JP2009269219A - Laminated resin molded product and its method for manufacturing - Google Patents
Laminated resin molded product and its method for manufacturing Download PDFInfo
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- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Abstract
Description
本発明は、特に剛性及び軽量性に優れた樹脂製ボード等の積層樹脂成形品及びその製造方法に関するものである。 The present invention relates to a laminated resin molded article such as a resin board having particularly excellent rigidity and light weight, and a method for producing the same.
本発明に係る積層樹脂成形品は、例えば、カーゴフロアボード(自動車荷室の蓋パネルまたはラゲージボード)、リアパーセルシェルフなどの自動車用内装品又は内装壁パーティションなどに用いられるものである。 The laminated resin molded product according to the present invention is used for, for example, an interior product for an automobile such as a cargo floor board (a cover panel or a luggage board of an automobile luggage compartment), a rear parcel shelf, or an interior wall partition.
この種の樹脂製ボードの剛性を向上するには、ボードの構成材料を改善するか、またはボードの形状を改善することにより行われる。そして、ボードの構成材料の改善策は次の(1)ないし(4)の通りであり、ボードの形状を改善する策は(5)及び(6)の通りである。
(1)機械的強度の優れた樹脂を使用する。
(2)機械的強度を向上させるため樹脂に充填材を配合する。
(3)金属パイプ等の棒状リンフォース部材をボードに取り付ける。
(4)プラスチック板等の面上リンフォース部材をボードに取り付ける。
(5)補強リブを設ける。
(6)剛性に優れた断面形状とする。
In order to improve the rigidity of this kind of resin board, it is performed by improving the constituent material of the board or improving the shape of the board. The measures for improving the material constituting the board are as follows (1) to (4), and the measures for improving the shape of the board are as follows (5) and (6).
(1) Use a resin with excellent mechanical strength.
(2) In order to improve mechanical strength, a filler is blended in the resin.
(3) A rod-like reinforcement member such as a metal pipe is attached to the board.
(4) A surface reinforcement member such as a plastic plate is attached to the board.
(5) Provide reinforcing ribs.
(6) The cross-sectional shape is excellent in rigidity.
強度に優れた樹脂組成物を使用して樹脂製ボードを構成するものとして、樹脂にフィラーを混入することが知られており、特表2001−514589公報は「ブロー成形パレット」を、特開平11−348104号公報は「フィルムインサートブロー」をそれぞれ紹介している。また、強度性に優れた補強材を樹脂製ボードの構成部材として、補強材として補強のための金属パイプをインサートした梁構成によるもの、あるいは補強材として表皮層または芯層によるものが知られており、特開2003−266526公報は「ブロー成形ダクト」を、特公平6−74072号公報は「自転車フレーム」を、特表2001−524898公報は「ブロー成形中空体」を、特許第3408627号公報は「表皮貼り時に水で湿潤する方法」を、特開平7−223255号公報は「ゴルフシャフト等」を、特公平5−213号公報は「ブロー成形タンク」をそれぞれ紹介している。 It is known that a resin board is formed using a resin composition having excellent strength, and a filler is mixed into the resin. Japanese Patent Laid-Open Publication No. 2001-514589 discloses “Blow Molding Pallet”. No.-348104 introduces “film insert blow”. In addition, it is known that a reinforcing material with excellent strength is used as a structural member of a resin board, a reinforcing material with a beam structure in which a metal pipe for reinforcement is inserted, or a reinforcing material with a skin layer or a core layer. JP-A-2003-266526 discloses a “blow-molded duct”, JP-B-6-74072 discloses a “bicycle frame”, JP-T-2001-524898 discloses “Blow-molded hollow body”, and Japanese Patent No. 3408627. Describes a “method of moistening with water when the skin is applied”, Japanese Patent Application Laid-Open No. 7-223255 discloses “Golf Shaft”, and Japanese Patent Publication No. 5-213 introduces “Blow Molded Tank”.
