JP2020066222A - Plastic laminate and method for manufacturing the same - Google Patents

Abstract

To provide a plastic laminate that realizes excellent strength while saving weight, and furthermore, is effectively used for various applications by performing bending processing into a shape adapted for applications.SOLUTION: In a plastic laminate, a second plate 32 is joined to a first plate 31. In the first plate 31 and the second plate 32, a plate material 2 made of fiber-reinforced plastic is joined onto one face of an inner core 3 having a trapezoidal wavy shape made of fiber-reinforced plastic, hollow reinforcing rib parts 5 and groove-type opening parts 6 are provided alternately in a lattice shape, the reinforcing rib parts 5 of the first plate 31 are guided into the groove-type opening parts 6 of the second plate 32, and the first plate 31 and the second plate 32 are joined.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a plastic laminate in which a plate material is joined to a corrugated core and a method for manufacturing the same.

A plastic cardboard or a plastic laminate in which a trapezoidal corrugated core is provided between two plates and the two plates are connected by the core has been developed. (See Patent Documents 1 and 2)
The plastic cardboard of Patent Document 1 is formed by extruding a plastic such as polypropylene or polyethylene and connecting two plate members with a rib serving as a core. In this plastic cardboard, the ribs are arranged in a posture inclined with respect to the plate material, and the cross-sectional shape is trapezoidal wavy to improve the compression strength.
Further, in the plastic laminate of Patent Document 2, a plate material is bonded to both surfaces of a core having a trapezoidal wavy cross section, and a cover layer is laminated on the surface of the plate material. This plastic laminate has a structure including natural fibers in a base material composed of a plate material and a core, and is used for a wood panel or a decorative board used for a wooden beam.

JP, 2003-1735, A Special table 2011-527650 gazette

  Conventional plastic corrugated cardboard and plastic laminates connect two plates with ribs and make the cross-sectional shape trapezoidal to reduce the weight while improving the compressive strength, which is effective for applications where weight reduction and strength are required. Can be used. Although this structure can be effectively used for plate-shaped applications, it has a drawback that it is difficult to effectively use it for three-dimensionally deformed applications.

  The present invention was developed with the object of eliminating the drawbacks of conventional plastic laminates, and the important object of the present invention is to realize excellent strength while reducing weight, and to bend it into a shape suitable for use. It is an object of the present invention to provide a plastic laminate that can be processed and effectively used for various purposes, and a method for producing the same.

  In the plastic laminate according to the embodiment of the present invention, the first plate 31 and the second plate 32 are joined to each other, and the first plate 31 and the second plate 32 have a trapezoidal wave shape made of fiber reinforced plastic. A plate material 2 made of fiber reinforced plastic is joined to one surface of a certain core 3, and hollow reinforcing ribs 5 and groove-shaped openings 6 are alternately provided in a grid pattern. The reinforcing rib portion 5 is guided to the groove-shaped opening 6 of the second plate 32 to join the first plate 31 and the second plate 32.

  The core 3 of the plastic laminate according to an embodiment of the present invention has a trapezoidal wave shape in which a trapezoidal groove 3E is provided between the protrusions 3G, and the core 3 is on the top surface of the protrusion 3G and is a plate material. 2, a flat joining plate portion 3A, a connecting portion 3H at the bottom of the trapezoidal groove 3E that is not joined to the plate material 2, and joining plate portion 3A and connecting portion 3H, and joining plate portion A trapezoidal wave shape formed by a flat inclined plate portion 3B having an obtuse connection angle (α) with 3A and the connection portion 3H, and the plate material 2 is joined to the joint plate portion 3A of the center core 3 to form a hollow cylindrical shape. The reinforcing ribs 5 and the groove-shaped openings 6 are alternately arranged adjacent to each other, and the reinforcing ribs 5 are hollow cylinders surrounded by the plate material 2, the pair of inclined plate portions 3B, and the connecting portions 3H, This hollow cylinder has a cross-sectional shape that extends from the connecting portion 3H to the plate member 2 at the bottom. The groove-shaped opening 6 has a two-layer structure in which the plate member 2 and the joining plate portion 3A of the core 3 are joined to each other, and the reinforcing rib portion of the first plate 31 is formed. 5 is placed in the groove-shaped opening 6 of the second plate 32, the first plate 31 and the center core 3 of the second plate 32 are joined, and the reinforcing rib portion 5 of the first plate 31 is joined. And the reinforcing rib portion 5 of the second plate 32 can be arranged adjacent to each other.

  In the plastic laminate according to an aspect of the present invention, the reinforcing fibers of the fiber reinforced plastic 9 may be carbon fibers, and the plastic of the fiber reinforced plastic 9 may be made of nylon resin, polycarbonate, acrylic resin, PET, PP, It may be a thermoplastic resin such as PPS or HTPE.

  In the plastic laminate according to an embodiment of the present invention, the plate materials 2 of the first plate 31 and the second plate 32 can be bonded to the core 3 in a curved state. Further, the joining plate portion 3A of the plate material 2 and the core 3 can be heat-welded, and furthermore, the first plate 31 and the second plate 32 can be heat-welded via the thermoplastic resin of the fiber reinforced plastic 9. can do.

  In the plastic laminate according to an embodiment of the present invention, the center core 3 has a longitudinal strength that is a tensile strength in the longitudinal direction of the reinforcing rib portion 5 than a lateral strength that is a tensile strength in a lateral direction orthogonal to the trapezoidal groove 3E. The fiber reinforced plastic 9 can be a large fiber reinforced plastic 9, and the fiber reinforced plastic 9 in which the carbon fibers are embedded in the core 3 without directivity can be used. It is possible to use the fiber-reinforced plastic 9 which is buried without any property.

  In the plastic laminate according to an embodiment of the present invention, the connection angle (α) between the core 3 of the first plate 31 and the second plate 32 is an obtuse angle of 100 degrees or more and 140 degrees or less, and The lateral width (W1) of the joining plate portion 3A is 1/3 or more of the lateral width (W2) of the inclined plate portion 3B and 1.5 times or less, and the thickness (t) of the center core 3 is set to be smaller than that of the plate material 2. The thickness can be set to 1/4 or more and 4 times or less of the thickness (d).

  In the method for manufacturing a plastic laminate according to the embodiment of the present invention, the first plate 2X is joined to one surface of the first core 3X having a trapezoidal cross section to form the first plate 31. Joining step, and joining the second plate 2Y to one surface of the second core 3Y having a trapezoidal wave shape that can be stacked in a fitted state on the first core 3X of the first plate 31 And the second plate 32 obtained in the second joining step are joined together with the core 3 fitted therein. In the first joining process and the second joining process, the hollow reinforcing ribs 5 and the groove-shaped openings 6 are alternately provided in a grid pattern in the first joining process. The reinforcing rib portion 5 is guided to the groove-shaped opening 6 of the second plate, and the first plate 31 and the first plate 31 are guided. Joining the plate 32.

  Further, in this method for manufacturing a plastic laminate, in the first joining step and the second joining step, the trapezoidal corrugated core 3 having the trapezoidal groove 3E between the ridges 3G is used, and the plate material 2 is used. The core 3 to be joined to is a flat joining plate portion 3A which is on the top surface of the convex strip 3G and is joined to the plate material 2, and a connecting portion 3H which is on the bottom portion of the trapezoidal groove 3E and which is not joined to the plate material 2. , A trapezoidal corrugated core 3 that connects the joining plate portion 3A and the connecting portion 3H and includes a flat inclined plate portion 3B that forms an obtuse angle (α) between the joining plate portion 3A and the connecting portion 3H Further, in the first joining step and the second joining step, the plate material 2 is joined to the joining plate portion 3A of the core 3 to form the hollow tubular reinforcing rib portion 5 and the groove-shaped opening portion 6. Are alternately arranged adjacent to each other, and the reinforcing rib portion 5 is paired with the plate member 2. A hollow tubular shape surrounded by the inclined plate portion 3B and the connecting portion 3H, and the hollow tubular shape is a hollow tubular shape having a cross-sectional shape that widens toward the plate member 2 from the connecting portion 3H, and has a groove shape. The opening 6 has a two-layer structure in which the bottom portion is joined to the plate material 2 and the joint plate portion 3A of the core 3, and the reinforcing rib portion 5 of the first plate 31 is formed in the groove-shaped opening portion 6 of the second plate 32. The reinforcing rib portion 5 of the second plate 32 is arranged in the groove-shaped opening 6 of the first plate 31, and the center core 3 of the first plate 31 and the second plate 32 is fitted. To join.

