JP2021062561A - Compact, and production method of compact - Google Patents

Abstract

To provide a compact having a light weight, while guaranteeing strength; and to provide a production method of the compact.SOLUTION: In one embodiment, a panel-shaped compact includes a core material, a reinforcement member and a skin member. The reinforcement member is formed in a sheet or tape shape, and constituted so as to be stuck onto at least a part of a surface or a rear face of the core material, and the skin member is a resin sheet, and is arranged on both faces of the core material.SELECTED DRAWING: Figure 1

Description

The present invention relates to a molded product and a method for producing the molded product.

Conventionally, molded bodies used for interior materials and the like in vehicle interiors have been manufactured. Among such molded bodies, a sandwich panel in which a skin member, which is a resin sheet, is arranged on both sides of a core material is often used.

Patent Document 1 discloses an example of a sandwich panel.

Japanese Unexamined Patent Publication No. 2016-43680

By the way, such a molded body (sandwich panel) has a problem that its strength becomes weaker when it is made larger. Further, in order to ensure the strength, a plurality of core materials may be used and a metal reinforcing member may be inserted between adjacent core materials like a splint (for example, as shown in FIG. 7), but in such a case. Has a problem that the weight of the molded body itself becomes large.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a molded body that is lightweight while ensuring strength, and a method for manufacturing the molded body.

According to one aspect of the present invention, it is a panel-shaped molded body, which includes a core material, a reinforcing member, and a skin member, and the reinforcing member is formed in a sheet or tape shape, and the surface of the core material is formed. Alternatively, the skin member is a resin sheet, which is configured to be attached to at least a part of the back surface, and is provided on both sides of the core material.

According to such a molded product, it is possible to realize a lightweight molded product while ensuring the strength, which is an advantageous effect.

FIG. 3 is a cross-sectional view of the molded body 1 according to the embodiment. FIG. 3 is a plan view of an insert member 15 in which a reinforcing member 13 is attached to a core material 12. A mode of a molding machine 3 for manufacturing a molded body 1. A mode in which the dies 71 and 72 are opened in the production of the molded body 1. A mode in which the molds 71 and 72 are closed in the production of the molded body 1. The plan view of the molded body 1 (insert member 15) which concerns on a modification. FIG. 3 is a cross-sectional view of a molded body 9 according to a comparative example.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each feature.

1. 1. Overall Configuration Section 1 describes the panel-shaped molded body 1 according to the present embodiment. FIG. 1 is a cross-sectional view showing the structure of the molded body 1. FIG. 2 is a plan view of the insert member 15 in which the reinforcing member 13 is attached to the core material 12.

As shown in FIG. 1, the panel-shaped molded body 1 includes skin members 11a and 11b, a core member 12, and a reinforcing member 13. Hereinafter, each configuration will be described in detail.

<Skin members 11a, 11b>
As shown in FIG. 1, the skin members 11a and 11b are resin sheets and are arranged on both sides of the core material 12 described later. Specifically, as the skin members 11a and 11b, a knitted fabric, a woven fabric, a non-woven fabric, or a polyvinyl chloride (PVC) obtained by processing natural fibers, regenerated fibers, semi-synthetic fibers, synthetic fibers, and fibers obtained by mixing these. ), Thermoplastic elastomer (TPE) such as thermoplastic polyurethane elastomer (TPU) or thermoplastic polyolefin elastomer (TPO), resin sheet made of thermoplastic resin such as polyethylene polyolefin resin, and laminated sheets thereof, plastic cardboard, It can be appropriately selected from a hard board or the like.

<Core material 12>
The core material 12 is made of, for example, a foam of a thermoplastic resin, and it is desirable that polyethylene, polypropylene, polystyrene or the like is appropriately adopted as the thermoplastic resin. Further, a filler such as glass fiber, carbon fiber, calcium carbonate, talc, or mica can be appropriately added to the foam.

More specifically, the core material 12 is a foam produced by so-called bead foam molding. The features of bead foam molding are that the shape can be freely designed and that a high-magnification foam molded product can be obtained. The bead foam molding process is divided into pre-foaming, aging, molding and curing. The beads used for bead foam molding are small-diameter resin particles impregnated with a physical foaming agent such as a hydrocarbon. As a method of impregnating with a foaming agent, in the case of polystyrene, polystyrene particles containing a foaming agent can be obtained by allowing a hydrocarbon (pentane or the like) as a foaming agent to be present in the polymerization system during suspension polymerization. In the case of PP or PE, the mini pellets prepared in advance are impregnated with hydrocarbons in water.

