JP2016135605A - Molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminated panel which has reinforcement materials facing in mutually different directions precisely arranged at predetermined positions and can efficiently obtain a strength.SOLUTION: A laminated panel (1) which is brought into contact with another member on a predetermined contact surface (31) has: a reinforcement material unit (5) including a first reinforcement material (51) and a second reinforcement material (51) arranged so as to bridge the contact surface (31), and a third reinforcement material (52) interposed between the first reinforcement material (51) and the second reinforcement material (51); and resin base materials (2 and 3) which sandwich the reinforcement material unit (5) from upper and lower surfaces of the reinforcement material unit (5).SELECTED DRAWING: Figure 1

Description

  The present invention relates to a laminated panel having reinforcing members facing in different directions.

  As a conventional panel, there is one in which a reinforcing material is disposed inside (for example, Patent Document 1: Japanese Patent Laid-Open No. 2006-281874). In this type of panel, a hollow blow molded product is molded, then a cut is made in the side surface of the blow molded product, and a reinforcing material is inserted into the inside from the side of the blow molded product into which the cut has been made.

  However, in the conventional molding method, since the reinforcing material is inserted into the inside from the side surface of the blow-molded product with the cut, only a linear reinforcing material such as a rod shape can be accommodated. Further, the arrangement position of the reinforcing material has been limited. As a result, the conventional molding method can arrange reinforcing members facing in the same direction, but cannot arrange reinforcing materials facing in different directions.

  For this reason, the above-mentioned conventional panel can obtain the strength in the direction perpendicular to the longitudinal direction of the reinforcing material, but cannot obtain the strength in the direction parallel to the longitudinal direction of the reinforcing material. The strength could not be given efficiently.

  For this reason, it is considered necessary to develop a panel that can be provided with reinforcing members that face in different directions and that can effectively give strength to the panel.

  For example, Patent Document 2: Japanese Patent No. 3322171 discloses a blow molded article in which reinforcing materials facing different directions are arranged.

  In the method disclosed in Patent Document 2, a support device that supports a reinforcing material for interposing inside a molded product is provided below the molds, and the mold is opened using the support device. Place reinforcements at appropriate positions between the molds. Then, softening resin is supplied so as to cover the reinforcing material, the mold is clamped, the softening resin and the reinforcing material are held in the mold, and blow molding is performed, so that the blow molding has the reinforcing material inside. The product is being molded. Thereby, it is possible to mold a blow molded product in which reinforcing materials facing different directions are arranged.

JP 2006-281874 A Japanese Patent No. 3221871

  However, in the method of Patent Document 2, the softening resin and the reinforcing material are brought into contact with each other when the mold is clamped, and blow molding is performed by blowing air into the mold after the clamping is completed. There is a possibility that the contact position with the shift from the desired position. For this reason, in the method of Patent Document 2, it is difficult to form a blow molded product in which reinforcing materials facing different directions are accurately arranged at predetermined positions.

  Moreover, although the said patent document 2 is disclosed about the blow molded article in which the reinforcing material which faces mutually different direction is arrange | positioned, it does not mention the arrangement position of the reinforcing material, but another member (for example, automobile) There is no description or suggestion about the point of arranging the end portion of the reinforcing material on the abutting surface that abuts on the other member.

  The present invention has been made in view of the above circumstances, and provides a laminated panel in which reinforcing materials facing in different directions are accurately arranged at predetermined positions and capable of efficiently obtaining strength, and a method for forming the same. The purpose is to do.

  In order to achieve this object, the present invention has the following features.

The laminated panel according to the present invention is
A laminated panel that contacts another member at a predetermined contact surface,
A first reinforcing member and a second reinforcing member arranged so as to be bridged over the contact surface; and a third reinforcing member interposed between the first reinforcing member and the second reinforcing member. And a reinforcing material unit comprising:
And a resin base material sandwiching the reinforcing material unit from the upper and lower surfaces of the reinforcing material unit.
The laminated panel according to the present invention is
A laminated panel that contacts another member at a predetermined contact surface,
A reinforcing material unit comprising a first reinforcing material arranged so as to be bridged over the abutting surface, and a second reinforcing material interposed between the first reinforcing material and the abutting surface. When,
And a base resin that sandwiches the reinforcing material unit from the upper and lower surfaces of the reinforcing material unit.

The method for forming a laminated panel according to the present invention includes:
A method for forming a laminated panel formed by sandwiching a reinforcing material unit composed of at least two reinforcing materials facing different directions from each other in a molten resin sheet,
A shaping step of shaping the resin sheet into a shape along the mold cavity;
An affixing step of attaching the reinforcing material unit to the resin sheet shaped into a shape along the cavity;
A mold clamping step of clamping the reinforcing material unit and the resin sheet with the mold, and molding the laminated panel;
It is characterized by having.

  According to the present invention, the reinforcing members facing in different directions can be accurately arranged at predetermined positions, and the strength can be obtained efficiently.

It is a diagram showing a configuration example of the laminated panel 1 of the present embodiment, (a) is an overall perspective view of the laminated panel 1, (b) is a top view of the laminated panel 1 shown in (a), (C) is an AA ′ sectional view shown in (a) and (b), and (d) is a BB ′ sectional view shown in (a) and (b). 3 is a diagram showing a configuration example of a reinforcing material unit 5. FIG. FIG. 5 is a view showing an example of a method of connecting the vertical reinforcing member 51 and the horizontal reinforcing member 52 constituting the reinforcing member unit 5. FIG. 2 is a diagram illustrating a configuration example of a forming apparatus 60 that forms the laminated panel 1 of the present embodiment. FIG. 3 is a first view showing an example of a forming process of the laminated panel 1. FIG. 3 is a second view showing an example of the forming process of the laminated panel 1. FIG. 6 is a third diagram showing an example of the forming process of the laminated panel 1. FIG. 10 is a fourth diagram showing an example of the forming process of the laminated panel 1. FIG. 10 is a fifth diagram showing an example of the forming process of the laminated panel 1. FIG. 10 is a sixth diagram illustrating an example of a forming process of the laminated panel 1. FIG. 10 is a seventh diagram showing an example of a forming process of the laminated panel 1. FIG. 10 is an eighth diagram illustrating an example of a forming process of the laminated panel 1. FIG. 6 is a first view showing another configuration example of the laminated panel 1. FIG. 6 is a second view showing another configuration example of the laminated panel 1. FIG. 6 is a third view showing another configuration example of the laminated panel 1. FIG. 10 is a fourth diagram illustrating another configuration example of the laminated panel 1. It is a figure which shows the structural example of the laminated panel 1 of 2nd Embodiment. FIG. 3 is a diagram showing an example of a method for connecting the horizontal reinforcing member 52 and the foam 50 constituting the reinforcing member unit 5, and an example of a method for connecting the vertical reinforcing member 51 and the foam 50. FIG. 6 is a first view showing another configuration example of the laminated panel 1. FIG. 6 is a second view showing another configuration example of the laminated panel 1. FIG. 6 is a third view showing another configuration example of the laminated panel 1. It is a figure which shows the structural example of the laminated panel 1 of 3rd Embodiment.

<Outline of laminated panel 1 of this embodiment>
First, the outline | summary of the laminated panel 1 of this embodiment is demonstrated, referring FIG.1, FIG.4-12, FIG.22. FIG. 1 and FIG. 22 show a configuration example of the laminated panel 1 of the present embodiment, and FIG. 4 to FIG. 12 show examples of a forming method of the laminated panel 1 shown in FIG.