  A method for manufacturing a plastic laminate according to an embodiment of the present invention uses carbon fibers as reinforcing fibers of the fiber reinforced plastic 9, and the plastic of the fiber reinforced plastic 9 includes nylon resin, polycarbonate, acrylic resin, PET, Thermoplastic resins such as PP, PPS and HTPE can be used.

  In the method for manufacturing a plastic laminate according to an embodiment of the present invention, the plate material 2 and the bonding plate portion 3A of the core 3 can be heat-welded in the first bonding step and the second bonding step, Further, in the first joining step and the second joining step, the plate material 2 and the core 3 can be heat-welded via the thermoplastic resin of the fiber reinforced plastic.

  In the method for manufacturing a plastic laminate according to an embodiment of the present invention, in the first joining step and the second joining step, the core 3 has a longitudinal strength which is a tensile strength in the longitudinal direction of the reinforcing rib portion 5, It is possible to use a fiber reinforced plastic 9 having a tensile strength in the lateral direction orthogonal to the trapezoidal groove 3E, which is greater than the lateral strength. Furthermore, in the first joining step and the second joining step, carbon is added to the core 3. It is possible to use the fiber reinforced plastic 9 in which the fibers are embedded without orientation.

  In the method for manufacturing a plastic laminate according to an embodiment of the present invention, in the first joining step and the second joining step, the connecting angle (α) of the trapezoidal corrugated core 3 is 100 degrees or more and 140 degrees or less. The obtuse angle of less than or equal to 10 degrees, and the lateral width (W1) of the joining plate portion 3A of the trapezoidal corrugated core 3 is 1/3 or more of the lateral width (W2) of the inclined plate portion 3B and 1.5 times or less, Further, the thickness (t) of the core 3 can be set to be ¼ or more and 4 times or less of the thickness (d) of the plate material.

  Furthermore, in the method for manufacturing a plastic laminate according to an embodiment of the present invention, the first plate 31 and the second plate 32 can be curved and joined in the third joining step.

  The present invention is characterized in that it realizes excellent strength while reducing the weight of a plastic laminate, and can be effectively used in various applications by bending it into a shape suitable for the application. It is a plastic laminate of the present invention, in which a fiber-reinforced plastic plate material is joined to one surface of a core having a trapezoidal corrugated fiber-reinforced plastic, and hollow reinforcing ribs and groove-shaped openings are alternately latticed. A first plate and a second plate, which are provided in the shape of a ring, and guide the reinforcing rib portion of the first plate to the groove-shaped opening of the second plate to form the first plate and the second plate. Because they are joined together. The cores of the first plate and the second plate, which have a trapezoidal wave shape and are joined to each other in a fitting structure, are firmly joined to each other in a large area without displacement, so that the first plate and the second plate are firmly joined. Join without peeling. Further, in the state where the first plate and the second plate are joined together, the core is joined in a two-layer structure, and the reinforcing rib portion is provided adjacent to the core portion, so that the bending rigidity of the reinforcing rib portion in the vertical direction is improved. Since the plate material is joined to both surfaces of the core of the two-layer structure, the bending rigidity in the lateral direction of the reinforcing rib portion is significantly improved.

  Further, the above-mentioned plastic laminate has a feature that it can be formed into a curved shape while achieving extremely excellent bending rigidity. It is because the plastic laminated body joins the first plate and the second plate, which are joined with the plate material on one surface of the core, with the trapezoidal corrugated core, with the fitting structure. This is because the second plate can be manufactured by bending it and then joining it. The fiber-reinforced plastic in which the plate material is joined to both sides of the core cannot be deformed, but the first plate and the second plate in which the plate material is joined to one side are formed by joining the joint plate part of the core to the plate material. The groove-shaped opening is flexible and can be deformed. Therefore, the groove-shaped opening is deformed to be curved as a whole, and the first plate and the second plate can be joined in a curved state to be fixed in a curved shape. In the plastic laminate fixed in a curved state, plate materials are joined to both surfaces of the core, and the core is joined in a two-layer structure to realize extremely strong bending rigidity. Further, in the above plastic laminate, since the bottom of the groove-shaped opening has sufficient strength as a two-layer structure of a plate material and a core, this portion is also deformed to realize sufficient strength.

  Further, in the above plastic laminate, the reinforcing rib portion of the second plate is guided to the groove-shaped opening of the first plate in a state where the first plate and the second plate are joined, and The reinforcing ribs of the first plate are guided in the groove-shaped openings of the plate. In the plastic laminated body laminated in this state, the reinforcing ribs in the form of a quadrangular prism with four sides have a two-layer structure with both sides protruding in a mountain shape and the three sides of the top surface being connected by a plate material. Therefore, in addition to the bending rigidity, the compressive strength acting on the plate materials on both sides is significantly improved.

It is a partially expanded sectional view of the plastic laminated body which concerns on one Embodiment of this invention. It is an expansion disassembled sectional view of the plastic laminated body shown in FIG. FIG. 3 is an exploded sectional view of a first plate and a second plate shown in FIG. 2. It is a front view which shows an example of the shaping | molding apparatus which shape | molds a core. It is a principal part enlarged view of the shaping | molding apparatus shown in FIG. It is a front view showing an example of a joining device which joins a core to a plate material. It is a principal part enlarged view of the joining apparatus shown in FIG. It is a front view which shows another example of the joining apparatus which joins a core to a board | plate material. It is a principal part enlarged view of the joining apparatus shown in FIG. It is a process drawing showing an example of the joining process which joins the 1st plate and the 2nd plate. It is process drawing which shows another example of the joining process which joins a 1st plate and a 2nd plate.

Hereinafter, the present invention will be described in detail with reference to the drawings. In the following description, terms indicating a specific direction or position are used as necessary (for example, “upper”, “lower”, and other terms including those terms), but use of those terms is not allowed. This is for facilitating the understanding of the invention with reference to the drawings, and the technical scope of the present invention is not limited by the meanings of the terms. Further, the portions having the same reference numerals appearing in a plurality of drawings indicate the same or equivalent portions or members.
Furthermore, the embodiments described below are specific examples of the technical idea of the present invention, and the present invention is not limited to the following. Further, the dimensions, materials, shapes, relative arrangements, and the like of the components described below are not intended to limit the scope of the present invention thereto, unless specifically stated, and are merely exemplified. It was intended. In addition, the contents described in one embodiment and example can be applied to other embodiments and examples. In addition, the sizes and positional relationships of members shown in the drawings may be exaggerated for clarity of explanation.

  As shown in FIG. 2, the plastic laminate shown in FIG. 1 has a first plate 31 and a second plate 32 bonded to each other. The first plate 31 and the second plate 32 are formed by joining a plate material 2 of fiber reinforced plastic to one surface of a core 3 having a trapezoidal corrugated shape of fiber reinforced plastic to form a hollow reinforcing rib 5 and a groove-shaped opening. The parts 6 are alternately provided in a grid pattern. The reinforcing rib portion 5 of the first plate 31 is guided by the groove-shaped opening 6 of the second plate 32, and the first plate 31 and the second plate 32 are joined. The fiber reinforced plastic has a plate shape in which reinforcing fibers are embedded in the plastic.

  As shown in FIG. 3, the center core 3 has a trapezoidal wave shape in which a trapezoidal groove 3E is provided between the convex stripes 3G, and is a flat bonding plate which is on the top surface of the convex stripe 3G and is bonded to the plate member 2. The portion 3A, the connecting portion 3H at the bottom of the trapezoidal groove 3E that is not joined to the plate material 2, connect the joining plate portion 3A and the joining portion 3H, and the joining angle between the joining plate portion 3A and the joining portion 3H (α ) Is an obtuse angle and has a trapezoidal wave shape including a flat inclined plate portion 3B. In the first plate 31 and the second plate 32, the plate member 2 is joined to the joining plate portion 3A of the core 3, and the groove-shaped opening 6 and the hollow tubular reinforcing rib portion 5 are alternately adjacent to each other. It is arranged. The reinforcing rib portion 5 has a hollow cylindrical shape surrounded by the plate material 2, the pair of inclined plate portions 3B and the connecting portion 3H, and the hollow cylindrical reinforcing rib portion 5 has a cross-sectional shape from the connecting portion 3H toward the plate material 2. It has a hollow cylindrical shape with a wide hem. The groove-shaped opening 6 is arranged between the reinforcing ribs 5 so that the bottom surface has a two-layer structure of the plate material 2 and the joining plate portion 3A.