一方、特開2006−103027公報においては、中空凸状部を有する中間シートの両面を表面側シートと裏面側シートとで挟持するように積層した積層シートを紹介している。
前掲の背景技術(1)のように機械的強度の優れた樹脂を使用したり、背景技術(2)のように機械的強度を向上させるため樹脂に充填材を配合する技術では、樹脂成形品の成形性に制約あるうえ材料自体が高価であり、期待するほどの剛性改善の効果が得られない。また、前掲の背景技術(3)のように金属パイプ等の棒状リンフォース部材をボードに取り付けたり、背景技術(4)のようにプラスチック板等の面上リンフォース部材をボードに取り付ける技術では、リンフォース自体の重量のため軽量化が困難であり、取り付けのための手段も煩雑である。さらに、背景技術(5)のように補強リブを設けたり、背景技術(6)のように剛性に優れた断面形状とする技術では、使用空間が限定されたり成形性の維持等のうえで形状に制約がある等の問題点がある。 As in the background art (1), a resin having an excellent mechanical strength is used, or in the technique of adding a filler to the resin to improve the mechanical strength as in the background technique (2), a resin molded product is used. The moldability is limited and the material itself is expensive, and the effect of improving the rigidity as expected cannot be obtained. Further, in the technology of attaching a rod-like reinforcement member such as a metal pipe to the board as in the background technology (3) described above, or attaching a surface reinforcement member such as a plastic plate to the board as in the background technology (4), It is difficult to reduce the weight due to the weight of the reinforcement itself, and the means for mounting is also complicated. Furthermore, with the technology of providing reinforcing ribs as in the background art (5) or the cross-sectional shape with excellent rigidity as in the background art (6), the shape of the space is limited and the formability is maintained. There are problems such as restrictions.
カーゴフロアボード(自動車荷室の蓋パネルまたはラゲージボード)、リアパーセルシェルフなどの自動車用内装品または内装壁パーティションなどに用いられる樹脂成形品は、優れた撓み強度を要求されるので、撓み強度向上のため金属パイプ等のリンフォースをボード裏面に嵌め込んでいるが、撓み強度向上の反面、軽量性は失われる。このため、リンフォースを使用することなく、剛性と軽量性を共に満足させたいとの強い要望があり、そのためにそれ自体では撓み強度を向上しなくとも、組み合わせにより撓み強度の向上を実現できないかが課題となるが、それに用いようとするポリエステル繊維・ガラス繊維・炭素繊維は、それ自体では撓み強度を有しないので、ボードの上面に荷重が掛かった際、繊維が伸びることや繊維がずれることは好ましくなく、これらの材料を樹脂成形品に対してしっかり固定しなくてはならないことになる。 Resin molded products used in interior parts for automobiles such as cargo floor boards (car compartment lid panels or luggage boards), rear parcel shelves, and interior wall partitions are required to have superior flexural strength. Therefore, reinforcements such as metal pipes are fitted on the back side of the board, but the lightness is lost while the bending strength is improved. For this reason, there is a strong demand for satisfying both rigidity and light weight without using reinforcement. Therefore, even if it does not improve the bending strength by itself, can it improve the bending strength by combination? However, the polyester fiber, glass fiber, and carbon fiber to be used for it do not have bending strength by themselves, so that when the load is applied to the upper surface of the board, the fiber stretches or the fiber shifts. Is not preferable, and these materials must be firmly fixed to the resin molded product.
ところで、カーゴフロアボード(自動車荷室の蓋パネルまたはラゲージボード)、リアパーセルシェルフなどの自動車用内装品または内装壁パーティションなどに用いられる樹脂成形品で、樹脂芯材の表面を樹脂外皮で覆い、かつ樹脂芯材に樹脂外皮を溶着して一体化する積層樹脂成形品にあっては、それを成型金型を用いて成形する工程において、金型を型締めをした際に外皮となる樹脂シートの金型のキャビティに接した部分の温度が急速に低下する現象によって他の部分に比して樹脂の収縮が早く進行することに起因して、積層樹脂成形品に引きつれのような形状歪みが生じて、成形精度が低下したり成形不良をきたすことの多いことが問題となっている。 By the way, it is a resin molded product used for interior parts for automobiles such as cargo floor boards (car lid panels or luggage boards) and rear parcel shelves or interior wall partitions. In addition, in the case of a laminated resin molded product in which a resin outer shell is welded and integrated with a resin core material, the resin sheet that becomes the outer shell when the mold is clamped in the process of molding it using the molding die Due to the phenomenon in which the temperature of the part in contact with the cavity of the mold rapidly decreases, the resin shrinks faster than other parts, resulting in shape distortions like pulling on the laminated resin molded product Has been a problem that molding accuracy is often lowered and defective molding occurs.
