JP2740195B2 - Plate-shaped member having a corrugated core - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a plate-shaped member having a corrugated core and a method for manufacturing the same, and more particularly to a molded plate-shaped member having a structure in which the corrugated core is reinforced as a double structure. And using the molded plate-like member,
The present invention relates to a liner member for an interior material used for various buildings including vehicles such as automobiles.

[Related Art] In recent years, corrugated cardboard members have been widely used as liner materials because of their excellent heat insulating and soundproofing properties. For example, as an example of use for a car body structure, a corrugated cardboard substrate is used as a roof trim or a door trim, and there is a conventionally known corrugated cardboard substrate and a method for producing the same. However, there are some problems with stiffness and strength when using conventional cardboard substrates. For example, when a corrugated cardboard substrate is used for a sunroof specification roof trim, there is no durability enough to resist stress concentration, and there is a problem in strength.

[Problems to be Solved by the Invention] Therefore, when used as a roof trim of a sunroof specification vehicle, since an opening having a large area is formed, the rigidity is reduced as a whole and the opening is bent and deformed around the opening. It will be easier. In addition, it is difficult to obtain sufficient strength against local stress concentration. Therefore, it is conceivable to have a multi-layer structure in which a plurality of cardboard substrates are bonded, but in this case, the weight increases,
The original purpose of using a corrugated cardboard as a weight reduction is not achieved. Furthermore, if the thickness of the base material increases, the efficiency of the moldability also decreases. Therefore, an object of the present invention is to provide a plate-like member having a sufficient rigidity while suppressing an increase in the weight and the thickness of the base material as much as possible, and a method of manufacturing the same.

[Means for Solving the Problems] According to the first invention, in order to solve the above problems, a corrugated core having substantially the same shape is adhered to one side surface of the liner member with a heat-sealing film, respectively, to form a single plate. A pair of members are formed, and these plate-shaped members are fitted with their corrugated cores and bonded with a heat welding film to form a closed cross section between the corrugated cores. A plate-like member having a core is provided.

Further, according to the second invention, the first and second liner members alternately spaced at a predetermined interval and arranged substantially in parallel with each other, and the first liner member having a plurality of wavy bent portions having substantially the same shape is formed.
And a second corrugated core, wherein the first and second corrugated cores are fitted to each other to form a closed cross-section, and at least a part of the fitted portion is interposed through a thermoplastic resin. The first corrugated core is adhered to the first liner member and the vicinity of the crest thereof,
A plate member having a corrugated core is provided, wherein the second corrugated core is bonded to the second liner member near a crest thereof.

Further, according to the third invention, the first and second liner members which are spaced apart from each other at a predetermined interval and are arranged substantially in parallel, and the first liner member in which a plurality of wavy bent portions having substantially the same shape are formed.
And a second corrugated core, wherein the first and second corrugated cores are fitted to each other to form a closed cross-section, and are bonded to each other via a thermoplastic resin at a first bonding point. The first corrugated core is bonded to the first liner member at a second bonding point near its crest, and the second corrugated core is bonded at a third bonding point near its crest. It is bonded to the second liner member, and the first, second, and third bonding points are displaced to bonding points that maintain the shape according to a desired molding shape during hot pressing. A plate-shaped member having a corrugated core formed at least partially in a three-dimensionally bent shape is provided.

Further, according to the fourth aspect, the first and second liner members are disposed at a predetermined interval from each other and arranged substantially in parallel, and the crests are joined and interposed between these liner members. A first section composed of a first corrugated core, first and second liner members extending from the first section at intervals substantially equal to the predetermined interval and extending from the first section; A first corrugated core disposed between the members and extending from the first section, and a second corrugated core having a plurality of corrugated bent portions having substantially the same shape as the corrugated core; The first and second corrugated cores are fitted with each other and bonded at least at a part of the fitting portion via a thermoplastic resin, and the first corrugated core is formed on the first liner member and its corrugated portion. Glued near the top, said second corrugated core Plate-shaped member having a waveform in the core, characterized in that it consists of a second section formed by bonding at the crest portion near said second liner member.

