JP2019025790A - Resin panel and production method - Google Patents

Abstract

To provide a resin panel capable of reducing a deformation of a resin sheet while reducing a formation of an air reservoir between the resin sheet and a foam when welding the resin sheet and the foam even in a case of using the resin sheet having a small thickness, and a production method.SOLUTION: In a hanging step, first and second resin sheets are suspended between first and second molds. In an insert step, a foam is welded to the first and second resin sheets. In a mold clamping step, the first and second molds are clamped, and the foam is disposed between the first and second resin sheets, and a resin panel production method which satisfies a following condition (1) or (2) is provided. (1) In a reference region of 2 cm×2 cm of a second opposing surface on a side facing the second resin sheet, two or more of the convex part or the concave part are provided in an independent state. (2) After the hanging step, the foam begins the insert step after the first resin sheet has cooled to 70 to 90°C.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a resin panel and a manufacturing method.

  In Patent Document 1, an outer peripheral space is formed around the foam sandwiched between the resin skin sheets by joining the peripheral edges of the two resin skin sheets, and the surface of the foam is formed on the surface of the foam. A resin sandwich panel is disclosed in which a lattice-shaped groove portion is provided and the groove portion and the outer peripheral space portion are communicated with each other. Thereby, even when an air pocket is unexpectedly formed when the foam and the resin skin sheet are surface-bonded, the air can be dispersed in the outer peripheral space.

Japanese Patent Laying-Open No. 2015-104887

  When the technique disclosed in Patent Document 1 is applied to a resin sheet, when the thickness of the resin sheet is thick (eg, 1.3 mm or more), the amount of heat of the resin sheet at the time of welding is sufficiently large, so As a result of the melting, the periphery of the groove of the foam melts, and the groove of the foam almost disappears. Thereby, the welding surface of a resin sheet and a foam becomes mutually substantially flat, and while being welded enough, the beauty | look is improved.

  However, when the thickness of the resin sheet is thin, the amount of heat of the resin sheet at the time of welding is not sufficient and the rigidity is low, so the resin sheet follows the shape of the groove at the time of welding and cannot guarantee sufficient welding. , Aesthetics may be impaired.

  The present invention has been made in view of such circumstances, and even when a thin resin sheet is used, the formation of an air pocket between the resin sheet and the foam is reduced while the resin sheet and the foam are welded. A resin panel capable of reducing deformation of a resin sheet and a manufacturing method thereof are provided.

  According to the present invention, a dripping process, an insert process, and a mold clamping process are provided. In the dripping process, the first and second resin sheets are suspended between the first and second molds, and in the insert process, The foam is welded to the first and second resin sheets, and in the mold clamping step, the first and second molds are clamped, and the foam is disposed between the first and second resin sheets, The foam has a convex portion or a concave portion on the second opposing surface facing the second resin sheet, and the convex portion or the concave portion is independent in a 2 cm × 2 cm reference region of the second opposing surface. Two or more are provided.

  In the method for manufacturing a resin panel according to the present invention, the foam includes a convex portion or a concave portion on the second opposing surface on the side facing the second resin sheet, and the 2 cm × 2 cm reference region of the second opposing surface is included. Two or more protrusions or recesses are provided in an independent state. Thereby, a 2nd resin sheet and a foam can contact the periphery of a convex part or a recessed part partially, and an air pocket can be disperse | distributed to an outer edge. Furthermore, even when the thickness of the second resin sheet is thin, the volume around the convex portion or the concave portion is smaller than that of the groove portion, so that the second resin sheet can be sufficiently melted and the aesthetics are improved.