Examples of the foaming agent that can be used for forming the core material 12 include known physical foaming agents, chemical foaming agents, and mixtures thereof. For example, as the physical foaming agent, an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, and an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, and dichloroethane can be applied. Examples of the chemical foaming agent include azodicarboxylic amide (ADCA), N, N'-dinitrosopentamethylenetetramine, 4,4'-oxybis (benzenesulfonylhydrazide), and diphenylsulfone-3,3'-disulfonyl. Organic foaming agents such as hydrazide, p-toluenesulfonyl semicarbazide, trihydrazinotriazine or azobisisobutyronitrile, citric acid, oxalic acid, fumaric acid, phthalic acid, malic acid, tartaric acid, cyclohexane-1,2-dicarboxylic acid , A mixture of polycarboxylic acids such as gyonoic acid, ethylenediamine tetraacetic acid, triethylenetetramine hexaacetic acid, and nitriloic acid, and inorganic carbonate compounds such as sodium hydrogencarbonate, sodium hydrogencarbonate aluminum, potassium hydrogencarbonate, ammonium hydrogencarbonate, and ammonium carbonate. , Salts of polycarboxylic acids such as sodium dihydrogen citrate and potassium oxalate can be mentioned as inorganic foaming agents.

The insert member 15 is formed by attaching the reinforcing member 13 described later to the core material 12 via the adhesive layer 14. It is preferable that the core material 12 has a recess 121 for attaching the reinforcing member 13, and the reinforcing member 13 is housed in the recess 121 provided in the core material 12. The insert member 15 will be described again in the method for manufacturing the molded body 1 in Section 2.

<Reinforcing member 13>
In the molded body 1, the reinforcing member 13 contains glass fiber reinforced plastic or carbon fiber reinforced plastic, or it is preferable to use these. Since the fiber reinforced plastic is used, it contributes to weight reduction as compared with the case where the metal reinforcing member 93 shown in FIG. 7 is used.

The reinforcing member 13 is configured to be attached to at least a part of the front surface or the back surface of the core material 12, and may be formed in the form of a sheet or tape. In particular, in FIGS. 1 and 2, an example is shown in which the reinforcing member 13 is configured to be attached to both the front surface and the back surface of the core material 12, and the reinforcing member 13 is formed in an elongated tape shape. There is. In particular, recesses 121 are provided on the front surface and the back surface of the core material 12, and a tape-shaped reinforcing member 13 is attached thereto. Since it is formed in a tape shape in this way, weight reduction is expected as compared with the case where the metal reinforcing member 93 shown in FIG. 7 is adopted. For reference, the molded body 9 (comparative example) shown in FIG. 7 includes skin members 91a and 91b, a core member 92, and an H-shaped reinforcing member 93 (so-called reinforce). Since the reinforcing member 93 of the molded body 9 has a metal reinforcing member 93 inserted between two adjacent core members 92 like a splint, the weight increases.

Further, as shown in FIG. 2, the reinforcing member 13 is preferably attached along the center line X on the surface of the core material 12. An adhesive or the like is used for such affixing. In other words, as shown in FIG. 1, the core material 12 and the reinforcing member 13 are adhered to each other via the adhesive layer 14. As a result, the rigidity of the reinforcing member 13 directly affects the core material 12, and the strength of the core material 12 which is relatively soft as compared with the reinforcing member 13 can be strengthened. As a result, the strength of the molded product 1 can be increased while maintaining the light weight.

More specifically, it is preferable that the reinforcing member 13 is a UD (Uni-Direction) sheet or a UD tape. These are sheets or tapes in which fibers are aligned in one direction and impregnated with a thermoplastic resin. It should be noted that the UD sheet or UD tape is a fiber reinforced plastic using long fibers and has high tensile strength in the direction in which the fibers are oriented. As a result, the strength of the molded product 1 can be remarkably increased.

In the molded body 1, the tensile elastic modulus of the reinforcing member 13 is preferably 12 GPa or more and 400 GPa or less. Specifically, for example, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34,35,36,37,38,39,40,50,60,70,80,90,100,110,120,130,140,150,160,170,180,190,200,210,220, It is 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400 GPa, and is between any two of the numerical values exemplified here. It may be within the range.