  As shown in FIG. 1, the laminated panel 1 of the present embodiment is a laminated panel 1 that comes into contact with another member (for example, another member in an automobile) at a predetermined contact surface 31. The laminated panel 1 of the present embodiment includes a first reinforcing member (corresponding to the vertical reinforcing member 51) and a second reinforcing member (corresponding to the vertical reinforcing member 51) arranged so as to be bridged over the contact surface 31. A reinforcing member unit 5 composed of a third reinforcing member (corresponding to the transverse reinforcing member 52) interposed between the first reinforcing member 51 and the second reinforcing member 51; And a resin base material (corresponding to the front wall 2 and the back wall 3) sandwiching the reinforcing material unit 5 from the lower surface.

  Further, as shown in FIG. 22, the laminated panel 1 of the present embodiment includes a first reinforcing member (corresponding to the vertical reinforcing member 51) disposed so as to be bridged over the contact surface 31, and a first reinforcing member. A reinforcing material unit 5 composed of a second reinforcing material (corresponding to the lateral reinforcing material 52) interposed between the material 51 and the abutment surface 31, and the reinforcing material unit 5 from above and below the reinforcing material unit 5. And a base resin (corresponding to the front wall 2 and the back wall 3) to be sandwiched.

  The laminated panel 1 of this embodiment shown in FIGS. 1 and 22 can be formed through the steps shown in FIGS. 5 to 12 using the forming apparatus 60 shown in FIG. 4, for example, as shown in FIG. Then, the molten resin sheet P constituting the resin bases 2 and 3 is shaped into a shape along the cavity 116 of the mold 32. Then, as shown in FIG. 9, the reinforcing material unit 5 is attached to the resin sheet P shaped into a shape along the cavity 116. Then, as shown in FIG. 11, the reinforcing material unit 5 and the resin sheet P are clamped with a mold 32 to form the laminated panel 1 shown in FIGS. Thereby, the laminated panel 1 having the reinforcing material unit 5 in which the reinforcing materials 51 and 52 facing in different directions can be accurately arranged at predetermined positions can be formed.

  In the molding method of the present embodiment, the reinforcing material unit 5 composed of the reinforcing materials 51 and 52 facing different directions from each other is attached to the resin sheet P shaped into a shape along the cavity 116. The laminated panel 1 shown in FIG. 1 and FIG. 22 that can be accurately placed at a predetermined position and can obtain strength efficiently can be formed. Hereinafter, the laminated panel 1 of the present embodiment will be described in detail with reference to the accompanying drawings.

(First embodiment)
<Configuration example of laminated panel 1>
First, a configuration example of the laminated panel 1 of the present embodiment will be described with reference to FIG. FIG. 1 is a diagram showing a configuration example of a laminated panel 1, FIG. 1 (a) is an overall perspective view of the laminated panel 1, and FIG. 1 (b) is a laminated panel 1 shown in FIG. 1 (a). 1 (c) is a cross-sectional view taken along line AA ′ of the laminated panel 1 shown in FIGS. 1 (a) and 1 (b), and FIG. 1 (d) is a cross-sectional view of FIG. FIG. 6 is a cross-sectional view of the laminated panel 1 shown in FIG.

  As shown in FIG. 1A, the laminated panel 1 of the present embodiment is configured to have a front wall 2, a back wall 3, a peripheral wall 4, and a reinforcing material unit 5. The reinforcing material unit 5 includes a vertical reinforcing material 51 and a horizontal reinforcing material 52. The laminated panel 1 of the present embodiment has a hollow portion 6 between the front wall 2 and the back wall 3 as shown in FIGS. 1 (c) and 1 (d). It is arranged between the back wall 3. In addition, the laminated panel 1 of this embodiment does not contact the end part of the vertical reinforcing material 51 with the inner side of the surrounding wall 4 as shown in FIG. The hollow portion 6 was formed between the two. However, the end portion of the vertical reinforcing member 51 may be brought into contact with the inner side of the peripheral wall 4 so that the hollow portion 6 is not formed between the end portion of the vertical reinforcing member 51 and the peripheral wall 4. The peripheral wall 4 is a portion that connects the front wall 2 and the back wall 3.

  Further, the laminated panel 1 of the present embodiment has a contact surface 31 on the back wall 3, and the end of the vertical reinforcing member 51 is disposed on the contact surface 31. The contact surface 31 is, for example, a portion that comes into contact with another member when the laminated panel 1 is placed on another member in the automobile. The contact surface 31 contacts the other member, and the laminated panel 1 is separated from the other member. Place on the member. In FIGS. 1A and 1B, the contact surfaces 31 at both ends are separated, but the contact surfaces 31 at both ends can be integrated into the contact surfaces 31 without being separated. is there. Further, the position of the contact surface 31 is not limited to the position shown in FIGS. 1A and 1B, and the contact between the laminated panel 1 and another member when the laminated panel 1 is placed on another member. The contact surface 31 can be set at an arbitrary position depending on the state.

  As shown in FIG. 1 (a), the laminated panel 1 of the present embodiment has a decorative member 7 for decoration or the like attached to the surface of the front wall 2, and FIGS. 1 (c) and 1 (d). As shown, the back wall 3, the front wall 2, and the decorative member 7 form a laminated structure. It is also possible not to attach the decorative member 7.

  The resin constituting the front wall 2 and the back wall 3 is not particularly limited, and a known resin can be applied. For example, engineering, such as polyethylene resin, polypropylene resin, ethylene-vinyl acetate copolymer, vinyl chloride resin, ABS resin (acrylonitrile-styrene-butadiene resin), polyamide resin, polystyrene resin, polyester resin, polycarbonate resin, modified polyphenylene ether, etc. Plastics and mixed resins obtained by blending them are suitable, and fillers such as glass fibers, carbon fibers, calcium carbonate, talc, mica can be appropriately added. In addition, the front wall 2 and the back wall 3 are preferably made of a resin material having a high melt tension from the viewpoint of preventing thickness variation due to drawdown, neck-in, etc. In order to improve transferability and followability, it is preferable to use a resin with high fluidity.

  The material constituting the decorative member 7 is not particularly limited, and a known material can be applied. For example, knitted fabrics, woven fabrics, non-woven fabrics, or polyvinyl chloride (PVC), thermoplastic polyurethane elastomer (TPU) or fibers obtained by processing natural fibers, recycled fibers, semi-synthetic fibers, synthetic fibers and blends thereof. A thermoplastic elastomer (TPE) such as a thermoplastic polyolefin elastomer (TPO), a resin sheet made of a thermoplastic resin such as a polyethylene polyolefin resin, and a laminate sheet thereof can be appropriately selected.

  The reinforcing material unit 5 of the present embodiment is composed of reinforcing materials 51 and 52 facing in different directions. Specifically, as shown in FIG. 2, the reinforcing material unit 5 includes two vertical reinforcing members 51 and two horizontal reinforcing members 52 spanned between the two vertical reinforcing members 51. It has a ladder shape. Both ends of the horizontal reinforcing member 52 are connected to the vertical reinforcing member 51 so as to be bridged over the vertical reinforcing member 51. The method of connecting the both ends of the horizontal reinforcing member 52 to the vertical reinforcing member 51 is not particularly limited, and can be connected by, for example, welding or fitting.

  Examples of a method of connecting the end of the horizontal reinforcing member 52 to the vertical reinforcing member 51 include a method example in which the horizontal reinforcing member 52 and the vertical reinforcing member 51 are configured in the shape shown in FIG. FIG. 3 shows a configuration example of a connecting portion between the horizontal reinforcing member 52 and the vertical reinforcing member 51 shown in FIG. 2, and FIGS. 3 (a 1) to (e 1) show the connection between the horizontal reinforcing member 52 and the vertical reinforcing member 51. An example of a cross-sectional configuration of the part is shown, and FIGS. 3A2 to 3E2 show the connecting part viewed from the A direction shown in FIGS. 3A1 to 3E1. FIG. 3 (a3) shows a state in which the ends of the upper and lower surfaces 522 of the horizontal reinforcing member 52 shown in FIGS. 3 (a1) and (a2) are cut and the shape of the end portion of the horizontal reinforcing member 52 is processed into a columnar shape 523. Show. The vertical reinforcing member 51 and the horizontal reinforcing member 52 of the reinforcing member unit 5 shown in FIG. 2 are shown in the case where they are connected in the configuration shown in FIGS. 3 (a1) and (a2). 3 (a2) to 3 (e2), the dotted line in the center between the vertical reinforcing member 51 and the horizontal reinforcing member 52 is obtained when the vertical reinforcing member 51 and the horizontal reinforcing member 52 are formed in an H shape. The columnar part which connects a lower surface is shown.

