JP2013104267A - Resin sandwich structure panel material and manufacturing method for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin sandwich structure panel material which is excellent in heat-resistance and incombustibility, and can sufficiently secure shape retaining property in spite of having light-weight, and a manufacturing method for the same.SOLUTION: A resin sandwich structure panel material 100 includes: a pair of fire retardant or heat-resistant foam resin core materials forming a hollow part in the inside thereof by being arranged in the state of facing each other; and skin material sheets 124A, 124B welded on the external surfaces of the core materials, respectively. One of the foam resin core materials has, on its inner surface, projection bodies projecting toward the other foam resin core material, and has, at positions to which the projection bodies correspond respectively, openings of a shape complementary to that of the projection bodies of other foam resin core material. The top faces of the projection bodies are welded on the inner surface of the skin material sheet 124A, and also the top faces of the projection bodies of the other foam resin core material are welded on the inner surface of the skin material sheet 124B.

Description

  The present invention relates to a resin sandwich structure panel material and a method for producing the same, and more specifically, a resin sandwich that is excellent in heat resistance and flame retardancy, while being lightweight and capable of ensuring sufficient shape retention. The present invention relates to a structural panel material and a manufacturing method thereof.

Conventionally, resin sandwich structure panel materials have been used for many applications.
For example, Patent Document 1 discloses an example used for a wall of a temporary toilet unit. This wall panel material is disposed between the pair of resin skin material sheets that are welded at the respective peripheral edges to form a hollow portion therein and between the pair of skin material sheets and disposed in the hollow portion. A sandwich panel structure in which a resin core material welded to each of the skin material sheets is integrally formed is used, and the core material has a foamed resin structure having a predetermined thickness and / or a predetermined expansion ratio.

According to such a wall panel material, by securing the bending rigidity through increasing the section modulus by increasing the bulk (thickness) of the core material, it is not necessary to provide a recess on the surface of the panel to compensate for the lack of rigidity, As a result, maintenance and curing can be simplified by eliminating the cumbersome work of cleaning the recesses, and the load on the toilet tank that supports it can be reduced as the panel itself becomes lighter. This makes it possible to reduce the weight of the toilet tub itself or simplify the assembly of the panel to the toilet tub, and improve the transportability and assembly by reducing the weight of the entire temporary toilet unit. By ensuring heat insulation or sound insulation by the resin core material provided inside, for example, an opening such as a ventilation opening is provided in the panel so that a pair of skin materials are hollow. Without holding the tightly sealed, it is possible to improve the use convenience of.

Such a resin sandwich structure panel material is required to be further reduced in weight depending on its use, but may be required to have flame retardancy or heat resistance. For example, when used in public facilities such as building materials for buildings and partition walls for vehicles, flame retardancy or heat resistance may be regulated by regulations.
In this case, even if an attempt is made to increase the expansion ratio in order to achieve further weight reduction, polyolefin, styrene, etc., which are typically used for the expandable resin material, are inferior in flame retardancy or heat resistance, If the foam is formed using an engineering plastic such as modified polyphenylene ether having excellent heat resistance, it is difficult to increase the expansion ratio and it is difficult to achieve the desired weight reduction.

Patent Document 2 discloses a panel in which a foaming raw material is injected into a panel body having a hollow interior, and the foaming raw material is foamed in the panel main body, and in particular, a nonwoven fabric is bonded to the inner surface of the panel main body. Thus, the foam is firmly bonded to the inner surface of the panel main body by the anchor effect of the nonwoven fabric, and the rigidity of the panel is ensured.
However, in this case as well, it is difficult to further reduce the weight while ensuring flame retardancy or heat resistance.
However, if the panel body is formed of a resin material having excellent flame retardancy or heat resistance, and the weight is reduced without injecting the foaming raw material into the hollow portion, the plate members facing each other constituting the panel body are Since it is not supported other than being joined at the periphery, it is difficult to ensure its own shape retention, and it becomes difficult to use the resin panel material for a desired application due to deformation with time.

JP2011-94427 JP 2010-82941 A

  In view of the above technical problems, the object of the present invention is to provide a resin sandwich structure panel material that is excellent in heat resistance and flame retardancy, while being sufficiently lightweight while ensuring sufficient shape retention, and its production It is to provide a method.

In order to achieve the above object, the resin sandwich structure panel material of the present invention is:
A pair of flame-retardant or heat-resistant foamed resin core materials that are arranged to face each other to form a hollow portion, and a skin material sheet welded to the outer surface of each of the foamed resin core materials; Have
One of the foamed resin cores has a protrusion on its inner surface that protrudes toward the other foamed resin core, and the other of the foamed resin cores has a double core on its inner surface. An opening having a shape complementary to the protrusion at a position corresponding to the protrusion when the materials are arranged to face each other, and the top surface of the protrusion is formed of the other foamed resin core material. Up to the inner surface of the skin material sheet welded to the outer surface, the top surface is welded to the inner surface of the skin material sheet,
The other of the foamed resin cores has a protrusion on its inner surface that protrudes toward one of the foamed resin cores, and one of the foamed resin cores has two cores on its inner surface. An opening having a shape complementary to the protrusion at a position corresponding to the protrusion when the materials are arranged to face each other, and the top surface of the protrusion is made of the one foamed resin core material. It extends to the inner surface of the skin material sheet welded to the outer surface, and the top surface is welded to the inner surface of the skin material sheet.

