JP2009262529A - Panel device and manufacturing process of the panel device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To raise the rigidity of a panel by strongly bonding a foamed material in the panel body to an inner surface of the panel body, in a panel made by introducing the foaming material into a hollow panel body made of a resin and foaming the material in the panel body. <P>SOLUTION: The panel 1 comprises a hollow panel body 2 of a resin, a nonwoven fabric 3 bonded to an inner surface of the panel body 2 and a foamed resin material 4 filled in the panel body 2. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a panel having a resin-made panel main body having a hollow interior, a resin foam filled in the panel main body, and a method for manufacturing the panel.

  For example, a panel of the above type that is widely used as a flooring material laid in an automobile luggage compartment, an interior material installed in a vehicle interior, an interior material for a building, or a partition wall has been known (patents). Reference 1). The panel body of such a panel is filled with foam, and the foam is welded to the inner surface of the panel body to increase the rigidity of the entire panel, so this panel can be used for many purposes. Can do.

  When manufacturing a panel body made of a resin having a hollow inside, the above-described panel is loaded with a molded foam in the panel body, and the foam is heated by the heat of the panel body to the inner surface of the panel body. It is manufactured by welding. Such a panel body is made of, for example, polypropylene, and as the foam, a material compatible with the panel body, for example, a foam of polypropylene resin is used. However, the end material is generated at the time of molding such a foam, and this disadvantageously increases the cost of the panel.

  Therefore, as a method of manufacturing a panel at a lower cost, there is a method of manufacturing a panel by injecting a liquid foaming raw material into a resin-made panel body having a hollow inside and foaming the foaming raw material in the panel main body. Conceivable.

  However, even when a panel is manufactured by such a method, depending on the foaming raw material and the material of the panel main body, the inner surface of the panel main body and the foam cannot be firmly bonded, and the finished panel has sufficient rigidity. There is a risk that it will not be able to be increased. For example, when using a panel body made of polypropylene or polyethylene and injecting a foaming raw material into the panel body and filling the panel body with polyurethane foam, the polyurethane foam in the panel body is replaced by a panel. It cannot be firmly bonded to the inner surface of the main body. When a large external force is applied to such a panel, a gap is formed between the inner surface of the panel body and the foam, so that the rigidity of the panel should be considered when the foam is filled in the panel body. It cannot be increased.

  Therefore, conventionally, when using a foam and a panel main body having poor adhesion as described above, before injecting the foaming raw material into the panel main body, the tip of the nozzle is inserted into the panel main body, The primer was sprayed from the nozzle, the primer was applied to the inner surface of the panel body, the adhesion of the surface was improved, and then the foaming raw material was injected into the panel body to foam it. . If it does in this way, the foam in a panel main body can be firmly joined to the inner surface of a panel main body via a primer, and the rigidity of a panel can be improved.

  However, when a primer is applied to the inner surface of the panel main body, a lot of time is required to dry the primer, so that the manufacturing process of the panel becomes complicated and the cost of the panel increases.

JP 2006-334801 A

  An object of the present invention is to provide a panel of the type described at the beginning, which eliminates the above-mentioned conventional drawbacks, and a method for manufacturing the panel.

  The present invention relates to a resin-made panel body having a hollow interior, at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat bonded to the inner surface of the panel body, and the inside of the panel body. A panel comprising a resin foam filled in the container is proposed.

  Similarly, the present invention relates to a resin-made panel body in which at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is bonded to the inner surface, and the inside is formed hollow, A panel comprising a foam formed by foaming a foaming raw material injected into is proposed.

  In that case, it is advantageous that the panel body is made of at least a panel body substrate obtained by extrusion molding, which is formed by blow molding.

  Further, the present invention provides a foam raw material in a resin panel body in which at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is bonded to the inner surface, and the inside is formed hollow. A method is proposed in which the foaming raw material is injected into the panel body and the panel body is filled with a resin foam.

