JP2010069744A - Synthetic resin hollow plate and manufacturing method for the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a synthetic resin hollow plate, which can solve, without requiring a high processing accuracy, such problems that the number of parts increases, and a sealing part becomes exposed with difficulty in improvement of the appearance. <P>SOLUTION: The synthetic resin hollow plate A comprises a core sheet 1 in three-dimensional structure for forming a hollow 4, and outer sheets 2, 3 provided respectively on both surfaces of the core sheet 1. At least a part of an end face 6 is covered with an end sheet 7 united with one outer sheet 2 (3), and the end of the end sheet 7 and the end of the other outer sheet 3 (2) are bonded substantially in an orthogonal state. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a synthetic resin hollow plate whose end face is sealed, and a method for producing the same.

  Recently, various types of synthetic resin hollow plates have been developed which include a core sheet having a three-dimensional structure for forming a cavity and outer sheets attached to both sides of the core sheet. Many of these hollow plates have their end faces sealed due to demands on durability and appearance. An example is as follows.

  First, it is known that a separate end member having a band shape is attached to the end face of a hollow plate body composed of a core sheet and outer sheets respectively attached to both surfaces of the core sheet (for example, Patent Documents). 1). This hollow plate can be used in various fields because the color and material of the hollow plate main body and the end member can be made different. However, since the number of parts increases, the man-hours required for parts management and manufacturing can be reduced. Difficult and not suitable for simple applications.

  In addition, there is also a type in which a back sheet and a liner sheet, which are outer sheets, are compressed in the thickness direction in a state where they are thermally melted, and the inner surfaces of these sheets are welded together to seal the end surfaces (for example, see Patent Document 2). This hollow plate has the advantage that the manufacturing process, particularly the end face sealing process can be simplified, but the sealing part formed by polymerizing and welding the two sheets is exposed to the outside, so the appearance of the end face is Not suitable for important applications.

Further, there is also known a technique in which the end portions of both outer sheets are curved inward in the thickness direction, the end surfaces of the fore edges are butted and the end surfaces of the butted ends are joined (see, for example, Patent Document 3). This hollow plate is excellent in appearance because the joint portion between the outer sheets is hardly exposed to the outside. However, high-precision processing is indispensable for abutting the end surfaces of the fore edges while curving and deforming both outer sheets.
JP 2006-346904 A JP2005-035071 JP2007-237419A

  The present invention has been made paying attention to the above-mentioned circumstances, and requires a high processing accuracy to solve the problem that the number of parts increases and the problem that it is difficult to adjust the appearance by exposing the sealing part. An object of the present invention is to provide a synthetic resin hollow plate that can be solved without any problems. Another object of the present invention is to provide a production method capable of reliably and efficiently producing such a synthetic resin hollow plate.

  The present invention employs the following configuration in order to solve the above-described problems.

  That is, the synthetic resin hollow plate according to the present invention includes a core sheet having a three-dimensional structure for forming a cavity, and outer sheets attached to both surfaces of the core sheet, and at least one of the end faces. The end portion is covered with an end sheet integrated with one outer sheet, and the end of the end sheet and the end of the other outer sheet are joined in a substantially orthogonal state.

  With such a configuration, the end face can be sealed with an end sheet integrated with one outer sheet, so the number of parts can be reduced as compared with the case where a separate end member is used. In addition, the number of joints can also be reliably reduced. Moreover, since the end portion of the end sheet and the end portion of the other outer sheet are joined in a substantially orthogonal state, a form as in the case of joining the sheets in a state of being superposed in parallel, that is, two sheets It is possible to eliminate the form in which the joint portion obtained by polymerizing the sheet is exposed to the outside.

  In the case of joining in a substantially orthogonal state, the end face of the other outer sheet is joined to the inner surface of the end part of the end sheet (hereinafter referred to as “end sheet priority type”), and the end of the other outer sheet. A mode (hereinafter referred to as “outer sheet priority type”) in which the end edge surface of the end sheet is joined to the inner surface of the part can be exemplified.

  In either case, the joint portion between the inner surface of the sheet and the edge edge surface is only exposed to the outside as a single line, and the entire joint portion is not exposed so as to be visible. In addition, since the inner surface of the sheet has a larger area than the edge edge surface of the sheet, the bonding allowable region can be set wide. Therefore, the processing accuracy as high as the case where the edge edges of the outer sheets are butted and joined together is not required.