そこで本発明は、成形金型を型締めして定形の樹脂芯材に対し外皮となる樹脂シート及び断熱性シートを溶着させ積層構造とする過程で、外皮となる樹脂シートと成形金型のキャビティ間に断熱層を形成することにより、積層樹脂成形品に引きつれのような形状歪みが生じないようにして、特に成形精度が高く、剛性及び軽量性に優れた積層樹脂成形品を得ることができるようにするものである。 Accordingly, the present invention provides a resin sheet as an outer shell and a cavity of the molding die in the process of sealing the molding die and welding the outer resin sheet and the heat insulating sheet to the fixed resin core material to form a laminated structure. By forming a heat insulating layer between them, it is possible to obtain a laminated resin molded product that has particularly high molding accuracy, rigidity, and lightness so that the laminated resin molded product does not undergo shape distortion such as pulling. It is something that can be done.
この目的を達成する本発明に係る積層樹脂成形品は、樹脂芯材の表面を樹脂外皮で覆い、かつ樹脂芯材に樹脂外皮を溶着して一体化した積層樹脂成形品であって、芯材となる樹脂を成形した定形の樹脂芯材と、前記定形の樹脂芯材を挟んで対向させた樹脂外皮と、前記外皮の少なくとも一方の面に対向させた断熱性シートとを、成形金型により押圧成形して定形の樹脂芯材、樹脂外皮及び断熱層の積層構造としたことを特徴とするものである。 A laminated resin molded product according to the present invention that achieves this object is a laminated resin molded product in which the surface of a resin core material is covered with a resin outer shell, and the resin outer shell is welded to the resin core material and integrated. A molded resin mold, a fixed resin core material molded with a resin, a resin outer skin facing the sandwiched resin core material, and a heat insulating sheet opposed to at least one surface of the outer skin It is characterized by having a laminated structure of a fixed resin core material, a resin shell and a heat insulating layer by press molding.
また、前記目的を達成する本発明に係る積層樹脂成形品の製造方法は、分割形式の成形金型間に、予め成形した定形の樹脂芯材と、この定形の樹脂芯材を挟んで対向させた外皮となる予備成形体と、この外皮となる予備成形体と金型のキャビティとの間に断熱性シートを介在するように配置し、次いで成形金型を型締めして定形の樹脂芯材に対し外皮となる予備成形体及び断熱性シートを溶着させ積層構造とする過程で、外皮となる予備成形体と成形金型のキャビティ間に断熱層を形成して積層樹脂成形品を成形することを特徴とするものである。なお、ここに予備成形体とは、最終形状の予備段階として加熱可塑化されたシート状又は筒状の成形体である。 Further, the manufacturing method of the laminated resin molded product according to the present invention that achieves the above-described object is such that a predetermined shaped resin core material is sandwiched between the divided molds and the fixed resin core material is sandwiched between them. A pre-molded body that forms a shell, and a heat-insulating sheet is disposed between the preform and the mold cavity, and then the mold is clamped to form a fixed resin core material. In the process of welding the preform and the heat-insulating sheet as the outer layer to form a laminated structure, a heat-insulating layer is formed between the preform as the outer shell and the cavity of the molding die to mold a laminated resin molded product It is characterized by. In addition, a preformed body here is a sheet-like or cylindrical shaped body heat-plasticized as a preliminary stage of the final shape.
本発明において、定形の樹脂芯材は、その成形により厚み方向に補強構造を成していること、多数の微小凹部からなる筒状、多数の空隙からなるハニカム状の補強構造を成していること、及び中空部に対向する壁間にわたるリブを形成してあることが好適である。 In the present invention, the fixed resin core material has a reinforcing structure in the thickness direction by molding, a cylindrical shape composed of a large number of minute recesses, and a honeycomb-shaped reinforcing structure composed of a large number of voids. It is preferable that a rib extending between the walls facing the hollow portion is formed.
