreover, the core part is embed | buried under the design part. In other words, the outer peripheral surface of the core part is covered with the design part. Therefore, it is difficult for heat to be transmitted to the core due to the heat insulating action of the design portion. For this reason, a core part cannot change easily and the design part currently fixed to the core part also cannot change easily.

  Furthermore, since the core portion has a cylindrical shape, a connecting member can be assembled therein. Therefore, the molded member of the present invention can be assembled to another molded member or a counterpart material even if the entire outer peripheral surface of the core is covered with the design portion (even if the core is not exposed to the outside of the molded member). For this reason, the molded member of the present invention is excellent in assembly workability and designability.

  Furthermore, since the design portion is made of a resin material, the molded member of the present invention is excellent in the degree of freedom of shape. Moreover, since the design part and the core part are integrally molded, the design part in the molded member of the present invention is difficult to peel from the core part. Therefore, the molded member of the present invention can be used even in an environment where it is repeatedly exposed to high and low temperatures. In other words, the molded member of the present invention is excellent in the degree of freedom of the environment in which it can be used.

  The molded member of the present invention having the above (1) is lightweight because the design portion is made of a foamed resin material. Moreover, the design part which uses a foamed resin material as a material makes a foam form (porous body form). For this reason, the quantity of the material (resin material) of the design part can be reduced. Therefore, according to the molded member of the present invention provided with the above (1), the material cost required for the design portion can be reduced and can be manufactured at low cost. Furthermore, since the design part in the form of a foam works as a heat insulating material, the core part embedded in the design part is thermally blocked from the outside. For this reason, the deformation of the core due to heating and cooling is further suppressed, and the deformation of the molded member is further suppressed. Furthermore, since the design portion made of the foamed resin material is composed of an aggregate of fine bubbles (hereinafter referred to as cells) partitioned by a resin thin film, it absorbs its deformation by expansion and contraction of the cells. Therefore, by configuring the design portion with the foamed resin material, deformation of the design portion due to heating / cooling can be suppressed, and deformation of the molded member due to heating / cooling can be suppressed.

  The molded member of the present invention having the above (2) is excellent in the strength of the core. For this reason, the molded member of this invention provided with said (2) is excellent in intensity | strength.

  Since the core part of the molded member of the present invention having the above (3) is made of a fiber reinforced resin material (so-called FRP), the core part can be further reduced in weight. Furthermore, since the fiber reinforced resin material is excellent in corrosion resistance, the molded member of the present invention having the above (3) can be preferably used in the vicinity of the coast or in a high humidity environment. Furthermore, the core part which consists of fiber reinforced resin materials contains resin material. For this reason, the core part which consists of fiber reinforced resin material materials has a small heat capacity compared with the core part which consists of metal materials, such as aluminum. For this reason, the core part which consists of fiber reinforced resin materials cannot take away the heat of the design part at the time of shaping | molding, and can make a design part thin. If it is a molded object with the same external shape, a core part can be enlarged by making a design part thin, and the surface area of a core part can be enlarged. For this reason, according to the shaping | molding member of this invention provided with said (3), the joining area of a design part and a core part can be enlarged further, and a design part and a core part can be integrated more firmly. Further, the FRP core has a small heat capacity. For this reason, for example, when the design portion is formed using a preformed core portion as an insert material, the core portion does not need to be heated to a high temperature. Therefore, in this case, the productivity of the molded member is improved. Furthermore, in this case, since the thickness of the design portion can be reduced because the endothermic amount of the core portion is small, the molded member can be further reduced in weight and the material cost of the molded member can be reduced.

  In the molded member of the present invention having the above (4), the core part is hardly deformed even by heating and cooling, and deformation of the entire molded member due to heating and cooling can be suppressed.

  The strength of the core part in the molded member of the present invention may be larger than the strength of the design part. In addition, the intensity | strength of the core part in the molded member of this invention and the intensity | strength of a design part point out mechanical strength, and point out bending strength in detail. The strength of the core portion and the strength of the design portion can be measured by a bending test based on JIS Z 2101.

  Since the core portion has a cylindrical shape and is excellent in strength, the strength of the core portion can be further increased by using a material having a higher strength than the material of the design portion as the material of the core portion. The cylindrical shape in the present invention is not limited to a cylindrical shape with a rectangular cross section (square tube shape) or a cylindrical shape with a circular cross section (cylindrical shape). For example, the inside of the core is divided into a plurality of parts. Also good. In this case, the strength of the core portion is further increased.