According to the resin sandwich structure panel material having the above configuration, a pair of core materials of heat-resistant or flame-retardant resin material is used, and both core materials are arranged to face each other to form a hollow portion inside On the other hand, each opposing surface is provided with a protrusion directed to the corresponding core material, and a protrusion that protrudes from the corresponding core material and a complementary opening, and the top surface of the protrusion is the corresponding core By extending to the inner surface of the skin material sheet welded to the outer surface of the material, the top surface is welded to the inner surface of the skin material sheet, thereby reducing the weight by securing a hollow portion without increasing the expansion ratio. While achieving this, it is possible to maintain the shape-retaining property of the resin sandwich structure panel material by fitting the protrusions and the openings, so that it is excellent in heat resistance and flame retardancy, while being lightweight and sufficient It is possible to ensure shape retention That.

Further, the pair of flame retardant or heat resistant foamed resin core material preferably has a hollow portion formed inside by abutting the peripheral edges of each other.
Further, at least one of the pair of foamed resin cores has a plurality of divided portions in a form of opposing surfaces thereof, and each of the plurality of divided portions includes at least the protrusion and the opening. It is preferable to have one and to form the core by assembling the plurality of divided portions.
Furthermore, the pair of foamed resin core materials may be made of a modified polyphenylene ether resin.
In addition, a metal reinforcing plate may be sandwiched between the hollow portions.

In order to achieve the above object, a method for producing a resin sandwich structure panel material of the present invention comprises:
Further, each of the pair of flame-retardant or heat-resistant foamed resin core materials according to claim 1 is preliminarily molded, and the protrusions of one of the core materials are joined to each other while the peripheral edges of both core materials are butted together. A pair of flame retardant foamed resin core material is cored by fitting the projection of the other core material into the corresponding opening of one core material. Assembling as a material body,
Arranging two molten thermoplastic resin sheets spaced apart from each other between a pair of split molds;
Forming a sealed space between each of the two thermoplastic resin sheets and the corresponding split mold cavity;
A step of pressing the corresponding thermoplastic resin sheet against the corresponding cavity by sucking the air in each sealed space from the corresponding split mold side, and shaping the thermoplastic resin sheet; and
Holding the core body by pressing the core body against any thermoplastic resin sheet;
By clamping the pair of split molds, the peripheral portions of the two thermoplastic resin sheets are welded to each other, and each of the two thermoplastic resin sheets is passed through the top surface of the protrusion. And a step of welding the core body.

Further, in the step of arranging the two molten thermoplastic resin sheets, the two molten thermoplastic resin sheets are supplied vertically downward in a suspended form, and the cavity is provided along the vertical direction. Placing between the divided molds,
In the step of forming the sealed space, the outer frame member that is movably fitted to the peripheral edge portion of the divided mold toward the thermoplastic resin sheet is brought into contact with the thermoplastic resin sheet. A sealed space is preferably formed by the cavity of the mold, the inner peripheral surface of the outer frame member, and the surface of the thermoplastic resin sheet facing the cavity.
Furthermore, it is preferable that the holding step of the core material body also serves to weld the core material body to any one of the thermoplastic resin sheets.

An embodiment of a thin resin panel 100 according to the present invention will be described in detail below with reference to the drawings.
As shown in FIG. 1 to FIG. 3, the resin sandwich structure panel member 100 is formed of a pair of flame retardant or heat resistant materials that are arranged to face each other and form a hollow portion by abutting the peripheral edges of each other. Foamed resin core material (one half 122A of the foamed resin core material and the other half 122B of the foamed resin core material) and the outer skin 210A, B welded to the entire outer surface 210A, B of each of the foamed resin core materials Material sheet (front surface skin material sheet 124A and back surface skin material sheet 124B).

The peripheral edge of each of the pair of skin material sheets 124 </ b> A and 124 </ b> B is formed with a curved edge on one side, and end peripheral surfaces of the edges are butted together to form a peripheral wall 129.
The foamed resin core half 122A, which is one of the foamed resin cores, protrudes on the inner surface 200A toward the foamed resin core 122B, which is the other foamed resin core. The other half body 122B of the foamed resin core material has a body 202A and is complementary to the projection body 202A at the position corresponding to the projection body 202A when the peripheral edges of both core materials are butted against the inner surface 204B. The top surface 208A of the protrusion 202A has a shape opening 206B (see FIG. 2), and is fixed to the outer surface 210B of the half body 122B of the foamed resin core material when the peripheral edges of both core materials are brought into contact with each other. The top surface 208A extends to the inner surface 212B of the back side skin sheet 124B and is welded to the inner surface 212B of the back side skin sheet 124B.

