JP2018051928A - Foamed structure and resin panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To securely prevent relative displacement of a reinforcement member with respect to foamed bodies in a foamed structure in which the reinforcement member is interposed between the two foamed bodies.SOLUTION: The foamed structure according to an embodiment includes: a reinforcement member having a pair of long plate-like parts opposing to each other with a prescribed gap provided therebetween; and a foamed body. The foamed body includes: a housing part formed on a top face or a back face for housing the reinforcement member; and a fitting part which is projected into the gap of the reinforcement member from at least one of both ends of the reinforcement member to be fitted with the reinforcement member. The fitting part has its thickness increased in a direction along which the pair of plate-like parts are opposing to each other from a top end of the part projected into the gap of the reinforcement member toward one end of the reinforcement member.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a foam structure and a resin panel.

Conventionally, resin panels have been used for various purposes such as automobiles, building materials, sports and leisure. The resin panel is a laminated body in which a foam structure including one or a plurality of foams made of a foam resin is covered with a skin material sheet.
In order to improve the rigidity and strength of the foam structure, it is known to interpose a reinforcing material between the two foams (for example, cited document 1).

Japanese Patent Laying-Open No. 2015-164863

  When molding a skin material on the surface of a foam structure in which a reinforcing material is interposed between two foams, if the reinforcing material moves relative to the foam in the molding process, molding the skin material This leads to defects that cannot be performed, or appearance defects of the skin material after molding.

  From such a viewpoint, an object of the present disclosure is to reliably prevent relative movement of the reinforcing material with respect to the foam in the foamed structure in which the reinforcing material is interposed between the two foams.

A first aspect of the present disclosure includes a reinforcing material having a pair of long plate-like portions facing each other with a predetermined amount of gap therebetween, and a foam.
The foam is
A housing portion formed on the front surface or the back surface, in which the reinforcing material is disposed;
A protruding portion that protrudes into the gap of the reinforcing material from at least one end of both ends of the reinforcing material, and has a fitting portion that fits with the reinforcing material;
The fitting portion is characterized in that a thickness in a direction in which the pair of plate-like portions face each other increases from a tip of a portion protruding into the gap of the reinforcing material toward the one end of the reinforcing material. To do.

  In the foam structure, the foam may include a stopper having a wall surface facing at least one of the ends of the reinforcing material in the longitudinal direction of the reinforcing material.

  In the foam structure, the foam may have a raised portion formed on a surface of the front surface and the back surface opposite to the surface on which the housing portion is formed.

  A second aspect of the present disclosure is a resin panel in which the above-described foam structure is covered with a skin material sheet.

  In a foam structure in which a reinforcing material is interposed between two foams, relative movement of the reinforcing material with respect to the foam can be reliably prevented.

The perspective view of the back side of the resin-made panels of embodiment. The perspective view of the back side of the interior material of embodiment. The perspective view of the front side of the interior material of embodiment. The perspective view of the reinforcing material integrated in the interior material of embodiment. The perspective view of the front side of the foam of embodiment. FIG. 6 is an enlarged view of a G1 portion and a G2 portion in FIG. 5. The top view of G1 part and G2 part of the foam of an embodiment. Sectional drawing of AA, BB, DD, EE shown in FIG. Sectional drawing of CC and FF shown in FIG. The figure explaining the method of assembling the interior material of embodiment. The figure explaining the process of shape | molding the skin material of the resin-made panels of embodiment. The figure explaining the process of shape | molding the skin material of the resin-made panels of embodiment. Sectional drawing of CC shown in FIG. 7 in a modification. The figure explaining the foam which concerns on a modification.

  Hereinafter, the resin panel 1 which is one embodiment of the present invention and the interior material 10 provided in the resin panel 1 will be described. The interior material 10 for the resin panel 1 is an example of the foam structure of the present invention.