  In the plastic laminate 1, the cores 3 are joined together in a state where the reinforcing rib portion 5 of the first plate 31 is arranged in the groove-shaped opening 6 of the second plate 32, and the first plate 31 and the second plate 31 are joined together. The plates 32 are joined together. Further, in this state, the reinforcing rib portion 5 of the second plate 32 is arranged in the groove-shaped opening 6 of the first plate 31. In the illustrated plastic laminate 1, the reinforcing rib portion 5 of the first plate 31 and the reinforcing rib portion 5 of the second plate 32 are adjacent to each other in a state where the first plate 31 and the second plate 32 are joined. Have been arranged. In order to join the first plate 31 and the second plate 32 in the above state, the reinforcing rib portion 5 of the first plate 31 has an outer shape that can be arranged in the groove-shaped opening 6 of the second plate 32. The groove-shaped opening 6 of the first plate 31 has an internal shape in which the reinforcing rib portion 5 of the second plate 32 can be arranged. The core 3 of the second plate 32 in the figure has a trapezoidal wave shape that can be stacked on the core 3 of the first plate 31 in a fitted state. In this plastic laminate 1, the bending rigidity is improved by the reinforcing rib portions 5 arranged in a grid. The groove-shaped opening 6 provided between the reinforcing ribs 5 realizes flexibility while maintaining sufficient strength as a two-layer structure of fiber reinforced plastic. The plastic laminate 1 is used by deforming the groove-shaped openings 6 arranged in a lattice shape and deforming it into a shape suitable for various applications as shown by the chain line in FIG.

  In the first plate 31 and the second plate 32 of FIG. 2, the reinforcing rib portions 5 are provided in a grid shape, and the groove-shaped openings 6 are arranged between the reinforcing rib portions 5, so that the reinforcing rib portions 5 and the groove are formed. The shaped openings 6 are alternately arranged in a grid pattern. Therefore, the plastic laminate 1 obtained by joining the first plate 31 and the second plate 32 to each other remarkably improves the bending rigidity in the vertical direction by the reinforcing rib portion 5 and is reinforced by the groove-shaped opening portion 6. The lateral flexibility of the rib portion 5 is realized. The reinforcing rib portion 5 having a hollow cylindrical shape and a trapezoidal cross section has an extremely high bending strength in the vertical direction, and the reinforcing rib portions 5 are arranged in a lattice shape to remarkably increase the bending rigidity of the plastic laminate 1. In particular, the reinforcing rib portion 5 has a hollow interior and a trapezoidal cross-sectional shape to improve bending rigidity while reducing weight. Further, the reinforcing rib portion 5 provided in a lattice shape by joining the plate material 2 to one surface of the trapezoidal corrugated core 3 has a trapezoidal hollow cylindrical shape with the plate material 2, the inclined plate portion 3B and the connecting portion 3H, and has a cross section. Since the shape is such that it extends from the connecting portion 3H of the center core 3 toward the plate member 2, the reinforcing rib portion 5 is not crushed by being compressed, and the compressive strength becomes extremely strong.

  The plastic laminate 1 of FIG. 1 is preferably used for a body steel plate of a vehicle, a case of an electronic device such as a mobile phone or a tablet, instead of a metal plate such as high-strength steel, aluminum or magnesium. For example, the plastic laminate 1 can be made thin to realize weight reduction and bending strength. For example, a plastic in which the total thickness (D) is considerably reduced to 2 mm and the thickness (d; t) of the plate material 2 and the core 3 of the first plate 31 and the second plate 32 is 0.15 mm. The laminated body 1 has a bending rigidity that is about 7 times as high as that of high-strength steel having a thickness of 0.65 mm that is used for a body steel plate of a vehicle, and has a characteristic that the weight can be extremely reduced to about 1/5. Lightening and bending rigidity are extremely important characteristics not only for body steel plates of vehicles but also for various other applications. This is because it is required to be thin, light, and hard to bend in all applications.

  The plastic laminate 1 is suitable for applications requiring weight reduction and strong bending rigidity. For example, the overall thickness (D) is 0.8 mm or more, preferably 1.5 mm or more, considering the application. More preferably, it is 2 mm or more. The plastic laminate 1 can be made thick to have high strength, but since it is bulky and heavy, it is preferably, for example, 10 cm or less, preferably 3 cm or less in consideration of the application, and is preferably used in applications requiring further weight reduction. It is 1 cm or less.

  In consideration of strength, the plate material 2 and the core 3 have a thickness (d; t) of, for example, 0.1 mm or more, preferably 0.15 mm or more. The plate member 2 and the core 3 become heavier when they are thicker, and therefore, in consideration of weight reduction, the plate member 2 and the core 3 are set to, for example, 1 mm or less, preferably 0.8 mm or less, more preferably 0.5 mm or less. Regarding the thickness ratio between the plate material 2 and the core 3, the core 3 and the plate 2 have the same thickness in consideration of strength and the total thickness (D), or the thickness of the core 3 is equal to that of the plate 2. It can be 1/4 or more of the thickness and 4 times or less. In the plastic laminate 1, the plate material 2 can be made thicker than the core 3 to improve the surface strength, and the plastic core 1 can be made thicker than the plate material to increase bending rigidity.

  The plate material 2 and the core 3 are fiber reinforced plastics in which carbon fibers are embedded in plastics. The fiber reinforced plastic of the plate material 2 and the core 3 is preferably a thermoplastic resin in which carbon fibers are embedded. The thermoplastic resin of the fiber reinforced plastic is preferably nylon or polycarbonate. However, the present invention does not specify the thermoplastic resin to the above plastics, and for example, considering the application, all other thermoplastic resins such as acrylic resin, PET, PP, PPS, HTPE, etc. can be used. . Further, as the fiber-reinforced plastic, an amphoteric plastic that exhibits thermosetting properties in an uncured state and thermoplastic properties in a state where it is heated and cured, such as a phenoxy resin or a thermosetting resin, can also be used. Amphoteric plastics are plastics that are liquid or pasty in the uncured state and have thermoplastic physical properties when cured. Further, the plastic laminate 1 can be used for applications having a high heat resistant temperature by using a thermosetting resin in which carbon fibers are embedded.

  The fiber reinforced plastic is made by embedding carbon fibers in the form of a sheet in the plastic. The carbon fibers are braided to form a mesh-like fiber sheet, or arranged in parallel to form a fiber sheet, and the carbon fibers arranged in parallel to each other are laminated in a crossing direction to form a fiber sheet, or three-dimensionally oriented. It gathers together and is embedded in plastic as a fiber sheet. A fiber sheet in which carbon fibers are aggregated in a three-dimensionally non-directional manner is produced by a wet papermaking method, or is aggregated in a dry thickness to a predetermined thickness to produce a nonwoven fabric in a sheet form. The fiber reinforced plastics of the plate material 2 and the core 3 which are joined to each other are used in a state in which a fiber sheet is embedded in a thermoplastic resin, or in a prepreg state in which the fiber sheet is impregnated with a thermoplastic resin or an amphoteric plastic. To be done. The amphoteric plastic prepreg used for the core 3 hardens the thermosetting resin into a thermoplastic resin in the step of forming into a trapezoidal wave, and the amphoteric plastic prepreg used for the plate 2 includes the core 3 and the plate 2. In the step of joining, the thermosetting resin is cured to obtain a thermoplastic resin.

  In the wet papermaking method, carbon fibers are suspended in water to prepare a papermaking slurry, and the papermaking slurry is wet-paper-made into a fiber sheet. This method can produce a fiber sheet as a papermaking slurry by suspending an additive such as an inorganic powder in carbon fiber, and further, in addition to carbon fiber, powdery or fine granular thermoplastic resin or uncured state. An amphoteric plastic is suspended in water to prepare a papermaking slurry, which is then paper-made and dried to produce a fiber-reinforced plastic. According to this manufacturing method, carbon fibers can be uniformly dispersed to manufacture a fiber-reinforced plastic having excellent rigidity. Further, it has a feature that various additives can be added and uniformly dispersed to mass-produce fiber reinforced plastics. Furthermore, the fiber-reinforced plastic can be manufactured by mixing carbon fibers having different lengths, thicknesses and the like. In addition, an inexpensive recycled material can be used as the carbon fiber, and further, the carbon fiber can be mixed with another synthetic fiber to produce a fiber reinforced plastic. However, the present invention does not specify the method for producing the fiber-reinforced plastic.