  3 (a1) and 3 (a2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 are each formed in an H shape, and the vertical reinforcing member 51 and the horizontal reinforcing member 52 are formed at the same height. Show the case. 3 (a1) and 3 (a2), the end of the horizontal reinforcing member 52 is brought into contact with the vertical reinforcing member 51 and welded to connect the vertical reinforcing member 51 and the horizontal reinforcing member 52. . 3 (a1) and 3 (a2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 can be aligned at the upper and lower positions. No step is generated at the upper and lower portions of the film, and a flat surface is formed. 3 (a1) and 3 (a2), the vertical reinforcing member 51 is formed in an H shape, and therefore the end of the lateral reinforcing member 52 shown in FIGS. 3 (a1) and 3 (a2). In the region on the vertical reinforcing member 51 side from the portion where the part and the vertical reinforcing member 51 are connected, the horizontal reinforcing member 52 and the vertical reinforcing member 51 do not come into contact with each other and a gap is generated. Therefore, in the configuration of FIGS. 3 (a1) and 3 (a2), as shown in FIG. 3 (a3), the ends of the H-shaped upper and lower surfaces 522 of the lateral reinforcing member 52 are cut, and the end of the lateral reinforcing member 52 is cut. The shape of the part is processed into a columnar shape 523, and the end of the lateral reinforcing material 52 processed into the columnar shape 523 is inserted inside the vertical reinforcing material 51, and the vertical reinforcing material is the same as in FIGS. 3 (a1) and (a2). It is also possible to connect the vertical reinforcing member 51 and the horizontal reinforcing member 52 by bringing 51 and the H-shaped horizontal reinforcing member 52 into contact with each other and welding them. As a result, the end of the horizontal reinforcing member 52 processed into the columnar 523 is concealed by the vertical reinforcing member 51, and the end of the horizontal reinforcing member 52 contacts along one side surface of the vertical reinforcing member 51. Therefore, the generation of the gap described above can be prevented.

  3 (b1) and 3 (b2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 are each formed in an H shape, and the horizontal reinforcing member 52 has a vertical reinforcing member 51 in the vertical direction of the horizontal reinforcing member 52. The case where it comprises with the height which adjoins inside is shown. 3 (b1) and 3 (b2), the end of the horizontal reinforcing member 52 is inserted inside the vertical reinforcing member 51, and the horizontal reinforcing member 52 and the vertical reinforcing member 51 are connected. . In the case of the configuration shown in FIGS. 3B1 and 3B2, the end of the lateral reinforcing member 52 is hidden by the vertical reinforcing member 51. In addition, since the positions of the upper and lower portions of the vertical reinforcing member 51 and the horizontal reinforcing member 52 cannot be matched, steps are generated at the upper and lower portions of the vertical reinforcing member 51 and the horizontal reinforcing member 52.

  3 (c1) and 3 (c2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 are each formed in an H shape, and the vertical reinforcing member 51 is formed at the upper part of the portion connected to the horizontal reinforcing member 52. The case where it comprises and has the opening part 51a is shown. 3 (c1) and 3 (c2), the end of the horizontal reinforcing member 52 is inserted inside the vertical reinforcing member 51, and the horizontal reinforcing member 52 and the vertical reinforcing member 51 are connected. . 3 (c1) and 3 (c2), the upper portion of the horizontal reinforcing member 52 is exposed from the opening 51a of the vertical reinforcing member 51. In addition, the position of the upper part of the vertical reinforcing member 51 and the upper part of the horizontal reinforcing member 52 can be matched, but the position of the lower part of the vertical reinforcing member 51 and the lower part of the horizontal reinforcing member 52 cannot be matched, A step is generated between the vertical reinforcing member 51 and the horizontal reinforcing member 52.

  3 (d1) and 3 (d2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 are each formed in an H-shape, and the horizontal reinforcing member 52 has a vertically extending end portion of the horizontal reinforcing member 52 in the vertical direction. The case where it comprises with the height which adjoins inside the reinforcement material 51 is shown. 3 (d1) and 3 (d2), the end of the horizontal reinforcing member 52 is inserted inside the vertical reinforcing member 51, and the horizontal reinforcing member 52 and the vertical reinforcing member 51 are connected. . In the case of the configuration shown in FIGS. 3D1 and 3D2, the end portion of the horizontal reinforcing member 52 is concealed by the vertical reinforcing member 51. Further, the position of the upper portion of the vertical reinforcing member 51 and the upper portion other than the end portion of the horizontal reinforcing member 52 and the position of the lower portion of the vertical reinforcing member 51 and the lower portion other than the end portion of the horizontal reinforcing member 52 may be matched. Therefore, there is no step between the upper and lower portions of the vertical reinforcing member 51 and the horizontal reinforcing member 52, and a flat surface is formed.

  3 (e1) and 3 (e2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 are each formed in an H shape, and the vertical reinforcing member 51 is formed at the upper part of the portion connected to the horizontal reinforcing member 52. The case where it comprises and has the opening part 51a is shown. 3 (e1) and 3 (e2), the end of the horizontal reinforcing member 52 is inserted inside the vertical reinforcing member 51, and the horizontal reinforcing member 52 and the vertical reinforcing member 51 are connected. . 3 (e1) and 3 (e2), the upper portion of the horizontal reinforcing member 52 is exposed from the opening 51a of the vertical reinforcing member 51. Further, the position of the upper part of the vertical reinforcing member 51 and the upper part of the horizontal reinforcing member 52 can be matched, and the position of the lower part of the vertical reinforcing member 51 and the lower part other than the end of the horizontal reinforcing member 52 can be matched. Therefore, a step is not generated between the vertical reinforcing member 51 and the horizontal reinforcing member 52, and a flat surface is formed. Note that the configuration shown in FIG. 3 is a preferred example, and is not limited to the configuration shown in FIG.

  As shown in FIG. 1, the reinforcing material unit 5 of the present embodiment is disposed so that the ends of the two vertical reinforcing materials 51 are positioned on the contact surface 31 of the laminated panel 1, and The horizontal reinforcing member 52 is arranged so as to be bridged between the two vertical reinforcing members 51. The lateral reinforcing members 52 are preferably arranged at equal intervals in order to improve the strength. The materials of the vertical reinforcing member 51 and the horizontal reinforcing member 52 constituting the reinforcing member unit 5 are not particularly limited, and known materials can be applied. For example, metal (aluminum or the like) or hard plastic is applicable. In addition, from the viewpoint of improving the strength while reducing the weight of the laminated panel 1, the vertical reinforcing member 51 disposed on the contact surface 31 is made of metal, and the horizontal reinforcing member 52 spanned over the vertical reinforcing member 51 is It is preferable to use a hard plastic. In addition, the shape of the vertical reinforcing member 51 and the horizontal reinforcing member 52 is not limited to the H type, and any shape that can connect the vertical reinforcing member 51 and the horizontal reinforcing member 52 is a cylindrical shape, a C type, It can also be configured in a U-shape or the like.

<Example of molding method for laminated panel 1>
Next, an example of a method for forming the laminated panel 1 of the present embodiment will be described with reference to FIGS. FIG. 4 shows a configuration example of a molding device 60 for molding the laminated panel 1, and FIGS. 5 to 12 are diagrams showing process examples for molding the laminated panel 1.