  According to the present invention, since at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is joined to the inner surface of the panel body, the foam filled in the panel body is a nonwoven fabric, a woven fabric. By the anchor effect of at least one of the cloth, the glass fiber mat, and the aramid fiber mat, the panel is firmly bonded to the inner surface of the panel body, thereby sufficiently increasing the rigidity of the panel.

  Embodiments of the present invention will be described below in detail with reference to the drawings.

  1 is an external perspective view of the panel 1, and FIG. 2 is a cross-sectional view taken along the line II-II of FIG. As shown in these drawings, the panel 1 of this example includes a resin-made panel main body 2 having a hollow inside, a non-woven fabric 3 bonded to the entire inner surface of the panel main body 2, and the panel main body 2 It has a resin foam 4 filled inside. As will be described in detail later, the foam 4 is obtained by foaming a foaming raw material injected into the panel body 2.

  The panel body 2 is made of polyolefin such as polypropylene or polyethylene, or polylactic acid or other relatively hard resin, and the foam 4 is made of polyurethane foam, for example. Since polyurethane is less expensive than other resins, the use of a polyurethane foam as the foam 4 can reduce the cost of the panel 1. However, as described above, when a panel body and foam of such a material are used, the foam in the panel body does not firmly join the inner surface of the panel body, thereby increasing the rigidity of the panel as desired. There is a risk that it will not be possible.

  However, since the nonwoven fabric 3 is bonded to the inner surface of the panel body of the panel 1 of this example, the foam 4 is firmly bonded to the nonwoven fabric 3 due to the anchor effect of the nonwoven fabric 3, and as a result, the foam 4 is It is firmly fixed to the panel body 2. For this reason, even when a large external force is applied to the panel 1, there is no gap between the inner surface of the panel body 2 and the foam 4, and the rigidity of the panel 1 is effectively increased. Can do. Moreover, in order to firmly bond the foam 4 to the inner surface of the panel body 2, it is not necessary to apply a primer to the inner surface of the panel body 2, and therefore a step of drying the primer when manufacturing the panel 1 is unnecessary. For this reason, the manufacturing process of the panel 1 can be simplified and the cost of the panel 1 can be reduced.

  In the panel 1 shown in FIG. 2, the nonwoven fabric 3 is bonded to the inner surface of the panel body 2. However, even if a woven fabric, a glass fiber mat, or an aramid fiber mat is bonded to the entire inner surface of the panel body 2, The same effects as described above can be achieved. Moreover, when the glass fiber mat is joined to the inner surface of the panel body 2, the rigidity of the panel is joined. When the aramid fiber mat is joined to the inner surface of the panel body 2, the impact strength of the panel 1 is joined. It can be higher than the case. Two or more of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat can be bonded to the inner surface of the panel body 2. Thus, at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is joined to the inner surface of the panel body 2.

  As described above, by joining at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat to the inner surface of the panel body 2, the panel body 2 made of polyolefin or polylactic acid which is not inherently adhesive. And the polyurethane foam 4 filled in the inside can be used. However, when the panel body 2 made of polyolefin or polylactic acid is used, an advantage that it can be recycled or incinerated can be obtained.

  Next, a specific example of the manufacturing method of the panel 1 in which the resin foam 4 is filled in the panel main body 2 as shown in FIG. 2 will be clarified. In this case, the case where the nonwoven fabric 3 is bonded to the inner surface of the panel body 2 will be described here, but the same applies to the case where a woven fabric, a glass fiber mat or an aramid fiber mat is bonded to the inner surface of the panel body 2. 1 can be manufactured.

  FIG. 3 is a cross-sectional view showing an example of a method of filling the foam body 4 in the panel body 2 as shown in FIG. First, as shown in FIG. 3A, a resin panel body 2 is prepared in which a nonwoven fabric 3 is bonded to the inner surface and the inside is formed hollow. As described above, the panel body 2 is made of a relatively high rigidity resin made of, for example, polypropylene or polyethylene.