  As shown in FIGS. 2 and 3, the first plate 31 and the second plate 32 join the joining plate portion 3A of the trapezoidal corrugated core 3 to the back surface of the plate member 2. The first plate 31 and the second plate 32 are trapezoidal corrugated cores in which planar fiber-reinforced plastics are formed by alternately arranging the joining plate portions 3A and the connecting portions 3H between adjacent inclined plate portions 3B. 3 is processed, and the flat plate member 2 is joined to one surface of the core 3 to manufacture it.

  The first plate 31 and the second plate 32 shown in FIG. 2 are provided with a curved portion 3C at the boundary between the inclined plate 3B and the joint plate 3A and at the boundary between the inclined plate 3B and the connecting portion 3H. ing. The inclined plate portion 3B is provided with a curved portion 3C at a boundary portion between the flat surface portion 3F and the joining plate portion 3A and a boundary portion between the flat surface portion 3F and the connecting portion 3H. The radius of curvature (R) of the curved portion 3C takes into consideration the fractured state of the carbon fibers embedded in the fiber-reinforced plastic, the thickness (t) of the core 3, the dimensional accuracy of the thickness (D) of the plastic laminate 1, and the like. And is set to an optimum value, for example, twice or more, preferably three times or more, the thickness (t) of the core 3. In the first plate 31 and the second plate 32, the radius of curvature (R) of the curved portion 3C can be increased to reduce the breakage of the carbon fibers, improve the strength, and further improve the overall dimensional accuracy. However, if the radius of curvature of the curved portion 3C is too large, the ratio of the curved portion 3C to the flat surface portion 3F becomes large and the strength is reduced, so that the strength of the plastic laminate 1 is reduced. Therefore, in the core 3, the lateral width (W1) of the curved portion 3C is set to ⅓ or less of the lateral width (W2) of the flat surface portion 3F, and the joint strength between the core 3 and the plate member 2 is set to a predetermined strength, and further The weight is reduced and a predetermined bending rigidity is realized.

  In the first plate 31 and the second plate 32 of FIG. 2, the connecting angle (α) on both sides of the inclined plate portion 3B of the core 3 is 110 degrees, and the lateral width (W) of the joining plate portion 3A is the plastic laminate 1 Although it is set to about 50% of the total thickness (D), the inclined plate portion 3B of the core 3 has a connection angle (α) of 100 degrees or more and 140 degrees or less, preferably 100 degrees or more. The width (W) of the joining plate portion 3A is 20% or more and 100% or less, preferably 30% or more of the total thickness (D) of the plastic laminate 1. 70% or less, more preferably 35% or more and 60% or less.

  The first plate 31 and the second plate 32 heat the ridges 3G of the core 3 in a state of pressurizing the plate 2 to bond the plate 2 to one surface of the core 3. The core 3 and the plate member 2 are joined together without using an adhesive or via an adhesive. The first plate 31 and the second plate 32, which join the plate material 2 and the core 3 without using an adhesive, heat and melt the thermoplastic resin contained in the fiber reinforced plastic to form the plate material 2 and the plate material 2. The core 3 is thermally bonded and bonded. The plastic laminate 1 for joining the plate material 2 and the core 3 with an adhesive agent preferably uses an amphoteric plastic as the adhesive agent.

  Amphoteric plastic is a plastic that exhibits both thermosetting resin and thermoplastic resin, and is a liquid or paste-like thermosetting physical property in the uncured state, and a thermoplastic physical property when cured. . Examples of the amphoteric plastic include phenoxy, which is a thermoplastic epoxy resin used in "NS-TEPreg (registered trademark)" of Nippon Steel & Sumikin Materials Co., Ltd., which is a prepreg in which carbon fibers are impregnated with a thermoplastic epoxy resin. Resin can be used.

  In the uncured state, an adhesive of a thermoplastic epoxy resin, which is an amphoteric plastic, is liquid or paste-like, and exhibits thermoplastic physical properties when heated or cured without heating. The amphoteric plastic adhesive is in a liquid or paste state in an uncured state, and is easily applied to the surfaces of the plate material 2 and the core 3, and then the core 3 and the plate 2 are pressed and cured to form the core. 3 and the plate material 2 are joined. The uncured liquid or paste amphoteric plastic adhesive is extruded into the curved gap 7 from the joint surface between the joint plate portion 3A and the plate material 2 while the core 3 and the plate material 2 are pressed. It moves between the curved portion 3C and the plate material 2 and becomes the gap filling adhesive 4A. The extruded gap filling adhesive 4A is heated and cured to bond the plate material 2 and the core 3. The liquid or paste adhesive in the uncured state is adjusted by adjusting the application amount and the pressing force to adjust the amount of the adhesive extruded from the joint portion into the curved gap 7, that is, the amount of the gap filling adhesive 4A. The region where the adhesive 4 joins the curved portion 3C to the plate member 2 can be controlled in an optimum state.

  The amphoteric plastic adhesive is applied in the form of an uncured liquid or paste, which is sprayed or transferred by a roller and applied to the surface of the core 3 or the plate 2. This adhesive can be controlled to the optimum amount by adjusting the spray amount from the nozzle and the coating amount on the roller surface. The amount of the adhesive applied specifies the region where the adhesive joins the curved portion 3C of the center core 3 and the plate member 2, so by adjusting it accurately, the specific position of the curved portion 3C can be reliably applied to the plate member 2. Can be joined. That is, the application amount of the adhesive is controlled to an amount that reliably joins the joining plate portion 3A to the plate material 2 and is extruded from the joining plate portion 3A to join the curved portion 3C to the plate material 2.

  Since the amphoteric plastic adhesive becomes a thermoplastic resin in a state where it is cured and the plate material 2 and the core 3 are bonded together, the plate-shaped first plate 31 and the second plate 32 are heated and heated. It can be pressed into a three-dimensional shape. This is because the thermoplastic plastic adhesive is melted or softened in the press molding step of heating and pressurizing, and the core 3 and the plate member 2 are relatively moved and can be deformed into a three-dimensional shape. Therefore, the first plate 31 and the second plate 32, which are manufactured in a plate shape by joining the core 3 and the plate material 2 with this adhesive, are applied in a large amount in a plate shape by applying the adhesive as a simple process. It has a feature that it can be produced and then pressed in a heated state to be molded into a three-dimensional shape suitable for the purpose.

  Further, the fiber-reinforced plastic of the thermoplastic resin can be heat-pressed to melt the thermoplastic resin for thermal bonding. Therefore, the fiber-reinforced plastic plate 2 and the core 3 can be joined without using an adhesive. The first plate 31 and the second plate 32 heat and pressurize the joint portion between the joint plate portion 3A and the plate material 2 to heat and melt the thermoplastic resin contained in the fiber reinforced plastic, and to melt the thermoplastic resin. A thermoplastic plastic is used as the adhesive 4 and is extruded from the joining surface between the joining plate portion 3A and the plate member 2 into the curved gap 7 and is moved between the bending portion 3C and the plate member 2 to form the gap filling adhesive 4A. Fill some or all of 7. The thermoplastic plastic transferred to the curved gap 7 is hardened to bond the core 3 and the plate member 2.

  Furthermore, as the fiber reinforced plastic, a prepreg of amphoteric plastic can be used. The prepreg of amphoteric plastic impregnates a fibrous sheet with uncured amphoteric plastic. The prepreg of the amphoteric plastic is heated with a hot plate or a joining roll in a state of being laminated as the plate material 2 and the core 3, or is pressurized without being heated to cure the amphoteric plastic. The hardened amphoteric plastic becomes a thermoplastic resin to bond the plate material 2 and the core 3. The amphoteric plastic prepreg is used for either the plate material 2 or the core 3, or for both the plate material 2 and the core 3. The first plate 31 and the second plate 32, which are manufactured by using the prepreg of the amphoteric plastic for the plate material 2, heat the amphoteric plastic of the prepreg or pressurize it without heating to bond the prepreg. There is a feature that the surface of the plate material can be made a smoother surface. The prepreg used for the core 3 is formed into a corrugated shape, and then laminated and joined to the plate material 2. The first plate 31 and the second plate 32 that use prepregs for both the plate member 2 and the core 3 can increase the bonding strength between the plate member 2 and the core 3.