  The laminated panel 1 of the present embodiment can be formed using a forming apparatus 60 shown in FIG. A molding apparatus 60 shown in FIG. 4 has an extrusion apparatus 12 and a mold clamping apparatus 14, and sends the molten resin sheet P extruded from the extrusion apparatus 12 to the mold clamping apparatus 14. A resin sheet P is blow-molded to form a laminated panel 1 shown in FIG. Hereinafter, an example of a method for forming the laminated panel 1 of the present embodiment will be described in detail.

  First, as shown in FIG. 5, the sheet-like decorative member 7 is inserted between one split mold 32A and one frame member 128A constituting the surface side, and is provided on one split mold 32A. A sheet-like decorative member 7 is temporarily fixed by a temporary fixing pin (not shown) so as to cover the cavity 116A of one split mold 32A.

  Next, as shown in FIG. 4, the resin sheet P is extruded from the T die 28 of the extrusion device 12, the extruded resin sheet P is passed through a pair of rollers 30, and the thickness of the resin sheet P is adjusted. It hangs down between the divided molds 32.

  The molding apparatus 60 of the present embodiment adjusts the relative speed difference between the extrusion speed of the resin sheet P and the delivery speed at which the resin sheet P is sent downward by the pair of rollers 30 by the rotational speed of the pair of rollers 30. When the resin sheet P passes between the pair of rollers 30, it is pulled downward by the pair of rollers 30, thereby stretching and thinning the resin sheet P, thereby preventing the occurrence of drawdown or neck-in. I am going to do it.

  When the resin sheet P is disposed between the divided molds 32, the frame member 128 is moved toward the corresponding resin sheet P by a frame member driving device (not shown), and as shown in FIG. 128 is brought into contact with the resin sheet P, and the resin sheet P is held by the frame member 128. The frame member 128 has an opening 130 and holds the resin sheet P with the frame member 128.

  Next, the frame member 128 is moved toward the split mold 32, and as shown in FIG. 7, the resin sheet P is brought into contact with the pinch-off part 118 of the split mold 32, and the resin sheet P, the pinch-off part 118, and the cavity 116 are contacted. Thus, the sealed space 117 is formed. Further, the reinforcing material unit 5 (see FIG. 2) held by the suction plate 119 of the manipulator (not shown) is inserted between the divided molds 32 as shown in FIG. 7 shows a state in which the reinforcing material unit 5 shown in FIG. 2 is viewed from the side. Although FIG. 7 shows a state in which the vertical reinforcing member 51 is held by the suction disk 119 along the longitudinal direction of the vertical reinforcing member 51 constituting the reinforcing member unit 5, the position where the reinforcing member unit 5 is held is not particularly limited. Instead, it can be held at any position.

  Next, the inside of the sealed space 117B is sucked through the split mold 32B, and one resin sheet P constituting the back wall 3 is pressed against the cavity 116B, and as shown in FIG. The resin sheet P is shaped into a shape along the cavity 116B.

  Further, the manipulator is moved toward the right split mold 32B, and, as shown in FIG. 9, the reinforcing material unit 5 is pressed against one resin sheet P adsorbed by the cavity 116B of the right split mold 32B. The material unit 5 is attached to one resin sheet P. At this time, the reinforcing material unit 5 is attached to the resin sheet P so that both ends of the vertical reinforcing material 51 constituting the reinforcing material unit 5 are located on the contact surface 31 (see FIG. 1) of the back wall 3.

  The resin sheet P of the present embodiment includes a filler. Examples of the filler include inorganic or organic fillers. From the viewpoint of obtaining a reinforcing effect, the fibrous filler includes glass fiber, potassium titanate whisker, carbon. Examples of the filler include talc, mica, and montmorillonite, and examples of the granular filler include calcium carbonate. Calcium carbonate can obtain reinforcing effects such as bending elastic modulus, bending strength, heat distortion temperature, and dimensional stability. In addition, talc and montmorillonite can obtain reinforcing effects such as bending elastic modulus, bending strength, heat distortion temperature, and dimensional stability. Mica can obtain reinforcing effects such as flexural modulus, flexural strength, thermal deformation temperature, dimensional stability, and compressive strength. Glass fiber, potassium titanate whisker, and carbon fiber can obtain reinforcing effects such as bending elastic modulus, bending strength, tensile elastic modulus, thermal deformation temperature, dimensional stability, and compressive strength. For this reason, it is preferable to use a fibrous filler from the viewpoint of obtaining a reinforcing effect.

  As the fibrous filler, for example, short fibers having a fiber length of 0.2 to 0.5 mm and long fibers having a fiber length of 3 to 12 mm can be used. When a fibrous filler is used, the fibrous filler is oriented in the extrusion direction of the resin sheet P, but the fibrous filler is oriented in the same direction as the longitudinal reinforcing material 51 or the lateral reinforcing material 52. It is preferable to extrude the resin sheet P so that the Thereby, the reinforcing material in the same direction as the orientation of the fibrous filler can be reduced in weight.

  Next, the suction platen 119 is detached from the reinforcing material unit 5, the manipulator is pulled out from between the two divided molds 32, and the other resin sheet P constituting the front wall 2 is pressed against the cavity 116A. As shown in FIG. 10, the other resin sheet P is shaped into a shape along the cavity 116A.

  Next, the two split molds 32 are clamped by the mold driving device, and the reinforcing material unit 5 is attached to the other resin sheet P adsorbed by the cavity 116A of the left split mold 32A as shown in FIG. The reinforcing material unit 5 is stuck to the other resin sheet P by pressing. Further, the periphery of the two resin sheets P is welded to form a parting line PL.

  In this embodiment, when the laminated panel 1 in which the reinforcing material unit 5 and the resin sheet P are integrated is clamped by the divided mold 32, the reinforcing material unit 5 and the resin sheet are formed by the divided mold 32. P is preferably compressed. Thereby, the adhesive strength between the reinforcing material unit 5 and the resin sheet P can be further improved.

  Through the above steps, the laminated panel 1 formed by sandwiching the reinforcing material unit 5 between the molten resin sheets P is completed.

  Next, as shown in FIG. 12, the two divided molds 32 are opened, the cavity 116 is separated from the completed laminated panel 1, and the burrs formed around the parting line PL are removed. Thus, the molding of the laminated panel 1 shown in FIG. 1 in which the reinforcing material unit 5 shown in FIG. 2 is housed is completed.

<Operation / Effect of Laminated Panel 1 of this Embodiment>
As described above, the laminated panel 1 of the present embodiment is provided with the reinforcing members 51 and 52 that are directed in different directions as shown in FIG. 2 is pasted, the divided mold 32 is closed, the resin sheet P and the reinforcing material unit 5 are clamped with the divided mold 32, and the reinforcing material unit 5 shown in FIG. The laminated panel 1 shown in FIG. 1 is molded. Thereby, the laminated panel 1 in which the reinforcing material units 5 in which the reinforcing materials 51 and 52 facing in different directions are accurately arranged at predetermined positions can be easily formed.

  In the present embodiment, the reinforcing material unit 5 composed of the reinforcing materials 51 and 52 facing in different directions is attached to the resin sheet P shaped into the shape along the cavity 116 of the split mold 32. Therefore, even if the reinforcing material unit 5 has an unstable shape, it can be placed in the laminated panel 1 with high accuracy. As a result, the end portion of the vertical reinforcing member 51 constituting the reinforcing member unit 5 can be accurately arranged on the contact surface 31. For example, the method disclosed in Patent Document 2 uses a support device to dispose a reinforcing material at an appropriate position between molds in a mold-open state. For this reason, in the method disclosed in Patent Document 2, it is difficult to dispose a reinforcing material having an unstable shape and a plurality of separated and independent reinforcing materials. In contrast, in the present embodiment, since the reinforcing material unit 5 is attached to the resin sheet P, even the reinforcing material unit 5 having an unstable shape can be easily attached to the resin sheet P. Further, even the reinforcing material unit 5 composed of a plurality of separate and independent reinforcing materials can be easily attached to the resin sheet P. However, when the reinforcing material unit 5 composed of a plurality of separate and independent reinforcing materials is attached to the resin sheet P, the separate and independent reinforcing materials are sequentially attached to the resin sheet P. In the laminated panel 1 of the present embodiment, since the reinforcing members 51 and 52 facing in different directions are accurately arranged at predetermined positions, the strength can be obtained efficiently.