The protrusion 202A has a solid cylindrical shape, and the outer surface 210A of the half body 122A of the foamed resin core material has a planar shape without providing a recess as the protrusion 202A is provided. A plurality of protrusions 202A are provided, and each of the protrusions 202A is provided at an intersecting portion of a vertical rib 218A and a horizontal rib 220A of a lattice-like rib 216A described later. More specifically, in FIG. 2, openings 206A described later are provided alternately in the vertical direction of the drawing. The shape and number of the protrusions 202A and the interval between the adjacent protrusions 202A may be appropriately determined according to the use of the resin sandwich structure panel material 100 and the environment in which it is used. For example, the resin sandwich structure panel material In the case of only maintaining the shape retention of 100, the number is small, and the interval between the adjacent protrusions 202A may be large.

Explaining the grid-like ribs 216A, the inner surface 200A of the foamed resin core half body 122A is provided with grid-like ribs 216A composed of vertical ribs 218A and horizontal ribs 220A that are perpendicular to each other. Nine ribs 218A and 16 horizontal ribs 220A are provided, and the protrusion 202A and the opening 206A are provided at the intersection of the vertical ribs 218A and the horizontal ribs 220A as described above. The width and pitch of the grid-like ribs 216A may be determined as appropriate according to the use of the resin sandwich structure panel material 100 and the environment in which it is used, as in the case of the protrusion 202A.
The height of the grid-like ribs 216A, that is, the heights of the vertical ribs 218A and the horizontal ribs 220A are provided to be the same as the height of the peripheral wall 129 of the half body 122A of the foamed resin core material. Thus, when the foamed resin core material half 122A and the foamed resin core material half 122B are butted together, the top surfaces of the peripheral walls 129 are butted against each other. The top surface of the grid-like ribs 216A of the half body 122A and the corresponding top surface of the grid-like ribs 216B of the half body 122B of the foamed resin core material are abutted, and foamed with the half body 122A of the foam resin core material. The resin core half body 122 </ b> B is reinforced by the lattice ribs 216.

As shown in FIGS. 2 and 3, similarly, the foam resin core half body 122 </ b> B has, on its inner surface 200 </ b> B, a protrusion 202 </ b> B protruding toward the foam resin core half body 122 </ b> A. The foamed resin core half 122A has an opening 206A complementary to the protrusion 202B at the position corresponding to the protrusion 202B when the peripheral edges of both cores are brought into contact with the inner surface 200A (see FIG. 2), and the top surface 208B of the projection 202B is fixed to the outer surface 210A of the half body 122A of the foamed resin core material when the peripheral edges of both core materials are brought into contact with each other. The inner surface 212A and the top surface 208B are welded to the inner surface 212A of the back surface skin sheet 124B.
In the foamed resin core half body 122B, the grid ribs 216B, the protrusions 202B, and the openings 206B include the positional relationship of the protrusions 202B and the openings 206B with respect to the grid ribs 216B. Since it is the same as that of the half body 122A, description thereof is omitted.
As a modified example, at least one of the pair of foamed resin core halves 122A, B has a plurality of divided portions in a form in which the opposing surfaces are divided, and each of the plurality of divided portions includes a protrusion 202 and Each of the openings 206 may have at least one, and may be formed as a core material by assembling a plurality of divided portions.

The foamed resin core half 122 is made of, for example, modified polyphenylene ether as a heat-resistant or flame-retardant material. For example, when a fire occurs in a vehicle, it prevents the spread of fire and generates toxic gas. And so on. This may be prescribed by law, especially in the case of public vehicles. In the half 122 of the foamed resin core material made of such a material, it is difficult to increase the expansion ratio as compared with polyolefin, styrene, etc. typically used for the foamable resin material, and the weight reduction is achieved accordingly. However, as described above, the hollow portion 103 is provided inside, and the hollow portion 103 is provided while using the foamed resin, thereby reducing the weight.
More specifically, as shown in FIGS. 1 and 2, a pair of foam resin core halves 122A and B are abutted so that the top surfaces of the respective grid-like ribs 216A and B are in contact with each other. A hollow portion 103 that is in contact with each other and is divided into small portions by vertical ribs 218 adjacent in the vertical direction and horizontal ribs 220 adjacent in the horizontal direction is formed.
As the foaming agent, any of physical foaming agents, chemical foaming agents and mixtures thereof may be used. As physical foaming agents, inorganic physical foaming agents such as air, carbon dioxide, nitrogen gas, and water, and organic physical foaming agents such as butane, pentane, hexane, dichloromethane, dichloroethane, and their supercritical fluids are used. be able to.

On the other hand, the material of the front side skin material sheet 124A and the back side skin material sheet 124B is a sheet formed of polypropylene, engineering plastics, olefin resin, or the like. More specifically, as will be described later, from the viewpoint of manufacturing the resin sandwich structure panel material 100 by integral molding, the front side skin material sheet 124A and the back side skin material sheet 124B are each in a molten state. Since the plastic resin sheets P1 and P2 are formed to hang down, the thermoplastic resin sheets P1 and P2 have high melt tension from the viewpoint of preventing variation in thickness due to drawdown, neck-in, or the like. It is preferable to use a resin material. On the other hand, it is preferable to use a resin material with high fluidity in order to improve transferability to a mold and followability.

