JP2019188749A - Production method of structure and panel - Google Patents

Abstract

To provide a production method of a structure, which suppresses degradation of the strength of the structure.SOLUTION: A production method of a structure is provided with a step of producing a structure with first and second split molds includes: an attachment step; a first mold closing step; a filling step; a molding step; and a first mold opening step. A mold for a core material is provided with a first split mold and a second split mold, and the first split mold has a holding part. The holding part has an energizing part, the energizing part is constituted with a planar member constituted so as to hold an insert member 1d, and, the energizing part protrudes into the filling space in the first mold closing step.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a structure and a panel.

  Various methods of manufacturing a panel including a core material having an insert member and a foam molded body and a resin molded body formed on the surface of the core material have been proposed (see, for example, Patent Document 1). In Patent Document 1, the foam molded article is formed by molding foam beads. In the manufacturing method of the core material of Patent Document 1, the foam molded body is fixed to the insert member by pushing the end of the foam molded body into the concave portion of the insert member.

Japanese Patent No. 2014-128938

  In a state where the foam molded body is fixed to the insert member, a gap may be generated between the foam molded body and the insert member. As described above, when the gap is generated between the foamed molded body and the insert member, the strength of the core material is lowered, and consequently the strength of the panel is lowered.

  Therefore, a method of manufacturing a core material using a mold that supports, for example, a block-shaped chuck that supports the insert member is conceivable. Specifically, in this manufacturing method, after the insert member is attached to the chuck, the mold is closed, the filled beads are filled in the filling space in which the insert member is disposed, and the foamed beads are molded. Here, in this manufacturing method, the chuck protrudes into the filling space. For this reason, a recessed part will be formed in the position where the chuck | zipper is provided in the foaming molding. Therefore, in this manufacturing method, the strength of the foamed molded product is reduced by the amount of the recess formed in the foamed molded product.

  This invention is made | formed in view of such a situation, and it aims at suppressing that the intensity | strength of a structure falls.

  According to the present invention, there is provided a structure manufacturing method including a process of manufacturing a structure using the first and second divided molds, and an attachment process, a first mold closing process, a filling process, A molding step and a first mold opening step; in the mounting step, an insert member is attached to a holding portion provided in the first split mold; in the first mold closing step, the first and second splits are performed. By closing the mold, a filling space is formed in the first and second divided molds. In the filling step, the filling space is filled with foam beads, and in the molding step, the filling space is filled. In the first mold opening step, the first and second divided molds are opened, and the holding part has a biasing part, The urging portion is composed of a plate-shaped member configured to hold the insert member, One, the biasing portion, protrudes into the filling space in the first mold closing step, a method is provided.

According to the structure manufacturing method of the present invention, the filling space is filled with the foam beads in a state where the insert member is attached to the holding portion provided in the first split mold. As a result, the foam beads are spread over the surface of the insert member. Therefore, it is possible to suppress a gap from being formed between the foam molded body and the insert member after molding the foam beads. As a result, a decrease in the strength of the structure is suppressed.
Moreover, according to the manufacturing method of the structure which concerns on this invention, since the urging | biasing part is comprised by the plate-shaped member, the volume of the recessed part of a foaming molding is suppressed by that much. As a result, a decrease in the strength of the structure is suppressed.

Hereinafter, various embodiments of the present invention will be exemplified. The following embodiments can be combined with each other.
Preferably, in the method, the holding part has a base part, the base part is fixed to the first split mold, and in the attaching step, the biasing part turns the insert member into the first split mold. The insert member is attached to the first split mold so as to be biased.
Preferably, in the method, the urging portion includes a first urging portion and a second urging portion, and the one end portion and the other end portion of the base portion are the first and second urging portions, respectively. The insert member is attached to the first split mold by sandwiching the insert member between the first and second urging portions in the attachment step.
Preferably, in the method, the base includes a first base and a second base, and the first and second bases are separated from each other.
Preferably, in the method, the biasing portion is curved so as to be convex toward the insert member.
Preferably, in the method, in the first mold opening step, the urging portion is forcibly removed from the foamed molded body.
Preferably, in the method, the first and second split molds are provided with a regulating member, the regulating member protrudes into the filling space in the first mold closing step, and the regulating member is It arrange | positions at the both ends of the longitudinal direction of the said insert member.
Preferably, in the method, the insert member has a facing surface facing the second divided mold, and the entire surface of the facing surface contacts the second divided mold in a state where the first mold closing step is completed. Or a gap between the facing surface and the second split mold is smaller than the foam beads.
Preferably, in the method, the insert member has a facing surface facing the second divided mold, and the filling space is formed between the entire surface of the facing surface and the second divided portion when the first mold closing step is completed. It exists between molds.
Preferably, in the method, the insert member is an elongated reinforcing member.
Preferably, in the method, the insert member is formed with a concave portion, and the insert member has a hook portion, and in the filling step, the foamed molded body is filled into the concave portion, In a state where the molding step is completed, the hooking portion is configured to be hooked on the foamed molded body.
Preferably, in the method, the insert member includes a base portion and a flange portion, and the concave portion is formed by the base portion and the flange portion, and the flange portion includes the base portion. And the hook portion is connected, and the hook portion is configured to be convex toward the base portion.
Preferably, the method includes a core material manufacturing process and a panel manufacturing process, wherein the core material manufacturing process includes the attachment process, the first mold closing process, the filling process, the molding process, and the first process. The panel manufacturing process includes a shaping process, a second mold closing process, and a second mold opening process. In the shaping process, the resin sheets are third and fourth. Forming along the inner surface of the split mold, and in the second mold closing step, the third and fourth split molds are closed, and the resin molded body formed by the resin sheet and the resin molded body A panel having the foamed molded body to be arranged is manufactured, and in the second mold opening step, the third and fourth divided molds are opened.
Preferably, in the method, the foamed molded article is formed with a concave relief portion in a state where the molding step is completed, and the relief portion is formed in a portion where the regulating member is provided in the molding step. In addition, the escape portion becomes an escape place for an extra portion of the resin sheet in the second mold closing step.
Preferably, in the method, the escape portion is formed in a portion of the foamed molded body provided on a peripheral edge of the insert member.
Preferably, the panel includes a core material and a resin molded body, wherein the core material includes an insert member and a foam molded body, and the core material is disposed in the resin molded body. The insert member and the foamed molded body are integrally molded, and a panel is provided in which a recessed pull-out trace is formed in the foamed molded body.
Preferably, in the panel, the insert member is a long reinforcing member.
Preferably, in the panel, the insert member is formed with a concave portion, and the insert member has a hook portion, and the concave portion is filled with the foamed molded body, and the hook portion is , And is configured to be caught by the foamed molded body.
Preferably, in the panel, the concave portion is formed by a base portion and a flange portion, the base portion and the hook portion are connected to the flange portion, and the hook portion faces the base portion. And configured to be convex.