  In the laminated panel 1 of the above embodiment, the contact surface 31 is configured by the flat surface of the back wall 3 as shown in FIG. However, as shown in FIG. 13, the contact surface 31 can be formed in a concave shape in which the back wall 3 is recessed inward. FIG. 13 (a) is an overall perspective view of the laminated panel 1 having a concave shape and constituting the contact surface 31, and FIG. 13 (b) is a top view of the laminated panel 1 shown in FIG. 13 (a). 13C is a cross-sectional view taken along line AA ′ shown in FIGS. 13A and 13B, and FIG. 13D is a cross-sectional view taken along line BB ′ shown in FIGS. 13A and 13B. FIG. In the laminated panel 1 having the configuration shown in FIG. 13, the end of the vertical reinforcing member 51 constituting the reinforcing member unit 5 is positioned on the concave contact surface 31. When the end portion of the vertical reinforcing member 51 is disposed on the contact surface 31 having a shape, the hollow portion 6 is provided between the back wall 3 and the reinforcing member unit 5 (51, 52). However, even in the configuration shown in FIG. 13, the strength of the laminated panel 1 is improved because the reinforcing material unit 5 composed of the reinforcing materials 51 and 52 facing in different directions is arranged in the laminated panel 1. Can do. When the laminated panel 1 shown in FIG. 13 is molded, the resin sheet constituting the back wall 3 on which the contact surface 31 is formed after the reinforcing material unit 5 is attached to the resin sheet P constituting the front wall 2. It is preferable to attach the reinforcing material unit 5 to P. Thereby, in a state where the adhesive strength between the resin sheet P and the reinforcing material unit 5 is increased, the resin sheet P and the reinforcing material unit 5 are clamped by the split mold 32 to form the laminated panel 1 shown in FIG. be able to.

  Further, in the above-described embodiment, the reinforcing members 51, 51 are configured so as to form a ladder shape by the two vertical reinforcing members 51 and the two horizontal reinforcing members 52 spanned between the two vertical reinforcing members 51. 52 were linked together. However, as long as the vertical reinforcing member 51 is located on the contact surface 31, the connecting shape of the vertical reinforcing member 51 and the horizontal reinforcing member 52 is not particularly limited. For example, as shown in FIG. It is also possible to connect the reinforcing members 51 and 52 so that the 51 and the lateral reinforcing member 52 form a triangular shape. FIG. 14 is a diagram illustrating a configuration example of the laminated panel 1 when the shape of the reinforcing material unit 5 is changed. In addition, when connecting the horizontal reinforcing member 52 to the vertical reinforcing member 51, as shown in FIG. 1, the horizontal reinforcing member 52 is connected to the vertical reinforcing member 51 so that the horizontal reinforcing member 52 is orthogonal to the vertical reinforcing member 51. It is not necessary to connect to 51, and it is also possible to connect the horizontal reinforcing member 52 to the vertical reinforcing member 51 so that the horizontal reinforcing member 52 is not parallel to the vertical reinforcing member 51 as shown in FIG. . Also in the case of the connection shape shown in FIG. 14, the lateral reinforcing member 52 and the vertical reinforcing member 51 can be connected with the configuration shown in FIG. 3 described above.

  In the above embodiment, the two horizontal reinforcing members 52 are bridged over the vertical reinforcing member 51. However, it suffices if at least one horizontal reinforcing member 52 is bridged over the vertical reinforcing member 51, and the number of the horizontal reinforcing members 52 is not particularly limited. The number of longitudinal reinforcing members 51 may be at least two, and the number is not particularly limited. Even when the vertical reinforcing members 51 are composed of three or more pieces, it is preferable that all the vertical reinforcing members 51 are bridged by the horizontal reinforcing members 52.

  In the above embodiment, the hollow portion 6 is formed between the back wall 3 and the front wall 2. However, a rib 53 can be provided in the region of the hollow portion 6 as shown in FIGS. 15 (a) and 15 (b), for example. FIG. 15A is a diagram illustrating a configuration example of the laminated panel 1 when the rib 53 is provided, and FIG. 15B is a cross-sectional view taken along line AA ′ illustrated in FIG. As shown in FIGS. 15A and 15B, the strength of the laminated panel 1 can be further increased by providing the ribs 53. The shape of the rib 53 is not particularly limited as long as the strength of the laminated panel 1 can be improved, and the rib 53 having any shape can be provided. For example, a groove-like rib or a plate-like rib can be provided. Further, the number of ribs 53 is not particularly limited, and an arbitrary number of ribs 53 can be provided. However, as shown in FIG. 15 (a), it is preferable to provide ribs 53 along the same direction as the arrangement direction of the longitudinal reinforcing members 51 and the lateral reinforcing members 52 constituting the reinforcing member unit 5. Thereby, the strength of the laminated panel 1 can be further increased by the reinforcing material unit 5 and the ribs 53 along the same direction as the arrangement direction of the vertical reinforcing material 51 and the horizontal reinforcing material 52 constituting the strong material unit 5. it can. FIG. 15A shows a case where the rectangular ribs 53 are provided along the same direction as the arrangement direction of the longitudinal reinforcing members 51 and the lateral reinforcing members 52 constituting the strong material unit 5. However, as shown in FIG. 15 (a), instead of the rectangular rib 53, a circular or elliptical rib is used in the same direction as the arrangement direction of the vertical reinforcing member 51 and the horizontal reinforcing member 52 constituting the reinforcing member unit 5. It is also possible to provide a plurality along the line. Moreover, the rib 53 shown to Fig.15 (a), (b) showed the example comprised by the shape dented toward the inner side of the front wall 2 from the back wall 3 side. However, it may be configured in a shape that is recessed from the front wall 2 side toward the inside of the back wall 3, or may be configured in a shape that is recessed from the front wall 2 and the back wall 3 toward the center. Also in the case of this rib shape, as shown in FIG. 15 (b), the back walls 3 are in contact with each other at the location where the back wall 3 is recessed without forming a space area at the location where the back wall 3 is recessed. It is also possible to form a flat plate. The laminated panel 1 shown in FIG. 13 has a hollow portion 6 between the reinforcing material unit 5 and the back wall 3 because the contact surface 31 of the back wall 3 has a concave shape. By providing the laminated panel 1 shown in FIG. 13 with ribs, the area of the hollow portion 6 between the reinforcing material unit 5 and the back wall 3 can be reduced. In this case, the rib having a shape recessed from the back wall 3 toward the reinforcing material unit 5 is provided.

  Moreover, in the said embodiment, the one laminated panel 1 was demonstrated to the example. However, as shown in FIG. 16, it is also possible to configure a laminated panel 1 in which a first laminated panel 1a and a second laminated panel 1b are connected via a hinge portion 10. FIG. 16 is a diagram showing a configuration example of the laminated panel 1 in which two laminated panels 1a and 1b are connected via the hinge portion 10. As shown in FIG. The laminated panel 1 shown in FIG. 16 can also be molded using the molding method described above, and is arranged on the first reinforcing material unit 5a arranged on the first laminated panel 1a and the second laminated panel 1b. The second reinforcing material unit 5b can be easily placed on the molten resin sheet P. As a result, the laminated panel 1 in which the reinforcing material units 5a and 5b that are separated and independent from each other can be easily formed. For example, in the method disclosed in Patent Document 2, it is difficult to arrange a plurality of reinforcing material units, each of which is separated and independent. On the other hand, in this embodiment, since the reinforcing material unit 5 is affixed to the resin sheet P, a plurality of reinforcing material units 5 each separated and independent can be easily affixed to the resin sheet P. The shape of the hinge portion 10 is not particularly limited, and the hinge portion 10 of any shape can be used as long as the first laminated panel 1a and the second laminated panel 1b can be rotated via the hinge portion 10. It is possible to shape | mold using the formed molding method.