本発明において、樹脂芯材は、エチレン、プロピレン、ブテン、イソプレンペンテン、メチルペンテン等のオレフィン類の単独重合体あるいは共重合体であるポリオレフィン(例えば、ポリプロピレン、高密度ポリエチレン)、ポリアミド、ポリスチレン、ポリ塩化ビニル、ポリアクリロニトリル、エチレン−エチルアクリレート共重合体等のアクリル誘導体、ポリカーボネート、エチレン−酢酸ビニル共重合体等の酢酸ビニル共重合体、アイオノマー、エチレン−プロピレン−ジエン類等のターポリマー、ABS樹脂、ポリオレフィンオキサイド、ポリアセタール等の熱可塑性樹脂が挙げられる。なお、これらは一種類を単独で用いても、二種類以上を混合して用いてもよい。特に、熱可塑性樹脂のなかでもでオレフィン系樹脂またはオレフィン系樹脂を主体にした樹脂、ポリプロピレン系樹脂またはポリプロピレン系樹脂を主体にした樹脂が、繊維層との溶着性、機械的強度および成形性のバランスに優れている点で好ましい。樹脂芯材は、添加剤が含まれていてもよく、その添加剤としては、シリカ、マイカ、タルク、炭酸カルシウム、ガラス繊維、カーボン繊維等の無機フィラー、可塑剤、安定剤、着色剤、帯電防止剤、難燃剤、発泡剤等が挙げられる。 In the present invention, the resin core material is a polyolefin (for example, polypropylene, high-density polyethylene), polyamide, polystyrene, poly olefin which is a homopolymer or copolymer of olefins such as ethylene, propylene, butene, isoprene pentene, and methyl pentene. Acrylic derivatives such as vinyl chloride, polyacrylonitrile, ethylene-ethyl acrylate copolymer, polycarbonate, vinyl acetate copolymers such as ethylene-vinyl acetate copolymer, terpolymers such as ionomer, ethylene-propylene-dienes, ABS resin And thermoplastic resins such as polyolefin oxide and polyacetal. In addition, these may be used individually by 1 type, or may mix and use 2 or more types. In particular, among the thermoplastic resins, olefin resins or resins mainly composed of olefin resins, polypropylene resins or resins mainly composed of polypropylene resins have good weldability to the fiber layer, mechanical strength and moldability. It is preferable in terms of excellent balance. The resin core material may contain an additive. Examples of the additive include silica, mica, talc, calcium carbonate, glass fiber, carbon fiber, and other inorganic fillers, plasticizers, stabilizers, colorants, and charging agents. An inhibitor, a flame retardant, a foaming agent, etc. are mentioned.
本発明において、樹脂外皮は、ポリプロピレン、エンジニアリングプラスチックス、オレフィン系樹脂などから形成されたシートからなる。 In the present invention, the resin skin is made of a sheet formed of polypropylene, engineering plastics, olefin resin, or the like.