Next, as shown in FIG. 3B, the tip of the nozzle 5 is inserted into the hole formed in the panel body 2, and the liquid foaming raw material is injected into the panel body 2 from the tip of the nozzle 5. The foaming raw material is foamed in the panel main body 2, and the panel main body 2 is filled with, for example, polyurethane foam. Chemical reaction type polyurethane foaming by mixing two liquids is performed. At this time, due to the anchor effect of the nonwoven fabric 3, the foam in the panel body is firmly bonded to the inner surface of the panel body 2 via the nonwoven fabric 3. After injecting the foaming raw material into the panel main body 2, the nozzle 5 is extracted, and the hole into which the nozzle 5 is inserted is closed with a softened resin as necessary.

  As described above, at least one of nonwoven fabric, woven fabric, glass fiber mat, and aramid fiber mat is bonded to the inner surface, and the foaming raw material is placed in the resin panel body in which the inside is formed hollow. By injecting, the foaming raw material is foamed in the panel body, and a panel in which a resin foam is filled in the panel body can be manufactured. At least one of nonwoven fabric, woven fabric, glass fiber mat, and aramid fiber mat is bonded to the inner surface, and the resin-made panel main body is formed hollow, and the foaming body injected into the panel main body A panel comprising a foam formed by foaming the raw material is obtained.

  4 and 5 are cross-sectional views showing an example of a method for manufacturing the panel body 2 in which the nonwoven fabric 3 is bonded to the inner surface, as shown in FIG.

  First, a thermoplastic resin is extruded by an extruder (not shown) to produce a sheet-like first panel body substrate 2A shown in FIG. At that time, the nonwoven fabric 3A is joined to one surface of the first panel body base material 2A extruded from the extruder. At this time, the anchor effect of the heated first panel body base material 2A and the nonwoven fabric 3A is obtained. Thus, the two can be firmly joined. It is also possible to join the non-woven fabric 3A to one surface of the first panel body base 2A with an adhesive.

  The first panel main body 2A thus manufactured is placed on the first mold 12 as shown in FIG. 4A in a state where the first panel main body 2A is heated and softened. At this time, the non-woven fabric 3A firmly bonded to the first panel main body 2A faces the opposite side to the first mold 12 so that the first panel main body 2A is first molded. Place on mold 12.

  In the first mold 12 shown here, a hollow chamber 14 is defined in the inside thereof, and a plurality of suction holes 16 are formed in the wall portion constituting the molding surface 15, and through the suction holes 16, The hollow chamber 14 communicates with the outside. After placing the first panel body base material 2A on the first mold 12, the air in the hollow chamber 14 is sucked through the exhaust port 17 formed in the first mold 12, The air in the hollow chamber is exhausted to the outside. Thus, the first panel main body 2A is molded into a shape along the molding surface 15 of the first molding die 12, as shown in FIG. The first panel body base 2A is vacuum formed.

  Next, as shown in FIG. 5A, between the first mold 12 and the second mold 18 positioned thereabove, a sheet made of a thermoplastic resin softened by heating. The 2nd panel main body base material 2B of this is arrange | positioned. The second panel main body 2B is manufactured in exactly the same manner as the first panel main body 2A, and the nonwoven fabric 3B is firmly bonded to one surface thereof. The second panel body substrate 2B is disposed between the first mold 12 and the second mold 18 so that the nonwoven fabric 3B faces the first mold 12.

  The second molding die 18 also has a hollow chamber 20 defined therein, and a plurality of suction holes 22 are formed in a wall portion constituting the molding surface 21, and the hollow chamber 20 is formed via the suction holes 22. And the outside communicates. The second mold 18 is lowered as shown in FIG. 5B, the molds 12 and 18 are clamped, and the edge portions of the first and second panel body bases 2A and 2B. Are joined together.