(Second Embodiment)
Next, a second embodiment will be described.

  As shown in FIG. 2, the reinforcing member unit 5 of the first embodiment is formed by integrally connecting a vertical reinforcing member 51 and a horizontal reinforcing member 52 in contact with each other, and reinforcing members 51 and 52 facing different directions. The reinforcing material unit 5 is formed.

  As shown in FIG. 17, the reinforcing material unit 5 of the second embodiment is configured by integrally connecting a vertical reinforcing material 51 and a horizontal reinforcing material 52 with a foam 50, and reinforcing materials 51 facing different directions. The reinforcing material unit 5 constituted by 52 is formed. FIG. 17 is a diagram illustrating a configuration example of the laminated panel 1 in which the reinforcing material unit 5 configured using the foam 50 is arranged. As shown in FIG. 17, by forming the reinforcing material unit 5 using the foam 50, the reinforcing materials 51 and 52 facing in different directions can be used without contacting the vertical reinforcing material 51 and the horizontal reinforcing material 52. The reinforcing material unit 5 that is configured can be formed. However, the strength of the reinforcing member unit 5 can be improved by connecting the vertical reinforcing member 51 and the horizontal reinforcing member 52 as in the first embodiment. Further, since the vertical reinforcing member 51 and the horizontal reinforcing member 52 are fixed by the foam 50, the stable reinforcing member unit 5 can be configured.

  In addition, since the reinforcing material unit 5 includes the foam 50, the reinforcing material unit 5 can be easily attached to the resin sheet P constituting the front wall 2 and the back wall 3. For example, in the first embodiment, as shown in FIG. 9, the reinforcing material unit 5 is attached to the resin sheet P shaped into a shape along the cavity 116B. For this reason, in the first embodiment, the reinforcing material unit 5 and the resin sheet P are bonded. In the second embodiment, the reinforcing material unit 5 is configured to include the foam 50. Therefore, when the reinforcing material unit 5 is attached to the resin sheet P, the foam 50 is also attached to the resin sheet P. Can do. Thereby, since the adhesion area | region of the reinforcing material unit 5 and the resin sheet P can be increased rather than 1st Embodiment, adhesive strength can be improved rather than 1st Embodiment.

  The foam 50 can be composed of a known resin, and can be composed of, for example, a styrene resin (including at least 30 wt% or more). By comprising a styrene resin, the rigidity in a high temperature environment (for example, 90 degrees or more) can be increased. Examples of the styrenic resin include acrylonitrile-styrene copolymer (AS), acrylonitrile-butadiene-styrene copolymer (ABS), polystyrene (PS), and high impact polystyrene (HIPS). Moreover, it is also possible to comprise including an olefin resin. Examples of the olefin resin include polypropylene (PP).

  As a method of connecting the vertical reinforcing member 51 and the horizontal reinforcing member 52 with the foam 50, for example, a method of forming the shape shown in FIG. 18 (a1) and (b1) show an example of the configuration of the connecting portion between the transverse reinforcing member 52 and the foam 50 shown in FIG. 17, and FIGS. 18 (a2) and (b2) show the longitudinal reinforcement shown in FIG. The structural example of the connection part of the material 51 and the foam 50 is shown. Note that the connection method illustrated in FIG. 18 is a preferred example, and any connection method can be applied without being limited to the connection method illustrated in FIG. 18.

  18 (a1) and 18 (a2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 are each formed in an H shape, and the vertical reinforcing member 51, the horizontal reinforcing member 52, and the foam 50 have the same height. The case where it is composed of h is shown. 18 (a1) and 18 (a2), the height α1 of the connecting portion between the lateral reinforcing member 52 and the foam 50 and the height β1 of the connecting portion between the vertical reinforcing member 51 and the foam 50 are used. Are configured to be the same (α1 = β1). Then, after the horizontal reinforcing member 52 is fitted into one pair of ends of the foam 50, the vertical reinforcing member 51 is fitted into the other pair of ends of the foam 50, and FIG. 3 (a1), As shown in (a2), the end of the horizontal reinforcing member 52 and the vertical reinforcing member 51 are welded, and the vertical reinforcing member 51 and the horizontal reinforcing member 52 are connected. As a result, since the positions of the upper and lower portions of the vertical reinforcing member 51, the horizontal reinforcing member 52, and the foam 50 can be matched, there are steps in the upper and lower portions of the vertical reinforcing member 51, the horizontal reinforcing member 52, and the foam 50. It does not occur and constitutes a flat surface.

  18 (b1) and 18 (b2), the vertical reinforcing member 51 and the horizontal reinforcing member 52 are each formed in an H shape, and the height γ of the horizontal reinforcing member 52 is such that the upper and lower sides of the horizontal reinforcing member 52 are The case where it comprises with the height (beta) 1 adjacent inside the longitudinal reinforcement 51, and the longitudinal reinforcement 51 and the foam 50 are comprised with the same height h is shown. 18 (b1) and 18 (b2), the height β1 of the connecting portion between the vertical reinforcing member 51 and the foam 50 is configured to be the same as the height γ of the lateral reinforcing member 52. And after fitting the horizontal reinforcing material 52 into one pair of ends of the foam 50, the vertical reinforcing material 51 is fitted into the other pair of ends of the foam 50 and the end of the horizontal reinforcing material 52, The vertical reinforcing member 51 and the horizontal reinforcing member 52 are connected. When the vertical reinforcing member 51 is fitted into the end portion of the horizontal reinforcing member 52, the configuration shown in FIGS. 3B1 and 3B2 is obtained. 18 (b1) and 18 (b2), the end of the lateral reinforcing member 52 is concealed by the vertical reinforcing member 51 as shown in FIG. 3 (b2). Further, although the positions of the upper and lower portions of the vertical reinforcing member 51 and the foam 50 can be matched, the horizontal reinforcing member 52 cannot be matched with the positions of the upper and lower portions of the vertical reinforcing member 51 and the foam 50. As a result, steps are generated at the upper and lower portions of the horizontal reinforcing member 52, the vertical reinforcing member 51, and the foam 50. Note that the configuration shown in FIG. 18 is a preferred example and is not limited to the configuration shown in FIG.

  The shape of the foam 50 is not particularly limited as long as the vertical reinforcing member 51 and the horizontal reinforcing member 52 can be fixed. For example, as shown in FIG. 19, the vertical reinforcing member 51 and the horizontal reinforcing member 52 are used. It is also possible to make the shape in contact with. In this case, a plurality of foams 50 are used. FIG. 19 is a diagram illustrating a configuration example of the laminated panel 1 in which the reinforcing material units 5 configured using a plurality of foams 50 are arranged. In the case of the configuration shown in FIG. 19, the area of the foam 50 can be reduced as compared with the configuration shown in FIG. 17, so that the weight of the laminated panel 1 can be reduced. Also in the case of the configuration shown in FIG. 19, the vertical reinforcing member 51 and the horizontal reinforcing member 52 can be connected by the foam 50 by the method shown in FIG. 18 described above.

  Moreover, the shape of the foam 50 can also be made into the shape which touches the two vertical reinforcement materials 51, for example, as shown in FIG. In this case as well, a plurality of foams 50 are used. FIG. 20 is a diagram illustrating a configuration example of the laminated panel 1 in which the reinforcing material units 5 configured using a plurality of foams 50 are arranged. In the case of the configuration shown in FIG. 20 as well, the area of the foam 50 can be reduced similarly to the configuration shown in FIG. 19 described above, so that the weight of the laminated panel 1 can be reduced. Further, since the foam 50 is provided so as to be bridged between the two vertical reinforcing members 51, the strength of the laminated panel 1 can be improved as compared with the configuration shown in FIG.