Hereinafter, various embodiments of the present invention will be exemplified. The following embodiments can be combined with each other.
Preferably, the reference area is 3 cm × 3 cm, and five or more protrusions or recesses are provided in the reference area in an independent state.
Preferably, three or more of the convex portions or the concave portions are provided in the adjacent reference regions in an independent state.
Preferably, the value of the total area of the protrusions or the recesses in the reference region / the area of the reference region is 0.05 to 1.
Preferably, the height of the convex portion or the depth of the concave portion is 1/3 or less of the thickness of the foam.
Preferably, the interval between the convex portions or the concave portions is 3 mm or less.
Preferably, the convex portion is formed in a tapered shape toward the tip of the convex portion.
Preferably, each of the convex portions has a mountain shape.
Preferably, each of the recesses is provided discontinuously.
Preferably, the foam includes a connecting surface that connects the first facing surface and the second facing surface, and a notch-like air pocket space is formed on the connecting surface.
According to another aspect, a hollow resin molded body and a foam are provided, the foam is disposed in the resin molded body, and the foam includes a facing surface facing one surface of the resin molded body. The opposing surface includes a convex portion or a concave portion, and two or more of the convex portions or the concave portions are provided in a 2 cm × 2 cm reference area of the opposing surface, and the convex portion or the concave portion A resin panel is provided in which a part is melted by the resin sheet on which the resin molded body is formed.

It is a partially cutaway perspective view of resin panel 30 concerning one embodiment of the present invention. It is a figure which shows an example of the molding machine 1 which can be utilized with the manufacturing method of the resin panels 30. It is an enlarged view of the vicinity of the 1st and 2nd metal molds 21 and 22 and the 1st resin sheet 23a. It is an upper surface perspective view of the foam 31 used for manufacture of the resin panels 30 which concern on one Embodiment of this invention. FIG. 5 is a partially enlarged view around a region X in FIG. 4. It is a bottom perspective view of foam 31 concerning one embodiment of the present invention. It is the side view of the foam 31 seen from the arrow Y direction of FIG. It is the elements on larger scale of the area | region Z of FIG. It is a figure showing a mode that the 1st resin sheet 23a was vacuum-sucked from the state of FIG. It is a figure showing the state which fixed the foam 31 to the 1st resin sheet 23a. It is a figure showing the state which suspended the 2nd resin sheet 23b. It is a figure showing a mode that the 2nd resin sheet 23b was vacuum-sucked from the state of FIG. It is sectional drawing showing the state which clamped the 1st and 2nd metal mold | die 21,22. 6 is a plan view illustrating a first modification of the foam 31. FIG. It is a top view showing the modification 2 of the foam 31. FIG.

  Hereinafter, embodiments of the present invention will be described. Various characteristic items shown in the following embodiments can be combined with each other. In addition, the invention is independently established for each feature.

1. Resin panel 30
As shown in FIG. 1, a resin panel 30 according to an embodiment of the present invention includes a hollow resin molded body 36 and a foam 31. A parting line PL is formed on the resin molded body 36. In addition, the foam 31 is disposed in the resin molded body 36.

2. Configuration of Molding Machine 1 Next, a molding machine 1 that can be used for carrying out a method for manufacturing a resin panel 30 according to an embodiment of the present invention will be described with reference to FIGS. 2 and 3.

  The molding machine 1 includes a resin supply device 2, a T die 18, and first and second molds 21 and 22. The resin supply device 2 includes a hopper 12, an extruder 13, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T die 18 are connected via a connecting pipe 27. Hereinafter, each configuration will be described in detail.

<Hopper 12, Extruder 13>
The hopper 12 is used for charging the raw resin 11 into the cylinder 13 a of the extruder 13. Although the form of the raw material resin 11 is not specifically limited, Usually, it is a pellet form. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer, and a mixture thereof. Moreover, you may mix | blend additives, such as glass fiber, a talc, and a pigment, with these. The raw material resin 11 is poured into the cylinder 13a from the hopper 12 and then melted by being heated in the cylinder 13a to become a molten resin. Moreover, it is conveyed toward the front-end | tip of the cylinder 13a by rotation of the screw arrange | positioned in the cylinder 13a. A screw is arrange | positioned in the cylinder 13a and conveys molten resin by kneading | mixing by the rotation. A gear device is provided at the base end of the screw, and the screw is driven to rotate by the gear device. The number of screws arranged in the cylinder 13a may be one or two or more.