  As a preferred embodiment of the hollow plate made of synthetic resin, the core sheet is a cap sheet having protrusions for forming bubbles, and the outer sheet is a back sheet attached to the protrusion opening side of the cap sheet, And a liner sheet attached to the tip end side of the cap sheet.

  The end sheet priority type synthetic resin hollow plate is manufactured by aligning the edge edge surface of one outer sheet and the edge edge surface of the core sheet with the virtual joining surface and making the other outer sheet hollow plate with respect to the virtual joining surface. Extending outwardly by an amount corresponding to the thickness dimension of the end sheet to make the extended portion an end sheet, and heating and melting the end edge surface of at least one outer sheet and the inner surface of the end sheet, There is a method comprising a step of bending a molten end sheet to a virtual joining surface and welding the end sheet to the end edge surface of at least one outer sheet. In the above manufacturing method, if necessary, after joining the end sheet to one outer sheet, the excessively projecting end of the end sheet is cut off, so that the end surface of the end sheet and the outer surface of the one outer sheet are separated. A step of leveling may be added. Thus, “the amount corresponding to the thickness dimension of the hollow plate” described above means a value that is the same as or slightly larger than the thickness dimension of the hollow plate.

  Outer sheet preferential type synthetic resin hollow plate manufacturing method is a raw sheet comprising a core sheet having a three-dimensional structure for forming a cavity and outer sheets attached to both sides of the core sheet. A step of setting a virtual sealing end face at a predetermined position of the body, and a corner portion of the heat seal bar is moved along the virtual sealing end face, and the one outer sheet is heated in a direction in contact with the other outer sheet. A step of pressing, and a step of cutting the both outer sheets by the corners of the heat seal bar to seal the end faces, and the end sheet is curved by the pressing of the one outer sheet. Can be mentioned.

  In addition, if a method according to such a manufacturing method is adopted, a synthetic resin hollow plate, which has been difficult to manufacture conventionally, that is, a core sheet having a three-dimensional structure for forming a cavity, and both surfaces of this core sheet, respectively. And a synthetic resin hollow plate in which at least a part of the end surface is covered with an end sheet integrated with each outer sheet, and ends of the end sheets are joined to each other. Can be easily manufactured without requiring high accuracy. The manufacturing method includes a step of setting a virtual sealing end face at a predetermined position of a green body comprising the core sheet and outer sheets attached to both surfaces of the core sheet, and a pair of heat. A step of moving the seal bar in a direction where the corners thereof are along the virtual sealing end surface and heating in a direction in which the outer sheets are in close contact with each other; and pressing both the outer bars by the both heat seal bars And a step of sealing the end face by cutting the sheet, and a method in which a portion curved by pressing the outer sheets is used as an end sheet.

  Since the present invention is configured as described above, the number of parts can be reduced, the number of man-hours required for manufacturing can be reduced, and the appearance of the sealing end face can be easily prepared, and high processing accuracy is required. It is possible to provide a synthetic resin hollow plate and a method for producing the same, which can be easily manufactured without being carried out.

  Hereinafter, an embodiment (end sheet priority type) of the present invention will be described with reference to FIGS.

  The synthetic resin hollow plate A includes a cap sheet 1 that is a core sheet, and a back sheet 2 and a liner sheet 3 that are outer sheets respectively attached to both surfaces of the cap sheet 1.

  The cap sheet 1 has a three-dimensional structure for forming the cavity 4, and specifically has a large number of bubble forming protrusions 5. The back sheet 2 is attached to the open side of the cap sheet 1 and the liner sheet 3 is attached to the tip end side of the protrusion.

  The end surface 6 of the hollow plate A is covered with an end sheet 7 that is integral with the back sheet 2, and the end of the end sheet 7 and the end of the liner sheet 3 are joined in a substantially orthogonal state. Yes. Specifically, the edge end surface 3a of the liner sheet is joined to the end portion inner surface 7a of the end sheet 7.