  Further, the shape of the foam 50 can be configured to accommodate the transverse reinforcing member 52 as shown in FIG. FIG. 21 is a diagram illustrating a configuration example of the laminated panel 1 in which the reinforcing material unit 5 configured using one large foam 50 is arranged. In the laminated panel 1 shown in FIG. 21 (a), as shown in FIG. 21 (b), an accommodating portion 54 for accommodating the lateral reinforcing material 52 is formed and formed on one large foam 50. The horizontal reinforcing material 52 is fitted into the housing portion 54, and the vertical reinforcing material 51 is fitted into the end portion of the foam 50 into which the horizontal reinforcing material 52 is fitted as shown in FIGS. 21 (c) and 21 (d). be able to. FIG. 21 (b) shows an enlarged configuration example of the AA ′ cross section shown in FIG. 21 (a), and FIG. 21 (c) shows the lateral reinforcing material 52 and the vertical reinforcing material 51 shown in FIG. 21 (a). Fig. 21 (d) shows a configuration example of a connection portion between the foam 50 and the vertical reinforcing member 51 shown in Fig. 21 (a). In FIG. 21 (c), the end portion of the lateral reinforcing member 52 protrudes from the storage portion 54 of the foam 50, and the protruding end portion of the lateral reinforcing member 52 is inserted inside the vertical reinforcing member 51 to be laterally reinforced. The material 52 and the longitudinal reinforcing material 51 are connected. In FIG. 21C, it is possible to prevent the end of the lateral reinforcing member 52 from protruding from the storage portion 54 of the foam 50. In this case, the foam 50 and the longitudinal reinforcing material 51 can be bonded together. In FIG. 21 (d), the end of the foam 50 is formed in a convex shape, the end of the convex shape is inserted inside the vertical reinforcing member 51, and the foam 50 and the vertical reinforcing member 51 are connected. Yes. Note that the laminated panel 1 having the configuration shown in FIG. 21A can also be configured using a plurality of foams 50 having the configuration shown in FIG.

  When the laminated panel 1 is molded using the reinforcing material unit 5 having the configuration shown in FIGS. 17, 19, 20, and 21, as shown in FIG. 7, as in the molding method example of the first embodiment. As described above, after the sealed space 117 is formed by the resin sheet P, the pinch-off portion 118, and the cavity 116, the reinforcing material unit 5 may be inserted between the split molds 32, but the reinforcing material unit 5 of the present embodiment is Since the foam 50 is provided, before the resin sheet P is pushed out from the T die 28 between the divided molds 32 as shown in FIG. 4, the reinforcement shown in FIGS. It is preferable that the material unit 5 is inserted between the split molds 32 in advance. Thereby, the surface of the foam 50 of the reinforcing material unit 5 can be warmed by the heat of the resin sheet P pushed out from the T die 28.

  When the laminated panel 1 is molded using the reinforcing material unit 5 having the configuration shown in FIGS. 17, 19, 20, and 21, two resins are used as in the molding method example of the first embodiment. After placing the sheet P between the divided molds 32, the reinforcing material unit 5 may be sequentially attached to the two resin sheets P. However, the two resin sheets P are separately divided into the divided molds 32. It is also possible to sequentially attach the reinforcing material units 5 to the two resin sheets P while arranging them in the above. Specifically, first, one resin sheet P is placed in the split mold 32, the resin sheet P is shaped into a shape along the cavity 116 of the split mold 32, and the resin sheet P is reinforced. Stick material unit 5. Also, the other resin sheet P is placed in the split mold 32, the resin sheet P is shaped into a shape along the cavity 116 of the split mold 32, and the reinforcing material unit 5 is attached to the resin sheet P. wear. As a result, the time until the reinforcing material unit 5 is attached to the resin sheet P extruded from the T-die 28 can be shortened, so that the surface of the foam 50 of the reinforcing material unit 5 is heated by the heat of the resin sheet P. It can be easily melted. As a result, the reinforcing material unit 5 can be easily attached to the resin sheet P.

  Further, when the laminated panel 1 is molded using the reinforcing material unit 5 having the configuration shown in FIGS. 17, 19, 20, and 21, the resin sheet P is formed using the molding method example of the first embodiment. The reinforcing material unit 5 can be attached to the resin sheet P while the surface of the foam 50 of the reinforcing material unit 5 is melted by heat. However, in the molding method example of the first embodiment, before the reinforcing material unit 5 is inserted between the divided molds 32, the surface of the foam 50 of the reinforcing material unit 5 is warmed by a heating means such as an infrared heater. It is also possible to leave. The timing for heating the surface of the foam 50 with the heating means is not particularly limited as long as it is before the resin sheet P and the reinforcing material unit 5 are welded, and the surface of the foam 50 can be heated at any timing. It is.

<Operation / Effect of Laminated Panel 1 of this Embodiment>
As described above, the laminated panel 1 of the present embodiment is configured by integrally connecting the vertical reinforcing member 51 and the horizontal reinforcing member 52 with the foam 50, and includes the reinforcing members 51 and 52 facing in different directions. The reinforcing material unit 5 is formed. Then, the reinforcing material unit 5 formed of the foam 50 is attached to the resin sheet P shaped into the shape along the cavity 116 of the split mold 32, and the split mold 32 is closed and the resin sheet P is closed. The reinforcing material unit 5 is clamped with the split mold 32, and the laminated panel 1 in which the reinforcing material unit 5 is housed is molded. Thereby, the laminated panel 1 in which the reinforcing material unit 5 composed of the reinforcing materials 51 and 52 facing in different directions can be easily formed.

  Further, since the reinforcing material unit 5 of the present embodiment has the foam 50, the reinforcing material unit 5 can be easily attached to the resin sheet P. Further, since the vertical reinforcing member 51 and the horizontal reinforcing member 52 are connected by the foam 50, a stable reinforcing member unit 5 can be obtained.

(Third embodiment)
Next, a third embodiment will be described.

  In the first and second embodiments, as shown in FIGS. 1, 21, etc., a lateral reinforcing member 52 is interposed between a plurality of vertical reinforcing members 51, 51 arranged on the contact surfaces 31 on both sides, The reinforcing material unit 5 constituted by the reinforcing materials 51 and 52 facing in different directions is arranged on the laminated panel 1.

  In the third embodiment, as shown in FIGS. 22A to 22C, a lateral reinforcing material 52 is interposed between the longitudinal directions of one vertical reinforcing material 51 arranged on the contact surfaces 31 on both sides. Then, the reinforcing material unit 5 composed of the reinforcing materials 51 and 52 facing in different directions is arranged on the laminated panel 1. However, in the case of the third embodiment, the lateral reinforcing material 52 constituting the reinforcing material unit 5 is also arranged on the contact surface 31. Thereby, the intensity | strength of the laminated panel 1 can be improved efficiently similarly to 1st, 2nd embodiment. FIG. 22 includes a vertical reinforcing member 51 arranged so as to be bridged between the contact surfaces 31 on both sides, and a horizontal reinforcing member 52 interposed between the vertical reinforcing member 51 and the contact surface 31. FIG. 3 is a diagram showing a configuration example of a laminated panel 1 in which a reinforcing material unit 5 is arranged.