More specifically, it is a polyolefin (for example, polypropylene, high density polyethylene) which is a homopolymer or copolymer of an olefin such as ethylene, propylene, butene, isoprene pentene, methyl pentene, etc., and has an MFR (JIS) at 230 ° C. According to K-7210, measured at a test temperature of 230 ° C. and a test load of 2.16 kg) of 3.0 g / 10 min or less, more preferably 0.3 to 1.5 g / 10 min, or acrylonitrile butadiene Amorphous resin such as styrene copolymer, polystyrene, high impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), MFR at 200 ° C. (test temperature 200 according to JIS K-7210) ℃, measured at a test load of 2.16 kg) is 3.0 to 60 g / 10 min More preferably, the melt tension at 30 to 50 g / 10 min and at 230 ° C. (using a melt tension tester manufactured by Toyo Seiki Seisakusho Co., Ltd., preheating temperature 230 ° C., extrusion speed 5.7 mm / min, diameter 2.095 mm, A strand is extruded from an orifice with a length of 8 mm, and the tension when the strand is wound around a roller with a diameter of 50 mm at a winding speed of 100 rpm is 50 mN or more, preferably 120 mN or more.

Further, in order to prevent the thermoplastic resin sheets P1 and P2 from being cracked by impact, it is preferable that a hydrogenated styrene thermoplastic elastomer is added in an amount of less than 30 wt%, preferably less than 15 wt%. . Specifically, a styrene-ethylene / butylene-styrene block copolymer, a styrene-ethylene / propylene-styrene block copolymer, a hydrogenated styrene-butadiene rubber and a mixture thereof are suitable as the hydrogenated styrene-based thermoplastic elastomer. The styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to JIS K-7210) is 1.0 to 10 g / 10. Minute, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more.

Furthermore, the thermoplastic resin sheets P1 and P2 may contain an additive. Examples of the additive include inorganic fillers such as silica, mica, talc, calcium carbonate, glass fiber, and carbon fiber, and plasticizer. , Stabilizers, colorants, antistatic agents, flame retardants, foaming agents and the like. Specifically, silica, mica, glass fiber or the like is added in an amount of 50 wt% or less, preferably 30 to 40 wt%, based on the molding resin.
Next, the manufacturing method of the resin sandwich structure panel material 100 according to the present embodiment will be described in detail below. First, a manufacturing apparatus for the resin sandwich structure panel material 100 will be described below.

As shown in FIG. 4, the molding apparatus for the resin sandwich panel material 100 includes an extrusion device 12 and a mold clamping device 14 disposed below the extrusion device 12, and the melt extruded from the extrusion device 12. The thermoplastic resin sheet P in the state is sent to the mold clamping device 14, and the molten thermoplastic resin sheet P is formed by the mold clamping device 14, thereby making the skin material sheet 124. Here, since the apparatus from which each of the pair of thermoplastic resins is extruded and sent to the mold clamping device 14 is the same, only one of them will be described, and the other will be denoted by the same reference numeral, and the description thereof will be omitted. To do.

The extruding device 12 is a conventionally known type, and a detailed description thereof is omitted. However, a cylinder 18 provided with a hopper 16, a screw (not shown) provided in the cylinder 18, and a screw are connected to the screw 18. The hydraulic motor 20, an accumulator 22 that communicates with the inside of the cylinder 18, and a plunger 24 provided in the accumulator 22, and a resin pellet introduced from the hopper 16 is screwed into the cylinder 18 by the hydraulic motor 20. The molten resin is melted and kneaded by the rotation of the resin, and the molten resin is transferred to the accumulator chamber 22 and stored in a certain amount. The plunger 24 is driven to feed the molten resin toward the T die 28, and through the extrusion slit 34, continuous heat A pair of rollers in which the plastic resin sheet P is extruded and spaced from each other 0 while clamped sent out downward by being suspended between the split mold blocks 32. Thereby, as will be described in detail later, the thermoplastic resin sheet P is disposed between the split molds 32 in a state of having a uniform thickness in the vertical direction (extrusion direction).

The extrusion capability of the extrusion device 12 is appropriately selected from the viewpoint of the size of the resin molded product to be molded, the draw-down of the thermoplastic resin sheet P, or the prevention of neck-in occurrence. More specifically, from a practical point of view, the extrusion amount of one shot in intermittent extrusion is preferably 1 to 10 kg, and the extrusion rate of the resin from the extrusion slit 34 is several hundred kg / hour or more, more preferably 700 kg / hour or more. Further, from the viewpoint of preventing the draw-down of the thermoplastic resin sheet P or the occurrence of neck-in, the extrusion process of the thermoplastic resin sheet P is preferably as short as possible, depending on the type of resin, MFR value, and melt tension value. In general, the extrusion process should be completed within 40 seconds, more preferably within 10 to 20 seconds. For this reason, the unit area and the amount of extrusion per unit time from the extrusion slit 34 of the thermoplastic resin are 50 kg / hour cm ² or more, more preferably 150 kg / hour cm ² or more.