  Since the core part in the molded member of the present invention is excellent in strength, it can be preferably used as an assembly part when the molded member is assembled to another molded member or a counterpart material.

The linear expansion coefficient of the core part (specifically, the linear expansion coefficient of the material constituting the core part) may be smaller than the linear expansion coefficient of the design part (specifically, the linear expansion coefficient of the material constituting the design part). The linear expansion coefficient of the core is preferably 25 × 10 ⁻⁶ / ° C. or less. The linear expansion coefficient of aluminum, titanium, steel, stainless steel, a fiber reinforced resin material containing carbon fiber as a fiber material, a fiber reinforced resin material containing glass fiber as a fiber material, and the like is 25 × 10 ⁻⁶ / ° C. or less. Therefore, it is preferable to use at least one selected from these as the material of the core. Depending on the strength of the design part, paper, wood, bamboo, or the like can be used as the material of the core part. The linear expansion coefficient of these materials is 25 × 10 ⁻⁶ / ° C. or less. In addition, when wood, bamboo, paper, etc. including plywood are used as the material of the core part and the molded member is cut and used, the cut surface of the core part may be impregnated with resin or subjected to antiseptic treatment. preferable.

  In order to reduce the weight of the molded member, it is preferable to use aluminum, titanium, or the like as the metal material for the core. In order to improve the dimensional accuracy and strength of the molded member, it is preferable to use steel or stainless steel as the metal material for the core. In addition, what is necessary is just to shape | mold the core part which consists of metal materials by methods, such as extrusion molding.

  When a fiber reinforced resin material is used as the core material, deformation of the molded member due to heating and cooling can be suppressed and the molded member can be manufactured at a lower cost than when a metal material is used as the core material. . That is, when a metal material is used as the material of the core part, the core part takes away the reaction heat of the design part at the time of molding, and the part corresponding to the boundary with the core part in the design part (hereinafter referred to as the boundary design part) Compared to the other part of the design part (hereinafter referred to as a general design part), it is greatly affected by heat and is subjected to a large stress. For this reason, the core portion made of a metal material needs to be subjected to a surface treatment or heated during molding in order to sufficiently increase the adhesive strength with the boundary design portion. The fiber reinforced resin material has a smaller linear expansion coefficient than the metal material. For this reason, when a fiber reinforced resin material is used as the material of the core portion, there is an advantage that the number of manufacturing steps of the molded member can be reduced because surface treatment and heating at the time of molding become unnecessary. Since the fiber-reinforced resin material has a small heat capacity, the core part is sufficiently heated by heat when the design part is integrally formed with the core part made of the fiber-reinforced resin material. For this reason, when the design part and the core part are integrally formed, a thin design part can be formed without heating the core part.

For reference, the linear expansion coefficient of a fiber reinforced resin material made of glass fiber and an unsaturated polyester resin material is about 7 × 10 ⁻⁶ / ° C., and consists of a core portion made of this fiber reinforced resin material and a foamed resin material. The linear expansion coefficient of the molded member having the design portion is about 3 to 4 × 10 ⁻⁶ / ° C. In addition, the linear expansion coefficient of the molding member here refers to the linear expansion coefficient of the molding member when mounted on a mating member or the like (hereinafter referred to as a mounting linear expansion coefficient). That is, when measuring the linear expansion coefficient, the specimen is usually heated to a uniform temperature, but the surface temperature and the internal temperature of the molded member when mounted on the mating material are different for each part of the molded member. Different. For this reason, the mounting linear expansion coefficient of the molded member may be slightly different from the linear expansion coefficient measured by a general method.

As described above, the linear expansion coefficient of the fiber reinforced resin material made of glass fiber and unsaturated polyester resin material is about 7 × 10 ⁻⁶ / ° C., and the core portion made of this fiber reinforced resin material and the foamed resin material The mounting linear expansion coefficient of the molded member having the design portion is about 3 to 4 × 10 ⁻⁶ / ° C. The mounting linear expansion coefficient of this molded member is about the same as the linear expansion coefficient of dried wood (about 1.2 to 2.5 × 10 ⁻⁶ / ° C.). Therefore, in this case, the molded member of the present invention can be used as a substitute for wood. In this case, since the molded member of the present invention is mainly composed of a resin material and a fiber material such as glass fiber, there is an advantage that generation of mold and insects can be suppressed as compared with wood. In addition, as will be described later, the design portion made of the foamed resin material is excellent in heat insulation. For this reason, when using a foamed resin material as the material of the design portion, the mounting linear expansion coefficient of the molded member can be made smaller than the linear expansion coefficient of the core portion.