  In this way, immediately after the first and second molds 12 and 18 are clamped, the tip of the blow pin 24 made of a hollow thin tube is placed between the first and second panel body bases 2A and 2B. The air is inserted into the space, and air is pumped through the blow pin 24 to the space between the first and second panel body base materials 2A and 2B. In this way, air is pumped into the space between the first and second panel body bases 2A and 2B, and at the same time, through the exhaust port 23 formed in the second mold 18, the second mold 18 The air in the hollow chamber 20 is sucked and the air is discharged to the outside. Even when the air in the hollow chamber 20 of the second mold 18 is sucked and the air is pumped between the first and second panel body base materials 2A and 2B, the first mold 12 The air in the hollow chamber 14 is continuously sucked. In this way, the first and second panel body base materials 2A and 2B are in close contact with the molding surface 15 of the first molding die 12 and the molding surface 21 of the second molding die 18, respectively. 2nd panel main body base materials 2A and 2B are shape | molded by the shape along the molding surfaces 15 and 21 of the 1st and 2nd shaping | molding die 12 and 18. FIG.

  Next, after the blow pin 24 is extracted from the first panel body base 2A, the first and second molds 12 and 18 are separated from each other, and the molded product is removed from the mold. Subsequently, if the edge of the molded product is trimmed, the panel body 2 constituted by the first and second panel body base materials 2A and 2B is completed, and the first and second panel body bases are formed on the inner surface thereof. A nonwoven fabric 3 made of nonwoven fabrics 3A and 3B joined to the surfaces of the materials 2A and 2B is joined. Thus, the panel main body 2 shown in FIG. 3A is completed, and the panel 1 can be manufactured by filling the foamed body 4 therein as described above. The hole of the 2nd panel main body base material 2A with which the blow pin 24 was fitted may close this, and the above-mentioned nozzle 5 can also be inserted in this hole.

  Moreover, the panel main body 2 can also be manufactured as follows.

  As shown in FIG. 6 (a), the sheet-like first and second panel body base materials 2A and 2B are overlapped to heat and soften them. The materials 2A and 2B are placed so that the nonwoven fabrics 3A and 3B face each other between the first and second molds 12 and 18 configured in the same manner as the molds shown in FIGS. Deploy. Next, as shown in FIG. 6 (b), the second mold 18 is lowered and the molds 12 and 18 are clamped to join the edges of these base materials 2A and 2B to each other.

  As described above, immediately after the first and second molds 12 and 18 are clamped, the tip of the blow pin 24 is inserted between the first and second panel body bases 2A and 2B, and the blow pin 24 is inserted. Then, air is pumped between the first and second panel body base materials 2A and 2B. At the same time, the air in the hollow chambers 14 and 20 is discharged to the outside through the exhaust ports 17 and 23 formed in the first and second molds 12 and 18. At this time, since a large number of suction holes 16 and 22 are also formed in the wall portions forming the molding surfaces 15 and 21 of the first and second molding dies 12 and 18, the first and second panel bodies are formed. As shown in FIG. 6C, the base materials 2A and 2B are vacuum-formed by the first and second forming dies 12 and 18 and simultaneously blow-molded. After that, exactly as in the method shown in FIGS. 4 and 5, the first and second molds 12 and 18 are separated and the molded product is taken out of the mold. In this way, the panel body 2 shown in FIG. 3A can be manufactured.

  According to the method shown in FIG. 6, since the first and second panel body base materials 2A and 2B are blow-molded simultaneously with the vacuum forming, the first and second panel body base materials 2A and 2B can be more accurately formed. The first and second molding dies 12 and 18 can be brought into close contact with the molding surfaces 15 and 21. Further, since the first and second panel body base materials 2A and 2B are overlapped with each other and the panel body base materials 2A and 2B are heated, the panel body base materials 2A and 2B are heated separately. Compared with the case where it does, a manufacturing man-hour can be reduced. At this time, even if the first and second panel body base materials 2A and 2B are superposed and heated, the nonwoven fabrics 3A and 3B exist between the base materials 2A and 2B. The panel body base materials 2A and 2B are not joined by the action of heat.