By feeding the thermoplastic resin sheet P sandwiched between the pair of rollers 30 by the rotation of the pair of rollers 30 downward, the thermoplastic resin sheet P can be stretched and thinned, and extruded thermoplastic. By adjusting the relationship between the extrusion speed of the resin sheet P and the feed speed of the thermoplastic resin sheet P by the pair of rollers 30, it is possible to prevent the occurrence of drawdown or neck-in. It is possible to reduce the restrictions on the type, in particular the MFR value and the melt tension value, or the extrusion rate per unit time.

As shown in FIG. 4, the extrusion slit 34 provided in the T die 28 is arranged vertically downward, and the continuous thermoplastic resin sheet P extruded from the extrusion slit 34 is suspended from the extrusion slit 34 as it is, It is sent vertically downward. The extrusion slit 34 can change the thickness of the continuous thermoplastic resin sheet P by making the interval variable.

The pair of rollers 30 will be described. In the pair of rollers 30, the rotation axes of the pair of rollers 30 are arranged substantially horizontally in parallel with each other, one is the rotation drive roller 30A, and the other is driven to rotate. The roller 30B. More specifically, as shown in FIG. 8, the pair of rollers 30 are arranged so as to be line-symmetric with respect to the thermoplastic resin sheet P extruded in a form that hangs downward from the extrusion slit 34.

The diameter of each roller and the axial length of the roller may be appropriately set according to the extrusion speed of the thermoplastic resin sheet P to be molded, the length and width of the sheet in the extrusion direction, the type of resin, and the like. As will be described later, from the viewpoint of smoothly feeding the thermoplastic resin sheet P downward by rotation of the roller with the thermoplastic resin sheet P sandwiched between the pair of rollers 30, the diameter of the rotational drive roller 30A Is preferably slightly larger than the diameter of the driven roller 30B. The diameter of the roller is preferably in the range of 50 to 300 mm, and the thermoplastic resin sheet P wraps around the roller even when the roller curvature is too large or too small in contact with the thermoplastic resin sheet P. It causes a malfunction.
On the other hand, the mold clamping device 14 is also a conventionally known type like the extrusion device 12, and detailed description thereof will be omitted, but the two divided molds 32A and 32B and the molds 32A and 32B are melted. And a mold driving device that moves between an open position and a closed position in a direction substantially perpendicular to the supply direction of the thermoplastic resin sheet P.

As shown in FIG. 4, the two divided molds 32 </ b> A and 32 </ b> B are arranged with the cavities 116 facing each other, and the cavities 116 are arranged so as to face substantially vertically. The surface of each cavity 116 is provided with irregularities according to the outer shape and the surface shape of the molded product molded based on the molten thermoplastic resin sheet P.

In each of the two divided molds 32A and 32B, a pinch-off part 118 is formed around the cavity 116. The pinch-off part 118 is formed in an annular shape around the cavity 116, and the opposing molds 32A and 32B are formed. Protrusively toward. As a result, when the two divided molds 32A and 32B are clamped, the tip portions of the pinch-off portions 118 come into contact with each other and parting lines are formed on the peripheral edges of the pair of molten thermoplastic resin sheets P1 and P2. It is welded so that PL is formed.

As shown in FIG. 5, on the outer periphery of the mold 32A, a mold 33A is slidably fitted in a sealed state, and the mold 33A is attached to the mold 32A by a mold moving device (not shown). It is relatively movable. More specifically, the mold frame 33A can be brought into contact with the side surface of the thermoplastic resin sheet P1 disposed between the molds 32A and 32B by projecting toward the mold 32B with respect to the mold 32A. is there. Similarly, a mold 33B is provided for the mold 32B.

The mold driving device is the same as the conventional one, and the description thereof is omitted. However, the two divided molds 32A and 32B are respectively driven by the mold driving device and are divided into two in the open position. A pair of molten continuous thermoplastic resin sheets P can be disposed between the molds 32A and 32B, and the pinch-off portions 118 of the two divided molds 32A and 32B come into contact with each other in the closed position. The annular pinch-off portions 118 are in contact with each other so that a sealed space is formed in the two divided molds 32A and 32B. Regarding the movement of the molds 32A, 32B from the open position to the closed position, the closed position, that is, the position where the pinch-off portions 118 are in contact with each other is between the pair of molten continuous thermoplastic resin sheets P1, P2. The two molds 32A and 32B are driven by a mold driving device so as to move toward the positions at equal positions from both the thermoplastic resin sheets P1 and P2.
Note that the extrusion device and the pair of rollers for one continuous thermoplastic resin sheet P1 and the extrusion device and the pair of rollers for the other continuous thermoplastic resin sheet P2 are arranged symmetrically with respect to this closed position. Has been.

As shown in FIG. 6, a vacuum suction chamber 80 is provided inside the divided mold 32 </ b> A, and the vacuum suction chamber 80 communicates with the cavity 116 </ b> A through the suction hole 82, and the suction hole 82 is opened from the vacuum suction chamber 80. By sucking through, the thermoplastic resin sheet P1 is adsorbed toward the cavity 116A and shaped into a shape along the outer surface of the cavity 116A. More specifically, the outer surface 117 of the thermoplastic resin sheet P1 that is the material of the back surface skin sheet 124B is shaped by the outer surface of the cavity 116A. The thermoplastic resin sheet P2 is shaped similarly.
A method for manufacturing the resin sandwich structure panel member 100 using the molding apparatus for the resin sandwich structure panel member 100 having the above configuration will be described below with reference to the drawings.
First, each of a pair of flame retardant or heat resistant foamed resin cores is molded in advance.