  Further, the fiber reinforced resin material includes a resin material. For this reason, the core part which consists of fiber reinforced resin materials also has the advantage which is excellent in bondability with the design part which consists of resin materials. In addition, it is preferable to use at least 1 type chosen from unsaturated polyester resin, an epoxy resin, vinyl ester, a polyurethane resin etc. as a resin material for fiber reinforced resin materials. Further, as the fiber material for the fiber reinforced resin material, it is preferable to use at least one selected from resin fibers such as glass fiber, carbon fiber, Kevlar, and vinylon. In addition, what is necessary is just to shape | mold the core part which consists of fiber reinforced resin materials by methods, such as drawing.

  The area of the outer peripheral surface of the core part is preferably 40% or more, more preferably 50% or more when the area of the outer peripheral surface of the design part is 100%. This is because by increasing the area of the outer peripheral surface of the core portion, the bonding area between the core portion and the design portion can be increased.

  The design part in the molded member of the present invention may be made of a resin material. As the resin material for the design portion, it is preferable to use at least one selected from thermosetting resins such as hard urethane resins and phenol resins. These materials have a small coefficient of linear expansion, and are excellent in compressive strength, nailing strength, screwing strength, surface hardness, surface wear resistance, weather resistance, and moldability. In addition, these materials have a texture similar to that of wood and the sound of hitting is similar to that of wood, and therefore can be preferably used as a substitute for wood. Furthermore, these materials are easy to paint, inexpensive, and easy to procure materials.

  When the design part is made of a foamed resin material, a surface layer called a skin layer is formed on the surface of the design part by pressure-molding the design part. In this case, the designability of the design portion made of the foamed resin material is improved. As the foamed resin material, it is preferable to use at least one selected from a hard foamed urethane resin material, a foamed styrene resin material, a foamed phenol resin material, and the like. This is because the design portion made of these foamed resin materials is excellent in design properties. In addition, the design part which consists of hard foaming urethane resin material is excellent in heat resistance, weather resistance, and dimensional stability, and when hard foaming urethane resin material is foamed and pressure-molded, a hard surface layer (skin layer) on the surface of the design layer Can be particularly preferably used. Since the skin layer is hard, there is an advantage that the screw head does not easily enter the design layer even when the molded member is screwed. This skin layer also has the advantage of excellent wear resistance and compressive strength. Further, the rigid foamed urethane resin material has an advantage that it is relatively inexpensive and easily available. Further, the rigid foamed urethane resin material has an advantage that it can be molded by a general molding apparatus. Further, since the hard foamed urethane resin material is excellent in moldability, there is an advantage that a design composed of dense irregularities can be imparted to the surface of the design layer. Furthermore, since the urethane resin is a material used also as an adhesive, the design portion made of the hard foamed urethane resin material can be firmly integrated with the core portion.

In addition, when a foamed resin material is selected as the material for the design portion, a design portion that is thin and excellent in design properties can be obtained by the foaming pressure during molding. Furthermore, since the design part which consists of foamed resin materials consists of an aggregate | assembly of a cell, its deformation amount is small. This is because the individual cells are deformed during heating and cooling, and the deformation of the individual cells is difficult to be transmitted to other cells. Moreover, since the design part which consists of foamed resin materials has small heat conductivity, it is hard to receive to the influence of a heat | fever. Therefore, in this case, deformation of the design portion and peeling of the design portion from the core portion can be further reduced, and the shape of the molded member can be maintained with high reliability. Furthermore, since the design part which consists of foamed resin materials is excellent in heat insulation, the temperature change of a core part can be suppressed. For this reason, a deformation | transformation of a core part can be suppressed further. Further, by suppressing the deformation of the core part, it is possible to suppress the deformation of the design part fixed to the core part, and there is an advantage that the deformation of the entire molded member can be suppressed. In consideration of the heat insulating property of the design portion, it is preferable to use a foamed resin material having a density with low thermal conductivity. For example, a foam made of a hard foamed urethane resin material has a particularly low thermal conductivity (excellent heat insulation) when its density is about 35 kg / cm ³ . In other words, when a hard foamed urethane resin material is used as the foamed resin material, the thermal conductivity is reduced if the density after foaming is about 1/33 of the density before foaming. Therefore, such a foamed resin material can be preferably used as a material for the design portion. Note that the density of the foamed resin material can be appropriately set according to the strength of the design portion.