  The above prepreg can control the shape retention in the uncured state of the amphoteric plastic. The prepreg used for the core 3 is formed into a corrugated shape in a sheet-like state in which the uncured state can be controlled and deformed, and then laminated and joined to the plate material 2. The prepreg is formed into a corrugated shape by being sandwiched by a pair of heat forming rollers. The heat-molding roller for molding the prepreg into a corrugated shape has a shape-retaining property capable of maintaining the corrugation in a state of being laminated on the plate material 2 although the amphoteric plastic is heated and pressed to completely cure the amphoteric plastic. Cure to a certain state.

  The first plate 31 and the second plate 32 that join the plate material 2 and the core 3 using the adhesive can be efficiently mass-produced by using the amphoteric plastic adhesive as the adhesive. Instead of the amphoteric plastic, a thermoplastic resin that is heated and melted like hot melt can be used as the adhesive. The amphoteric plastics can be efficiently mass-produced by using the adhesive, which makes it possible to easily apply the adhesive in the manufacturing process, and by hardening the applied adhesive, the plate material 2 and the core can be quickly produced. This is because 3 can be joined.

  The fiber reinforced plastic of the core 3 is formed into a trapezoidal wave shape by the forming device 10 shown in FIG. The molding apparatus 10 in this figure includes a pair of molding dies 11 and a cylinder 12 of an actuator that reciprocates one of the molding dies 11. The pair of molding dies 11 have trapezoidal corrugations in which the opposing molding surfaces 11X are meshed with each other so that the fiber-reinforced plastic 9 is sandwiched between the molding dies 11. The pair of molding dies 11 press the fiber-reinforced plastic 9 while sandwiching it, and heat in this state to form trapezoidal waves. The fiber reinforced plastic 9 of the thermoplastic resin is pressed in a heated state to be formed into a trapezoidal wave shape, and then cooled to cure the thermoplastic resin and released from the molding die 11. Since the amphoteric plastic heats the thermosetting resin to make it a thermoplastic resin, the fiber-reinforced plastic of the amphoteric plastic is pressed in a heated state and shaped into a trapezoidal wave to cure the thermosetting resin. Since the thermosetting resin is cured by heating the amphoteric plastic, it can be discharged from the molding die without necessarily cooling.

  The opposing molding surfaces 11X of the molding die 11 are trapezoidal waves that are fitted to each other with the fiber-reinforced plastic 9 sandwiched therebetween, and the fiber-reinforced plastic 9 of the core 3 is sandwiched in a heated state to be trapezoidal-shaped. As shown in FIGS. 4 and 5, the molding die 11 is an elongated trapezoidal corrugated shape in which the molding surface 11X is provided with the parallel ridges 13 at a constant pitch and the grooves 14 are provided between the adjacent ridges 13. I am trying. The pair of molding dies 11 is configured such that the ridges 13 provided on one molding surface 11X face each other and fit into the grooves 14 provided on the other molding surface 11X. Then, the fiber reinforced plastic 9 is sandwiched from both sides, and the protruding ridges 13 and the grooves 14 facing each other are fitted to each other to form a trapezoidal wave shape. In the molding die 11 shown, chamfered portions 13B are provided on both side edges of the tip end surface 13A of the ridge 13, and curved corner portions 14B are provided on both side edges of the bottom surface 14A of the groove 14. The chamfered portion 13B and the curved corner portion 14B are curved surfaces, and by sandwiching the fiber reinforced plastic 9 from both sides in a heated state, the curved portion 3C is formed at the boundary portion between the inclined plate portion 3B of the core 3 and the joining plate portion 3A. Mold. The radius of curvature (r1, r2) of the chamfered portion 13B and the curved corner portion 14B specifies the radius of curvature (R) of the curved portion 3C. Therefore, in the chamfered portion 13B and the curved corner portion 14B, the radius of curvature (R) of the curved portion 3C provided on the core 3 is at least twice the thickness (t) of the core 3, and preferably at least three times. To be a curved surface.

  The pair of molding dies 11 are provided with heating and cooling circulation paths (not shown) inside for heating and pressurizing the fiber reinforced plastic 9 and further cooling. The circulation path for heating circulates a fluid such as heating oil to heat the molding surface 11X, and the circulation path for cooling circulates a fluid such as cooling water to cool the molding surface 11X. The circulation circuit for heating is connected to a heating system that circulates a liquid such as hot water or heating oil, or a gas such as steam, and the circulation circuit for cooling is such as cooling water or a refrigerant that is vaporized and cooled by heat of vaporization. A cooling system for circulating a fluid is connected. The heating system heats the fluid to circulate it in the circulation path of the molding die 11. The cooling system cools the fluid and circulates the fluid in the circulation path of the molding die 11.

The above molding apparatus 10 molds the fiber reinforced plastic 9 into a trapezoidal wave shape in the following steps.
1. The molding surface 11X is in a horizontal posture, and the upper molding die 11B is lifted by the cylinder 12 to open the pair of molding dies 11. In this state, the sheet-shaped fiber reinforced plastic 9 is set on the molding surface 11X which is the upper surface of the lower molding die 11A.
2. A heating fluid such as heating oil or heating steam in the circulation paths of both molding dies 11 is circulated to bring the molding surface 11X of the molding dies 11 into a heated state.
3. The cylinder 12 lowers the upper molding die 11B, presses the fiber-reinforced plastic 9 in a heated state on the molding surfaces 11X of the pair of molding dies 11 to form a trapezoidal wave shape.
4. The circulation of the heating fluid circulated in the circulation paths of both molding dies 11 is stopped, and the cooling liquid is circulated in the circulation paths to cool the molding surface 11X.
5. After the trapezoidal wave-shaped fiber reinforced plastic 9 is cooled, the upper molding die 11B is raised by the cylinder 12 to release the fiber-reinforced plastic 9 from the trapezoidal wave-shaped center core 3.
The core 3 of the fiber-reinforced plastic of the thermoplastic resin is cooled to a temperature at which the thermoplastic resin is hardened and released from the molding die 11, and the core of the amphoteric plastic is thermoplastic because the thermoplastic resin is lowered. It can be removed from the mold when it becomes a resin.

  The first plate 31 and the second plate 32 shown in FIG. 2 thermally bond the plate material 2 and the core 3 with the bonding apparatus 20 shown in FIGS. 6 and 7. In this joining device 20, the joining plate portion 3A of the core 3 is locally pressed against the plate material 2 by the press projections 23 to perform heat joining. In this step, the press projection 23 inserted between the adjacent inclined plate portions 3B locally presses the joint plate portion 3A of the center core 3 and the plate material 2 and the plastic of the center core 3 are joined to the joint plate portion 3A. The core 3 and the plate material 2 are bonded together by extruding into the curved gap 7 from the joint surface with the plate material 2.

  The joining device 20 of FIGS. 6 and 7 includes a joining plate 21 as a heating / pressurizing plate for thermally joining the core 3 to the plate member 2. The joining device 20 of FIGS. 6 and 7 includes a pair of joining plates 21 for thermally joining the core 3 to the plate member 2, and an actuator cylinder 22 for reciprocating one joining plate 21. In the joining device 20 shown in the figure, the plate material 2 is laminated on the core 3, and the lower joint plate 21A and the upper joint plate 21B press the joint plate portion 3A of the middle core 3 against the plate material 2 in a heated state to thermally bond them. The lower joint plate 21A and the upper joint plate 21B are provided with press protrusions 23 on their opposing surfaces. The joining plate 21 is provided with press protrusions 23 on its opposing surface at a pitch that locally presses the joining plate portion 3A of the core 3. This joining apparatus can guide the press protrusion 23 of the lower joining plate 21A to the trapezoidal groove 3E of the core 3, and arrange the press protrusion 23 on the joint plate portion 3A of the core 3. The plate material 2 is laminated on the center core 3, and the center core 3 and the plate material 2 are bonded by the upper and lower bonding plates 21. The press protrusions 23 provided on the upper and lower joining plates 21 locally join the joining plate portion 3A of the core 3 and the surface of the plate material joined to the joining plate portion 3A by locally applying pressure in a heated state.