More specifically, the production of the foamed resin core half 122 will be described. For example, a modified polyphenylene ether resin is supplied to an extruder (not shown), kneaded while being heated and melted, and then a predetermined amount of foam is produced. Add the agent, and further knead in the extruder to make a foamed molten resin, and with the gate at the tip of the extrusion nozzle open, extruding the foamed molten resin is opened to the low pressure region, the foamed resin strand It is formed. The strands are cut at predetermined intervals and cooled to form foam beads. For example, by filling a pair of the foam beads into a mold and introducing water vapor to cause secondary foaming and welding the foam beads to each other, the respective half parts 122A and B of the foam resin core material are formed. Can be molded.

Next, while abutting the foam resin core halves 122A and B, the protrusion 202A of one core halves 122A is fitted into the corresponding openings 206B of the other core halves 122B, and The protrusions 202B of the other core member half body 122B are fitted into the corresponding openings 206A of the one core member half member 122A so that the pair of flame retardant foamed resin core member halves are cored. Assemble as the material body 140.
More specifically, the hollow portions 103 of the small sections are formed by abutting the peripheral edges of the half halves 122A and B of the foamed resin core material and the lattice-like ribs 216, and the protrusions 202 and the openings 206 It becomes possible to maintain the shape-retaining property of the resin sandwich structure panel member 100 by fitting. In this state, on the outer surface 210A of the foam resin core half 122A, the top surface 208B of the protrusion 202B of the foam resin core half 122B is flush with the outer surface 210A from the opening 206A. The top surface 208A of the protrusion 202A of the foamed resin core half 122A is flush with the outer surface 210B from the opening 206B on the outer surface 210B of the foam resin core half 122B. Exposed in a state.

  Next, in FIG. 4, a predetermined amount of the melt-kneaded thermoplastic resin is stored in the accumulator 22, and the stored thermoplastic resin is discharged from the extrusion slits 34 provided at predetermined intervals on the T die 28. In this case, the thermoplastic resin swells and is extruded at a predetermined extrusion speed with a predetermined thickness so as to hang downward into a molten sheet.

Subsequently, the pair of rollers 30 is moved to the open position, and the gap between the pair of rollers 30 arranged below the extrusion slit 34 is expanded from the thickness of the thermoplastic resin sheet P, thereby being extruded in a molten state. The lowermost part of the thermoplastic resin sheet P is smoothly supplied between the pair of rollers 30. In addition, the timing which expands the space | interval of the rollers 30 from the thickness of the sheet | seat P made from a thermoplastic resin may be performed at the time of the completion | finish of secondary shaping | molding for every one shot not after an extrusion start.
Next, the pair of rollers 30 are moved close to each other and moved to the closed position, the interval between the pair of rollers 30 is narrowed to sandwich the thermoplastic resin sheet P, and the thermoplastic resin sheet P is moved downward by the rotation of the rollers. Send it out.
Next, as shown in FIG. 4, the thermoplastic resin sheet P having a uniform thickness in the extrusion direction is disposed between the divided molds 32 </ b> A and 32 </ b> B disposed below the pair of rollers 30. Thereby, the thermoplastic resin sheet P is positioned in a form that protrudes around the pinch-off portion 118.
The above steps are performed for each of the pair of thermoplastic resin sheets P1 and P2, and the thermoplastic resin sheet P2 which is the material of the front side skin sheet 124A and the material of the back side skin sheet 124B. The thermoplastic resin sheet P1 is disposed between the divided molds 32A and 32B in a state of being spaced apart from each other.
In this case, the pair of thermoplastic resin sheets P1 and P2 are arranged between the divided molds 32A and 32B by adjusting the distance between the extrusion slits 34 or the rotation speed of the pair of rollers 30 independently of each other. It is possible to adjust the thickness at the time.

Next, as shown in FIG. 5, the mold 33A is made of the thermoplastic resin facing the mold 32A toward the thermoplastic resin sheet P1 which is the material of the back surface sheet material 124B with respect to the mold 32A. The sheet P1 is moved until it hits the outer surface 117 of the sheet P1. Similarly, the mold 33B is moved until it contacts the outer surface 117 of the thermoplastic resin sheet P2.

Next, as shown in FIG. 5 and FIG. 6, the mold 116A includes the cavity 116A, the inner peripheral surface 102 of the mold 33A, and the outer surface 117 of the thermoplastic resin sheet P1 facing the mold 32A. The thermoplastic resin sheet P1 is pressed against the cavity 116A by being sucked from the vacuum suction chamber 80 through the suction hole 82 through the closed space 84, and is made of the thermoplastic resin into a shape along the surface of the cavity 116A. The sheet P1 is shaped. The thermoplastic resin sheet P2 is similarly sucked and shaped.
Next, as shown in FIG. 6, the core body main body 140 formed in advance is placed between the divided molds 32, pressed against the thermoplastic resin sheet P <b> 1 and welded to hold the core body main body 140. .
The core material main body 140 is disposed between the split molds 32 while adsorbing and holding the side surfaces of the core material main body 140 using, for example, a known adsorption manipulator, and welded to the thermoplastic resin sheet P1. The adsorption manipulator may be detached from the core body 140 and retracted from between the split molds 32.