For reference, when a hard foamed urethane resin material is used as the material of the design part and aluminum (linear expansion coefficient is about 23 × 10 ⁻⁶ / ° C.) is used as the material of the core part, the design part made of the hard foamed urethane resin material The temperature change of the core is reduced by the heat insulation effect. For this reason, the mounting linear expansion coefficient of the whole molded member is about the same as that of concrete (about 1/2 of the linear expansion coefficient of aluminum). For this reason, when using a rigid foaming urethane resin material as a material of the design layer in the shaping | molding member of this invention, the shaping | molding member of this invention can be preferably used also in an environment with a large temperature change. In addition, in order to suppress the temperature change of a core part and to further suppress a deformation | transformation of a core part, it is preferable to use a thing with small heat conductivity as a material of a core part.

  The molded member of the present invention can be formed into various shapes according to the application, such as flat plate shape, columnar shape, rod shape, and spherical shape. The shape of the core portion can be various shapes according to the shape of the molded member. For example, when the forming member is formed into a flat plate shape, the core portion may be formed into a thin cylindrical shape. Note that the shape of the core portion may not be similar to the shape of the molded member. For example, you may use a cylindrical thing as a core part of the shaping | molding member which makes prismatic shape.

  The design part of the present invention can be molded by various methods represented by injection molding, injection press molding, foam molding, pressure foam molding, cast molding, and the like. In addition, if the end part of the core part is closed in advance, the design part can be extruded or pultruded.

  When the design part is molded by injection molding, injection press molding, foam molding, pressure foam molding, etc., the surface of the design part is a discontinuous and fine uneven pattern found in natural wood or stone. Can be provided, and a molded member excellent in design can be obtained.

  The molded member of the present invention can be used for various applications typified by architectural plate materials, square members, columns, floor columns, beams, doors, wood deck plate materials, table top plates, sleepers, paving stones, garden stones and the like.

Hereinafter, the molded member of the present invention will be described with reference to the drawings.
(Example 1)
The molded member of Example 1 includes the above (1), (2), and (4). A partially cutaway perspective view schematically showing the molded member of Example 1 is shown in FIG. FIG. 2 is a cross-sectional view schematically showing how the molded members of Example 1 are assembled together.

The molded member 1 of Example 1 has a design portion 10 and a core portion 20. The core portion 20 is made of aluminum, which is a kind of metal material, and has a rectangular tube shape. The design portion 10 is made of a hard foamed urethane resin material. On the surface of the design part 10, unevenness of wood grain is formed. The core part 20 is embedded in the design part 10. The linear expansion coefficient of aluminum is about 23 × 10 ⁻⁶ / ° C., and the linear expansion coefficient of the foamed resin made of the hard foamed urethane resin material is about 60 × 10 ⁻⁶ / ° C. Therefore, the linear expansion coefficient of the core part 20 is smaller than the linear expansion coefficient of the design part 10.

  The outer dimensions of the molded member 1 of Example 1 are a width of 40 mm, a thickness of 35 mm, and a length of 3000 mm. The thickness of the design part 10 is 10 mm. The core 20 extends over the entire length of the molded member 1 (the total length in the longitudinal direction). The thickness of the core part 20 is 1 mm.

  The molded member 1 of Example 1 was obtained by insert molding (pressure foam molding) the design portion 10 on the outer side of the core portion 20 using the core portion 20 that was previously extruded and formed as an insert material.

  As shown in FIG. 2, the molded member 1 according to the first embodiment can be assembled to the molded member 1 according to another embodiment 1 by butt bonding. For the butt connection, the connecting member 30 and the fixing screw 40 shown in FIG. 2 were used. The coupling member 30 is separate from the molded member 1 and has an outer diameter smaller than the inner diameter of the core portion 20. The fixing screw 40 is a separate body from the molding member 1 and the coupling member 30. In Example 1, a square tube made of aluminum was used as the coupling member 30. Note that the thickness of the coupling member 30 was thicker than the thickness of the core portion 20.