Further, in the molded body 1, if the thickness of the core material 12 is t1 and the thickness of the reinforcing member 13 is t2, it is preferable that 0.01 ≦ t2 / t1 ≦ 0.3 is satisfied (see FIG. 1). This is because the reinforcing member 13 is in the form of a sheet or a tape, and when preparing the insert member 15, it is preferable that the reinforcing member 13 is thin enough to be easily attached by an operator. Specifically, for example, the value of t2 / t1 is 0.01,0.015,0.02,0.025,0.03,0.035,0.04,0.045,0.05,0. 055, 0.06, 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, 0.095, 0.1, 0.105, 0.11, 0.115, 0.12, 0.125, 0.13, 0.135, 0.14, 0.145, 0.15, 0.155, 0.16, 0.165, 0.17, 0.175, 0. 18, 0.185, 0.19, 0.195, 0.2, 0.205, 0.21, 0.215, 0.22, 0.225, 0.23, 0.235, 0.24 It is 0.245, 0.25, 0.25, 0.26, 0.265, 0.27, 0.275, 0.28, 0.285, 0.29, 0.295, 0.3. It may be within the range between any two of the numerical values exemplified here.

Further, in the molded body 1, if the width of the core material 12 is w1 and the width of the reinforcing member 13 is w2, it is preferable that 0.05 ≦ w2 / w1 ≦ 0.95 is satisfied (see FIG. 2). This is a balance with cost, and if high strength is desired, the value of w2 / w1 may be relatively high, and if cost reduction is considered, the value of w2 / w1 may be relatively low. Specifically, for example, the value of w2 / w1 is 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0. 14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0. 39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58, 0.59, 0.6, 0.61, 0.62, 0.63, 0. 64,0.65,0.66,0.67,0.68,0.69,0.7,0.71,0.72,0.73,0.74,0.75,0.76 0.77, 0.78, 0.79, 0.8, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0. It is 89, 0.9, 0.91, 0.92, 0.93, 0.94, 0.95, and may be within the range between any two of the numerical values exemplified here.

2. Manufacturing Method of Molded Body 1 Section 2 describes a manufacturing method of the molded body 1. FIG. 3 shows an aspect of a molding machine 3 for manufacturing a molded body 1. FIG. 4 shows a mode in which the molds 71 and 72 are opened in the production of the molded product 1. FIG. 5 shows a mode in which the molds 71 and 72 are closed in the production of the molded product 1.

2-1. Configuration of Molding Machine 3 The molding machine 3 includes a resin supply device 4, a T-die 5, and a pair of molds 71 and 72. The resin supply device 4 includes a hopper 41, an extruder 42, and an accumulator 45. The extruder 42 and the accumulator 45 are connected via a connecting pipe 61. The accumulator 45 and the T-die 5 are connected via a connecting pipe 62. Hereinafter, each configuration will be described in detail.

<Hopper 41, extruder 42>
The hopper 41 is used to put the raw material resin M1 into the cylinder 43 of the extruder 42. The form of the raw material resin M1 is not particularly limited, but is usually in the form of pellets. The raw material resin M1 is charged into the cylinder 43 from the hopper 41 and then melted by being heated in the cylinder 43 to become a molten resin. Further, it is conveyed toward the tip of the cylinder 43 by the rotation of the screw arranged in the cylinder 43. The screw is arranged in the cylinder 43, and the molten resin is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device. The number of screws arranged in the cylinder 43 may be one or two or more.

<Accumulator 45, T-die 5>
The foamed resin M2, which is obtained by melt-kneading the molten resin and the foaming agent, is extruded from the resin extrusion port of the cylinder 43 and injected into the accumulator 45 through the connecting pipe 61. The accumulator 45 includes a cylinder 46 and a piston 47 slidable inside the cylinder 46, and the foamed resin M2 melted in the cylinder 46 can be stored in the cylinder 46. Then, by moving the piston 47 after a predetermined amount of the foamed resin M2 is stored in the cylinder 46, the foamed resin M2 is pushed out from the slit provided in the T die 5 through the connecting pipe 62 and hung down to form a pair of resins. Sheets 21 and 22 are formed.