1A is a perspective view of the panel 1, and FIG. 1B is a cross-sectional view through three points X shown in FIG. 1A. 2A is a perspective view of the core material 1b, FIG. 2B is an enlarged view of the escape portion 1e shown in the region A, and FIG. 2C is an enlarged view of the extraction trace portion 1f shown in the region B. It is a perspective view of the metal mold | die 2 for core materials. It is a perspective view of the 1st division mold 2a. It is an enlarged view of the area | region C shown in FIG. 6A is an exploded perspective view of the mounting member 2c, the holding portion 3, and the regulating member 2e, and FIG. 6B is an enlarged view of a region D in FIG. 6A. 7A is a perspective view of the holding unit 3, FIG. 7B is a front view of the holding unit 3, and FIG. 7C is a cross-sectional view taken along line AA shown in FIG. 7B. It is a perspective view of the metal mold | die 2 for core materials in the state in which the insert member 1d was attached to the 1st division | segmentation metal mold | die 2a. It is an enlarged view of the area | region E shown in FIG. FIG. 10A shows a state in which the opening / closing part 2g protrudes toward the second split mold 2A, and FIG. 10B is an enlarged view of a region F shown in FIG. 10A. FIG. 11A is a perspective view of the second split mold 2A, and FIG. 11B is an enlarged view of a region G shown in FIG. 11A. 12A shows a state before the insert member 1d is attached to the first split mold 2a, and FIG. 12B shows a state where the insert member 1d is attached to the first split mold 2a. FIG. 13A shows a state where the first mold closing process is completed, and FIG. 13B shows a state where the expanded beads bi are filled in the filling process. FIG. 14A shows a state where the pressing step is completed, and FIG. 14B shows a state where the forming step is completed. It is explanatory drawing of the various structures used in a panel manufacturing process. The state which the shaping process of the panel manufacturing process was completed is shown. The state where the sticking process of the panel manufacturing process is completed is shown. The state which the 2nd type | mold closing process of the panel manufacturing process was completed is shown. 10 is a perspective view of a first split mold 2a according to Modification 1. FIG. It is an expansion perspective view of the holding | maintenance part 4 shown to the area | region H of FIG. It is a side view of the holding | maintenance part 4 shown in FIG. It is sectional drawing of the panel 1 which concerns on the modification 2. FIG. FIG. 23A is a perspective view of an insert member 1d according to Modification 3, and FIG. 23B is a cross-sectional view of the insert member 1d according to Modification 3. It is sectional drawing of the panel 1 which concerns on the modification 3. 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.

<Configuration according to the core material manufacturing process of the embodiment>
In the manufacturing method according to the embodiment, the core material 1 b is manufactured using the core material mold 2 (see FIG. 3), and then the panel 1 is manufactured using the panel mold 22. As shown in FIGS. 1A and 1B, the panel 1 includes a core material 1b and a resin molded body 1a. As shown in FIG. 1B, the surface of the core material 1b is covered with a resin molded body 1a. That is, the core material 1b is arrange | positioned inside the resin molding 1a. The core material 1b has an insert member 1d and a foam molded body 1c.