(1) Resin panel 1 and interior material 10 for resin panel 1
First, with reference to FIGS. 1-4, the structure of the resin panels 1 and the interior material 10 of this embodiment is demonstrated. FIG. 1 is a perspective view of the back side of the resin panel 1 of the present embodiment. FIG. 2 is a perspective view of the back side of the interior material 10 of the present embodiment. FIG. 3 is a perspective view of the front side of the interior material 10 of the present embodiment. FIG. 4 is a perspective view of the reinforcing material 3 incorporated in the interior material 10.

As shown in FIGS. 1 and 2, the surface of the resin panel 1 according to the present embodiment is constituted by a skin material sheet S of a thermoplastic resin, and an interior material 10 is housed therein. That is, the resin panel 1 has a structure in which the interior material 10 is covered with the skin sheet S of the thermoplastic resin.
As shown in FIG. 1, the exemplary resin panel 1 in the present embodiment has a configuration in which a raised portion 12 is formed on a base 11 having a substantially rectangular parallelepiped shape on the back side.

  In the resin panel 1 of the embodiment, the skin material sheet S serving as the skin material sheet is not limited to the resin material, but is preferably formed from a non-foamed resin in order to ensure the rigidity of the resin panel 1. For example, in consideration of moldability, the skin material sheet S may be obtained by mixing polystyrene (PS) and styrene ethylene butylene styrene block copolymer resin (SEBS) with polypropylene (PP) as a main material.

As shown in FIG. 2 and FIG. 3, the interior material 10 is a foam made up of foamed portions 21 to 23 corresponding to the base portion 11 of the resin panel 1 and a foamed portion 25 corresponding to the raised portion 12 of the resin panel 1. It is a composite structure including a body 2 and two reinforcing members 3 fitted to the foam 2. The reinforcing material 3 is interposed between the foaming part 21 and the foaming part 22 and between the foaming part 22 and the foaming part 23, respectively.
As shown in FIG. 2, a foamed portion 25 is formed on the back surface 2 b of the foam 2 so as to protrude from the back surface of the foamed portions 21 to 23. As shown in FIG. 3, the front surface 2a of the foam 2 is a substantially flat surface.

As shown in FIG. 4, the reinforcing member 3 includes a pair of long first plate portion 31 and second plate portion 32 that face each other with a predetermined amount of gap therebetween, and a first plate shape. And a connecting plate 33 that connects the portion 31 and the second plate-like portion 32. In the example shown in FIG. 4, the cross section of the reinforcing material 3 is H-shaped (H-shaped reinforcement).
Projections 311 projecting toward the second plate portion 32 are provided at both ends of the first plate portion 31, and the first plate portion 31 is provided at both ends of the second plate portion 32. A protrusion 321 that protrudes toward the surface is provided.
The material of the reinforcing material 3 is not particularly limited, but is preferably made of a metal such as aluminum or a hard plastic in order to ensure the strength of the resin panel 1. The reinforcing material 3 is formed by, for example, extrusion molding.
The cross-sectional shape of the reinforcing member 3 is not limited to that shown in the figure, and may be, for example, a C shape, a U shape, a square pipe shape, a circular pipe shape, etc. Any appropriate one may be used.

  In the resin panel 1 of the embodiment, the foamed portions 21 to 23 and 25 are formed using, for example, a thermoplastic resin. The resin material is not limited, but includes any one of polyolefins such as polypropylene and polyethylene, acrylic derivatives such as polyamide, polystyrene, and polyvinyl chloride, or a mixture of two or more. The expansion ratio of the foamed portions 21 to 23 and 25 is not particularly limited, but is, for example, in the range of 1.5 to 60 times, typically 20 times or 30 times, preferably 10 to 45 times. More preferably, it is 15 to 35 times. The expansion ratio is a value obtained by dividing the density of the mixed resin before foaming by the apparent density of the foamed resin after foaming.