<A pair of molds 71, 72>
The pair of resin sheets 21 and 22 are guided between the pair of molds 71 and 72. The pair of dies 71 and 72 are each provided with a large number of decompression suction holes (not shown), and the resin sheets 21 and 22 are decompressed and suctioned to form a shape along the pair of dies 71 and 72. It is possible to do. The molds 71 and 72 have a shape having recesses 71c and 72c, and pinch-off portions 71p and 72p are provided so as to surround the recesses 71c and 72c. In the mold clamping step described later, the resin sheets 21 and 22 are cut off by the pinch-off portions 71p and 72p.

2-2. Flow of Manufacturing Method The manufacturing method of the molded product 1 includes a preparation step, a hanging step, an arrangement step, and a molding step. Hereinafter, a detailed description will be given.

<Preparation process>
In the preparatory step, the reinforcing member 13 is attached to at least a part of the surface of the core material 12. Specifically, as shown in FIG. 2, a reinforcing member 13 containing a fiber reinforced plastic is adhered (adhered) to at least one of the front surface and the back surface of the panel-shaped core material 12 which is a foam. By sticking (via the layer 14), the insert member 15 is configured.

<Dripping process>
In the hanging step, the two molten resins are drooped between the pair of molds 71 and 72. Specifically, as shown in FIG. 3, the reinforcing member 13 is attached to the core material 12 by the adhesive layer 14, and the insert member 15 prepared in the preparatory step is arranged between the pair of molds 71 and 72. Further, as shown in FIG. 4, two resin sheets 21 and 22 are hung on both sides of the insert member 15.

Then, a pair of resin sheets 21 and 22 formed by extruding the molten foam resin M2 from the slit of the T die 5 and hanging it between the pair of dies 71 and 72 are hung. In the present embodiment, direct vacuum forming is performed using the pair of resin sheets 21 and 22 extruded from the T die 5 as they are, so that the pair of resin sheets 21 and 22 are cooled to room temperature and solidified before molding. The solidified pair of resin sheets 21 and 22 are not heated before molding. Here, in FIG. 3, the insert member 15 is shown between the pair of resin sheets 21 and 22 during the hanging step, but in the hanging step, the insert member 15 may be kept on standby at another place. Good.

<Shaping process>
Next, in the shaping step, after the pair of resin sheets 21 and 22 are brought into contact with a part of the pair of molds 71 and 72, respectively, the two resin sheets 21 are provided by both of the pair of molds 71 and 72. , 22 are sucked under reduced pressure to form a shape along the pair of molds 71 and 72.

<Placement process>
Next, in the arrangement step, the core material 12 and the reinforcing member 13 are arranged between the two foamed resins. Then, the insert member 15 is welded to the pair of resin sheets 21 and 22.

<Molding process>
Finally, in the molding step, the pair of dies 71 and 72 are molded and then opened to form the two foamed resins into the skin members 11a and 11b to manufacture the molded body 1. Specifically, as shown in FIG. 5, the pair of molds 71 and 72 are molded. That is, the insert member 15 is arranged at a position sandwiched between the two resin sheets 21 and 22. As a result, the resin sheets 21 and 22 become the skin members 11a and 11b in the molded body 1 shown in FIG. Finally, by taking out the molded product from the pair of molds 71 and 72 and removing the burr 25, the molded product 1 shown in FIG. 5 is obtained.

3. 3. Modification Example Section 3 describes a modification of the molded body 1. That is, the molded body 1 or the molded body 1 may be carried out according to the following aspects.

Although the molded body 1 has a panel shape, it does not necessarily have to be a rectangular parallelepiped shape. For example, as shown in FIG. 6, the molded body 1 (core material 12 forming the insert member 15) may be configured to further include the eggplant 12s. In such a case, the reinforcing member 13 is attached to the core material 12 so as to avoid the shavings 12s.

As long as the reinforcing member 13 is attached to the core material 12, the number, arrangement, shape, etc. of the reinforcing member 13 are not limited. Various examples are shown below. Of course, it is not limited to these.
(1) Two may be attached at a position away from the center line X of the core material 12.
(2) It may be attached along the two diagonal lines of the core material 12.
(3) Although the tape-shaped reinforcing member 13 is attached in the longitudinal direction in FIG. 2, the reinforcing member 13 may be attached in place of or together with the reinforcing member 13 in the lateral direction.
(4) In FIG. 2, the reinforcing member 13 is shorter than the length of the core material 12 in the longitudinal direction, but the lengths of the core material 12 and the reinforcing member 13 may be the same.

The core material 12 may be a honeycomb structure instead of the foam formed by bead foam molding.