  Each of the sheets 2 and 3 is made of a thermoplastic synthetic resin, and the end sheet 7 and the liner sheet 3 are joined by thermal welding. In this embodiment, the end edge surface 1 a of the cap sheet 1 is also heat-welded to the inner surface 7 a of the end sheet 7.

  If it is such a structure, since the end of the back seat | sheet 2 can be extended and utilized as the end seat | sheet 7, the number of parts can be reduced compared with what uses a special end member. . Therefore, the man-hours required for parts management and manufacturing can be reduced without difficulty. Further, since the liner sheet 3 and the end sheet 7 are joined in an orthogonal state, the joining portion is not exposed to the outside as in the case where the sheets are joined together by polymerization in the thickness direction, and the appearance is good. Can be a thing. In particular, since the edge edge surface 3a of the liner sheet 3 is bonded to the inner surface 7a of the end sheet 7, the bonded portion is only exposed to the outside as a single line on the surface on the liner sheet 3 side. For this reason, not only the end face but also the appearance of all faces can be improved. Moreover, since it is sufficient to join the edge edge surface 3a of the liner sheet 3 to the inner surface 7a of the end sheet 7 that can set a wide bonding allowable region, the processing accuracy is as high as when the edge edge surfaces of the sheets are butted together. It is never required. For example, the extension dimension of the end sheet 7 is set to be larger than the thickness dimension of the hollow plate, and after the end edge surface 3 a of the liner sheet 3 is joined to the inner surface 7 a of the end sheet 7, If the part 7b is excised, it is possible to perform a good-looking end surface treatment without requiring high processing accuracy.

  A method for producing the synthetic resin hollow plate A will be described with reference to FIGS.

  In this manufacturing method, the fore edge surface 3a of the liner sheet 3 as one outer sheet and the fore edge surface 1a of the cap sheet 1 as a core sheet are substantially aligned with the virtual joining surface 8 and the back sheet 2 as the other outer sheet is arranged. A first step of extending outwardly by an amount corresponding to the thickness dimension of the hollow plate A from the virtual joining surface 8 and using the extended portion as an end sheet 7, and a liner sheet 3 as one outer sheet The second step of heating and melting the small edge end surface 3a and the inner surface 7a of the end sheet 7; the small edge end surface 3a of the liner sheet 3 as one outer sheet by bending the molten end sheet 7 to the virtual joining surface 8; And a fourth step of cutting off the excessive protruding end portion 7b of the end sheet 7 after the welded portion is cooled.

  Specifically, as shown in FIG. 2, first, a green body A1 whose end face is not sealed is prepared. The green body A1 is attached to the cap sheet 1 having the bubble forming protrusion 5, the back sheet 2 attached to the cap sheet 1 on the opening side of the protrusion 5, and the protrusion front side of the cap sheet 1. The liner sheet 3 is provided. For example, as shown in Japanese Patent Application Laid-Open No. 2008-18653, a cap sheet having a bubble forming protrusion is formed using a forming roll having a suction cavity. In addition, a back sheet is attached to one side of the cap sheet, and a liner sheet is attached to the other side of the cap sheet.

  A virtual joint surface 8 is set in the vicinity of the end surface of the green body A1. And as shown in FIG. 3, this unprocessed body A1 is mounted on the table 9, and the heat seal bar 11 is disposed thereabove. The heat seal bar 11 is a thick plate having a front horizontal surface 11a and upstanding surfaces 11b and 11c continuous to the front horizontal surface, and the surface temperature melts the sheets 1, 2, and 3. Is maintained at a sufficient value. As shown in FIG. 3, the heat seal bar 11 is lowered in a state where one of the standing surfaces 11 b is positioned so as to substantially coincide with the virtual joint surface 8. As a result, the end portions of the liner sheet 3 and the cap sheet 1 are melted and removed so that the end surfaces 3a and 1a thereof are substantially aligned with the virtual joining surface 8, and the inner surface 7a of the end sheet 7 is also in a molten state. Is obtained. With the above operation, the first process and the second process described above are executed. The first intermediate A2 is pushed into a mold 12 having a horizontal receiving surface 12a for receiving and a rising surface 12b for bending. As a result, as shown in FIG. 4, the end sheet 7 is bent to the virtual joint surface 8 and is thermally welded to the fore edge surface 3 a of the liner sheet 3 and the fore edge surface 1 a of the cap sheet 1. Will finish. Thereby, 2nd intermediate body A3 is obtained. Thereafter, the welded portion of the second intermediate A3 is cooled, and the blade 13 disposed along the upper surface of the mold 12 is moved horizontally. As a result, the excessive protruding end 7b of the end sheet 7 in the burr state is cut off, and the fourth step is completed. As a result, a finished product as shown in FIG. 5, that is, a synthetic resin hollow plate A according to the present invention is obtained.