  In the resin panel 1 of the embodiment, examples of the foaming agent that can be used for the foamed portions 21 to 23 and 25 include known physical foaming agents, chemical foaming agents, and mixtures thereof. For example, as the physical foaming agent, inorganic physical foaming agents such as air, carbon dioxide gas and nitrogen gas, and organic physical foaming agents such as butane, pentane, hexane, dichloromethane and dichloroethane can be applied. Examples of the chemical foaming agent include azodicarbonamide (ADCA), N, N′-dinitrosopentamethylenetetramine, 4,4′-oxybis (benzenesulfonylhydrazide), diphenylsulfone-3,3′-disulfonyl. Organic blowing agents such as hydrazide, p-toluenesulfonyl semicarbazide, trihydrazinotriazine or azobisisobutyronitrile, citric acid, oxalic acid, fumaric acid, phthalic acid, malic acid, tartaric acid, cyclohexane-1,2-dicarboxylic acid , A mixture of polycarboxylic acids such as camphoric acid, ethylenediaminetetraacetic acid, triethylenetetraminehexaacetic acid, nitrilolic acid and inorganic carbonic acid compounds such as sodium bicarbonate, sodium aluminum bicarbonate, potassium bicarbonate, ammonium bicarbonate, ammonium carbonate Citric dihydrogen sodium hydrogen salts of polycarboxylic acids, such as potassium oxalate and the like as the inorganic foaming agent.

The skin material sheet S and the foamed portions 21 to 23 and 25 may be molded using a resin material mixed with a glass filler for the purpose of increasing rigidity and strength.
Examples of the glass filler include glass fiber, glass fiber cloth such as glass cloth and glass nonwoven fabric, glass beads, glass flakes, glass powder, and milled glass. Examples of the glass include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, quartz, low dielectric constant glass, and high dielectric constant glass.
In addition to the glass filler, inorganic fillers such as talc, calcium carbonate, wollastonite, magnesium-based material, and the like for increasing rigidity may be mixed.

(2) Detailed structure of interior material 10 Next, with reference to FIGS. 5-9, the detailed structure of the interior material 10 of this embodiment is demonstrated.

(2-1) Configuration of Foam 2 First, the configuration of the foam 2 will be described below with reference to FIGS.
FIG. 5 is a perspective view of the front side of the foam 2 of the present embodiment. FIG. 6 is an enlarged view of the G1 portion and the G2 portion of FIG. FIG. 7 is a plan view of the G1 portion and the G2 portion of the foam 2 of the present embodiment. 8 is a cross-sectional view taken along lines AA, BB, DD, and EE shown in FIG. 9 is a cross-sectional view taken along lines CC and FF shown in FIG.
The foam 2 is formed by, for example, a bead method in-mold foam molding method. For a molding example by the bead method in-mold foam molding method, refer to, for example, Japanese Patent Application Laid-Open No. 2014-128938.

  As shown in FIG. 5, linear accommodating portions 201 and 202 are formed on the front surface of the foam 2 from one end to the other end. In the example of this embodiment, the accommodating parts 201 and 202 have the same shape. The accommodating part 201 is formed between the foaming part 21 and the foaming part 22, the accommodating part 202 is formed between the foaming part 22 and the foaming part 23, and each accommodating part is the reinforcing material 3 (H-shaped) shown in FIG. Reinforce) is provided for disposing the foam 2.

Referring to FIGS. 6 and 7, in the foam 2, the fitting portions 213 and 223 that are fitted to one end in the longitudinal direction of the reinforcing material 3 are provided on the G1 and G2 portions in the vicinity of both ends of the accommodating portion 201, and the reinforcing material. 3 is formed with fitting portions 217 and 227 that are fitted to the other end in the longitudinal direction. Further, stoppers 215, 225, 219, and 229 are formed in the G1 portion and the G2 portion of the foam 2 in order to surely prevent the reinforcing material 3 from dropping from the foam 2 in the longitudinal direction.
In FIG. 7, the bottom surface 230 of the housing portion 201 is a surface on which the reinforcing material 3 is placed, and is a surface that contacts the second plate-like portion 32 of the reinforcing material 3.