<Accumulator 17, T-die 18>
The molten resin 11 a is extruded from the resin extrusion port of the cylinder 13 a and is injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b that can slide inside the cylinder 17a, and the molten resin 11a can be stored in the cylinder 17a. Then, by moving the piston 17b after a predetermined amount of foamed resin is stored in the cylinder 17a, the foamed resin is pushed out from the slit provided in the T-die 18 through the connecting pipe 27, and is dropped. Resin sheets 23a and 23b are formed.

<First and second molds 21, 22>
The first and second resin sheets 23 a and 23 b are guided between the first and second molds 21 and 22. As shown in FIG. 3, the first mold 21 is provided with a number of reduced-pressure suction holes (not shown), and the first resin sheet 23 a is sucked under reduced pressure along the cavity 21 b of the first mold 21. It is possible to shape into different shapes. The cavity 21b has a shape having a recess 21c, and a pinch-off portion 21d is provided so as to surround the recess 21c. The second mold 22 is provided with a number of reduced-pressure suction holes (not shown), and the second resin sheet 23b is sucked under reduced pressure and shaped into a shape along the cavity 22b of the second mold 22. Is possible. The cavity 22b has a shape having a recess 22c, and a pinch-off portion 22d is provided so as to surround the recess 22c. Here, the decompression suction hole is a very small hole, and one end is connected to the inner surfaces of the cavities 21b and 22b through the first and second molds 21 and 22, and the other end is connected to the decompression device. Has been.

3. Manufacturing Method of Resin Panel 30 Next, a manufacturing method of the resin panel 30 according to an embodiment of the present invention will be described with reference to FIGS. The method of this embodiment includes a drooping process, a shaping process, an insert process, and a mold clamping process. Details will be described below. In this embodiment, the timing which processes the 1st resin sheet 23a and the 2nd resin sheet 23b is shifted.

3.1 Foam 31
First, the foam 31 used for manufacturing the resin panel 30 will be described. As shown in FIGS. 1-8, the foam 31 is arrange | positioned in the resin molding 36, for example, is a bead foam of the expansion ratio 25-60 times, and the thickness after shaping | molding becomes 15-25 mm Can be used. The expansion ratio is preferably 30 to 55 times, and more preferably 40 to 50 times. The foam 31 is selected from resins that can be welded to the first resin sheet 23a and the second resin sheet 23b. The foam 31 includes a facing surface that faces one surface of the resin molded body 36. In this embodiment, as shown in FIGS. 4 to 8, the foam 31 includes a first facing surface 31 f on the side facing the first resin sheet 23 a (described later with reference to FIG. 3), and a second resin sheet 23 b. A second opposing surface 31s that opposes (described later with reference to FIG. 3), and a connecting surface 32 that connects the first opposing surface 31f and the second opposing surface 31s are provided. Further, the facing surface includes a convex portion 34. Here, as shown in FIGS. 4, 5, and 8, in the present embodiment, the foam 31 includes a convex portion 34 on the second facing surface 31 s. Here, as shown in FIG. 8, in the present embodiment, the convex portion 34 is formed in a tapered shape toward the tip of the convex portion 34. In other words, each of the convex portions 34 has a mountain shape.

  In addition, as a method of providing the convex part 34 on the surface of the foam 31, there is a method of forming the convex part 34 on the surface by post-processing on a flat foam. As another method, there is a method of forming the convex portion 34 by forming a shape corresponding to the convex portion 34 in the mold and transferring the shape of the mold during foam molding. Here, in the former case, the number of work steps increases, and in the latter case, the transfer shape is limited. Therefore, when the latter method is employed, among the tapered shapes, a simple shape such as a mountain shape, in particular, an arc-shaped convex portion or a frustum-shaped convex portion is preferable. In addition, the shape of the convex part 34 is not limited to these, The aspect which the convex part formed in the surface of the foam 31 by transferring the mesh shape provided in the metal mold | die, or the convex part of multiple shapes may be mixed. .