  The insert member 1d can be made of, for example, metal or reinforced plastic. The insert member 1d is a long reinforcing member. That is, the insert member 1 d is a skeleton that improves the load resistance of the panel 1 and has a function of reinforcing the panel 1. As shown in FIG. 1B, the insert member 1d has a pair of flange portions d1 and a base portion d2. Each flange portion d1 is formed with a facing surface d4 that contacts the inner surface of the resin molded body 1a. The base part d2 is provided between one flange part d1 and the other flange part d1. One flange part d1 is connected to one end of the base part d2, and the other flange part d1 is connected to the other end of the base part d2. A pair of concave portions d3 is formed in the insert member 1d. The concave portion d3 is formed by a pair of flange portions d1 and a base portion d2. The recessed portion d3 is filled with the foam molded body 1c. The foam molded body 1c is configured by molding foam beads. As shown in FIGS. 2B and 2C, the foamed molded body 1c is formed with a relief portion 1e and a withdrawal trace portion 1f. The escape portion 1e is formed in a concave shape. The pull-out trace portion 1f is formed by pulling out an urging portion 3b of the holding portion 3 described later from the foamed molded body 1c. The escape portion 1e and the withdrawal trace portion 1f are formed on the periphery of the insert member 1d.

  In the embodiment, the insert member 1d is described as a long reinforcing member, but the embodiment is not limited thereto. The insert member 1d may not be long, and the insert member 1d may be a member that does not have a function of reinforcing the panel 1. For example, the insert member 1d may be a resin tapping member to which a fixing member such as a bolt is fixed, or may be a metal plate.

  As shown in FIG. 3, the core material mold 2 includes a first split mold 2a and a second split mold 2A. As shown in FIGS. 4 and 5, the first split mold 2a includes a cavity 2b, a mounting member 2c, a regulating member 2e, an opening / closing part 2g, an ejector 2h, a holding member 2j, and a holding part 3. Have Moreover, the end surface 2i is formed in the 1st division mold 2a. The second split mold 2A includes a core 2B and a regulating member 2C. An end face 2E is formed on the second split mold 2A. Furthermore, as shown in FIG. 14 to be described later, in a state where the first divided mold 2a and the second divided mold 2A are closed, the gap is between the first divided mold 2a and the second divided mold 2A. The filling space Sp is formed.

  An insert member 1d can be attached to the inner surface of the cavity 2b. As shown in FIGS. 4 and 5, an attachment member 2c, a regulating member 2e, an opening / closing part 2g, an ejector 2h, and a holding part 3 are provided on the inner surface of the cavity 2b. The holding part 3 has a function of holding the insert member 1d. When the insert member 1d is attached to the holding portion 3, the insert member 1d is biased to the inner surface of the cavity 2b, and as a result, the insert member 1d is attached to the cavity 2b. The cavity 2b is formed in a concave shape so as to be filled with foam beads.

  As shown in FIG. 6B, a mounting recess 2d is formed in the mounting member 2c. As shown in FIG. 6A, three attachment recesses 2d are arranged on one side and the other side in the longitudinal direction of the attachment member 2c. A holding portion 3 is fixed to each mounting recess 2d. In the state where the holding member 3 is attached to the first split mold 2a, the front surface of the mounting member 2c is in contact with the facing surface d4 (see FIGS. 2B and 2C) of the flange portion d1 of the insert member 1d. To do. The first divided mold 2a is formed with a long concave portion (not shown) that accommodates the attachment member 2c. In a state where the mounting member 2c is accommodated in the recess, the end surface 2i of the first split mold 2a and the front surface of the mounting member 2c form a flat surface. Moreover, the regulating member 2e is being fixed to the longitudinal direction one end part and other end part of the attachment member 2c, respectively.

  The holding part 3 has a function of holding the insert member 1d. As shown in FIGS. 7A to 7C, the holding portion 3 includes a base portion 3a, a biasing portion 3b, a plate-like portion 3f, and a fixing member 3g. The base 3a and the urging portion 3b are leaf springs. The first urging portion corresponds to one urging portion 3b of the pair of urging portions 3b, and the second urging portion corresponds to the other urging portion 3b of the pair of urging portions 3b.

  The base portion 3a is a plate material, and a pair of urging portions 3b are connected to the base portion 3a. One biasing portion 3b of the pair of biasing portions 3b is connected to one end portion of the base portion 3a, and one biasing portion 3b of the pair of biasing portions 3b is connected to the other end portion of the base portion 3a. It is connected. The base portion 3a is provided in contact with the plate-like portion 3f.

  The urging portion 3b is a plate material, and the urging portion 3b has a function of urging the insert member 1d toward the first split mold 2a. Further, the urging portion 3b can sandwich the insert member 1d. The urging portion 3b has a proximal end portion 3c, a distal end portion 3d, and a curved portion 3e. The base end 3c is connected to the base 3a. The curved portion 3e is curved so as to be convex toward the insert member 1d.

  A through hole into which the fixing member 3g is inserted is formed in the plate-like portion 3f. A fixing member 3g is inserted into the base portion 3a and the plate-like portion 3f. Thereby, the base 3a is fixed to the mounting recess 2d of the mounting member 2c. When the holding | maintenance part 3 is not provided with the fixing member 3g, possibility that the base 3a will be distorted by the pressing force of the fixing member 3g increases. For this reason, the fixing member 3g is inserted into the base portion 3a via the plate-like portion 3f.

  The regulating member 2e has a function of preventing the insert member 1d from being displaced in the longitudinal direction of the insert member 1d. As shown in FIGS. 5, 8, and 9, in a state where the insert member 1d is attached to the first split mold 2a, the restricting member 2e is one of the pair of flange portions d1 of the insert member 1d. It is arrange | positioned at the both ends of the flange part d1, respectively. The restricting member 2e is fixed to the attachment member 2c by a fixing member 2f. The regulating member 2e protrudes into the filling space Sp. Therefore, when the foam beads are molded in the filling space Sp, the escape portion 1e described with reference to FIG. 2B is formed in the foam molded body 1c.