Hereinafter, it will be described in more detail with reference to the cross-sectional views of FIGS. In FIG.8 and FIG.9, the position of the reinforcing material 3 when the reinforcing material 3 is integrated in the foam 2 is shown with the virtual line. In the following description, the accommodation unit 201 will be referred to, but the accommodation unit 202 has the same shape as the accommodation unit 201.
As shown in the AA cross section and the DD cross section of FIG. 8, side surfaces 211 and 221 and a bottom surface 230 that face each other are formed in the accommodating portion 201 of the foam 2. The side surface 211 is interposed between the bottom surface 230 and the front surface 21 a of the foamed portion 21, and the side surface 221 is interposed between the bottom surface 230 and the front surface 22 a of the foamed portion 22.
In a state in which the reinforcing material 3 is fitted with the foam 2, the second plate-like portion 32 of the reinforcing material 3 abuts on the bottom surface 230, and the first plate-like portion 31 and the second plate-like portion of the reinforcing material 3. Both side surfaces of 32 abut against the side surfaces 211 and 221.

  The depth of the accommodating portion 201 is such that the foaming surfaces 21 and 22 have the front surfaces 21 a and 22 a and the first plate-like portion 31 of the reinforcing member 3 in a state where the reinforcing member 3 is in contact with the bottom surface 230 of the accommodating portion 201. Although it is preferable to set the upper surface so as to be substantially in the same plane, the present invention is not limited to this.

As shown in the BB cross section of FIG. 6A and FIG. 8, the fitting portions 213 and 223 are formed so as to protrude from the side surfaces 211 and 221 of the housing portion 201 in a direction opposite to each other. By being located in the gap between the first plate-like portion 31 and the second plate-like portion 32, it is fitted to one end in the longitudinal direction of the reinforcing material 3.
As shown in the EE cross section of FIG. 6B and FIG. 8, the fitting portions 217 and 227 are formed so as to protrude from the side surfaces 211 and 221 of the housing portion 201 in a direction facing each other. By being located in the gap between the first plate-like portion 31 and the second plate-like portion 32, the other end of the reinforcing member 3 in the longitudinal direction is fitted.

As shown in the CC cross section of FIG. 9, the fitting portion 213 is a plate-like portion formed along the longitudinal direction of the reinforcing material 3, and the first plate of the reinforcing material 3 from one end of the reinforcing material 3. It protrudes into the gap between the shaped part 31 and the second plate-like part 32 and fits with the reinforcing material 3.
The front surface 213 a of the fitting portion 213 is substantially parallel to the longitudinal direction of the reinforcing member 3, that is, substantially parallel to the upper surface of the first plate-like portion 31 and the bottom surface of the second plate-like portion 32. The back surface 213b of the fitting portion 213 is inclined toward the one end of the reinforcing member 3 from the tip end surface 213t of the portion protruding into the gap of the reinforcing member 3. Therefore, the first plate-like portion 31 and the second plate-like portion 32 face each other as the fitting portion 213 moves from the tip end surface 213t of the portion protruding into the gap of the reinforcing member 3 toward one end of the reinforcing member 3. The thickness in the direction to increase.

As shown in the FF cross section of FIG. 9, the fitting portion 217 is a plate-like portion formed along the longitudinal direction of the reinforcing material 3, and the first plate of the reinforcing material 3 from one end of the reinforcing material 3. It protrudes into the gap between the shaped part 31 and the second plate-like part 32 and fits with the reinforcing material 3.
The front surface 217 a and the back surface 217 b of the fitting portion 217 are substantially parallel to the longitudinal direction of the reinforcing material 3, that is, substantially parallel to the top surface of the first plate-like portion 31 and the bottom surface of the second plate-like portion 32. It is. That is, the fitting portion 217 is formed so that the thickness thereof is substantially constant in the direction from the tip surface 217 t of the portion protruding into the gap of the reinforcing material 3 toward one end of the reinforcing material 3.

As shown in the CC cross section of FIG. 9, the stopper 215 has a wall surface 215 w that faces one end of the reinforcing member 3 at the end opposite to the front end surface 213 t of the fitting portion 213. Although not shown, the stopper 225 also has a similar wall surface.
As shown in the FF cross section of FIG. 9, the stopper 219 has a wall surface 219 w that faces one end of the reinforcing member 3 at the end opposite to the tip end surface 217 t of the fitting portion 217. Although not shown, the stopper 229 also has a similar wall surface.