本発明において、断熱層を形成する断熱性シートは、外観性向上、装飾性、成形品と接触する物(例えば、カーゴフロアボードの場合、ボード上面に載置される荷物など)の保護を目的として構成されるものである。表皮層の材質は、繊維表皮材、シート状表皮材、フィルム状表皮材等が適用される。かかる繊維表皮材の素材としては、ポリエステル、ポリプロピレン、ポリアミド、ポリウレタン、アクリル、ビニロン等の合成繊維、アセテート、レーヨン等の半合成繊維、ビスコースレーヨン、銅アンモニアレーヨン等の再生繊維、綿、麻、羊毛、絹等の天然繊維、又はこれらのブレンド繊維が挙げられる。これらの中でも、触感、耐久性及び成形性の観点から、ポリプロピレン又はポリエステルであることが好ましく、ポリエステルであることがより好ましい。繊維表皮材30に用いられる糸は、例えば、ポリエステル:(3〜5)デニール×(50〜100)mm等の繊度が3〜15デニール、繊維長さが2〜5インチ程度のステープルの紡績糸と、細い柔軟なフィラメントを束にしたポリエステル:約5デニール×(約30〜200本)=約150〜1000デニール/1等のマルチフィラメント、又は、ポリエステル:400〜800デニール/1等の太いモノ・フィラメントと、を組み合わせて用いることが好ましい。繊維表皮材の組織としては、不織布、織物、編物、それらを起毛した布地等が挙げられる。なお、織物には、織組織が縦糸、横糸が順次上下に交絡する平組織のほか、何本かの糸を跳び越して交絡する種々の変化織も含まれる。これらの中でも、伸びに対する方向性がないため、立体形状に成形し易く、且つ表面の触感、風合いに優れることから、不織布であることが好ましい。ここで、不織布とは、繊維を平行に又は交互させて積上げるか又はランダムに散布してウエブを形成し、次いでウエブとなった繊維を接合してなる布状品を意味する。これらの中でも、成形品の立体形状再現性及び外観特性の観点から、ニードルパンチ法により製造された不織布であることが好ましい。また、ニードルパンチ法にて得られた不織布は、織物に比べて強度が小で伸度が大であり任意方向に対する変形度合いが大きいので、不織布としての強度を向上させると共に寸法の安定化を図るために、不織布にバインダーを付着させる、又は、ウエブと不織布を重ね針でパンチさせておくことがより好ましい。これらのことから、繊維表皮材は、ポリプロピレン不織布又はポリエステル不織布であることがより好ましい。この場合、繊維表皮材自体が熱可塑性であるので、剥離回収後、加熱して変形させることによって、別の用途に用いることも可能である。例えば主体樹脂層をポリプロピレンにて構成し、繊維表皮材をポリプロピレン不織布で構成すると、成形品の主体樹脂層と繊維表皮材とが同じ素材であることから、リサイクルが容易になる。一方、繊維表皮材がポリエステル不織布であると、ポリプロピレンにて構成した主体樹脂層と繊維表皮材との融点が異なるので、成形品に繊維表皮材を接着する際、熱により変質、変形したり、正しい位置に接着できない等の不具合が生じるのを抑制できる。また、この場合、成形性、剛性、外観及び耐久性にも優れる。また、繊維表皮材の引張強度は、立体形状再現性及び成形性の観点から、15kg/cm2以上であることが好ましく、伸度は、30%以上であることが好ましい。なお、かかる引張強度及び伸度の値は、温度20℃においてJIS−K−7113に準拠して測定したものである。シート状表皮材、フィルム状表皮材としては、熱可塑性エラストマ−、エンボス加工された樹脂層、印刷層が外面に付された樹脂層、合成皮革、滑り止め用メッシュ形状の表皮層等が使用できる。 In the present invention, the heat-insulating sheet forming the heat-insulating layer is intended to improve the appearance, to enhance the decorativeness, and to protect an object that comes into contact with the molded product (for example, a cargo floor board, a load placed on the upper surface of the board). It is comprised as. As the material of the skin layer, a fiber skin material, a sheet-like skin material, a film-like skin material, or the like is applied. As the material of such a fiber skin material, synthetic fibers such as polyester, polypropylene, polyamide, polyurethane, acrylic and vinylon, semi-synthetic fibers such as acetate and rayon, regenerated fibers such as viscose rayon and copper ammonia rayon, cotton, hemp, Examples thereof include natural fibers such as wool and silk, or blended fibers thereof. Among these, polypropylene or polyester is preferable and polyester is more preferable from the viewpoints of touch, durability, and moldability. The yarn used for the fiber skin material 30 is, for example, polyester: (3-5) denier x (50-100) mm, etc., a fineness of 3-15 denier, and a staple spun yarn having a fiber length of about 2-5 inches Polyester in a bundle of thin flexible filaments: multifilaments of about 5 denier × (about 30 to 200) = about 150 to 1000 denier / 1, or thick polyester such as polyester: 400 to 800 denier / 1 -It is preferable to use in combination with a filament. Examples of the structure of the fiber skin material include non-woven fabrics, woven fabrics, knitted fabrics, and fabrics obtained by raising them. The woven fabric includes not only a plain structure in which the woven structure is tangled up and down in order, but also various changed woven forms in which some yarns are entangled and jumped. Among these, since there is no directionality with respect to elongation, a non-woven fabric is preferable because it can be easily formed into a three-dimensional shape and has excellent surface feel and texture. Here, the non-woven fabric means a cloth-like product in which fibers are stacked in parallel or alternately or are randomly dispersed to form a web, and then the fibers that become the