  First, one end portion of the coupling member 30 was inserted into the core portion 20 of one molding member 1a, and the other end portion of the coupling member 30 was inserted into the core portion 20 of the other molding member 1b. Next, the fixing screw 40 was screwed from the design portion 10 toward the coupling member 30, and the two molded members 1 a and 1 b and the coupling member 30 were fixed with the fixing screw 40. The fixing screws 40 were screwed into two places in the longitudinal direction for the respective molded members 1a and 1b. Since the coupling member 30 is made of aluminum, it can be easily fixed with screws. At this time, the fixing screw 40 is screwed into only one surface of the molded member 1. For this reason, on the surface of the molded member 1 (the surface of the design portion 10), there is a surface (the lower surface in FIG. 2, hereinafter referred to as the design surface 13) to which the fixing screw 40 is not screwed. If this design surface 13 is arranged on the front side of the structure, the plurality of molded members 1 can be assembled to the structure without impairing the design. Further, a mounting hole 15 for the fixing screw 40 is formed in a surface (the upper surface in FIG. 2, hereinafter referred to as the mounting surface 14) into which the fixing screw 40 is screwed in the design portion 10. For this reason, the screw head of the fixing screw 40 has entered the mounting hole 15. Therefore, the molded members 1a and 1b of Example 1 are also excellent in design when viewed from the mounting surface 14.

  In addition, as the coupling member 30, a hollow member such as a cylinder may be used, or a solid member such as a middle member or a plate member may be used. Furthermore, the material of the coupling member 30 is not limited to aluminum. Further, the method for fixing the molding member 1 and the coupling member 30 is not limited to screwing. For example, the molding member 1 and the coupling member 30 may be fixed by a method such as adhesion or welding.

  The linear expansion coefficient of the core part 20 in the molded member 1 of Example 1 is smaller than the linear expansion coefficient of the design part 10. For this reason, even if the core part 20 is heated and cooled, it is hard to deform | transform, and even if the molded member 1 of Example 1 which has the core part 20 integrally is also heated and cooled, it is hard to deform | transform. Moreover, since the core part 20 makes a cylinder shape, it is lightweight and excellent in strength. Therefore, the molded member 1 of Example 1 is also lightweight and excellent in strength.

  Furthermore, since the core portion 20 has a cylindrical shape (hollow shape) and the design portion 10 has a porous shape (hollow shape), the molded member 1 of Example 1 has excellent heat insulation properties, and is heated and cooled. hard. For this reason, the molded member 1 of Example 1 is not easily heated and cooled, and is not easily deformed even when heated and cooled. Furthermore, since the core part 20 and the design part 10 are hollow, the molded member 1 of Example 1 has an advantage that the material cost required for the core part 20 and the design part 10 can be reduced and can be manufactured at low cost.

The molded member 1 of Example 1 was heated until its surface temperature (that is, the temperature of the design portion 10 surface) reached 80 ° C. At this time, the temperature at an arbitrary position inside the core portion 20 was 56 ° C. The mounting linear expansion coefficient of the entire molded member 1 of Example 1 calculated based on this result was about 13.5 × 10 ⁻⁶ / ° C. This is smaller than the linear expansion coefficient (about 23 × 10 ⁻⁶ / ° C.) of aluminum which is the material of the core part 20. From this result, it can be seen that the molded member 1 of Example 1 can have a linear expansion coefficient smaller than the linear expansion coefficient of the core portion 20 by having a design layer made of a hard foamed urethane resin material. As described above, this is considered due to the fact that the design layer made of the foamed resin material works as a heat insulating material. For reference, the linear expansion coefficient of a molded member having the same dimensions as the molded member 1 of Example 1 and including only the design portion 10 (that is, a conventional molded member) was about 60 × 10 ⁻⁶ / ° C.

  Since the core part 20 in the molded member 1 of Example 1 has a cylindrical shape, an electric wire or the like can be passed through the core part 20. In this case, a lighting fixture, a speaker, etc. can be integrally attached to the molding member 1 of the first embodiment.

(Example 2)
The molded member of Example 2 is the same as the molded member of Example 1 except for the shape of the design portion. A perspective view schematically showing the molded member 1 of Example 2 is shown in FIG.