  The cross-sectional shape of the fitting part 223 and the stopper 225 is the same as the CC cross section of FIG. The cross-sectional shape of the fitting part 227 and the stopper 229 is the same as the FF cross section of FIG.

(2-2) Assembly of Interior Material 10 Next, a method for assembling the interior material 10 based on the foam 2 described above will be described with reference to FIG.
FIG. 10 is a diagram for explaining a method of assembling the interior material 10 of the present embodiment, and shows a procedure for fitting the reinforcing material 3 to the foam 2 in the order of (a) and (b).

In order to assemble the interior material 10, after the foam 2 is molded, the foam 2 is disposed so that the front surface of the foam 2 faces upward.
Then, as shown in FIG. 10A, the reinforcing member 3 is tilted so that one end of the reinforcing member 3 is obliquely downward, and the first plate-like portion 31 and the second plate-like member of the reinforcing member 3 at the one end. The reinforcing material 3 is pressed against the foam 2 so that the fitting parts 217 and 227 of the foam 2 are inserted into the gaps between the parts 32. Thereby, one end of the reinforcing member 3 is fitted to the fitting portions 217 and 227 of the foam 2.

  Next, as shown in FIG. 10 (b), the foam is formed in the gap between the first plate portion 31 and the second plate portion 32 of the reinforcing member 3 at the other end where the reinforcing member 3 is not fitted. The reinforcing member 3 is positioned so that the two fitting portions 213 and 223 are inserted. Thereby, the other end of the reinforcing member 3 is fitted to the fitting portions 213 and 223 of the foam 2.

As shown in the CC cross section of FIG. 9, in a state where the other end of the reinforcing member 3 is fitted to the fitting portions 213 and 223 of the foam 2, the fitting portions 213 and 223 are the first of the reinforcing member 3. It will be in the state protruded in the clearance gap between the plate-shaped part 31 and the 2nd plate-shaped part 32 of this.
At this time, the fitting portion 213 increases from the tip end surface 213t of the portion protruding into the gap between the first plate-like portion 31 and the second plate-like portion 32 of the reinforcing member 3 toward one end of the reinforcing member 3. The thickness in the direction in which the first plate-like portion 31 and the second plate-like portion 32 face each other is increased. The same applies to the fitting portion 223. Therefore, the second plate-like portion 32 of the reinforcing member 3 is sandwiched between the back surface 213b of the fitting portion 213 and the bottom surface 230 (see FIG. 8) of the accommodating portion 201, and the back surface of the fitting portion 223 (not shown). 2) and the bottom surface 230 of the housing portion 201, the reinforcing member 3 is positioned in the longitudinal direction.

  Furthermore, in the foam 2 of the present embodiment, the stoppers 215, 225, 219, and 229 reliably prevent the reinforcing material 3 from falling off the foam 2. In particular, as shown in the FF cross section of FIG. 9, the fitting portion 217 does not sandwich the second plate-like portion 32 with the bottom surface 230, but the reinforcing material 3 temporarily moves to the fitting portion 217 side. Even in this case, the reinforcing material 3 is not dropped from the foam 2 by the stopper 219.

Although FIG. 10 shows the case where the reinforcing material 3 is disposed in the housing portion 201, the reinforcing material 3 is similarly disposed in the housing portion 202. As a result, the two reinforcing members 3 are fitted into the foam 2 to complete the interior material 10.
In the above-described method of assembling the interior material 10, the fitting portions 217 and 227 of the foam 2 are first inserted into one end of the reinforcing material 3, and then the fitting portions 213 and 223 of the foam 2 are inserted into the reinforcing material 3. However, this order may be changed.

  The fitting method of the reinforcing material 3 of this embodiment is suitable when the foaming part 25 (refer FIG. 2) which protrudes in the back surface 2b of the foam 2 is formed. That is, when there is a raised portion on at least one of the front surface and the back surface of the foam, the thickness of the raised portion becomes relatively large. Therefore, if the method of fitting the reinforcing material after cutting the foam at the ridge is taken, the ridge having a large thickness will be divided into two, so that the local rigidity of the ridge is reduced. A decline is inevitable. On the other hand, in this embodiment, since the reinforcing material 3 can be fitted without the foam 2 being cleaved by the foamed portion 25 that is the raised portion, a local rigidity decrease in the foamed portion 25 is avoided. be able to.