  As shown in FIG. 5, two or more convex portions 34 are provided in an independent state in the reference region S surrounded by the broken line of the second facing surface 31 s. Here, the reference region S is a partial region of the foam 31 in plan view. Further, the state in which the protrusions 34 are independent in the reference region S is that the plurality of protrusions 34 are discontinuous at least in the reference region S. Furthermore, as shown in FIG. 8, in this embodiment, the convex part 34 is a part which protrudes from 31s 2nd opposing surface. Here, the definition of the convex part 34 is not limited to this. For example, as shown in FIG. 8, when the height d from the second facing surface 31 s is set as shown in FIG. It is good.

  As shown in FIG. 5, in the present embodiment, 100 convex portions 34 are provided in the reference region S. The number of convex portions 34 in the reference region S is, for example, 1 to 500. Preferably, the number of convex portions 34 in the reference region S is 2 to 400, more preferably 5 to 300, and still more preferably 9 to 200. Specifically, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, There are 250, 300, 350, 400, 450, and 500, and may be in the range between any two of the numerical values exemplified here.

In the present embodiment, the size of the reference region S is a square of 2 cm × 2 cm, and 100 convex portions 34 are provided. Moreover, the space | interval of the convex part 34 is 3 mm or less. The size of the reference region S is, for example, 4 to 2,500 cm ² . Specifically, they are 2 cm × 2 cm, 3 cm × 3 cm, 5 cm × 5 cm, 10 cm × 10 cm, 20 cm × 20 cm, 25 cm × 25 cm, 50 cm × 50 cm. The reference area S may be other than a square, and may be, for example, a rectangle, a circle, an ellipse, a triangle, a polygon, a star, or the like.

  Here, when the reference region S is 3 cm × 3 cm, it is preferable that five or more convex portions 34 (225 in the present embodiment) are provided in the reference region S in an independent state. Further, when the adjacent reference regions S are observed, it is preferable that three or more convex portions 34 are provided in the adjacent reference regions S in an independent state.

  As shown in FIGS. 5 and 8, the value of the total area of the protrusions 34 in the reference region S / the area of the reference region S is, for example, 0.05 to 1. Preferably, such a value is preferably from 0.1 to 0.8, more preferably from 0.2 to 0.7, and even more preferably from 0.3 to 0.6. Specifically, for example, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, where It may be within a range between any two of the exemplified numerical values. Note that the case where the value of the total area of the protrusions 34 in the reference region S / the area of the reference region S is 1 includes, for example, an aspect in which the convex portions 34 having a quadrangular pyramid shape are spread without gaps.

  Here, the area of the convex part 34 is an area when the convex part 34 is vertically projected on the second facing surface 31s. As described above, when the portion protruding from the second facing surface 31s by 1 / 2d or more is the convex portion 34, the portion protruding from the second facing surface 31s by 1 / 2d or more is the second facing surface 31s. Is the area when projected vertically.

  As shown in FIG. 8, in the present embodiment, the height d of the convex portion 34 is 1/3 or less of the thickness of the foam 31. Preferably, such a value is 1/10 or less, more preferably 1/20 or less. Specifically, for example, 1/50, 1/40, 1/30, 1/20, 1/10, 1/5, 1/3 or less, and the range between any two of the numerical values exemplified here It may be within.

  As for the height d of the convex part 34, 0.05-10 mm is preferable. If it is 0.05 mm or less, there is a high possibility of welding before air can escape from the gap between the convex portions 34, and if it is 10 mm or more, it is difficult to provide the set number of convex portions 34 in the reference region S. Because.

  The surface area including the convex portion 34 in the reference region S / the value of the area of the reference region S is, for example, 1.01 to 2.0. Preferably, such a value is 1.03-1.5, more preferably 1.05-1.3. Specifically, for example, 1.01, 1.03, 1.05, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 and 2.0, and may be within a range between any two of the numerical values exemplified here.