  Next, another embodiment (outer sheet priority type) of the present invention will be described with reference to FIGS.

  The synthetic resin hollow plate B includes a cap sheet 101 as a core sheet, and a back sheet 102 and a liner sheet 103 as outer sheets attached to both surfaces of the cap sheet 101, respectively.

  The cap sheet 101 has a three-dimensional structure for forming the cavity 104, and specifically has a large number of bubble forming protrusions 105. The back sheet 102 is attached to the bubble release side of the cap sheet 101, and the liner sheet 103 is attached to the tip end side of the protrusion.

  The end face 106 of the hollow plate B is covered with an end sheet 107 that is integrated with the liner sheet 103, and the end of the end sheet 107 and the end of the back sheet 102 are joined in a substantially orthogonal state. Yes. Specifically, the end edge surface 107 a of the end sheet 107 is joined to the inner surface 102 a of the end portion of the backsheet 102.

  Each of the sheets 101, 102, 103 is made of a thermoplastic synthetic resin, and the end sheet 107 and the back sheet 102 are joined by heat welding. In this embodiment, the fore end surface 101a of the cap sheet 101 is also thermally welded to the inner surface 102a of the back sheet 102.

  If it is a thing of such a structure, the effect according to the thing of an end sheet priority type will be acquired. Furthermore, since the end sheet is joined to the back sheet with a smooth curved surface, corners are removed, and it is possible to appropriately respond to safety requirements and appearance requirements.

  A method for producing the synthetic resin hollow plate B will be described with reference to FIGS.

  This manufacturing method includes a cap sheet 101 which is a core sheet having a three-dimensional structure for forming a cavity, and a back sheet 102 and a liner sheet 103 which are outer sheets attached to both surfaces of the cap sheet 101, respectively. A step of setting the virtual sealing end surface 108 at a predetermined position of the green body B1, and a liner sheet which is the one outer sheet by moving the corner portion 111a of the heat sealing bar 111 along the virtual sealing end surface 108. The step of pressing the sheet 103 while heating it in a direction in contact with the back sheet 102, which is the other outer sheet, and the corners 111a of the heat seal bar 111 cut the sheets 102 and 103 to seal the end face 106. And a portion curved by pressing the liner sheet 103. The is the end sheet 107.

  According to such a manufacturing method, end face sealing is completed only by reciprocating the heat seal bar 111 once. Therefore, the end face sealing process can be made extremely simple, and the intended purpose can be suitably realized.

  By the way, if a method according to such a manufacturing method is used, it is possible to relatively easily manufacture the synthetic resin hollow plate C, which has been conventionally difficult to manufacture. That is, as shown in FIG. 11, the synthetic resin hollow plate C is a cap sheet 201 which is a core sheet having a three-dimensional structure for forming a cavity, and an outer sheet attached to both surfaces of the cap sheet 201. The back sheet 202 and the liner sheet 203 are provided, and at least a part of the end surface 206 is covered with an end sheet 207 integrated with the back sheet 202 and the liner sheet 203 as the outer sheets. The ends of each are joined together.

  A method for producing the synthetic resin hollow plate C will be described with reference to FIGS.

  This manufacturing method includes a green sheet C1 including a cap sheet 201 that is a core sheet, and a back sheet 202 and a liner sheet 203 that are outer sheets attached to both surfaces of the cap sheet 201 that is a core sheet. A step of setting the virtual sealing end surface 208 at a predetermined position, and the pair of heat seal bars 211 are moved in the direction in which the corner portions 211a are along the virtual sealing end surface 208 to move toward each other. A step of pressing while heating in a direction in which the liner sheet 203 is superposedly adhered, and a step of cutting the back sheet 202 and the liner sheet 203 by the both heat seal bars 211 to seal the end surfaces, The portions curved by the press of the back sheet 202 and the liner sheet 203 are encased. And a sheet 207.