  As shown in FIGS. 10A and 10B, the opening / closing part 2g is configured to be movable in a direction parallel to the second divided mold 2A side from the first divided mold 2a side. As shown in FIG. 10B, when the opening / closing part 2g moves and the opening / closing part 2g protrudes from the end face 2i, the bead supply hole Ho of the first split mold 2a is opened, and the foam beads are filled with the filling space Sp (see FIG. 14). To be supplied. The ejector 2h has a function of extruding the core material 1b molded in the filling space Sp. The ejector 2h is configured to be movable in a direction parallel to the second divided mold 2A side from the first divided mold 2a side.

  As shown in FIGS. 11A and 11B, the core 2B has a regulating member 2C. The function of the regulating member 2C is the same as the function of the regulating member 2e. The restricting member 2C is fixed to the end surface 2E by a fixing member 2D. In a state where the core material mold 2 is closed, the core 2B is inserted into the cavity 2b. In a state where the insert member 1d is attached to the attachment member 2c and the core material mold 2 is closed, the restricting member 2C is the other flange portion d1 of the pair of flange portions d1 of the insert member 1d. (Refer to FIG. 9). The holding member 2j has a function of holding the insert member 1d. Note that the holding member 2j may be eliminated by increasing the holding force of the holding unit 3. The holding member 2j is provided directly below the insert member 1d. Moreover, the holding member 2j is arrange | positioned at the both ends of the longitudinal direction of the insert member 1d, respectively.

<Core Material Production Process of Embodiment>
The core material manufacturing process includes an attaching process, a first mold closing process, a filling process, a pressing process, a molding process, a first mold opening process, and a removing process. First, as shown in FIGS. 12A and 12B, the insert member 1d is attached to the holding portion 3 provided in the first split mold 2a (attachment process). Next, as shown in FIG. 13A, the first split mold 2a and the second split mold 2A are closed to form a filling space Sp between the first split mold 2a and the second split mold 2A. Form (first mold closing step). In the state where the first mold closing process is completed, a gap c1 is formed between the first split mold 2a and the second split mold 2A. It should be noted that, in order to allow the subsequent pressing process, the expanded beads bi cannot enter between the insert member 1d and the second split mold 2A when the first mold closing process is completed. The gap c2 is formed.

  Next, as shown in FIG. 13B, the filling space Sp is filled with foam beads bi (filling step). Specifically, as shown in FIG. 10A, the opening / closing part 2g protrudes from the end face 2i. As a result, the foam beads bi are supplied to the filling space Sp. Next, as shown in FIG. 14A, the second split mold 2A further moves to the first split mold 2a side (pressing process). As a result, the foam beads bi in the filling space Sp are pressed, and the filling density of the foam beads bi in the filling space Sp increases. In addition, the core material manufacturing process does not need to have this press process. That is, in the first mold closing step, the gap c1 between the first split mold 2a and the second split mold 2A is filled, and the entire surface of the facing surface d4 and the second split mold 2A are in contact with each other. It may be. Next, the foamed beads bi filled in the filling space Sp are heated and then cooled (molding process). Thereby, as shown in FIG. 14B, the foam molded body 1 c is formed in the core material mold 2. That is, the insert member 1d and the foam molded body 1c are integrally molded. Here, a heating / cooling mechanism (not shown) is attached to the first split mold 2a. The heating / cooling mechanism is configured to be able to supply high-temperature steam or cold water. The heat of the heating / cooling mechanism is transmitted to the foam beads in the filling space Sp through the surface of the cavity 2b. When high-temperature steam is supplied to the heating and cooling mechanism, the foam beads in the filling space Sp are fused together. When the cold water is supplied to the heating / cooling mechanism, the fused foam beads are solidified.

  Next, the first split mold 2a and the second split mold 2A are opened (first mold opening process). At this time, the urging portion 3b is still embedded in the foam molded body 1c. Thereafter, when the ejector 2h moves, the ejector 2h presses the core material 1b, and the foam molded body 1c is removed from the first split mold 2a (removal step). Thereby, the urging | biasing part 3b is pulled out from the foaming molding 1c. That is, the urging portion 3b is forcibly removed from the foam molded body 1c. By forcibly removing the urging portion 3b from the foam molded body 1c, the drawing trace portion 1f shown in FIG. 2C is formed in the foam molded body 1c.

<Configuration related to panel manufacturing process of embodiment>
A molding apparatus 100 shown in FIG. 15 is an apparatus for manufacturing a structure that is an integrally molded body. Specifically, the molding apparatus 100 is an apparatus that integrally molds the resin sheets P1 and P2 and the core material 1b. The molding apparatus 100 includes an extrusion mechanism 10, a panel mold 22, a roller 20, and a moving mechanism 21. The extrusion mechanism 10 has a function of extruding molten resin. The molding apparatus 100 includes two extrusion mechanisms 10. The panel mold 22 is provided below the extrusion mechanism 10. The roller 20 sends out the resin sheets P <b> 1 and P <b> 2 extruded from the extrusion mechanism 10 to the panel mold 22. The moving mechanism 21 has a function of moving the roller 20.