Further, according to the fifth aspect, the first and second liner members are disposed at a predetermined interval from each other and arranged substantially in parallel, and the wave crests are joined and interposed between these liner members. A first section composed of a first corrugated core, first and second liner members extending from the first section at intervals substantially equal to the predetermined interval and extending from the first section; A first corrugated core disposed between the members and extending from the first section, and a second corrugated core having a plurality of corrugated bent portions having substantially the same shape as the corrugated core; The first and second corrugated cores are fitted to each other via a thermoplastic resin at a second bonding point that is at least a part of the fitted portion, and the first corrugated core is The first liner member and the first liner near the crest Wherein the second corrugated core is composed of the second liner member and a second section adhered at a fourth adhesion point near the crest of the second liner member, Second, third and fourth
There is provided a plate-like member having a corrugated core, wherein the bonding point is displaced to a bonding point that retains the shape according to a desired molding shape during hot pressing.

Further, according to the sixth aspect, the first and second liner members are disposed at a predetermined interval from each other and are arranged substantially in parallel with each other, and the crests of the first and second liner members are bonded between the liner members as a first bonding point. A first section composed of a first corrugated core interposed therebetween, and first and second liner members extending from the first section so as to be substantially parallel to each other at intervals substantially equal to the predetermined interval. A first corrugated core disposed between the liner members and extending from the first section;
A second corrugated core having a plurality of corrugated bent portions having substantially the same shape as the corrugated core, and a second corrugated core interposed between the first corrugated core and the first liner member; A third liner member interposed between the first liner member and the third liner member, wherein the first and second corrugated cores are fitted to each other and at least a part of the fitted portion. The first corrugated core is adhered to the third liner member at a third adhesion point near the crest of the third liner member, and the third liner is adhered to the first liner at the second adhesion point via a thermoplastic resin. And the second corrugated core is composed of the third liner member and a second section bonded at a fourth bonding point near the crest of the third liner member. The first, second, third and fourth adhesion points are:
A plate-shaped member having a corrugated core formed into a desired shape is provided, which is displaced to an adhesion point that retains the shape according to a desired forming shape during hot pressing.

Further, according to the seventh invention, a pair of temporary assembly of a single-plate-shaped corrugated member composed of a liner member and a corrugated core member is constituted, and is in a solid state at normal temperature, and has an adhesive property at a predetermined melting temperature. After the adhesive having is interposed between the pair of temporary assemblies, the corrugated cores of the pair of temporary assemblies are fitted together to form a closed cross section, and then at a temperature equal to or higher than the predetermined melting temperature, Manufacturing a plate-shaped member having a corrugated core, wherein the corrugated cores are bonded to each other by pressing at least one of the pair of temporary assemblies against the other, cured and the adhesive is cured; A method is provided.

Further, according to the eighth aspect, the first and second temporary assemblies of the single-plate-shaped corrugated member composed of the liner member and the corrugated core member are in a solid state at normal temperature, and have a predetermined melting temperature. After bonding the adhesive having adhesiveness to the corrugated core of the first temporary assembly, the corrugated cores of the first and second temporary assemblies are fitted together to form a closed cross section. And forming a pre-assembly, and pressing the pre-assembly at a temperature equal to or higher than the predetermined melting temperature to one temporary assembly of the pre-assembly via the other temporary assembly, thereby bonding the pre-assembly to the plate. A method for manufacturing a plate-shaped member having a corrugated core is provided, wherein the plate-shaped member is formed, cured, and the adhesive is cured.

Further, according to the ninth aspect, the first liner member and the second liner member are disposed substantially in parallel with each other at a predetermined interval, and the skin material adhered to the second liner member. And a first and a second corrugated core formed with a plurality of wavy bent portions having substantially the same shape, and the first and second corrugated cores are fitted to each other to form a closed cross section. At the same time, at least a part of the fitting portion is bonded via a thermoplastic resin, the first corrugated core is bonded to the first liner member near the crest thereof, and the second corrugated core is bonded to the first corrugated member. A vehicle plate member having a corrugated core is provided, wherein the core is bonded to the second liner member near the crest thereof.