Next, as shown in FIG. 7, the thermoplastic resin sheets P1 and P2 are sucked and held with the molds 33A and 33B contacting the outer surfaces 117 of the thermoplastic resin sheets P1 and P2 held in their positions. However, the molds 32A and 32B are moved toward each other until the respective annular pinch-off portions 118A and B contact each other. In this case, the contact position in the mold clamping direction between the pinch-off portions 118A and 118B is between a pair of thermoplastic resin sheets P1 and P2 that are separated from each other. As shown in FIG. By contacting each other, the pair of thermoplastic resin sheets P1 and P2 are hermetically sealed by the periphery of the thermoplastic resin sheet in a state in which the peripheral edge portions 126 are welded and fixed to each other and the core body 140 is disposed inside. In addition to forming the peripheral wall 129, the back side skin sheet 124B and the front side skin sheet 124A are welded to the core body 140, and are further flush with the outer surface 210A from the opening 206A. The top surface 208B of the protrusion 202B of the exposed foam resin core half 122B is welded to the inner surface of the thermoplastic resin sheet P1, while the opening 20 The top surface 208A of the protrusion 202A of the halves 122A of the foamed resin core material is exposed in a state of the outer surface 210B flush is welded to the inner surface of the thermoplastic resin sheet P2 from B.
Next, as shown in FIG. 8, the split molds 32A and 32B are opened, the molded resin sandwich structure panel material 100 is taken out, and the burr portions B outside the pinch-off portions 118A and B are cut. The molding is completed.

As described above, the sheet-like resin sandwich structure panel material 100 can be formed one after another by repeating the above-described steps each time the molten resin is extruded intermittently in the primary forming. A thermoplastic resin sheet P is intermittently extruded as a molten thermoplastic resin sheet P by molding (extrusion molding), and the thermoplastic resin sheet P extruded by secondary molding (blow molding or vacuum molding) is used as a mold. Can be molded.
According to the resin sandwich structure panel material 100 having the above-described configuration, a pair of core materials 122 of heat-resistant or flame-retardant resin material are used, and both the core materials 122 are arranged to face each other so as to be hollow inside. While forming the portion 103, each opposing surface is provided with a protrusion 202 that faces the corresponding core member 122, and a protrusion 202 that protrudes from the corresponding core member 122 and a complementary opening 206. The top surface 208 of the body 202 extends to the inner surface of the skin material sheet 124 welded to the outer surface 210 of the corresponding core material 122, so that the top surface 208 is welded to the inner surface of the skin material sheet 124. The resin sandwich structure panel material 10 is achieved by fitting the protrusion 202 and the opening 206 while achieving weight reduction by securing the hollow portion 103 without increasing the expansion ratio. It is possible to maintain the shape retention, heat resistance Te following, while excellent flame retardancy, it is possible to ensure a sufficient shape retention yet lightweight.

The embodiments of the present invention have been described in detail above, but various modifications or changes can be made by those skilled in the art without departing from the scope of the present invention.

For example, in the present embodiment, the foamed resin core material has been described as a half body of a thin plate-shaped core material. However, the present invention is not limited thereto, and may be a three-dimensional shape including a curved surface.
Moreover, in this embodiment, although demonstrated as what does not insert an insertion body in the inside of a foaming resin core material main body, it is not limited to it, The form inserted | pinched by the half body of a pair of foaming resin core materials It may be possible to insert a metal reinforcing plate in order to ensure the strength of the resin sandwich structure panel material, in particular the bending rigidity, in which case it is limited to a single metal reinforcing plate In accordance with the size of the resin sandwich structure panel material, a plurality of metal reinforcing plates are prepared, and the corresponding hollow portions 103 are formed on the foamed resin core material with the respective metal reinforcing plates spaced from each other. You may arrange in. In this case, as long as the metal reinforcing plate can be stably positioned by being sandwiched between the pair of foamed resin core materials, the four side surfaces of the metal reinforcing plate are not surrounded by the foamed resin core material. Any or all of them may be exposed to the outside.
On the contrary, as long as the shape-retaining property is maintained in the resin sandwich structure panel material, the grid-like ribs may be omitted if a high strength is not required.