  The lateral reinforcing member 52 constituting the reinforcing member unit 5 of the present embodiment is not particularly limited as long as the horizontal reinforcing member 52 is connected to the vertical reinforcing member 51 and disposed on the contact surface 31. It can be arranged in any shape or any position. If the horizontal reinforcing member 52 is connected to the vertical reinforcing member 51 and disposed on the contact surface 31, the vertical reinforcing member 51 and the horizontal reinforcing member 52 can efficiently improve the strength of the laminated panel 1. it can. In addition, since the horizontal reinforcement material 52 of 3rd Embodiment is arrange | positioned at the contact surface 31, it is preferable to comprise the vertical reinforcement material 51 and the horizontal reinforcement material 52 with metal. Further, the position of the contact surface 31 is not limited to the position shown in FIGS. 22A to 22C, and the contact between the laminated panel 1 and another member when the laminated panel 1 is placed on another member. The contact surface 31 can be set at an arbitrary position depending on the state. For this reason, in this embodiment, the reinforcing material unit 5 is configured by changing the arrangement positions of the vertical reinforcing material 51 and the horizontal reinforcing material 52 in accordance with the position of the contact surface 31 of the laminated panel 1. The method shown in FIG. 3 and the like can be applied to the method of connecting the vertical reinforcing member 51 and the horizontal reinforcing member 52 shown in FIGS. 22A and 22B as in the first embodiment. Further, the method shown in FIG. 3 or the like can be applied to the method of connecting the vertical reinforcing members 51 and the horizontal reinforcing members 52 shown in FIG. However, in the case of the configuration of the reinforcing member unit 5 shown in FIG. 22 (c), the shape of the connecting portion between the vertical reinforcing member 51 and the horizontal reinforcing member 52 and the connecting portion between the horizontal reinforcing members 52 depends on the connecting state. Need to be processed appropriately.

  Note that the reinforcing material unit 5 shown in FIGS. 22A to 22C is composed of a vertical reinforcing material 51 and a horizontal reinforcing material 52 that face in different directions. However, the reinforcing material unit 5 shown in FIGS. 22A to 22C can be configured to have the foam 50 as in the second embodiment. In this case, the vertical reinforcing member 51 and the horizontal reinforcing member 52 are fixed by the foam 50. The shape of the foam 50 can be configured in any shape as shown in FIGS. 17, 19, 20, etc. as long as the vertical reinforcing member 51 and the horizontal reinforcing member 52 can be fixed. is there. Further, the connecting method between the vertical reinforcing member 51 and the foam 50 and the connecting method between the horizontal reinforcing member 52 and the foam 50 are not particularly limited. For example, the method shown in FIG. 18 as in the second embodiment, etc. Is applicable.

  Moreover, the laminated panel 1 of this embodiment can be shape | molded by the method similar to the 1st, 2nd embodiment, for example, faces the mutually different direction as shown to FIG.22 (a)-(c). The reinforcing material unit 5 composed of the reinforcing materials 51 and 52 is attached to the resin sheet P shaped into the shape along the cavity 116 of the split mold 32, and the split mold 32 is closed to close the resin sheet P and the reinforcing material unit 5 Are clamped with the split mold 32, the laminated panel 1 in which the reinforcing material unit 5 shown in FIGS. 22 (a) to 22 (c) is housed can be formed. In the laminated panel 1 of the present embodiment, a lateral reinforcement member 52 is interposed between the longitudinal directions of the longitudinal reinforcement members 51 disposed on the contact surface 31, and the lateral reinforcement member 52 is also disposed on the contact surface 31. Therefore, the strength of the laminated panel 1 can be improved efficiently.

<Operation / Effect of Laminated Panel 1 of this Embodiment>
As described above, the laminated panel 1 of the present embodiment includes the vertical reinforcing member 51 arranged so as to be bridged over the contact surface 31, and the lateral reinforcement interposed between the vertical reinforcing member 51 and the contact surface 31. Since the reinforcing member unit 5 is constituted by the material 52, the strength of the laminated panel 1 can be efficiently improved as in the first and second embodiments.

  The above-described embodiment is a preferred embodiment of the present invention, and the scope of the present invention is not limited to the above-described embodiment alone, and various modifications are made without departing from the gist of the present invention. Implementation is possible.

  For example, the laminated panel 1 of the above-described embodiment is formed by sandwiching the reinforcing material unit 5 between two resin sheets P. However, the laminated panel 1 of the present embodiment may be formed by sandwiching the reinforcing material unit 5 between at least two resin sheets P. For example, the laminated panel 1 may be formed by sandwiching the reinforcing material unit 5 between four resin sheets P. Is also possible. The layer structure of the laminated panel 1 in this case is resin sheet / resin sheet / reinforcing material unit / resin sheet / resin sheet.

  Further, the laminated panel 1 of the above-described embodiment is configured to provide the hollow portion 6 inside the laminated panel 1. However, it is also possible to make the entire interior of the laminated panel 1 solid by using the foam 50 without providing the hollow portion 6. For example, an accommodating portion 54 for accommodating the reinforcing material unit 5 shown in FIG. 2 is formed for one large foam 50, and the reinforcing material unit 5 is fitted into the formed accommodating portion 54, so that the reinforcing material unit 5 It is also possible to mold the laminated panel 1 by using the foam 50 in which is inserted as the reinforcing material unit 5 used in the above-described molding method example. As a result, the foam 50 containing the reinforcing material unit 5 composed of the reinforcing materials 51 and 52 facing in different directions shown in FIG. 2 was covered with the resin sheet P constituting the front wall 2 and the back wall 3. The laminated panel 1 can be formed.

1 Laminated panel 2 Front wall (resin base material)
3 Back wall (resin base material)
31 Contact surface
4 Surrounding walls
5 Reinforcement unit
51 Vertical reinforcement
52 Lateral reinforcement
51a opening
53 Ribs
6 Hollow part
7 Cosmetic material
10 Hinge part
50 Foam

The present invention relates to a method of molding a laminated panel having a reinforcing member.

Claims (7)

A laminated panel that contacts another member at a predetermined contact surface,
A first reinforcing material and a second reinforcing material arranged so as to be bridged over the contact surface;
A reinforcing material unit comprising a reinforcing material of the second reinforcing material and a third reinforcing material interposed between the reinforcing material of the second reinforcing material,
And a resin base material sandwiching the reinforcing material unit from the upper and lower surfaces of the reinforcing material unit. The reinforcement unit is
At least one of the first reinforcing material and the second reinforcing material, the first reinforcing material and the third reinforcing material, or the second reinforcing material and the third reinforcing material is at least The laminated panel according to claim 1, wherein the laminated panel is fixed with a foam. A laminated panel that contacts another member at a predetermined contact surface,
A reinforcing material unit comprising a first reinforcing material arranged so as to be bridged over the abutting surface, and a second reinforcing material interposed between the first reinforcing material and the abutting surface. When,
And a base resin that sandwiches the reinforcing material unit from above and below the reinforcing material unit. The laminated panel according to claim 3, wherein the first reinforcing material and the second reinforcing material are fixed with a foam. A method for forming a laminated panel formed by sandwiching a reinforcing material unit composed of at least two reinforcing materials facing different directions from each other in a molten resin sheet,
A shaping step of shaping the resin sheet into a shape along the mold cavity;
An affixing step of attaching the reinforcing material unit to the resin sheet shaped into a shape along the cavity;
A mold clamping step of clamping the reinforcing material unit and the resin sheet with the mold, and molding the laminated panel;
A molding method characterized by comprising: The reinforcing material unit is composed of a first reinforcing material, a second reinforcing material, and a third reinforcing material interposed between the first reinforcing material and the second reinforcing material,
At least one of the first reinforcing member and the second reinforcing member, the first reinforcing member and the third reinforcing member, the second reinforcing member and the third reinforcing member, or the like. 6. The molding method according to claim 5, further comprising a forming step of forming the reinforcing material unit fixed with a foam. The reinforcing material unit is composed of a first reinforcing material and a second reinforcing material interposed between the longitudinal directions of the first reinforcing material,
The molding method according to claim 5, further comprising a forming step of forming the reinforcing material unit in which the first reinforcing material and the second reinforcing material are fixed with a foam.