Furthermore, according to the tenth aspect, the skin material, the first and second liner members that are spaced apart from each other at a predetermined interval and are arranged substantially in parallel, and a plurality of wavy bent portions having substantially the same shape are formed. The first and second corrugated cores;
And the second corrugated cores are fitted to each other to form a closed cross-section, and are bonded to each other via a thermoplastic resin at a first bonding point, and the first corrugated core is near the crest portion thereof. And the second corrugated core is adhered to the second liner member at a third adhesion point near the crest of the first and second liners. And the third bonding point is, at the time of hot pressing, displaced to a bonding point that retains the shape according to a desired molding shape, and is bent at least partially three-dimensionally. A plate member for a vehicle, comprising a plate member formed into a shape, is provided.

Further, according to the eleventh aspect, the skin material, the first and second liner members spaced apart from each other at a predetermined interval and arranged substantially in parallel, and the crests between the liner members are placed in the first direction.
A first section composed of a first corrugated core bonded and interposed as an adhesion point; and a first section extending from the first section at a distance substantially equal to the predetermined distance and substantially parallel to each other. And a second liner member, a first corrugated core disposed between the liner members and extending from the first section, and a plurality of wavy bent portions having substantially the same shape as the corrugated core, A second corrugated core interposed between the first corrugated core and the first liner member;
A third liner member interposed between the first and second corrugated cores, and the second and third corrugated cores are mutually fitted and at least a part of the fitted portion.
The first corrugated core is bonded at a bonding point via a thermoplastic resin, the first corrugated core is bonded to a third liner member and a third bonding point near a crest thereof, and the third liner is bonded to the first liner member. The second corrugated core is composed of the third liner member and a second section adhered at a fourth adhesion point near the crest of the third liner member, while being adhered to the entire surface of the liner. , The second, third and fourth bonding points are displaced, at the time of hot pressing, into bonding points that retain the shape according to a desired molding shape, and are at least partially three-dimensionally folded. A plate member for a vehicle, comprising a plate member bent and formed into a desired shape, is provided.

[Operation] By forming a double structure in which a reinforcing core is engaged with part or all of the double-sided cardboard structure, weak parts are easily reinforced. Also, a pair of temporary assemblies made of a liner member, a corrugated core and a thermoplastic resin interposed therebetween are formed in advance, and then the members are displaced by heat molding so that the bonding points are displaced so as to maintain a desired shape. Molding.

Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

As shown in FIG. 1, a paper corrugated cardboard substrate 10 is constituted by single corrugated cardboard substrates 12 and 14. As shown in FIG. 2, the single-faced cardboard substrates 12 and 14 have a structure having a flat plate-like member on one side.
That is, the single corrugated cardboard substrate 12 is formed from the corrugated core 12a and the corrugated cardboard liner 12b. The corrugated cardboard liner 12b is bonded to each crest 18a of the corrugated core 12a by a thermoplastic resin 16. This thermoplastic resin 16 is in the form of a solid film at room temperature, but has the property of melting when heated to function as an adhesive,
Further, the pressure is applied under a certain pressure, and then the resin is cooled and solidified, whereby each crest and the liner can be bonded. Further, the single corrugated cardboard substrate 14 is also composed of a corrugated core 14a and a corrugated cardboard liner 14b, similarly to the corrugated cardboard substrate 12, and the corrugated cardboard liner 14b is interposed through a thermoplastic resin 20.
And each crest 22a of the corrugated core 14a is adhered. The waveform shape is substantially the same as the waveform core 12a. The thermal superplastic resin 20 is also in the form of a solid film at normal temperature, and can be thermally welded to the corrugated cardboard liner and the crest by applying heat and pressing.