It is a perspective view of a resin sandwich structure panel material according to an embodiment of the present invention. It is sectional drawing which follows the line AA of FIG. It is a perspective view of each half of one and the other foamed resin core material of the resin sandwich structure panel material according to the embodiment of the present invention. It is a figure which shows the state by which the molten resin sheet was arrange | positioned between the split molds with the shaping | molding apparatus of the resin sandwich structure panel material which concerns on embodiment of this invention. It is a figure which shows the state which is making the outer frame of a division mold contact the side surface of a molten resin sheet in the shaping | molding apparatus of the resin sandwich structure panel material which concerns on embodiment of this invention. It is a figure which shows the state which is shaping the molten resin sheet in the shaping | molding apparatus of the resin sandwich structure panel material which concerns on embodiment of this invention. It is a figure which shows the state which clamped the division mold in the shaping | molding apparatus of the resin sandwich structure panel material which concerns on embodiment of this invention. It is a figure which shows the state which the mold was opened in the shaping | molding apparatus of the resin sandwich structure panel material which concerns on embodiment of this invention.

P Thermoplastic resin sheet PL Parting line 12 Extruding device 14 Clamping device 16 Hopper 18 Cylinder 20 Hydraulic motor 22 Accumulator 24 Plunger 28 T die 30 Roller 32 Split mold 33 Mold 34 Extrusion slit 80 Vacuum suction chamber 82 Vacuum Suction hole 84 1st sealed space 86 2nd sealed space 100 Resin sandwich structure panel material 102 Inner peripheral surface 116 Cavity 117 Outer surface 118 Pinch-off portion 122 Half body of foamed resin core material 124 Skin material sheet 126 Peripheral portion 129 Peripheral wall 140 Core body 200 Inner surface 202 Projection body 204 Inner surface 206 Opening 208 Top surface 210 Outer surface 212 Inner surface 216 Grid-like rib 218 Vertical rib 220 Horizontal rib

Claims (8)

A pair of flame-retardant or heat-resistant foamed resin core materials that are arranged to face each other to form a hollow portion, and a skin material sheet welded to the outer surface of each of the foamed resin core materials; Have
One of the foamed resin cores has a protrusion on its inner surface that protrudes toward the other foamed resin core, and the other of the foamed resin cores has a double core on its inner surface. An opening having a shape complementary to the protrusion at a position corresponding to the protrusion when the materials are arranged to face each other, and the top surface of the protrusion is formed of the other foamed resin core material. Up to the inner surface of the skin material sheet welded to the outer surface, the top surface is welded to the inner surface of the skin material sheet,
The other of the foamed resin cores has a protrusion on its inner surface that protrudes toward one of the foamed resin cores, and one of the foamed resin cores has two cores on its inner surface. An opening having a shape complementary to the protrusion at a position corresponding to the protrusion when the materials are arranged to face each other, and the top surface of the protrusion is made of the one foamed resin core material. Up to the inner surface of the skin material sheet welded to the outer surface, the top surface is welded to the inner surface of the skin material sheet,
A sandwich structure panel made of resin.   2. The resin sandwich structure panel material according to claim 1, wherein the pair of flame-retardant or heat-resistant foamed resin core material forms a hollow portion inside by abutting the peripheral edges of each other. At least one of the pair of foamed resin cores has a plurality of divided portions in which the opposing surfaces are divided, and each of the plurality of divided portions includes at least one of the protrusion and the opening. The resin sandwich structure panel material according to claim 1 or 2, wherein the resin sandwich structure panel material is formed as a core material by assembling the plurality of divided portions. 3. The resin sandwich structure panel material according to claim 1, wherein the pair of foamed resin core materials are made of a modified polyphenylene ether resin. 4. The resin sandwich structure panel material according to claim 4, wherein a metal reinforcing plate is sandwiched between the hollow portions. Each of the pair of flame-retardant or heat-resistant foamed resin core materials according to claim 1 is preliminarily molded, and the protrusions of one core material are made to correspond to the other core material while abutting the peripheral edges of both core materials. A pair of flame retardant foamed resin core material is formed into a core body body by fitting the opening of the other core material into the corresponding opening of the one core material. Assembling as
Arranging two molten thermoplastic resin sheets spaced apart from each other between a pair of split molds;
Forming a sealed space between each of the two thermoplastic resin sheets and the corresponding split mold cavity;
A step of pressing the corresponding thermoplastic resin sheet against the corresponding cavity by sucking the air in each sealed space from the corresponding split mold side, and shaping the thermoplastic resin sheet; and
Holding the core body by pressing the core body against any thermoplastic resin sheet;
By clamping the pair of split molds, the peripheral portions of the two thermoplastic resin sheets are welded to each other, and each of the two thermoplastic resin sheets is passed through the top surface of the protrusion. And a step of welding the core material main body. A method for producing a resin sandwich structure panel material. The step of disposing the two melted thermoplastic resin sheets supplies the two melted thermoplastic resin sheets vertically downwardly, and the cavities are provided along the vertical direction. Having a stage of placing between the split molds;
In the step of forming the sealed space, the outer frame member that is movably fitted to the peripheral edge portion of the divided mold toward the thermoplastic resin sheet is brought into contact with the thermoplastic resin sheet. The method for producing a resin sandwich structure panel material according to claim 5, wherein a sealed space is formed by the cavity of the mold, the inner peripheral surface of the outer frame member, and the surface of the thermoplastic resin sheet facing the cavity. The method for producing a resin sandwich structure panel material according to claim 6, wherein the holding step of the core material body also serves to weld the core material body to any one of the thermoplastic resin sheets.

Images