  The extrusion mechanism 10 includes a hopper 16, a cylinder 15, a screw (not shown), a motor 17, an accumulator 13, a T die 11, and a plunger 14. The hopper 16 is a charging portion for resin pellets. The cylinder 15 is connected to a hopper 16, and a screw is provided in the cylinder 15. The motor 17 is connected to a screw provided in the cylinder 15. The accumulator 13 has a function of storing a resin, and the accumulator 13 is connected to the cylinder 15 and the T die 11. The plunger 14 has a function of pushing out the resin in the accumulator 13 to the T die 11.

  The panel mold 22 includes a third divided mold a3 and a fourth divided mold a4. The third split mold a3 has a cavity 24 and a pinch-off 26, and the fourth split mold a4 has a cavity 25 and a pinch-off 26. The cavity 24 is a portion where the resin sheet P <b> 1 depending from the roller 20 is shaped. The cavity 25 is a portion where the resin sheet P <b> 2 depending from the roller 20 is shaped. The pinch-off 26 is a convex portion that cuts the resin sheets P1 and P2.

<Panel manufacturing process of embodiment>
A panel manufacturing process according to the embodiment will be described with reference to FIGS. First, a sheet forming process for manufacturing the resin sheets P1 and P2 will be described. The resin pellets put into the hopper 16 reach into the cylinder 15. The resin pellet of the cylinder 15 is melted by a screw to become a molten resin. The molten resin is supplied to the accumulator 13. The molten resin of the accumulator 13 is pushed out of the T die 11 by the pushing action of the plunger 14. The resin sheets P <b> 1 and P <b> 2 extruded from the T die 11 hang down on the roller 20. The above series of flows is the sheet forming process.

  Next, the resin sheets P1 and P2 are sent out from the inlet side to the outlet side of the roller 20 (feeding step). The resin sheet P1 that has passed through the roller 20 is shaped along the inner surface of the cavity 24 of the third divided mold a3, and the resin sheet P2 that has passed through the roller 20 is formed on the inner surface of the cavity 25 of the fourth divided mold a4. It is shaped along (shaped process). A vacuum suction hole (not shown) communicating with the cavity 24 is formed in the third divided mold a3. A vacuum suction hole (not shown) that communicates with the cavity 25 is also formed in the fourth divided mold a4. By the vacuum suction hole being vacuum-sucked, the resin sheet P1 is shaped along the inner surface of the cavity 24 of the third divided mold a3, and the resin sheet P2 is formed along the inner surface of the cavity 25 of the fourth divided mold a4. Is shaped.

  The manipulator holding the core material 1b presses the core material 1b against the resin sheet P1 (sticking step). Here, the core material 1b has the foaming molding 1c. The foamed molded body 1c of the core material 1b is welded to the resin sheet P1 by the heat of the resin sheet P1. Thereby, the core material 1b is affixed on the resin sheet P1. When the panel mold 22 is closed (second mold closing step), the resin sheets P1 and P2 are integrally formed with the core material 1b to become the resin molded body 1a. Thereafter, the panel mold 22 is opened (second mold opening step), and the resin molded body 1a is removed from the third divided mold a3.

<Operation and Effect of Embodiment>
The manufacturing method according to the embodiment fills the filling space Sp with foam beads in a state where the insert member 1d is attached to the holding portion 3 provided in the first split mold 2a. As a result, the foam beads are spread over the surface of the insert member 1d. Accordingly, it is possible to prevent a gap from being formed between the foam molded body 1c and the insert member 1d after molding the foam beads. As a result, the strength of the structure, that is, the strength of the core material 1b and the strength of the panel 1 are suppressed.
Moreover, in the manufacturing method which concerns on embodiment, the urging | biasing part 3b is comprised with the plate-shaped member. For this reason, the biasing portion 3b is thinner than, for example, a block-shaped chuck. Therefore, the volume of the extraction trace part 1f of the foaming molding 1c is suppressed by that amount. As a result, the strength of the structure, that is, the strength of the core material 1b and the strength of the panel 1 are suppressed.

In the attaching step, the insert member 1d is attached to the first split mold 2a so that the biasing portion 3b biases the insert member 1d to the first split mold 2a. That is, in the embodiment, in a state where the insert member 1d is attached to the first split mold 2a, the insert member 1d is pressed against the first split mold 2a by the restoring force of the urging portion 3b. In the state where the insert member 1d is attached to the holding portion 3, the restoring force of the biasing portion 3b continues to act on the insert member 1d. For this reason, attachment of the insert member 1d to the first split mold 2a by the holding portion 3 is less likely to loosen than attachment of the insert member 1d to the first split mold 2a by a chuck. Accordingly, the displacement of the insert member 1d is suppressed.
Moreover, since the insert member 1d is pressed against the first split mold 2a by the restoring force of the urging portion 3b, it is suppressed that a gap is generated between the insert member 1d and the first split mold 2a. . Thereby, in a filling process, it is suppressed that a foam bead penetrate | invades in the clearance gap between the insert member 1d and the 1st division mold 2a.
As described above, the displacement of the insert member 1d is suppressed, and the foamed beads are suppressed from entering the gap between the insert member 1d and the first split mold 2a. In the manufacturing method, the occurrence of defects in the core material 1b is suppressed.