(3) Molding method of resin panel 1 Next, with reference to FIGS. 11 and 12, a method of molding the resin panel 1 covering the interior material 10 with the skin sheet S using a mold will be described. FIGS. 11 and 12 are diagrams illustrating a process of forming the skin material sheet S of the resin panel 1 of the present embodiment.

  Referring to FIG. 11, the mold clamping device 70 is positioned between an open position and a closed position in a direction substantially orthogonal to the molten resin sheets P and P extruded vertically from an extrusion device (not shown). It has a pair of split molds 71A and 71B to be moved. The pair of split molds 71A and 71B are arranged in a state where the formation surfaces 72A and 72B corresponding to each of them are opposed to each other. The formation surface 72A has a shape corresponding to the front surface and the back surface of the foam 2.

  In each of the pair of split molds 71A and 71B, pinch-off portions 74A and 74B are formed in the vicinity of upper and lower ends of the corresponding formation surfaces 72A and 72B. The pinch-off portions 74A and 74B are formed annularly around the formation surfaces 72A and 72B, respectively, and project toward the opposing split molds 71B and 71A. As a result, when clamping the pair of split molds 71A and 71B, the tip portions of the pinch-off portions 74A and 74B come into contact with each other, and a parting line is formed at the periphery of the molten resin sheets P and P. ing.

  The pair of split molds 71A and 71B are provided with sliding portions 75A and 75B that can protrude from the formation surfaces 72A and 72B around the formation surfaces 72A and 72B. The sliding portions 75A and 75B are in a state of projecting from the formation surfaces 72A and 72B, and their end surfaces are brought into contact with the molten resin sheets P and P, whereby the molten resin sheets P and P and the pair of split molds 71A and 71B It is provided to form a sealed space between the formation surfaces 72A and 72B.

  The pair of split molds 71A and 71B includes a vacuum chamber (not shown). The vacuum chamber is connected to a vacuum pump and a vacuum tank (both not shown). A communication path (not shown) for vacuum suction is provided between the vacuum chamber and the formation surfaces 72A and 72B.

  The pair of split molds 71A and 71B are driven by a mold driving device (not shown) so as to be movable between an open position and a closed position. In the open position, two continuous molten resin sheets P, P can be arranged at a distance from each other between the pair of split molds 71A, 71B. The two molten resin sheets P and P become the skin material sheet S in the resin panel 1 after molding. In the closed position, the pinch-off portions 74A and 74B of the pair of split molds 71A and 71B abut.

Next, a method for forming the resin panel 1 will be described.
First, as shown in FIG. 11, the molten resin sheets P and P are extruded vertically downward from the extrusion device, and are supplied between the forming surfaces 72A and 72B of the pair of split molds 71A and 71B. At this point, the pair of split molds 71A and 71B are in the open position.

  Next, the sliding portions 75A and 75B around the formation surfaces 72A and 72B are protruded, and the end surfaces thereof are brought into contact with the molten resin sheets P and P. As a result, a sealed space is formed between the molten resin sheets P and P and the formation surfaces 72A and 72B of the pair of split molds 71A and 71B. And the air in sealed space is attracted | sucked by the communicating path provided between the vacuum chamber and formation surface 72A, 72B. By this suction, the two molten resin sheets P and P are pressed against the formation surfaces 72A and 72B of the pair of split molds 71A and 71B, respectively, and along the formation surfaces 72A and 72B as shown in FIG. It is shaped (formed) into the shape, that is, the substantially outer shape of the resin panel 1.

Next, the interior material 10 assembled as described above is positioned between the pair of split molds 71A and 71B using a manipulator (not shown), and as shown in FIG. It inserts so that it may press against a division mold (in FIG. 12, division mold 71B). Thereby, the interior material 10 is welded to one molten resin sheet P.
At this time, as described above, in the interior material 10, since the reinforcing material 3 is positioned in the longitudinal direction, the interior material 10 is arranged so that the longitudinal direction of the reinforcing material 3 is the vertical direction. However, it is possible to prevent the reinforcing material 3 from falling off the interior material 10.