Corrugated cardboard liners 12a and 14b shown in this embodiment
Is made of paper, but the material forming the liner is not limited to paper quality, and other materials may be used as long as they have appropriate weight and rigidity. As practical ones, for example, it is possible to use a laminated paper or a resin film, etc., and a paper-type liner material or a glass fiber having a configuration in which a resin film is sandwiched between papers or a configuration in which a paper and a resin film are laminated.
A nonwoven fabric of pulp or synthetic resin pulp can be used by being bonded to a cardboard liner. Further, a cardboard liner can be formed by laminating a resin film such as a polyester film, a polyethylene film as an adhesive, and a paper liner. When the above-mentioned laminated material is used as the material of the corrugated cardboard liner or the surface layer of the corrugated cardboard liner, it has a moisture-proof effect, and when a nonwoven fabric or the like containing graphiber is used, the expansion and shrinkage due to humidity changes are significantly suppressed. Can be. It is also possible to form the corrugated cardboard liner itself with a relatively thin resin film, or the corrugated core with a resin sheet. Further, the resin material constituting the corrugated core may be a synthetic resin of the same material as the corrugated cardboard liner, or the corrugated resin core may be used for a corrugated cardboard liner having a paper quality liner. In addition, even when a resin-based member is used for the corrugated cardboard liner and / or the corrugated core, the moisture-proof effect is also exhibited.

Adhesion between the corrugated core and the corrugated core can be performed by a conventionally known method.
It is also possible to form a corrugated cardboard substrate by temporarily bonding 12 and 14 and then bonding them.

With respect to the adhesion of the single corrugated cardboard substrates 12 and 14, the corrugated cores 12a and 13a are arranged so as to face each other, and the thermoplastic film 24 is interposed between the corrugated cores 12a and 14a,
By applying a heat press, the film is melted and the corrugated cores 12a and 14a are bonded.

Various types of resinous films can be used as the thermoplastic film. For example, polyethylene, polypropylene, polyvinyl chloride, polyvinyl acetate, polystyrene, ethylene propylene copolymer, ethylene vinyl acetate copolymer, hot melt and the like are suitable. Further, a thermoplastic resin may be formed by adding a mixture of a filler such as talc to the resin. However, when a resin material is used for the corrugated cardboard liner and / or the corrugated core, it is necessary to select a resin film having a melting point lower than the melting point of the resin material as the adhesive.

As a method of molding the corrugated cardboard substrate, as described above, after temporarily assembling with the thermoplastic resin film 24 inserted between the single corrugated cardboard substrates 12 and 14, the heating press machine 100 shown in FIGS. Molding is also possible. This temporary assembly can be easily performed because the corrugated shapes of the corrugated cores 12a and 14a have substantially the same shape. In addition, as the temporary assembling method, the entire surface of the corrugated cardboard liner and the corrugated core may be adhered, but temporarily assembling a part thereof is sufficiently effective.

The heating press 100 has curved molding surfaces 122a and 124, respectively.
The dies 122 and 124 shown in this embodiment have a flat semicircular curved surface, but the dies 122 and 124 shown in this embodiment have a shape corresponding to the desired shape of the molded cardboard. The shape can be determined. This die
Each of 122 and 124 further includes a heating means 126 having a configuration in which a spiral or bent pipe is provided therein to allow the passage of heated steam or heated oil through the pipe. Further, the heating means may be constituted by an electric heater whose temperature is easier to control than the heating fluid.

Further, it is desirable that the temperature of the heating means 126 be controlled so that the temperature of the die of the male mold 122 is higher than that of the female mold 124. This is because heat is transmitted from the male mold 122 to the female mold 124 due to the temperature difference, and the thermoplastic resin film 24 can be effectively melted.

The dies 122 and 124 are heated and the thermoplastic resin film
When the temperature rises to the softening point of 24, the melting point, the corrugated cardboard assemblies 12 and 14 are placed between the dies 122 and 124. Next, the die 124 is lowered, pressurized at a predetermined pressure, and heated.

In the pressurized manufacturing method in this heated state, first, the female mold 124 is lowered onto the male mold 122 to a position where the clearance is slightly larger than the final thickness d of the cardboard, and the male mold having a high temperature difference is formed. This state is maintained over the time required for the thermoplastic resin film to melt by heat conduction from the mold 122 to the lower female mold 124. Under this heating, the corrugated cores 12a and 1a
The thermoplastic resin layers 16 and 20, which bond the cardboard liners 12b and 14b to the crests of 4a, also melt. This thermoplastic resin 16
And 20 melt, the crests of the corrugated cores 12a and 14a and their corrugated cardboard liners 12b and 14b slip, that is,
The position fluctuates relatively. That is, the corrugated cores 12a and 14a and the corrugated cardboard liners 12b and 14b adhered thereto.
Is displaced to a new bonding position that maintains a desired shape after the thermoplastic resin is cured.