  Further, as shown in FIG. 6, a groove 35 is provided in the first facing surface 31 f of the foam 31. Furthermore, a notch-like air pocket space is formed on the connecting surface 32. Specifically, in the connecting surface 32, a first air pool space 33f is provided on the first facing surface 31f side, and a second air pool space 33s is provided on the second facing surface 31s side. Each groove 35 communicates with the first air pool space 33f. The significance of the first air pool space 33f and the second air pool space 33s will be described later with reference to FIGS.

  As described above, the resin panel 30 according to the present embodiment has a structure in which the foam 31 is disposed in the resin molded body 36. Here, as shown in FIG. 1, the fine protrusions 34 are formed on the foam 31 before the resin panel 30 is manufactured. However, when the resin panel 30 is completed, the protrusions are formed by the second resin sheet 23b. The portion 34 is melted, and the second facing surface 31s has a flat shape (described later with reference to FIG. 13). In other words, a part of the convex portion 34 is melted by the second resin sheet 23b on which the resin molded body 36 is formed.

  Next, each step will be described. In the following, the first and second resin sheets 23a and 23b are made by mixing polypropylene with talc, and the foam 31 is made of polypropylene having an expansion ratio of 45 times.

3.2 First resin sheet 23a
3.2.1 Dripping Process In the dripping process, as shown in FIG. 3, the foam 31 is placed between the first and second molds 21 and 22 using a jig (not shown). At this time, it arrange | positions so that the 1st opposing surface 31f may oppose the 1st metal mold | die 21, and the 2nd opposing surface 31s may oppose the 2nd metal mold | die 22. FIG.

  Then, a first resin sheet 23 a formed by extruding a molten foamed resin from the slit of the T die 18 and hanging between the first and second molds 21 and 22 is hung. In this embodiment, the temperature of the 1st resin sheet 23a at this time is about 200 degreeC. The thickness of the first resin sheet 23a is preferably 0.5 to 1 mm, but may be 1 to 1.5 mm. In the present embodiment, since direct vacuum forming is performed using the first and second resin sheets 23a and 23b extruded from the T-die 18 as they are, the first and second resin sheets 23a and 23b are allowed to have room temperature before forming. The solidified first and second resin sheets 23a and 23b are not heated before being molded. Here, in FIG. 3, the foam 31 is illustrated between the first and second resin sheets 23 a and 23 b during the drooping process. However, in the drooping process, the foam 31 is allowed to wait in another place. It may be left.

3.2.2 Forming Step Next, as shown in FIG. 9, the first resin sheet 23 a is sucked under reduced pressure by the first mold 21 and shaped into the shape along the cavity 21 b of the first mold 21. . Further, a jig (not shown) is set on the foam 31 by this time. The jig supports the foam 31 by sucking the second opposing surface 31s side of the foam 31 with a suction cup or the like provided on the jig. And after the 1st resin sheet 23a is shaped in the shaping process, after the 1st resin sheet 23a cools to 70-90 degreeC, the below-mentioned insert process is started. In other words, a resin cooling step is provided before the below-described insert step. Here, in this embodiment, it waits for the temperature of the 1st resin sheet 23a of about 200 degreeC to cool to 70-90 degreeC. Such temperature is preferably 72 to 88 ° C, more preferably 74 to 86 ° C, and further preferably 76 to 84 ° C. Specifically, for example, 70, 72, 74, 76, 78, 80, 82, 84, 86, 88, 90 ° C., and may be within a range between any two of the numerical values exemplified here. . The temperature is preferably an average value. For example, an average value of nine temperatures of the first resin sheet 23a can be employed. Here, the temperature of the first resin sheet 23a can be measured by a non-contact temperature sensor or the like.

  Here, the temperature of the first resin sheet 23a varies depending on the type of resin and the presence or absence of additives (glass fiber, talc, pigment, etc.). Therefore, the cooling temperature varies depending on the resin used.