  The molded member 1 of Example 2 is an example in which the design portion 10 is made thick, and the design portion 10 is provided with a thick portion and a small portion so that the design portion 10 has a wavy shape. As shown in FIG. 3, a design such as a natural wood log can be imparted to the molded member 1 by forming the design portion 10 in a wavy shape. The molded member 1 of Example 2 can be suitably used for a ceiling beam or the like.

  In addition, the design part 10 in the molded member 1 of Example 2 consists of hard foaming urethane resin materials. Since the hard foamed urethane resin material is a thermosetting resin, deformation and sink marks are unlikely to occur even when the design portion 10 having a large thickness difference is formed. Therefore, there exists an advantage which can design the shape of the design part 10 variously.

  Further, since the core portion 20 in the molded member 1 of the second embodiment is cylindrical, the two molded members 1 can be firmly assembled using a coupling member, a fixing screw, etc. (not shown) as in the first embodiment. it can.

(Example 3)
The molded member of Example 3 is the same as the molded member of Example 1 except for the shape of the end portion. The principal part expansion perspective view which represents a mode that the shaping | molding members of Example 3 are assembled | attached is shown in FIG.

  As shown in FIG. 4, the end portions 11 a and 11 b of the molded member 1 of Example 3 are halved. When the molded members 1a and 1b of Example 3 are assembled together, the end 11a of one molded member 1a and the end 11b of the other molded member 1b face each other, and the cores of the two molded members 1a and 1b. A coupling member 30 (not shown) is inserted into 20, and the coupling member 30, the core portion 20, and the design portion 10 are fixed by a fixing screw 40. For this reason, the molding member 1a of Example 3 can be firmly integrated with the other molding member 1b, similarly to the molding member of Example 1.

  In addition, since the end portions 11a and 11b of the molded members 1a and 1b of Example 3 are halved, the core portion 20 at the end portions 11a and 11b has a shape (curved plate shape) obtained by dividing the cylinder in the longitudinal direction. ). However, since the portions embedded in the portions other than the end portions 11a and 11b of the molded members 1a and 1b in the core portion 20 have a cylindrical shape, the core portion 20 has a cylindrical shape as a whole. For this reason, the core part 20 in the molded members 1a and 1b of Example 3 is excellent in strength as a whole.

  Moreover, since the contact area between one molding member 1a and the other molding member 1b is increased by making the ends of the molding members 1a and 1b into a half, the cross-sectional area in the direction perpendicular to the longitudinal direction is large. The molding members 1a and 1b can be assembled stably.

Example 4
The molded member of Example 4 is the same as the molded member of Example 1 except that it has a plate shape and rib-shaped protrusions are formed on the core. The principal part expansion perspective view which represents typically the shaping | molding member of Example 4 is shown in FIG.

  The molded member 1 of Example 4 has a flat plate shape with a width of 90 mm, a length of 3000 mm, and a thickness of 20 mm. The core part 20 is made of aluminum and has a rectangular tube shape (a shape according to the standard of JIS-A6030S) having ribs 21 extending in the longitudinal direction. The molded member 1 of Example 4 is excellent in strength because the core portion 20 has the ribs 21. When the molding member 1 is formed in a wide plate shape, the strength of the entire molding member 1 can be increased by forming the core portion 20 in a flat cylindrical shape. At this time, the core portion 20 includes a portion having excellent strength. Some parts are relatively inferior in strength. That is, in the flat cylindrical core portion 20, the central portion in the width direction (the direction perpendicular to the longitudinal direction, the width direction in FIG. 5) is inferior in strength to the end portion in the width direction. However, since the core part 20 in the molded member 1 of Example 4 has the ribs 21, it is excellent in strength despite having a flat cylindrical shape. Therefore, the molded member of Example 4 is also excellent in strength.

  Furthermore, the core part 20 without the ribs 21 is difficult to fix the end part in the width direction of the design part 10. Therefore, in this case, when the temperature of the molded member 1 rises, there is a possibility that a difference occurs in the expansion amount (or contraction amount) between the central portion in the width direction of the design portion 10 and the end portion in the width direction. However, by providing the ribs 21 on the core part 20, the entire design part 10 can be stably fixed by the core part 20. Further, when the molded member 1 is fixed to another molded member or a mating member with a fixing screw or a nail, a large load is applied to the core portion 20. By providing the rib 21 on the core portion 20, this load can be reduced. There exists an advantage which can be disperse | distributed to the rib 21. FIG. For this reason, the molded member of Example 4 is excellent in attachment strength.