web are joined. Among these, it is preferable that it is a nonwoven fabric manufactured by the needle punch method from a viewpoint of the three-dimensional shape reproducibility of a molded article, and an external appearance characteristic. In addition, since the nonwoven fabric obtained by the needle punch method has lower strength and higher elongation than the woven fabric and has a large degree of deformation in any direction, it improves the strength of the nonwoven fabric and stabilizes its dimensions. Therefore, it is more preferable that a binder is attached to the nonwoven fabric, or the web and the nonwoven fabric are punched with overlapping needles. For these reasons, the fiber skin material is more preferably a polypropylene nonwoven fabric or a polyester nonwoven fabric. In this case, since the fiber skin material itself is thermoplastic, it can be used for another purpose by being heated and deformed after separation and collection. For example, when the main resin layer is made of polypropylene and the fiber skin material is made of polypropylene nonwoven fabric, the main resin layer and the fiber skin material of the molded product are the same material, which facilitates recycling. On the other hand, if the fiber skin material is a polyester nonwoven fabric, the melting point of the main resin layer composed of polypropylene and the fiber skin material is different, so when the fiber skin material is bonded to the molded product, it is altered or deformed by heat, Generation | occurrence | production of malfunctions, such as being unable to adhere | attach on the correct position, can be suppressed. In this case, the moldability, rigidity, appearance and durability are also excellent. The tensile strength of the fiber skin material is preferably 15 kg / cm 2 or more, and the elongation is preferably 30% or more, from the viewpoint of three-dimensional shape reproducibility and moldability. In addition, the value of this tensile strength and elongation is measured according to JIS-K-7113 at the temperature of 20 degreeC. As the sheet-like skin material and film-like skin material, thermoplastic elastomer, embossed resin layer, resin layer with printed layer attached to the outer surface, synthetic leather, non-slip mesh-shaped skin layer, etc. can be used. .
本発明において積層樹脂成形品とは、カーゴフロアボード、フットレスト、サイドドアトリム、シートバック、リアーパーセルシェルフ、ドアパネル、座席シート等の自動車内装材、機械器具のキャリングケース、弱電製品の部品、壁材、パーティション等の建築用内装材、椅子等の家具、その他にも、タンク、ダスト、ケース、ハウジング、トレイ、コンテナ等の用途に好適に用いられる。例えば、積層樹脂成形品を自動車用カーゴフロアボードに適用する場合、ボードの表壁に繊維表皮材が貼り付けられ、ボードの裏壁は繊維表皮材を貼り付けず、金型にて成形された樹脂面にて構成される。また、ボードの表壁の一部を繊維表皮材にて覆うこともできる。本発明の積層樹脂成形品は、軽量でしかも高剛性を発揮する効果を有するので、上面に何らかの荷重が作用し、耐撓み強度の要求される平面上に設置して使用される、例えばカーゴフロアボード等のボード状の製品に好適である。 In the present invention, the laminated resin molded product is a cargo floor board, a footrest, a side door trim, a seat back, a rear parcel shelf, a door panel, a seat, etc. It is suitably used for building interior materials such as partitions, furniture such as chairs, and other uses such as tanks, dust, cases, housings, trays and containers. For example, when a laminated resin molded product is applied to an automobile cargo floor board, a fiber skin material is pasted on the front wall of the board, and a fiber skin material is not pasted on the back wall of the board. Consists of a resin surface. Moreover, a part of the front wall of the board can be covered with a fiber skin material. Since the laminated resin molded product of the present invention is lightweight and has an effect of exhibiting high rigidity, some load acts on the upper surface, and is used by being installed on a plane that requires flexural strength, for example, cargo floor Suitable for board-like products such as boards.