  In the plastic laminate 1 shown in FIG. 1, the plate material 2 and the core 3 can be thermally joined by the joining device 20 shown in FIGS. 8 and 9. In this joining device 20, one joining plate 21 for thermally joining the core 3 to the plate member 2 is made flat, and the other joining plate 21 is provided with a press protrusion 23. The press protrusions 23 are arranged at a pitch that locally presses the joint plate portion 3A of the core 3. In the joining device 20 of this figure, a press projection 23 is provided on the lower joining plate 21A, and the surface of the upper joining plate 21B is made flat. The lower joining plate 21A guides the press protrusion 23 to the trapezoidal groove 3E of the center core 3 to press the joining plate portion 3A, and the upper joining plate 21B presses the surface of the plate material 2 with a flat pressing surface. This joining device 20 guides the press protrusion 23 of the lower joining plate 21A into the trapezoidal groove 3E of the middle core 3 to set the middle core 3 on the lower joining plate 21A and stack the plate material 2 on the middle core 3. The upper and lower joining plates 21 press the core 3 and the plate material 2 to join them. The press projection 23 provided on the lower joining plate 21A presses the joining plate portion 3A of the center core 3 against the plate material 2, and the upper joining plate 21B presses the surface of the plate material 2 into a flat shape, so that the center core 3 and the plate material 3 2 and 2 are pressed and joined in a heated state. Since this joining device 20 holds the surface of the plate material 2 in a planar shape and joins the trapezoidal corrugated core 3, the plate material surface can be joined as a smooth surface.

  In the joining device 20 shown in FIGS. 6 to 9, the pair of joining plates 21 presses the plate material 2 and the core 3 in a heated state to thermally join them, and then cools them in the same manner as the molding die 11. A circulation path (not shown) for heating and cooling is provided inside. The circulation path for heating circulates a fluid such as heating oil to heat the joining plate 21, and the circulation path for cooling circulates a fluid such as cooling water to cool the joining plate 21. The circulation circuit for heating is connected to a heating system that circulates a liquid such as hot water or heating oil, or a gas such as pressurized steam, and the circulation circuit for cooling is a cooling water or a refrigerant that is vaporized and cooled by heat of vaporization. A cooling system that circulates a fluid such as is connected. The heating system heats the fluid to circulate it in the circulation path of the joint plate 21. The cooling system cools the fluid and circulates it in the circulation path of the joint plate 21.

  The joining device 20 described above manufactures the first plate 31 and the second plate 32 in the following steps. Here, the first plate 31 is manufactured by joining the first plate member 2X to one surface of the first core 3X having a trapezoidal cross section in the first joining step. In addition, the second plate 32 is manufactured by joining the second plate member 2Y to one surface of the second core 3Y having a trapezoidal cross section in the second joining step. The second core 3B has a trapezoidal wave shape that can be stacked on the first core 3A of the first plate 31 in a fitted state. The first plate 31 and the second plate 32 shown in FIG. 2 are the same for the first center core 3X and the second center core 3Y. In these cores 3, the reinforcing rib portion 5 of one plate can be arranged in the groove-shaped opening 6 of the other plate so that the first plate 31 and the second plate 32 can be joined together in a fitted state. Is formed. That is, as shown in FIG. 2, these cores 3 are fitted to each other by making the inner surface shape of the ridge 3G having the joining plate portion 3A and the outer surface shape of the trapezoidal groove 3E having the connecting portion 3H substantially equal to each other. The structure is such that they can be stacked together.

1. The upper and lower joining plates 21 are in a horizontal posture, and the upper joining plate 21B is lifted by the cylinder 22 to open the pair of joining plates 21. In this state, the core 3 is set on the lower joining plate 21A. The core 3 is set at a position where the press protrusion 23 is guided in the trapezoidal groove 3E, and is set on the lower joining plate 21A in a state where the press protrusion 23 can press the joining plate portion 3A from below. Then, the plate material 2 is laminated on the core 3.
2. A heating fluid such as heating oil or heating steam in the circulation paths of both joining plates 21 is circulated to bring the press projections 23 of the joining plates 21 into a heated state.
3. The cylinder 22 lowers the upper joining plate 21B, and the press projections 23 of the pair of joining plates 21 pressurize the core 3 and the plate material 2 to a heated state, and the joint plate portion 3A of the core 3 is thermally bonded to the plate material 2. Then, the first plate 31 and the second plate 32 are formed.
4. The circulation of the heating fluid circulated in the circulation paths of both joint plates 21 is stopped, and the cooling liquid is circulated in the circulation paths to cool the press protrusions 23.
5. After cooling the heating parts of the first plate 31 and the second plate 32 where the core 3 and the plate material 2 are thermally bonded, the upper bonding plate 21B is raised by the cylinder 22 to move the first plate 31 and the second plate 32 to each other. The plate 32 of is removed from the joining plate 21.
The first plate 31 and the second plate 32 are removed from the joining plate 21 by cooling until the thermoplastic resin of the fiber reinforced plastic becomes hard. The first plate 31 and the second plate 32, in which the core 3 and the plate member 2 are thermally bonded to each other by the fiber-reinforced plastic of amphoteric plastic or the amphoteric plastic, are thermoplastic resins obtained by curing the thermoplastic resin of amphoteric plastic. Then, it is cooled to a hardened state and demolded.

  The first plate 31 obtained in the first joining step and the second plate 32 obtained in the second joining step are joined in the third joining step to form the plastic laminate 1. In the third joining step, the plastic plate 1 is manufactured by joining the first plate 31 and the second plate 32 using the pressing devices 41 and 45 shown in FIG. 10 or FIG. 11, for example. Here, FIG. 10 shows a process of manufacturing the planar plastic laminate 1 by using the pressing device 41 in which the pressing surface 42X of the pressing plate 42 is planar. Further, FIG. 11 shows a process of manufacturing the curved plastic laminate 1 by using the pressing device 45 in which the pressing surface 46X of the pressing plate 46 is curved.

The planar plastic laminate 1 is manufactured by the following steps.
1. As shown in (1) of FIG. 10, the upper press plate 42B is raised by the cylinder 43 to bring the pair of press plates 42 into an open state. In this state, the first plate 31 is set on the pressing surface 42X of the lower pressing plate 42A with the center core 3 positioned on the upper surface. An adhesive (not shown) is applied to the upper surface of the first plate 31 in a state where the first plate 31 is placed at a fixed position on the lower press plate 42A.

  An optimum adhesive is selected in consideration of properties required for the application of the plastic laminate 1, such as heat resistance temperature, impact resistance, and durability. For example, in the plastic laminate 1 used for a vehicle loop panel, an epoxy-based or silicon-based two-component adhesive is used. However, since an adhesive that is suitable for the application is selected, other adhesives having a heat resistant temperature of 100 ° C. to 200 ° C. are generally used in consideration of the application. Since an adhesive having a short curing time can be used to shorten the joining time and efficiently produce a large amount, the plastic laminate 1 produced in large quantities at a low cost can also use an instant adhesive having a short curing time. .

2. As shown in (2) of FIG. 10, the second plate 32 is laminated on the first plate 31. In this state, as shown in FIG. 2, the reinforcing rib portion 5 projecting on the surface of the first plate 31 is arranged in the groove-shaped opening 6 of the second plate 32, and the first plate 31 and the first plate 31 The trapezoidal corrugated core 3 of the second plate 32 is laminated in a fitted state.

3. As shown in (3) of FIG. 10, the first plate 31 and the second plate 32, in which the cores 3 are stacked in a fitted state, are sandwiched between the press surfaces 42X of the upper and lower press plates 42 and pressed. In this state, the adhesive is hardened to bond the core 3 of the first plate 31 and the second plate 32.
4. The pressurizing state of the press plate 42 is released, the upper press plate 42B is raised by the cylinder 43, and the plastic laminate 1 formed in a flat shape is taken out from the press device 41.

The curved plastic laminate 1 is manufactured by the following steps.
1. The first plate 31 and the second plate 32 are manufactured by curving the whole and stacking the core 3 in a fitted state. Here, the pitch of the cores 3 is different between the first plate 31 and the second plate 32 that are curved to stack the cores 3 in the fitted state. For example, as shown in FIG. 11, in the plastic laminate 1 in which the first plate 31 is laminated on the inner side and the second plate 32 is laminated on the outer side, the pitch of the cores 3 of the first plate 31 is The first plate 31 and the second plate 32 are manufactured so as to be smaller than the pitch of the center core 3 of the plate 32.