  According to such a manufacturing method, end face sealing is completed only by reciprocating the heat seal bar 211 making a pair. Therefore, it is possible to easily manufacture a synthetic resin hollow plate in which end portions of an end sheet, which have conventionally been required to have high accuracy, are joined to each other without requiring high accuracy.

  In addition, this invention is not limited to embodiment described in full detail above.

  The position of the liner sheet and the back sheet described above is not limited to this embodiment, and may be reversed. Various shapes can be applied to the cap sheet.

  In addition, the specific configuration of each part is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the present invention.

The schematic perspective view of the synthetic resin hollow plate which is one Embodiment of this invention. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are this invention. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are this invention. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are this invention. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are this invention. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are this invention. The schematic perspective view of the synthetic resin hollow plate which is other embodiment. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are other embodiment. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are other embodiment. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are other embodiment. The schematic perspective view of the synthetic resin hollow plate which is other embodiment. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are other embodiment. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are other embodiment. It is process explanatory drawing explaining the manufacturing method of the synthetic resin hollow plates which are other embodiment. The schematic sectional drawing of the synthetic resin hollow plate which is other embodiment.

Explanation of symbols

A ... hollow plate made of synthetic resin 1 ... core sheet 2, 3 ... outer sheet 4 ... cavity 7 ... end sheet

Claims (7)

  An end sheet comprising a core sheet having a three-dimensional structure for forming a cavity and an outer sheet attached to both sides of the core sheet, and at least a part of the end surface being integrated with one outer sheet A synthetic resin hollow plate characterized in that the end portion of the end sheet and the end portion of the other outer sheet are joined in a substantially orthogonal state.   The synthetic resin hollow plate according to claim 1, wherein the end surface of the other outer sheet is joined to the inner surface of the end portion of the end sheet.   The synthetic resin hollow plate according to claim 1, wherein the end edge of the end sheet is joined to the inner surface of the end of the other outer sheet.   The core sheet is a cap sheet having a bubble forming protrusion, the outer sheet is a back sheet attached to the protrusion opening side of the cap sheet, and a liner attached to the protrusion leading end side of the cap sheet. The synthetic resin hollow plate according to claim 1, which is a sheet.   It is a manufacturing method of the synthetic resin hollow plate of Claim 2, Comprising: The edge edge surface of one outer sheet | seat and the edge edge surface of a core sheet | seat are substantially aligned with a virtual joining surface, and the other outer sheet | seat is made rather than the said virtual joining surface. A step of extending outward by an amount corresponding to the thickness dimension of the hollow plate and using the extended portion as an end sheet, and a step of heating and melting the end edge surface of at least one outer sheet and the inner surface of the end sheet And a step of bending the melted end sheet to the virtual joining surface and welding it to the end edge surface of at least one outer sheet.   A method for producing a synthetic resin hollow plate according to claim 3, comprising: a core sheet having a three-dimensional structure for forming a cavity; and outer sheets respectively attached to both surfaces of the core sheet. A step of setting a virtual sealing end face at a predetermined position of the workpiece, and a corner portion of the heat seal bar is moved along the virtual sealing end face to heat the one outer sheet in a direction in contact with the other outer sheet. A step of cutting the outer sheets by the corners of the heat seal bar and sealing the end faces, and the end curved by the pressing of the one outer sheet. A method for producing a synthetic resin hollow plate, characterized in that it is a sheet. An end sheet comprising a core sheet having a three-dimensional structure for forming a cavity and an outer sheet attached to both sides of the core sheet, and at least a part of the end surface being integrated with each outer sheet Is a synthetic resin hollow plate manufacturing method in which the ends of the end sheets are joined to each other,
A step of setting a virtual sealing end face at a predetermined position of a green body comprising the core sheet and outer sheets attached to both surfaces of the core sheet, and a pair of heat seal bars And a step of pressing while heating in the direction in which the outer sheets are in close contact with each other so as to be aligned with the virtual sealing end surface, and cutting the both outer sheets by the both heat seal bars. And the step of bending the outer sheets by pressing the outer sheets is used as an end sheet.

Images