In the press molding in this heated state, the corrugated cores 12a and 14a are tightly fitted through the thermoplastic resin film 24, and the thermoplastic resin film 24 is melted by heating to bond the fibers of the corrugated core. . Thereafter, the dissolved resin film 24 is cooled and cured in a state of being joined to the corrugated core fiber. As a result, the corrugated cores 12a and 14a are bonded. FIG. 5 shows the paper-type corrugated cardboard base material obtained by the above-described hot press manufacturing method.

As shown in FIG. 1, after hot press molding, a closed section 26 is formed between the corrugations of the corrugated cores 12a and 14a. However, the closed section 26 can be eliminated by applying a higher pressure to the corrugated cores 12a and 14a. However, by providing the closed cross section 26, the heat insulation and soundproofing effects unique to cardboard can be obtained. Therefore, it is desirable to control the pressing force so that the closed cross section 26 is formed even after the heat molding. That is, the closed section 26
The air inside functions as a thermal insulation material that absorbs heat and blocks sound.

In addition, the paper-type corrugated cardboard substrate 10 is used for automobile roof trim,
When used as door trim material, woven fabric,
A decorative liner 28 such as leather may be used by bonding it to the cardboard liner 14b.

6a and 6b show a preferred embodiment of the present invention. In this embodiment, the molded paper-type corrugated board 30
Are designed for roof trim of automobiles.
As is clear from FIGS. 6a and 6b, the paper-type corrugated
Has a cross-sectional shape different from that of the other part in a part thereof. That is, the paper-type corrugated cardboard base material 30 of FIG. 6a has vertically long edges 32F and 32R, both of which have a double-structured corrugated core, and the middle portion 32M is a single-layer corrugated core. It has a single-layer structure. Alternatively, the paper-type corrugated cardboard substrate 30 shown in FIG. 6b has a horizontally long edge 34L of a double corrugated core structure.
And 34R, and the central portion 34M has a single-layer corrugated core structure.

It has been pointed out that the edge of the paper-type corrugated board tends to be weaker in strength than other parts, but it is possible to guarantee sufficient strength by using a corrugated core having a double structure. . That is, by applying the double structure as described above to the edge of the paper-type corrugated cardboard substrate, it is possible to obtain a strength that can withstand the stress acting on the edge.

Further, by partially forming the double corrugated core structure, the substantial strength can be increased without significantly increasing the weight of the paper corrugated cardboard substrate.

FIG. 7 shows a paper-type corrugated cardboard substrate 30 to be used for a roof trim of a sunroof specification. It is known that in the case of an automobile roof having a sunroof opening, bending stress and tensile stress acting on the roof tend to concentrate on the edge of the sunroof opening. Therefore, higher strength is required for the paper-based corrugated cardboard base material in the periphery of the sunroof opening.

The molded paper corrugated cardboard substrate 30 needs to be provided with an opening 36 at a portion corresponding to a sunroof opening of a roof panel (not shown) of a vehicle. Generally, the edge of paper-based corrugated cardboard is known to have a problem in strength,
In order to guarantee the strength of the periphery of the opening 36 and to make use of the characteristics of the paper corrugated cardboard base material as a reinforcing material for the vehicle roof of the sunroof specification, it is sufficiently effective to adopt the double corrugated core structure 38 described above. is there. On the other hand, making the corrugated core a double structure is a problem in reducing the weight of the roof trim, but in order to minimize the increase in the weight of the paper-type corrugated cardboard substrate 30, in this embodiment, the outline of the roof is reduced. Has a single-layer corrugated core structure. The stress acting on this region 40 is not so large, and the corresponding roof portion is usually reinforced by a frame or a reinforcing material, so that substantial strength is not required. Therefore, the roof trim structure can sufficiently satisfy the requirements for strength and weight reduction around the sunroof opening.