(Example 5)
The molded member of Example 5 is the same as the molded member of Example 4 except that it has two core parts and a fiber reinforced resin material is used as the core part material. The molded member of Example 5 includes the above (1), (3), and (4). The principal part expansion perspective view which represents typically the shaping | molding member of Example 5 is shown in FIG.

The molded member 1 of Example 5 has a plate shape. The molded member 1 of Example 5 has two core parts 20a and 20b. The two core portions 20a and 20b are arranged in the width direction of the molding member 1 and extend in the longitudinal direction. The two core portions 20a and 20b have substantially the same shape. The design part 10 in the molded member 1 of Example 5 is made of a hard foamed urethane resin material. The core parts 20a and 20b are made of a fiber reinforced resin material made of glass fiber and epoxy resin. The linear expansion coefficient of the design portion 10 in the molded member 1 of Example 5 is about 60 × 10 ⁻⁶ / ° C., and the linear expansion coefficients of the core portions 20 a and 20 b are about 7 × 10 ⁻⁶ / ° C. For this reason, the linear expansion coefficient of core part 20a, 20b is smaller than the linear expansion coefficient of the design part 10. FIG.

  Since the core parts 20a and 20b are made of a fiber reinforced resin material, the molded member 1 of Example 5 is difficult to be deformed even when heated and cooled, is lightweight, has excellent flexibility in use environment, and can be manufactured at low cost. .

  Furthermore, since the molding member 1 of Example 5 has the two core portions 20a and 20b arranged in the width direction and extending in the longitudinal direction, the core portions 20a and 20b having excellent strength are provided over the entire width direction of the molding member 1. Can be placed. For this reason, the molded member 1 of Example 5 is further excellent in strength.

  In addition, although the shaping | molding member 1 of Example 5 has two core part 20a, 20b, as shown in FIG. 7, the shaping | molding member 1 of this invention has three or more core parts (20a, 20b, 20c, 20d). You may have it. Moreover, when the shaping | molding member of this invention has a some core part, each core part does not need to extend mutually parallel. Furthermore, each core part may extend in directions other than the longitudinal direction. For example, the cores may extend in the width direction and be arranged in the longitudinal direction. In any case, it is preferable that the cores are distributed over the entire (or almost the entire) molded member.

(Example 6)
The molded member of Example 6 is the same as the molded member of Example 5 except for the shape of the core. FIG. 8 shows a cross-sectional view schematically showing the core part in the molded member of Example 6. As shown in FIG.

  As shown to Fig.8 (a), the core part 20 in the shaping | molding member 1 of Example 6 has two division bodies 20a and 20b integrated. Specifically, as shown in FIG. 8B, the split bodies 20 a and 20 b of the core portion 20 have a shape obtained by dividing the core portion 20 into two in the longitudinal direction of the molding member 1. The two halves 20a and 20b engage with each other. The two halves 20a and 20b are assembled and integrated after being molded separately.

  Since the core part 20 in the molded member 1 of Example 6 is composed of a plurality of split bodies 20a and 20b, there is an advantage that it can be formed into a complicated shape. In addition, there is an advantage that a flat and wide core portion 20 can be easily formed.

  In addition, although the core part 20 in the shaping | molding member 1 of Example 6 consists of two divisions divided | segmented into the longitudinal direction of the shaping | molding member 1, it may consist of three or more divisions. Furthermore, the core part 20 may be composed of a plurality of segments divided in a direction perpendicular to the longitudinal direction of the molded member 1. Furthermore, when the core part 20 is composed of a plurality of divisions divided in the length direction of the molded member 1, ribs 21 and the like can be formed inside the core part 20 as shown in FIG. 9. In this case, the strength of the core part 20 is further improved.

  Furthermore, when assembling the molding member 1 of Examples 1 to 6 to another molding member or a counterpart material, if the air flows inside and outside the core portion 20, the temperature rise of the molding member 1 can be suppressed, and the temperature rises. The deformation of the molded member 1 due to the above can be further suppressed. This is because the molded member 1 is air-cooled by the air flowing inside and outside the cylindrical core portion 20. In this case, when the molding member 1 is assembled so that the core portion 20 extends in the vertical direction, the amount of air flowing through the inside and outside of the core portion 20 can be increased by the chimney effect, so that the temperature rise of the molding member 1 is further increased. Can be suppressed.