  In the attaching step, the insert member 1d is attached to the first split mold 2a by sandwiching the insert member 1d between the pair of urging portions 3b. That is, not only the biasing force of the upper biasing portion 3b but also the biasing force of the lower biasing portion 3b acts on the insert member 1d. Thereby, attachment to the 1st division mold 2a of insert member 1d by holding part 3 becomes still more difficult to loosen, and as a result, position shift of insert member 1d is further controlled.

  The urging portion 3b is curved so as to be convex toward the insert member 1d. Thereby, the urging force of the urging portion 3b acts not only in the direction parallel to the vertical direction but also in the direction from the second divided mold 2A toward the first divided mold 2a. Specifically, the urging portion 3b has a curved portion 3e that curves so as to be convex toward the insert member 1d. The curved portion 3e is inclined with respect to the horizontal plane. For this reason, the urging force of the bending portion 3e has not only a component parallel to the vertical direction but also a component in the direction from the second divided mold 2A toward the first divided mold 2a. Therefore, the urging portion 3b can urge the insert member 1d toward the first split mold 2a.

  Since the urging portion 3b is composed of a plate-like member, the urging portion 3b has appropriate elasticity. For this reason, when the urging portion 3b is forcibly removed from the foamed molded body 1c, the urging portion 3b bends. Therefore, when the urging portion 3b is forcibly removed from the foam molded body 1c, the urging portion 3b is suppressed from damaging the foam molded body 1c.

  The restricting members 2e and 2C protrude into the filling space Sp in the first mold closing step, and the restricting members 2e and 2C are disposed at both ends in the longitudinal direction of the insert member 1d. Thereby, in the filling process and the molding process, it is possible to suppress the displacement of the insert member 1d in the longitudinal direction.

  The insert member 1d is a long reinforcing member. Since the panel 1 includes this reinforcing member, the load resistance of the panel 1 is improved. In addition, since the insert member 1d is long, the wide range of the panel 1 is reinforced by the insert member 1d. For this reason, it becomes difficult for the panel 1 to undergo deformation such as distortion, and the strength of the panel 1 is improved.

Since the regulating members 2e and 2C protrude into the filling space Sp in the first mold closing process, the recessed molded part 1e is formed in the foamed molded body 1c in a state where the molding process is completed. In the second mold closing process of the panel manufacturing process, the escape part 1e serves as an escape area for an excess part of the resin sheets P1 and P2.
Here, the hardness of the insert member 1d is higher than the hardness of the foam molded body 1c. For this reason, the resin sheets P1 and P2 on the surface of the insert member 1d are radially expanded from the surface side of the insert member 1d to the surface side of the foam molded body 1c by being pressurized in the second mold closing step. Therefore, if the relief portion 1e is not formed, the difference between the thickness of the resin sheets P1 and P2 on the surface of the insert member 1d and the thickness of the resin sheets P1 and P2 on the surface of the foam molded body 1c is large. It may become. However, since the relief part 1e is formed in the foam molded body 1c in the state where the molding process is completed, a part of the resin sheets P1 and P2 on the surface of the insert member 1d is part of the relief part 1e in the second mold closing process. Break into. This suppresses an increase in the difference between the thickness of the resin sheets P1 and P2 on the surface of the insert member 1d and the thickness of the resin sheets P1 and P2 on the surface of the foam molded body 1c.

  As described above, the resin sheets P1 and P2 on the surface of the insert member 1d are radially expanded from the surface side of the insert member 1d to the surface side of the foam molded body 1c by being pressurized in the second mold closing step. Here, the resin sheets P1 and P2 on the surface of the insert member 1d move to the periphery of the insert member 1d. Therefore, in the manufacturing method according to the embodiment, the relief portion 1e is formed in a portion of the foamed molded body 1c that is provided on the periphery of the insert member 1d. This more reliably suppresses the difference between the thickness of the resin sheets P1 and P2 on the surface of the insert member 1d and the thickness of the resin sheets P1 and P2 on the surface of the foam molded body 1c from increasing.

  The insert member 1d has a facing surface d4 that faces the second split mold 2A. Further, in the state where the first mold closing process is completed, the entire surface of the facing surface d4 comes into contact with the second split mold 2A, or the gap c2 between the facing surface d4 and the second split mold 2A (FIG. 13A) Is smaller than the expanded beads. Thereby, in a filling process, it is suppressed that a foam bead penetrate | invades between the opposing surface d4 and 2nd division mold 2A. Therefore, in the manufacturing method according to the embodiment, the occurrence of defects in the core material 1b is suppressed.

<Modification 1 of Embodiment>
In the embodiment, one base 3a has two urging portions. The base part of the holding part according to Modification 1 shown in FIGS. 19 to 21 is separated into two parts. Each base 4a has a plate-like urging portion 4b. The first base corresponds to one base of the pair of bases 4a, and the second base corresponds to the other base of the pair of bases 4a. Further, the first urging portion corresponds to the urging portion 4b provided on one base portion of the pair of base portions 4a, and the second urging portion is disposed on the other base portion of the pair of base portions 4a. It corresponds to the urging portion 4b provided. Each base 4a is fixed to the first split mold 2a by a fixing member 4g. The urging portion 4b has a proximal end portion 4c, a distal end portion 4d, and a curved portion 4e. The base end 4c is connected to the base 4a. The curved portion 4e is curved so as to be convex toward the insert member 1d. One end of the bending portion 4e is connected to the base end portion 4c, and the other end of the bending portion 4e is connected to the distal end portion 4d. As shown in FIGS. 20 and 21, the insert member 1 d is sandwiched between a pair of urging portions 4 b arranged vertically. Thereby, the insert member 1d is biased to the first split mold 2a, and the insert member 1d is attached to the first split mold 2a.