  The first plate 31 and the second plate 32 are bonded to the core 3 with an adhesive, and the adhesive is filled between the fitted cores 3 to close the gap. Therefore, the cores 3 of the first plate 31 and the second plate 32 do not necessarily have to be shaped so as to be fitted completely without a gap, and the reinforcing rib portion 5 of the first plate 31 may be connected to the second plate 32. The groove-shaped opening 6 can be guided and joined. However, if the gap between the cores 3 to be joined is large, the coupling strength between the first plate 31 and the second plate 32 will decrease, so ideally the pitch of the cores should be made as small as possible. Adjust.

2. As shown in (1) of FIG. 11, the upper bending press plate 46B is raised by the cylinder 47 to bring the pair of bending press plates 46 into an open state. In this state, the first plate 31 is set at a fixed position on the press surface 46X of the lower curved press plate 46A with the core 3 positioned on the upper surface. The first plate 31 is placed on the lower curved press plate 46A as a flat surface without being curved. Since the plastic laminate 1 shown in the figure is formed in a shape in which the central portion is flat and both side portions are curved, the curved press plate 46 has curved portions 46b on both sides of the flat portion 46a. An adhesive (not shown) is applied to the upper surface of the first plate 31 with the first plate 31 placed in a fixed position on the lower curved press plate 46A.

3. As shown in (2) of FIG. 11, the second plate 32 is laminated on the first plate 31. In this state, the first plate 31 and the second plate 32 are curved, and the reinforcing rib portion 5 protruding on the surface of the first plate 31 is arranged in the groove-shaped opening 6 of the second plate 32. The cores 3 of the first plate 31 and the second plate 32 are stacked in a fitted state.

4. As shown in (3) of FIG. 11, the first plate 31 and the second plate 32, in which the cores 3 are stacked in a fitted state, are sandwiched between the press surfaces 46X of the upper and lower curved press plates 46 and added. The pressure is maintained and the adhesive is hardened to join the core 3 of the first plate 31 and the second plate 32.
5. The pressurizing state of the curved press plate 46 is released, the upper curved press plate 46B is raised by the cylinder 47, and the plastic laminated body 1 formed in the curved shape is taken out from the press device 45.

[Example 1]
The plastic laminate 1 shown in FIG. 1 realizes excellent physical properties as the following dimensions.
The plate material 2 and the core 3 are made of fiber-reinforced plastic in which carbon fibers are embedded in nylon 6. In this fiber reinforced plastic, carbon fiber is embedded in nylon 6, and the volume ratio of carbon fiber and nylon 6 is 6: 4. The fiber-reinforced plastic is made by arranging carbon fibers in a three-dimensionally non-directional manner and impregnating nylon 6.
The plate material 2 has a thickness (d) of 0.15 mm, the core 3 has a thickness (t) of 0.15 mm, and the core 3 has a trapezoidal wave shape that alternately connects the joint plate portion 3A and the inclined plate portion 3B. A trapezoid in which the width (W) of the joint plate portion 3A is 1.5 mm, the connecting angle (α) on both sides of the inclined plate portion 3B is 110 degrees, and the total thickness (D) of the plastic laminate 1 is 2.3 mm. It is shaped like a wave.

  As shown in FIGS. 6 and 7, the first plate 31 and the second plate 32 sandwich the plate material 2 and the core 3 with a pair of bonding plates 21 and heat-weld and bond them. As shown in FIG. 7, the pair of joining plates 21 are provided with press protrusions 23 for locally sandwiching and pressing the joining plate portion 3A of the core 3 and the plate member 2. The joining plate 21 presses the joining plate portion 3A and the plate member 2 with the press protrusion 23 to thermally join the plate member 2 and the core 3, and then cools and joins them.

  In the step of joining the joining plate portion 3A to the plate material 2, the thermoplastic plastic of the sheet material 2 and the core 3 that has been heated and melted is bent from the joining surface between the joining plate portion 3A and the plate material 2 to the curved portion 3C and the plate material 2. It is extruded in between and filled in the curved gap 7 as a gap filling adhesive 4A. The gap filling adhesive 4A bonds the curved portion 3C to the plate member 2, but leaves the surface of the flat portion 3F exposed in the air.

  In the first plate 31 and the second plate 32, as shown in FIG. 2, the reinforcing rib portion 5 of the first plate 31 is arranged in the groove-shaped opening 6 of the second plate 32. The reinforcing ribs 5 of 32 are arranged in the groove-shaped openings 6 of the first plate 31, and the cores 3 of the first plate 31 and the second plate 32 are joined together in a fitted state. As shown in (2) of FIG. 10, the first plate 31 and the second plate 32 are laminated so that the cores 3 are fitted to each other with the adhesive applied to the joint surface. Further, as shown in (3) of FIG. 10, the first plate 31 and the second plate 32, which are stacked on each other, are sandwiched by a pair of press plates 42 and held in a pressurized state to cure the adhesive. The first plate 31 and the second plate 32 are joined together to form the plastic laminated body 1.

The above plastic laminate 1 exhibits the following extremely excellent bending rigidity in a test piece having a total length of 500 mm and a lateral width of 150 mm in the direction of the convex stripes 3G and the trapezoidal grooves 3E of the trapezoidal corrugated core 3. .
However, since the plastic laminate 1 has a large rigidity in the longitudinal direction of the convex strips 3G and the trapezoidal grooves 3E of the trapezoidal corrugated core 3, the rigidity in this direction is shown.

Plastic laminate of Example 1 Flexural rigidity 4210 GPa
Deflection 4 mm
Bending stress 37MPa
Weight 150g
Steel plate for automobile with thickness of 0.65 mm Flexural rigidity 690 GPa
Deflection 24.6 mm
Bending stress 205MPa
Weight 380g

  As described above, the plastic laminate of Example 1 has an extremely light weight of about ⅕ of a steel sheet for automobiles, and a bending rigidity of 4210 Pa against 690 GPa of a steel sheet for automobiles having a thickness of 0.65 mm. It becomes extremely strong, about 6 times or more. Further, since the groove-shaped opening 6 is provided between the reinforcing ribs 5, it can be used by being deformed as shown by the chain line in FIG.

  INDUSTRIAL APPLICABILITY The plastic laminate of the present invention replaces a metal plate in applications where weight reduction and high bending rigidity are required, particularly in body steel plates of vehicles, cases used for portable devices such as laptop computers, mobile phones and tablets. Are used extremely effectively.

DESCRIPTION OF SYMBOLS 1 ... Plastic laminated body 2 ... Plate material 2X ... 1st board material 2Y ... 2nd board material 3 ... Core 3X ... 1st core 3Y ... 2nd core 3A ... Joining plate part 3B ... Sloping plate part 3C ... Curved portion 3E ... Trapezoidal groove 3F ... Flat portion 3G ... Convex ridge 3H ... Connecting portion 4 ... Adhesive 4A ... Gap filling adhesive 5 ... Reinforcing rib 6 ... Groove-shaped opening 7 ... Curved gap 9 ... Fiber reinforced plastic 10 ... Molding device 11 ... Molding die 11A ... Lower molding die 11B ... Upper molding die 11X ... Molding surface 12 ... Cylinder 13 ... Convex ridge 13A ... Tip surface 13B ... Chamfer 14 ... Groove 14A ... Bottom 14B ... Curved corner 20 ... Joining device 21 ... Joining plate 21A ... Lower joining plate 21B ... Upper joining plate 22 ... Cylinder 23 ... Press protrusion 31 ... First plate 32 ... Second plate 41 ... Press device 42 ... Press plate 42A ... Lower side Press plate 42B ... Upper pre Plate 42X ... pressing surface 43 ... cylinder 45 ... press 46 ... press plate 46A ... lower press plate 46B ... upper press plate 46X ... press surface 46a ... flat portion 46b ... bent portion 47 ... cylinder

Claims (26)