  By the way, the end of the molded member may be covered with another member (so-called end cap). When the end cap 500 is assembled to the conventional molded member 100 having the plate-shaped core portion 102, the end cap 500 is adhered to the end of the molded member 100 with an adhesive 600 as shown in FIG. It was necessary to cover the end of the molded member 100 with a cap-shaped end cap 500 as shown in FIG. As shown in FIG. 16, when the end cap 500 is bonded to the end portion of the molding member 100, there is a problem that the end cap 500 is easily peeled off from the end portion of the molding member 100. In addition, when the cap-shaped end cap 500 is placed on the end of the molded member 100 as shown in FIG. 17, the portion of the molded member 100 that is covered with the end cap 500 becomes larger. There was a problem that the property was impaired. Further, in this case, there is a problem in that the design of the molded member 100 is impaired by the step L being generated between the outer peripheral surface of the end cap 500 and the outer peripheral surface of the molded member 100. Further, if the thickness of the end cap 500 is reduced in order to reduce this step, there is a problem that the strength of the end cap 500 is lowered.

  According to the molded member 1 of Examples 1 to 6, the core 20 has a cylindrical shape, so that the end cap 5 can be easily and firmly assembled to the molded member 1. That is, as shown in FIG. 10, a protrusion 51 having a shape corresponding to the internal shape of the core portion 20 is provided on the end cap 5 assembled to the molded member 1 of Examples 1 to 6, and the protrusion 51 is connected to the core portion 20. The end cap 5 can be easily assembled to the molded member 1. Further, if the protruding portion 51 of the end cap 5 is fixed to the core portion 20 with a fixing screw 41 or the like, the end cap 5 can be more stably assembled to the molded member 1.

FIG. 3 is a partially cutaway perspective view schematically showing a molded member of Example 1. It is sectional drawing which represents typically a mode that the shaping | molding members of Example 1 are assembled | attached. FIG. 6 is a perspective view schematically showing a molded member of Example 2. It is a principal part expansion perspective view which represents a mode that the shaping | molding members of Example 3 are assembled | attached typically. FIG. 6 is an enlarged perspective view of a main part schematically showing a molded member of Example 4. FIG. 10 is an enlarged perspective view of a main part schematically showing a molded member of Example 5. It is a principal part expansion perspective view which represents typically the other example of the shaping | molding member of this invention. 10 is a cross-sectional view schematically showing a core part in a molded member of Example 6. FIG. It is sectional drawing which represents typically the other example of the core part in the shaping | molding member of this invention. It is explanatory drawing which represents a mode that the end cap is assembled | attached to the shaping | molding member of this invention typically. It is explanatory drawing which represents a mode that the conventional shaping | molding member is assembled | attached to the other party material typically. It is explanatory drawing which represents a mode that the conventional shaping | molding member is assembled | attached to the other party material typically. It is explanatory drawing which represents a mode that the conventional shaping | molding member is assembled | attached to the other party material typically. It is explanatory drawing which represents a mode that the conventional shaping | molding member is assembled | attached to the other party material typically. It is explanatory drawing which represents a mode that the conventional shaping | molding member is assembled | attached to the other party material typically. It is explanatory drawing which represents a mode that the end cap is assembled | attached to the conventional shaping | molding member typically. It is explanatory drawing which represents a mode that the end cap is assembled | attached to the conventional shaping | molding member typically.

Explanation of symbols

1, 1a, 1b: Molding member 10: Design part 20, 20a, 20b: Core part

Claims (5)

Having a design part made of a resin material and a core part embedded in the design part,
The core portion has a cylindrical shape,
The strength of the core is greater than the strength of the design portion,
The linear expansion coefficient of the core part is smaller than the linear expansion coefficient of the design part,
The molded part, wherein the design part and the core part are integrally molded.   The molded part according to claim 1, wherein the design portion is made of a foamed resin material.   The molded member according to claim 1, wherein the core portion is made of a metal material.   The molded member according to claim 1, wherein the core portion is made of a fiber reinforced resin material. 5. The molded member according to claim 1, wherein the core has a linear expansion coefficient of 25 × 10 ⁻⁶ / ° C. or less.

Images