3.2.3 Insert Step Next, after the drooping step, the first resin sheet is cooled to 70 to 90 ° C., and then the insert step is started. In other words, after the first resin sheet is shaped in the shaping step, the insert step is started after the first resin sheet is cooled to 70 to 90 ° C. In the insert step, as shown in FIG. 10, the foam 31 is moved and fixed to the first resin sheet 23a by a jig (not shown). Here, in this embodiment, since the foam 31 is a foam, the foam 31 is fixed to the first resin sheet 23a by melting the foam by the heat of the first resin sheet 23a. In the present embodiment, since the rigidity of the first resin sheet 23a is improved by waiting for the temperature of the first resin sheet 23a to cool to 70 to 90 ° C., the first resin sheet 23a is inserted into the groove 35 of the foam 31. Conformity can be reduced.

  Furthermore, since the groove 35 provided in the first opposing surface 31f of the foam 31 communicates with the first air reservoir space 33f, it is unintentionally formed between the first resin sheet 23a and the first opposing surface 31f. The air reservoir can be dispersed through the groove 35 into the first air reservoir space 33f. Thereby, even if it is the 1st resin sheet 23a with which temperature was cooled, it can fully be welded with the 1st opposing surface 31f.

3.3 Second resin sheet 23b
3.3.1 Drooping process In the dripping process, as shown in FIG. 11, the foamed resin in a molten state is extruded from the slit of the T-die 18 and dripped between the first and second molds 21 and 22. The second resin sheet 23b is suspended. In this embodiment, the temperature of the 2nd resin sheet 23b at this time is about 200 degreeC. Further, the thickness of the second resin sheet 23b is preferably 0.5 to 1 mm.

3.3.2 Forming Step Next, as shown in FIG. 12, the second resin sheet 23 b is sucked under reduced pressure by the second mold 22 and shaped into a shape along the cavity 22 b of the second mold 22. .

3.4 Clamping Process In the mold clamping process, the first and second molds 21 and 22 are clamped as shown in FIG. Unlike the first resin sheet 23a, the second resin sheet 23b does not wait for cooling to 70 to 90 ° C., and the second resin sheet 23b and the second facing surface 31s are partially in contact with each other at the convex portion 34. Therefore, even if the convex part 34 provided in the 2nd opposing surface 31s of the foam 31 is a case where the thickness of the 2nd resin sheet 23b is comparatively thin, it melt | dissolves with the temperature of the 2nd resin sheet 23b. As a result, the second facing surface 31s has a substantially flat shape.
Here, at the time of mold clamping, the temperature of the first resin sheet 23a is lower than the temperature of the second resin sheet 23b.

  In the present embodiment, the second resin sheet 23b and the second facing surface 31s are not in surface contact, and the second resin sheet 23b and the convex portion 34 are partially in contact with each other. Compared to the case where the air reservoir is provided, an air reservoir is less likely to be formed between the second resin sheet 23b and the second facing surface 31s. Furthermore, when an air pocket is still formed, the air pool can be dispersed in the second air pool space 33s through a portion other than the convex portion 34 of the first facing surface 31f. Furthermore, although the temperature of the 1st resin sheet 23a is cooled to 70-90 degreeC, since the temperature of the 2nd resin sheet 23b is before cooling, the 1st resin sheet 23a and the 2nd resin sheet are pinched off by 21d and 22d. 23b is sufficiently welded to form parting line PL.

  Thereby, the molded object of the shape along the cavities 21b and 22b of the 1st and 2nd metal mold | dies 21 and 22 is obtained.

  And the resin-made panel 30 shown by FIG. 1 is obtained by taking out a molded object from the 1st and 2nd metal mold | die 21 and 22, and removing the burr | flash 26 outside the pinch-off parts 21d and 22d.