本発明によれば、成形金型を型締めして定形の樹脂芯材に対し外皮となる樹脂シート及び断熱性シートを溶着させ積層構造とする過程で、外皮となる樹脂シートと成形金型のキャビティ間に断熱層を形成することにより、積層樹脂成形品に引きつれのような形状歪みが生じないようにして、特に成形精度が高く、剛性及び軽量性に優れた積層樹脂成形品を得ることができる。 According to the present invention, in the process of clamping the molding die and welding the resin sheet and the heat insulating sheet as the outer shell to the fixed resin core material to form a laminated structure, the resin sheet and the molding die as the outer shell are formed. By forming a heat insulating layer between the cavities, it is possible to obtain a laminated resin molded product having particularly high molding accuracy and excellent rigidity and light weight so as not to cause a shape distortion such as pulling in the laminated resin molded product. Can do.
図面は本発明に係る積層樹脂成形品としてカーゴフロアボード及びその成形工程について例示している。図1は分割形式の成形金型間に、予め成形された定形の樹脂芯材とその定形の樹脂芯材を挟んで対向させた外皮となる樹脂シートと、その外側と金型のキャビティとの間に断熱性シートを配置した態様を示す断面図、図2は同上成形金型を外皮となる樹脂シートと断熱性シートとが金型のキャビティを塞ぐ位置まで型締めして真空成形した態様を示す断面図、図3は図2の態様から型締めして積層樹脂成形品を成形した態様を示す断面図である。図4は成形された積層樹脂成形品であるカーゴフロアボードの平面図、図5は積層樹脂成形品の要部破断拡大図、図6は図5の破線円部分の詳細斜視図、図7は図5のA−A断面図である。また、図8ないし図11は定形の樹脂芯材のそれぞれ他の形態を示す断面図である。 The drawings illustrate a cargo floor board and a molding process thereof as a laminated resin molded product according to the present invention. FIG. 1 shows a split resin mold having a fixed-shaped resin core material, a resin sheet serving as an outer skin sandwiched between the fixed-shaped resin core materials, and the outside and the mold cavity. FIG. 2 is a cross-sectional view showing an embodiment in which a heat insulating sheet is arranged between them, and FIG. 2 shows a state in which the molding die is vacuum-molded by clamping to a position where the resin sheet and the heat insulating sheet serving as the outer shell block the cavity of the die. FIG. 3 is a cross-sectional view showing a mode in which a laminated resin molded product is molded by clamping from the mode of FIG. 4 is a plan view of a cargo floor board, which is a molded laminated resin molded product, FIG. 5 is an enlarged view of a principal part of the laminated resin molded product, FIG. 6 is a detailed perspective view of a broken-line circle portion of FIG. It is AA sectional drawing of FIG. 8 to 11 are cross-sectional views showing other forms of the regular resin core material.
本発明による積層樹脂成形品の一例であるカーゴフロアボード1は(図4参照)、定形の樹脂芯材2の表面を樹脂外皮3、3で覆い、かつ定形の樹脂芯材2に樹脂外皮3、3を溶着し、樹脂外皮3、3の表面に断熱シート4、4を溶着して積層構造としたものである(図3参照)。
A cargo floor board 1 which is an example of a laminated resin molded product according to the present invention (see FIG. 4), covers the surface of a regular
すなわち、予め成形された定形の樹脂芯材2を分割形式の成形金型5、5間に配置するとともに、前記定形の樹脂芯材2を挟んで対向させた外皮3、3となる樹脂シート6、6を押出ヘッド7より押し出して配置し、さらに樹脂シート6、6と金型のキャビティ7、7との間に断熱シート4、4を配置する(図1参照)。そして、成形金型5、5を型締め方向に、外皮3、3となる樹脂シート6、6及び断熱シート4、4が成形金型5、5のピンチオフ部8、8に接する状態まで型締めして金型のキャビティ9、9に断熱シート4、4及び樹脂シート6、6が吸着されるように真空成形する(図2参照)。次いで、成形金型5、5の型締めを完了させることにより、定形の樹脂芯材2に対し樹脂シート6、6及び断熱シート4、4を押圧成形して定形の樹脂芯材2の表面に樹脂外皮殻3、3及び断熱シート4、4を溶着させて積層構造としたカーゴフロアボード1を成形する(図3、図4参照)。