  The second mold 18 shown in FIG. 6 has a trim blade 25 protruding around the molding surface 15 and when the first and second molds 12 and 18 are clamped, The trim blade 25 is configured to trim the edge portions of the first and second panel body base materials 2A and 2B. The mold shown in FIGS. 4 and 5 can be configured in the same manner.

  Also, as shown in FIG. 6B, when the tip of the blow pin 24 is inserted between the first and second panel body base materials 2A and 2B, the blow pin 24 is softened to the first panel base material. 2A can be broken through, but the nonwoven fabric 3A bonded to the substrate 2A may not be broken through. Also in such a case, since the nonwoven fabrics 3A and 3B have air permeability, air can be pumped between the first and second panel body base materials 2A and 2B without any trouble. This is the same when the method shown in FIGS. 4 and 5 is performed.

  FIGS. 4 to 6 show an example in which the panel body 2 is manufactured by vacuum molding and blow molding, and the panel body 2 is manufactured only by blow molding. It can also be manufactured. Air is pumped between the extrusion-molded first and second panel body bases, and the first and second panel body bases are formed along the molding surfaces of the first and second molding dies, respectively. It is molded into a different shape. As described above, the panel body 2 is formed by molding the first and second panel body base materials 2A and 2B obtained by extrusion molding at least by a blow molding method.

  Moreover, the panel main body 2 can also be manufactured by the injection molding method instead of manufacturing the panel main body 2 with a nonwoven fabric by using a vacuum forming method and a blow molding method together. In this case, first, as shown in FIG. 7A, the non-woven fabric 3C is set on the molding surface of the first mold 30 and then, as shown in FIG. 7B, the first mold 30 and the second mold 31 are clamped, and a molten thermoplastic resin is injected into the cavity 32. As a result, the first panel body base material 2C shown in FIG. 7C is molded, and the nonwoven fabric 3C is firmly bonded to one surface thereof.

  In exactly the same manner as described above, as shown in FIG. 8A, a second panel body base material 2D in which the nonwoven fabric 3D is firmly bonded to one surface is molded. Next, as shown in FIG. 8B, if the first and second panel body base materials 2C and 2D are aligned and the butted portion 33 is welded, the first and second panel body base materials 2C are obtained. , 2D panel body 2 is completed. A nonwoven fabric 3 made of nonwoven fabrics 3C and 3D is firmly bonded to the inner surface. By filling the inside of the panel body 2 with the foam as described above, the panel 1 shown in FIG. 2 is completed.

  As mentioned above, although the manufacture example of the panel main body formed by joining a nonwoven fabric to an inner surface was shown, the panel main body formed by joining a woven fabric, a glass fiber mat, or an aramid fiber mat to the inner surface can be manufactured in the same manner as described above. Is as described above.

It is an external appearance perspective view of a panel. It is II-II sectional drawing of FIG. It is sectional drawing which shows a mode when inject | pouring the raw material for foaming into a panel main body. It is sectional drawing which shows the method of manufacturing a panel main body. It is sectional drawing which shows the method of manufacturing a panel main body. It is sectional drawing which shows the other method of manufacturing a panel main body. It is sectional drawing which shows the further another method of manufacturing a panel main body. It is sectional drawing which shows the further another method of manufacturing a panel main body.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Panel 2 Panel main body 2A, 2B Panel main body base material 3 Nonwoven fabric 4 Foam

Claims (4)

A panel body made of resin having a hollow interior, at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat bonded to the inner surface of the panel body, and the panel body filled A panel comprising a resin foam. At least one of nonwoven fabric, woven fabric, glass fiber mat, and aramid fiber mat is bonded to the inner surface, and the resin-made panel main body is formed hollow, and the foaming body injected into the panel main body A panel comprising a foam formed by foaming a raw material. The panel according to claim 1, wherein the panel body is formed by molding a panel body base material obtained by extrusion molding at least by a blow molding method. A foaming raw material is injected into a resin-made panel body in which at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is bonded to the inner surface, and the inside is formed hollow. A method for producing a panel in which the foaming raw material is foamed and the panel body is filled with a resin foam.

Images