  Thereafter, the pair of split molds 71A and 71B are moved from the open position to the closed position and clamped. Thereby, the interior material 10 that has been welded to one molten resin sheet P (right side of the drawing) is also welded to the other molten resin sheet P (left side of the drawing). Furthermore, in the pinch-off portions 74A and 74B of the pair of split molds 71A and 71B, the peripheral edges of the pair of molten resin sheets P and P are welded to form the parting line PL.

Finally, the pair of split molds 71A and 71B are moved again to the open position, the molded resin panel 1 is separated from the formation surfaces 72A and 72B, and the burrs formed around the parting line PL are removed with a cutter or the like. Cut and remove. Thus, the resin panel 1 having a structure in which the interior material 10 is covered with the skin sheet S is completed.
In the method for molding the resin panel 1 described above, the case where the molten resin sheet P is pressed against the formation surfaces 72A and 72B of the pair of split molds 71A and 71B by suction has been described, but the present invention is not limited thereto. The molten resin sheet P may be pressed against the formation surfaces 72A and 72B of the pair of split molds 71A and 71B by blowing a fluid such as air onto the molten resin sheet P (blow molding).

  As mentioned above, although each embodiment of this invention was described in detail, the resin-made panel and foam structure of this invention are not limited to said each embodiment, In the range which does not deviate from the main point of this invention, various improvement and change Of course, you may do.

In the fitting part 213 shown in the CC cross section of FIG. 9, the reinforcing material 3 from the tip surface 213 t of the portion protruding into the gap between the first plate-like part 31 and the second plate-like part 32 of the reinforcing material 3. Although the case where the back surface 213b is inclined as it goes to one end is illustrated, it is not limited thereto. The thickness of the fitting portion increases from the front end surface 213t of the portion protruding into the gap between the first plate-like portion 31 and the second plate-like portion 32 of the reinforcing member 3 toward one end of the reinforcing member 3. The inclined surface is not limited to the back surface 213b.
For example, like the fitting portion 213A of the modification shown in FIG. 13A, the tip end surface 213At of the portion protruding into the gap between the first plate-like portion 31 and the second plate-like portion 32 of the reinforcing material 3 Both the front surface 213Aa and the back surface 213Ab may be inclined from one end to the other end of the reinforcing member 3. Reinforcing from the front end surface 213Bt of the portion protruding into the gap between the first plate-like portion 31 and the second plate-like portion 32 of the reinforcing member 3, like the fitting portion 213B of the modification shown in FIG. As it goes to one end of the material 3, the front surface 213Ba may be inclined.

  In the above-described embodiment, as illustrated in FIGS. 6 and 9, the case where the fitting portion and the stopper are connected has been described, but the present invention is not limited thereto. The fitting portion and the stopper may be formed apart from each other. In that case, in FIG. 6, for example, the position where the fitting portions 213 and 223 protrude from the side surface of the housing portion 201 may be set closer to the center of the housing portion 201.

  In the embodiment described above, the case where the stoppers 215, 219, 225, and 229 are formed on the foam 2 has been described. However, at least one of the stoppers may not be provided, or no stopper may be provided at all. Also good. Even when the stopper is not provided, as long as the reinforcing member 3 is held by the fitting portion, the reinforcing member 3 is positioned, and therefore the possibility that the reinforcing member 3 is detached from the foam 2 is extremely low.

  In the above-described embodiment, as illustrated in FIGS. 6 and 7, the case where the fitting portions are provided on both ends of the accommodating portion 201 has been described, but the present invention is not limited thereto. You may provide a fitting part only in the any one end side of the accommodating part 201. FIG. Even in that case, the reinforcing material 3 can be positioned if the reinforcing material 3 is held by the fitting portion on one end side of the accommodating portion 201.