That is, the
本発明において、定形の樹脂芯材2は、多数の空隙からなるハニカム構造9の補強構造をとしたものが用いられる(図5、図6、図7参照)。そして、ハニカム構造10としたものにおいて、その少なくとも一面に拡開状の突条11を形成してあって、樹脂外皮3、3なる樹脂シート6、6との噛み合い溶着構造として、定形の樹脂芯材2の表面に対する外皮3、3の溶着一体化の強化を図っている。なお、図5及び図6に示す態様では、前記突条11を定形の樹脂芯材2の一面に設けているが、必要に応じてこれを定形の樹脂芯材2の両面に設けてもよい。
In the present invention, the
本発明において、定形の樹脂芯材2は、図5及び図6に示す態様のほか、図8、図9、図10及び図11に示す態様とすることができる。すなわち、図8に示す態様は、定形の樹脂芯材2が中空二重壁構造であって、その対向する両壁に対し垂直方向に起立するハニカム構造10としたものであり、図9に示す態様では、図7に示すものの中空部に樹脂発泡材12を充填してある。また、図10に示す態様では、定形の樹脂芯材2の補強構造としてハニカム状ではなく対向する両壁から点状に凹設してその突端を互いに溶着一体化した、いわゆるツインコーン状13としてある。図11に示す態様は、定形の樹脂芯材2を中空二重壁構造としてその中空部に樹脂発泡材12を充填したものである。なお、本発明において定形の樹脂芯材2は、これらの形態のほかのものであってもよいことは勿論である。
In the present invention, the fixed
1 カーゴフロアボード
2 定形の樹脂芯材
3、3 樹脂外皮
4、4 断熱シート
5、5 成形金型
6、6 樹脂シート
7 押出ヘッド
8、8 ピンチオフ部
9、9 金型のキャビティ
10 ハニカム構造
11 拡開状の突条
12 樹脂発泡材
13 ツインコーン状
DESCRIPTION OF SYMBOLS 1
Claims (5)
芯材となる樹脂を成形した定形の樹脂芯材と、
前記定形の樹脂芯材を挟んで対向させた樹脂外皮と、
前記外皮の少なくとも一方の面に対向させた断熱性シートとを、
成形金型により押圧成形して定形の樹脂芯材、樹脂外皮及び断熱層の積層構造とした
ことを特徴とする積層樹脂成形品。 It is a laminated resin molded product in which the surface of the resin core is covered with a resin outer shell, and the resin outer shell is welded and integrated with the resin core,
A fixed-shaped resin core formed by molding a resin as a core;
A resin outer skin facing the sandwiched resin core material,
A heat insulating sheet opposed to at least one surface of the outer skin,
A laminated resin molded product characterized by being formed into a laminated structure of a fixed resin core material, a resin shell and a heat insulating layer by press molding with a molding die.
分割形式の成形金型間に、予め成形した定形の樹脂芯材と、この定形の樹脂芯材を挟んで対向させた外皮となる予備成形体と、この外皮となる予備成形体と金型のキャビティとの間に断熱性シートを介在するように配置し、
次いで成形金型を型締めして定形の樹脂芯材に対し外皮となる予備成形体及び断熱性シートを溶着させ積層構造とする過程で、外皮となる予備成形体と成形金型のキャビティ間に断熱層を形成して積層樹脂成形品を成形する
ことを特徴とする積層樹脂成形品の製造方法。 A method for producing a laminated resin molded product according to any one of claims 1 to 4,
Between the molded molds of the split type, a preformed molded resin core material, a preformed body that is an outer skin that faces this sandwiched resin core material, and a preformed body that serves as the outer skin and the mold Arrange so that a heat insulating sheet is interposed between the cavity,
Next, in the process of clamping the molding die and welding the pre-molded body that becomes the outer shell and the heat-insulating sheet to the fixed resin core material to form a laminated structure, between the pre-molded body that becomes the outer shell and the cavity of the molding die A method for producing a laminated resin molded product, comprising forming a heat insulating layer to mold a laminated resin molded product.
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WO2014168120A1 (en) * | 2013-04-08 | 2014-10-16 | キョーラク株式会社 | Duct and method for manufacturing same |
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