4. Conclusion As described above, it is possible to provide a molded product capable of realizing a lightweight molded product while ensuring strength.

It may be provided in each of the following aspects.
In the molded body, the reinforcing member is formed in an elongated tape shape and is attached along the center line on the surface of the core material.
In the molded body, assuming that the thickness of the core material is t1 and the thickness of the reinforcing member is t2, 0.01 ≦ t2 / t1 ≦ 0.3 is satisfied.
In the molded body, assuming that the width of the core material is w1 and the width of the reinforcing member is w2, 0.05 ≦ w2 / w1 ≦ 0.95 is satisfied.
In the molded product, the reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic.
In the molded body, the tensile elastic modulus of the reinforcing member is 12 GPa or more and 400 GPa or less.
In the molded body, the reinforcing member is configured to be attached to both the front surface and the back surface of the core material.
In the molded body, the core material has a recess for attaching the reinforcing member, and the reinforcing member is housed in the recess.
In the molded product, one further provided with a shaving.
The method for manufacturing a molded product includes a preparation step, a hanging step, an arrangement step, and a molding step. In the preparation step, the reinforcing member is attached to at least a part of the surface of the core material. In the hanging step, two foamed resins in a molten state are drooped between a pair of molds, and in the placement step, the core material and the reinforcing member are placed between the two foamed resins, and the molding step. Then, a method of manufacturing the molded body in which the two foamed resins serve as the skin member by molding the pair of molds and then opening the molds.
Of course, this is not the case.

Finally, various embodiments of the present invention have been described, but these are presented as examples and are not intended to limit the scope of the invention. The novel embodiment can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. The embodiment and its modifications are included in the scope and gist of the invention, and are included in the scope of the invention described in the claims and the equivalent scope thereof.

1: Molded body 11a: Skin member 11b: Skin member 12: Core material 121: Recessed portion 12s: Nusumi 13: Reinforcing member 14: Adhesive layer 15: Insert member 21: Resin sheet 22: Resin sheet 25: Burr 3: Molding machine 4 : Resin supply device 41: Hopper 42: Extruder 43: Cylinder 45: Accumulator 46: Cylinder 47: Piston 5: T-die 61: Connecting pipe 62: Connecting pipe 71: Mold 71c: Recessed part 71p: Pinch-off part 72: Mold 72c: Recessed portion 72p: Pinch-off portion 9: Molded body 91a: Skin member 91b: Skin member 92: Core material 93: Reinforcing member M1: Raw material resin M2: Foamed resin X: Center line

Claims (10)

It is a panel-shaped molded body
It is provided with a core material, a reinforcing member, and a skin member.
The reinforcing member is
Formed in the form of a sheet or tape,
It is configured to be attached to at least a part of the front surface or the back surface of the core material.
The skin member is
It is a resin sheet,
Those arranged on both sides of the core material. In the molded product according to claim 1,
The reinforcing member is
Formed in the form of an elongated tape,
Those attached along the center line on the surface of the core material. In the molded product according to claim 1 or 2.
Assuming that the thickness of the core material is t1 and the thickness of the reinforcing member is t2,
0.01 ≤ t2 / t1 ≤ 0.3
Those that meet. In the molded product according to any one of claims 1 to 3.
Assuming that the width of the core material is w1 and the width of the reinforcing member is w2,
0.05 ≦ w2 / w1 ≦ 0.95
Those that meet. In the molded product according to any one of claims 1 to 4.
The reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic. In the molded product according to any one of claims 1 to 5.
The reinforcing member has a tensile elastic modulus of 12 GPa or more and 400 GPa or less. In the molded product according to any one of claims 1 to 6.
The reinforcing member is configured to be attached to both the front surface and the back surface of the core material. In the molded product according to any one of claims 1 to 7.
The core material has a recess for attaching the reinforcing member, and the reinforcing member is housed in the recess. In the molded product according to any one of claims 1 to 8.
Those with more Nusumi. The method for producing a molded product according to any one of claims 1 to 9.
It has a preparation process, a hanging process, a placement process, and a molding process.
In the preparatory step, the reinforcing member is attached to at least a part of the surface of the core material.
In the hanging step, two foamed resins in a molten state are drooped between a pair of molds.
In the arrangement step, the core material and the reinforcing member are arranged between the two foamed resins.
In the molding step, the pair of molds are molded and then opened to form the two foamed resins as the skin member to manufacture the molded product.

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