A plastic laminate comprising a first plate and a second plate joined to the first plate,
The first plate and the second plate are
On one side of the trapezoidal wavy core made of fiber reinforced plastic,
By joining plate materials made of fiber reinforced plastic,
Hollow tubular reinforcing ribs and groove-shaped openings are alternately arranged in a grid pattern,
The bottom surface of the groove-shaped opening has a two-layer structure of the plate material and the core,
A plastic characterized in that the reinforcing rib portion of the first plate is guided to the groove-shaped opening portion of the second plate, and the first plate and the second plate are joined to each other. Laminate. The plastic laminate according to claim 1, wherein
The core has a trapezoidal wave shape in which a trapezoidal groove is provided between the ridges,
A planar joint plate portion formed on the top surface of the ridge and joined to the plate material;
A connecting portion that is not joined to the plate material at the bottom of the trapezoidal groove,
A trapezoidal wavy shape that is formed by connecting the joining plate portion and the connecting portion, and a flat inclined plate portion having a joining angle (α) between the joining plate portion and the joining portion as an obtuse angle,
The plate material is joined to the joining plate portion of the core,
The hollow tubular reinforcing rib portion and the groove-shaped opening are alternately arranged adjacent to each other,
The reinforcing rib portion is
A hollow cylindrical shape in which the opening of the trapezoidal groove is closed by the plate member and is surrounded by the plate member, the pair of inclined plate parts, and the connecting part,
The hollow tubular shape of the reinforcing rib portion is a hollow tubular shape whose cross-sectional shape is a skirt spreading shape from the connecting portion toward the plate material,
The groove-shaped opening has a two-layer structure in which the bottom surface is joined to the plate material and the joint plate portion,
The reinforcing rib portion of the first plate is arranged in the groove-shaped opening of the second plate, and the cores of the first plate and the second plate are joined to each other, and A plastic laminate, wherein the reinforcing rib portion of the first plate and the reinforcing rib portion of the second plate are adjacently arranged in a grid pattern. The plastic laminate according to claim 1 or 2, wherein
A plastic laminate characterized in that the reinforcing fibers of the fiber-reinforced plastic are carbon fibers. The plastic laminate according to any one of claims 1 to 3,
A plastic laminate, wherein the plastic of the fiber-reinforced plastic is a thermoplastic resin. The plastic laminate according to claim 4, wherein
The plastic laminate, wherein the thermoplastic resin of the fiber-reinforced plastic is any one of nylon resin, polycarbonate, acrylic resin, PET, PP, PPS, and HTPE. The plastic laminate according to any one of claims 1 to 5,
A plastic laminate, wherein the first core and the second core are joined together in a curved state of the plate materials of the first plate and the second plate. A plastic laminate according to any one of claims 1 to 6, wherein:
A plastic laminate, wherein the plate material and the joint plate portion of the core are heat-welded. The plastic laminate according to claim 7,
The first plate and the second plate are
A plastic laminate, characterized in that the plate material and the core are heat-welded via a thermoplastic resin of the fiber-reinforced plastic. A plastic laminate according to any one of claims 1 to 8, wherein:
A plastic characterized in that the center core is a fiber-reinforced plastic having a longitudinal strength that is a tensile strength in the longitudinal direction of the reinforcing rib portion is larger than a lateral strength that is a tensile strength in a lateral direction orthogonal to the trapezoidal groove. Laminate. The plastic laminate according to claim 9,
A plastic laminate characterized in that the fiber-reinforced plastic of the core is embedded with carbon fibers in a non-directional manner. The plastic laminate according to any one of claims 1 to 10,
A plastic laminate, wherein the fiber-reinforced plastic of the plate material is embedded with carbon fibers in a non-directional manner. The plastic laminate according to any one of claims 1 to 11,
A plastic laminate characterized in that a connection angle (α) between the cores of the first plate and the second plate is an obtuse angle of 100 degrees or more and 140 degrees or less. The plastic laminate according to any one of claims 1 to 12,
The lateral width (W1) of the joining plate portion is 1/3 or more of the lateral width (W2) of the inclined plate portion and is 1.5 times or less, which is a plastic laminate. The plastic laminate according to any one of claims 1 to 13,
The thickness of the said core is 1/4 or more of the said board | plate material, and is 4 times or less, The plastic laminated body characterized by the above-mentioned. A first joining step of joining a first plate member to one surface of a first core having a trapezoidal wavy cross section to form a first plate;
A second joining step of joining a second plate member to one surface of a trapezoidal corrugated second core that can be stacked in a fitted state on the first core of the first plate to form a second plate; ,
From the third joining step of joining the first plate obtained in the first joining step and the second plate obtained in the second joining step in the fitted state of the core. Becomes
In the first bonding step and the second bonding step,
The core has a trapezoidal wavy shape in which a trapezoidal groove is provided between the ridges,
A planar bonding plate portion that is bonded to the plate material on the top surface of the ridge,
A connecting portion that is not joined to the plate material at the bottom of the trapezoidal groove,
A trapezoidal corrugated core is used which connects the joining plate portion and the connecting portion, and includes a flat inclined plate portion having an obtuse connecting angle between the joining plate portion and the connecting portion,
In the first bonding step and the second plate bonding step,
The plate material is joined to the joining plate portion of the center core, and hollow tubular reinforcing rib portions and groove-shaped opening portions are alternately arranged in a lattice shape,
The reinforcing rib portion is
As a hollow cylinder surrounded by the plate member, a pair of the inclined plate parts, and the connecting part, the hollow cylindrical shape of the reinforcing rib part is a hollow whose cross-sectional shape is flared toward the plate member from the connecting part. And cylindrical
The channel opening is
The bottom surface has a two-layer structure of the plate material and the joint plate portion,
In the third joining step,
Arranging the reinforcing rib portion of the first plate in the groove-shaped opening of the second plate,
Arranging the reinforcing rib portion of the second plate in the groove-shaped opening of the first plate,
A method for manufacturing a plastic laminate, comprising joining the cores of the first plate and the second plate in a fitted state. A method for manufacturing a plastic laminate according to claim 15, wherein
A method for producing a plastic laminate, wherein carbon fiber is used as a reinforcing fiber of the fiber-reinforced plastic. A method for manufacturing a plastic laminate according to claim 15 or 16, wherein
A method for producing a plastic laminate, wherein a thermoplastic resin is used as the plastic of the fiber-reinforced plastic. A method of manufacturing a plastic laminate according to claim 17,
A method for producing a plastic laminate, wherein any one of nylon resin, polycarbonate, acrylic resin, PET, PP, PPS, and HTPE is used as the thermoplastic resin of the fiber-reinforced plastic. A method for manufacturing a plastic laminate according to any one of claims 15 to 18, comprising:
In the first bonding step and the second bonding step,
A method for manufacturing a plastic laminate, wherein the plate material and the joining plate portion of the core are heat-welded. A method of manufacturing a plastic laminate according to claim 19, wherein
In the first bonding step and the second bonding step,
A method for producing a plastic laminate, wherein the plate material and the core are heat-welded via a thermoplastic resin of fiber reinforced plastic. A method for manufacturing a plastic laminate according to any one of claims 15 to 20, comprising:
In the first bonding step and the second bonding step,
For the core, a fiber-reinforced plastic is used, in which the longitudinal strength of the reinforcing ribs in the longitudinal direction is greater than the lateral strength of the transverse direction orthogonal to the trapezoidal groove. Method for manufacturing laminated body. A method of manufacturing a plastic laminate according to claim 21,
In the first bonding step and the second bonding step,
A method for producing a plastic laminate, comprising using a fiber-reinforced plastic in which carbon fibers are embedded in the core without being oriented. A method for manufacturing a plastic laminate according to any one of claims 15 to 22, comprising:
In the first bonding step and the second bonding step,
A method for producing a plastic laminate, wherein a fiber-reinforced plastic having an obtuse angle of 100 degrees or more and 140 degrees or less is used for the trapezoidal corrugated core. A method for manufacturing a plastic laminate according to any one of claims 15 to 23,
In the first bonding step and the second bonding step,
For the trapezoidal corrugated core, a fiber reinforced plastic whose lateral width (W1) of the joining plate portion is 1/3 or more of the lateral width (W2) of the inclined plate portion and 1.5 times or less is used. A method for producing a plastic laminate, comprising: A method for manufacturing a plastic laminate according to any one of claims 15 to 24,
In the first bonding step and the second bonding step,
A method for producing a plastic laminate, wherein a fiber-reinforced plastic having a thickness of ¼ or more and 4 times or less that of the plate material is used for the trapezoidal corrugated core. A method for manufacturing a plastic laminate according to any one of claims 15 to 25,
In the third joining step, the first plate and the second plate are curved and joined, and the method for producing a plastic laminate is characterized.

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