  In general, the plate-like member constituting the leaf spring is less likely to be bent as the thickness increases. That is, the workability of the plate-like member decreases as the thickness of the plate-like member increases, and as a result, the plate-like member becomes difficult to be processed into a leaf spring shape. Moreover, when the thickness of the plate-shaped member which comprises a leaf | plate spring becomes large, it will become difficult to fit in the attachment recessed part 2d. On the other hand, if the thickness of the plate-like member is thin, the urging force of the leaf spring is reduced accordingly. Therefore, in the first modification, the base portions are separated from each other. Thereby, although the number of parts of a holding part increases, the shape of a holding part is simplified. As a result, even if the thickness of the plate-like member is large, the plate-like member is easily processed into a leaf spring shape. That is, according to the modification 1, the freedom degree of design regarding the thickness of a plate-shaped member can be raised.

  Further, since the base portions are separated from each other in the first modification, the first split mold 2a does not require the attachment member 2c for attaching the holding portion. For this reason, according to the modification 1, the structure of the 1st division mold 2a can be simplified.

  Furthermore, according to the modification 1, the holding force of the insert member 1d by the holding part 3 can be increased by setting the thickness of the plate-like member large. Thereby, according to the modification 1, even if there is no holding member 2j, the insert member 1d can be attached to the 1st division mold 2a.

<Modification 2 of Embodiment>
The panel 1 according to the modified example 2 shown in FIG. 22 has a configuration in which the resin molded body 1a is filled between one flange portion d1 of the pair of flange portions d1 and the inner surface of the resin molded body 1a. is there. In the second modification, in the state where the first mold closing process is completed, the filling space Sp also exists between the entire surface of the facing surface d4 and the second divided mold 2A. For this reason, the foam beads are uniformly filled between the facing surface d4 and the second divided mold 2A. Thus, although the shape of the insert member 1d in the modified example 2 is different from the shape of the insert member 1d in the embodiment, the modified example 2 can also exhibit the operations and effects of the above-described embodiment.

A portion of the resin molded body 1a that is in contact with the insert member 1d is referred to as a first wall portion 1a1, and a portion of the resin molded body 1a that is not in contact with the insert member 1d is referred to as a second wall portion 1a2. . In the case where the panel 1 is manufactured by the above-described method using the core material 1b according to the modified example 2, in the second mold closing step, the second wall portion 1a2 is softer than the panel mold 22 and the insert member 1d. It is pinched | interposed with the foaming molding 1c. For this reason, the flange part d1 of the insert member 1d is not directly pressed against the second wall part 1a2, and a pressing trace corresponding to the flange part d1 is hardly formed on the second wall part 1a2, and the appearance of the panel 1 is improved. improves.
In addition, since the insert member 1d and the foam molded body 1c are made of different materials, the insert member 1d and the foam molded body 1c have different heat dissipation characteristics. For this reason, when the resin molded body 1a is in contact with the insert member 1d, the heat radiation unevenness between the portion of the resin molded body 1a that is in contact with the insert member 1d and the portion that is not in contact is increased. End up. As a result, a heat radiation unevenness mark corresponding to the flange portion d1 may be formed on the resin molded body 1a. However, in the case where the panel 1 is manufactured by the above-described method using the core material 1b according to the modified example 2, since the second wall 1a2 is not in contact with the insert member 1d, the above-described heat radiation unevenness is suppressed. As a result, the heat radiation uneven trace corresponding to the flange part d1 is hardly formed on the resin molded body 1a, and the appearance of the panel 1 is improved.
In addition, about the 1st wall part 1a1, you may attach a member different from the resin molding 1a, such as a carpet, for example. Thereby, it can avoid that the 1st wall part 1a1 is exposed.

<Modification 3 of embodiment>
As shown in FIGS. 23A, 23B, and 24, the insert member 1d includes a hooking portion d5 in addition to the base portion d2 and the flange portion d1. The hook portion d5 is connected to both ends of each flange portion d1. That is, the insert member 1d according to the modified example 3 has four hook portions d5. Here, the hook part d5 is configured to be convex toward the base part d2. For this reason, even if an external force is generated so as to pull out the foam molded body 1c from the concave portion d3, the foam molded body 1c is caught by the catching portion d5, so that the foam molded body 1c is prevented from being detached from the insert member 1d.