<Modification 1>
Next, Modification 1 of the foam 31 according to this embodiment will be described with reference to FIG. As shown in FIG. 14, grooves 35 having a narrow interval may be provided in a lattice shape on the second facing surface 31 s of the foam 31. In the first modification, a portion other than the groove 35 of the second facing surface 31 s has the same function as the above-described convex portion 34.

<Modification 2>
Next, Modification 2 of the foam 31 according to the present embodiment will be described with reference to FIG. As shown in FIG. 15, in Modification 2, the second facing surface 31 s on the side facing the second resin sheet 23 b is provided with a recess 37, and in the reference region S (see FIG. 5) of the second facing surface 31 s, Two or more recesses 37 are provided in an independent state. In this modification, each of the recesses 37 is provided discontinuously. Here, the concave portion 37 is formed by the convex portion 34 continuously provided on the second facing surface 31s. Moreover, it is preferable that the depth of the recessed part 37 is 1/3 or less of the thickness of the foam 31.

<Others>
A groove 35 may be provided in the first facing surface 31f and the second facing surface 31s.
-The convex part 34 may be provided in the 1st opposing surface 31f and the 2nd opposing surface 31s.
-The convex part may be thinned out.

DESCRIPTION OF SYMBOLS 1: Molding machine 2: Resin supply apparatus 11: Raw material resin 11a: Molten resin 12: Hopper 13: Extruder 13a: Cylinder 17: Accumulator 17a: Cylinder 17b: Piston 18: T die 21: 1st metal mold | die 21b: Cavity 21c : Concave portion 21d: pinch-off portion 22: second mold 22b: cavity 22c: convex portion 22d: pinch-off portion 23a: first resin sheet 23b: second resin sheet 25: connecting pipe 26: burr 27: connecting pipe 30: made of resin Panel 31: Foam 31f: 1st opposing surface 31s: 2nd opposing surface 32: Connection surface 33f: 1st air pool space 33s: 2nd air pool space 34: Convex part 35: Groove 36: Resin molded object 37: Concave part PL: Parting line

Claims (11)

It has a drooping process, an insert process, and a mold clamping process.
In the hanging step, the first and second resin sheets are suspended between the first and second molds,
In the insert step, the foam is welded to the first and second resin sheets,
In the mold clamping step, the first and second molds are clamped,
The foam is disposed between the first and second resin sheets,
The foam has a convex portion or a concave portion on the second opposing surface facing the second resin sheet, and the convex portion or the concave portion is independent in a 2 cm × 2 cm reference region of the second opposing surface. A method for producing a resin panel, wherein two or more are provided. The reference area is 3 cm × 3 cm;
The method according to claim 1, wherein five or more convex portions or concave portions are provided in the reference region in an independent state.   The method according to claim 1, wherein three or more of the convex portions or the concave portions are provided in the adjacent reference regions in an independent state.   The method according to any one of claims 1 to 3, wherein a value of a total area of the convex portions or the concave portions in the reference region / an area of the reference region is 0.05-1.   The method according to any one of claims 1 to 4, wherein a height of the convex portion or a depth of the concave portion is 1/3 or less of a thickness of the foam.   The method according to claim 1, wherein an interval between the convex portions or the concave portions is 3 mm or less.   The method according to claim 1, wherein the convex portion is formed in a tapered shape toward a tip end of the convex portion.   The method according to claim 1, wherein each of the convex portions has a mountain shape.   The method according to claim 1, wherein the recesses are provided discontinuously. The foam includes a connecting surface that connects the first facing surface and the second facing surface;
The method according to claim 1, wherein a notch-like air pocket space is formed on the connection surface. A hollow resin molded body and a foam are provided.
The foam is disposed in the resin molded body,
The foam includes a facing surface facing one surface of the resin molded body,
The facing surface includes a convex portion or a concave portion,
In the 2 cm × 2 cm reference region of the facing surface, two or more of the convex portions or the concave portions are provided in an independent state,
A part of the convex part or the concave part is melted by the resin sheet forming the resin molded body,
Resin panel.