  In the above-described embodiment, the front surface and / or the back surface of one of the fitting portions of the pair of fitting portions (for example, the fitting portion 213 and the fitting portion 223) facing each other with the bottom surface 230 interposed therebetween. It is good also as an inclined surface, and it is good also considering the front surface and / or back surface of both the fitting parts as an inclined surface.

The reinforcing material 3 may be fitted to the foam 2 by cleaving the molded foam and inserting two foamed portions obtained by cleaving from one and the other of the reinforcing materials 3. FIG. 14 shows a foam according to such a modification. FIG. 14 is a diagram for explaining a foam according to a modification, in which (a) shows a part of a plan view of the foam, and (b) shows an HH cross section of (a). In FIG.14 (b), the reinforcing material 3 arrange | positioned after cleaving is shown with the virtual line.
In the modification shown in FIG. 14, the accommodating portion 201 includes a protruding portion 241 protruding from the end portion of the foaming portion 21, a protruding portion 242 protruding from the end portion of the foaming portion 22, and the protruding portion 241 and the protruding portion 242. And a thin wall portion 243 interposed therebetween. After forming the foam, the foam is cleaved at the thin-walled portion 243, the protruding portion 241 is inserted into one side of the reinforcing material 3 along the longitudinal direction of the reinforcing material 3, and the protruding portion 242 is aligned along the longitudinal direction of the reinforcing material 3. And insert it into the other side of the reinforcing member 3. As a result, the reinforcing material 3 is fitted to the foam 2.

  It goes without saying that the shape of the fitting portion is appropriately changed according to the cross-sectional shape of the reinforcing material. That is, when the cross-sectional shape of the reinforcing material is a C-shape, a U-shape, a square pipe shape, a circular pipe shape, or the like, from the front end surface of the portion located in the gap in the reinforcing material of the fitting portion toward one end of the reinforcing material, The shape of the fitting portion can be set so that the thickness of the fitting portion is increased or the surface pressure between the fitting portion and the reinforcing material is increased.

DESCRIPTION OF SYMBOLS 1 ... Resin panel 11 ... Base part 12 ... Raised part S ... Skin material sheet 10 ... Interior material (example of foam structure)
DESCRIPTION OF SYMBOLS 2 ... Foam 2a ... Front surface 2b ... Back surface 21-23, 25 ... Foam part 21a, 22a ... Front surface 21b, 22b ... Back surface 201, 202 ... Storage part 211, 221 ... Side surface 230 ... Bottom surface 213 217, 223, 227, 213A, 213B ... fitting part 213a, 217a, 213Aa, 213Ba ... front face 213b, 217b, 213Ab, 213Bb ... back face 213t, 217t, 213At, 213Bt ... tip face 215, 219, 225 229 ... Stopper 215w, 229w ... Wall surface 3 ... Reinforcing material 31 ... First plate-like portion 311 ... Protruding portion 32 ... Second plate-like portion 321 ... Protruding portion 33 ... Connecting portion 70 ... Clamping devices 71A, 71B ... Divided Mold 72A, 72B ... Forming surface 74A, 74B ... Pinch-off part 75A, 75B ... Sliding part P ... Molten resin sheet

Claims (4)

A reinforcing member having a pair of long plate-like portions facing each other with a predetermined amount of gaps therebetween;
A foam, and
The foam is
A housing portion formed on the front surface or the back surface, in which the reinforcing material is disposed;
A protruding portion that protrudes into the gap of the reinforcing material from at least one end of both ends of the reinforcing material, and has a fitting portion that fits with the reinforcing material;
The fitting portion is characterized in that a thickness in a direction in which the pair of plate-like portions face each other increases from a tip of a portion protruding into the gap of the reinforcing material toward the one end of the reinforcing material. To
Foam structure. The foam is provided with a stopper having a wall surface facing at least one of the ends of the reinforcing material in the longitudinal direction of the reinforcing material,
The foam structure according to claim 1. The foam is characterized in that a raised portion is formed on the surface opposite to the surface on which the housing portion is formed, of the front surface and the back surface.
The foam structure according to claim 1 or 2.   The resin-made panel which covered the foam structure described in any one of Claims 1-3 with the skin material sheet.

Images