1: Panel 1a: Resin molded body 1a1: First wall portion 1a2: Second wall portion 1b: Core material 1c: Foam molded body 1d: Insert member 1e: Escape portion 1f: Pull-out trace portion 2: Core material mold 2A: Second split mold 2B: Core 2C: Restriction member 2D: Fixing member 2E: End face 2a: First split mold 2b: Cavity 2c: Mounting member 2d: Mounting recess 2e: Restricting member 2f: Fixing member 2g: Opening / closing part 2h : Ejector 2i: End surface 2j: Holding member 3: Holding part 3a: Base part 3b: Energizing part 3c: Base end part 3d: Tip part 3e: Curved part 3f: Plate-like part 3g: Fixing member 4: Holding part 4a: Base part 4b: Energizing part 4c: Base end part 4d: Tip part 4e: Curved part 4g: Fixing member 10: Extrusion mechanism 11: T die 13: Accumulator 14: Plunger 15: Cylinder 16: Hopper 17: Motor 20: Roller 21: Movement mechanism 22: Panel mold 24: Cavity 25: Cavity 26: Pinch off 100: Molding device P1: Resin sheet P2: Resin sheet Sp: Filling space Ho: Bead supply hole a3: Third divided mold a4: Fourth divided mold d1: Flange part d2: Base part d3: Concave part d4: Opposing surface d5: Hook part c1: Gap c2: Gap bi: Foamed beads

Claims (19)

A method of manufacturing a structure comprising a step of manufacturing a structure using first and second divided molds,
An attachment process, a first mold closing process, a filling process, a molding process, and a first mold opening process;
In the attaching step, the insert member is attached to the holding portion provided in the first split mold,
In the first mold closing step, a filling space is formed in the first and second divided molds by closing the first and second divided molds,
In the filling step, the filling space is filled with foam beads,
In the molding step, a foamed molded body configured by molding the foam beads filled in the filling space is manufactured,
In the first mold opening process, the first and second divided molds are opened,
The holding part has a biasing part,
The urging portion is constituted by a plate-like member configured to hold the insert member, and the urging portion protrudes into the filling space in the first mold closing step. The method of claim 1, comprising:
The holding part has a base part,
The base is fixed to the first split mold,
In the attaching step, the insert member is attached to the first split mold such that the biasing portion biases the insert member to the first split mold. The method of claim 2, comprising:
The urging portion has a first urging portion and a second urging portion,
One end and the other end of the base are connected to the first and second urging portions, respectively.
In the attachment step, the insert member is attached to the first split mold by sandwiching the insert member between the first and second urging portions. The method of claim 3, comprising:
The base has a first base and a second base,
The method, wherein the first and second bases are separated from each other. A method according to any one of claims 2 to 4, comprising
The urging portion is curved to be convex toward the insert member. A method according to any one of claims 1 to 5, comprising
In the first mold opening step, the urging portion is forcibly removed from the foamed molded body. A method according to any one of claims 1 to 6, wherein
The first and second split molds are provided with regulating members,
The method, wherein the restricting member protrudes into the filling space in the first mold closing step, and the restricting member is disposed at both ends in the longitudinal direction of the insert member. A method according to any one of claims 1 to 7, comprising
The insert member has a facing surface facing the second divided mold,
In the state where the first mold closing process is completed, the entire surface of the facing surface comes into contact with the second split mold, or the gap between the facing surface and the second split mold is smaller than the foam beads. Is that way. A method according to any one of claims 1 to 7, comprising
The insert member has a facing surface facing the second divided mold,
In the state where the first mold closing step is completed, the filling space is also present between the entire opposite surface and the second divided mold. A method according to any one of claims 1 to 9, comprising
The method, wherein the insert member is an elongated reinforcing member. A method according to any one of claims 1 to 10, comprising
The insert member is formed with a concave portion, and the insert member has a hook portion,
In the filling step, the foamed molded body is filled in the concave portion,
The method, wherein the hooking portion is configured to be hooked on the foamed molded body when the molding step is completed. The method of claim 11, comprising:
The insert member has a base portion and a flange portion,
The concave portion is formed by the base portion and the flange portion,
The base portion and the hook portion are connected to the flange portion,
The method, wherein the hook portion is configured to be convex toward the base portion. A method according to any one of claims 1 to 12, comprising
It has a core material manufacturing process and a panel manufacturing process,
The core material manufacturing process includes the attachment process, the first mold closing process, the filling process, the molding process, and the first mold opening process.
The panel manufacturing process includes a shaping process, a second mold closing process, and a second mold opening process,
In the shaping step, the resin sheet is shaped along the inner surfaces of the third and fourth divided molds,
In the second mold closing step, the third and fourth divided molds are closed, and a panel having a resin molded body formed by the resin sheet and the foam molded body disposed inside the resin molded body is provided. Manufacture and
In the second mold opening step, the third and fourth divided molds are opened. 14. A method according to claim 13, which cites claim 7.
In the foamed molded product, a concave relief portion is formed in a state where the molding process is completed,
The escape portion is formed in a portion where the restricting member is provided in the molding step, and the escape portion becomes a escape place for an extra portion of the resin sheet in a second mold closing step. . 15. A method according to claim 14, comprising
The said escape part is formed in the part provided in the periphery of the said insert member among the said foaming moldings. A panel comprising a core material and a resin molded body,
The core material has an insert member and a foam molded body, and the core material is disposed in the resin molded body,
The insert member and the foamed molded body are integrally molded,
The said foaming molding is a panel in which the concave extraction trace part is formed. A panel according to claim 16, comprising:
The insert member is a long reinforcing member. A panel according to claim 16 or claim 17, wherein
The insert member is formed with a concave portion, and the insert member has a hook portion,
The concave portion is filled with the foam molded article,
The said hook part is a panel comprised so that it may catch on the said foaming molding. The panel according to claim 18, wherein
The concave portion is formed by a base portion and a flange portion,
The base portion and the hook portion are connected to the flange portion,
The said hook part is a panel comprised so that it may become convex toward the said base | substrate part.