FIG. 8 shows another embodiment of the paper-type corrugated cardboard substrate 30 of the present invention. Paper-based corrugated cardboard substrate 30 shown here
Are formed for roof trim of T-bar roof specification. As in the above-described embodiment, the paper-type corrugated cardboard base material 30 is also divided into a double corrugated core portion 42 and a single-layer corrugated core portion 44, and in this structure, the necessity at the edge of the T-bar structure is obtained. The strength and the weight of the entire structure can be sufficiently obtained.

A practical manufacturing method is to achieve a partially reinforced paper-type corrugated cardboard substrate by providing a single-corrugated cardboard substrate on the surface of a partially reinforced single-corrugated cardboard substrate to form a double corrugated core structure. Can be. FIG. 9 is an exploded view of the structure, in which a single corrugated cardboard substrate 52 composed of a corrugated core 52a and a corrugated cardboard liner 52b is provided in the entire area as a base and formed in a smaller area than the single corrugated cardboard substrate 52. Single corrugated cardboard base material 54 as a reinforcing base material, its corrugated core 54a
Are arranged on the single-cardboard base material 52 in opposition to the corrugated core 52a. The size of the thermoplastic film 56 should be
Corresponding to the size of 54, opposing corrugated cores 52a and 52
Intervene between 4a. The corrugated cardboard liner 58 is provided on the corrugated cardboard liner 54b of the single corrugated cardboard substrate 54, and the thermoplastic resin film 60 is provided between the corrugated cardboard liners 54b and 58, and further between the corrugated cardboard liner 58 and the corrugated core 52a. It is also placed on nonexistent parts.

Combine the single cardboard base materials 52, 54 and the cardboard liner 58, press them with light pressure and paste them in advance,
Heat welding. Temporary assembly in such a forming structure before heat welding facilitates subsequent heat forming. FIG. 10 shows the paper-type corrugated cardboard substrate 50 after hot press molding.
As shown in FIG. 10a, the paper-type corrugated cardboard substrate 50 has a single-layer structure with only the corrugated core 52a in the first section at the center thereof, while the corrugated core 52a has a single-layer structure in the second sections on both sides. The cores 52a and 54a have a double structure in which the cores are fitted to each other. That is, the corrugated core 52a of the first section and the corrugated cardboard liners 52b, 58 extend on the second section side, and another corrugated core 54a is fitted to the corrugated core 52a.

As will be apparent from the above description, the paper-type corrugated cardboard substrate according to the present invention can increase the strength without substantially increasing the thickness and weight of the corrugated cardboard. The present invention is not limited to the above-described embodiment. For example, the double corrugated core structure may be a triple or multilayer structure. Furthermore, in the above-described embodiment, the use of the paper-type corrugated cardboard substrate has been described with respect to an automobile. However, the present invention is not limited to this. For example, it can be used as a building material for buildings and dwellings. Further, as another utilization method, the present invention can be applied to a cardboard container or other cardboard substrate products.

[Effects of the Invention] In the plate-shaped member according to claim 1, a pair of single corrugated cardboard substrates are fitted with a corrugated core and bonded with a thermoplastic resin, thereby providing a corrugated cardboard base having a closed cross section. Since the material is formed, the corrugated core functions as a hollow reinforcing skeleton material, and the rigidity can be further increased.

In the plate-shaped member of the second aspect, the rigidity of the member can be increased by providing the double corrugated core as the reinforcing structure.

In the plate-shaped member according to the third aspect, since each bonding point in the double corrugated core structure provided with the corrugated core as the liner member and the reinforcing member can be displaced so as to maintain the member shape, it is desirable. It is possible to obtain a plate-shaped member having the required rigidity of the formed shape.

In the plate-shaped member according to the fourth aspect, the plate-shaped member can be lightweight and have desired strength by partially providing and reinforcing the double corrugated core.

In the plate-shaped member according to claim 5, the plate-shaped member can be lightweight and have a desired strength by partially providing and reinforcing the double corrugated core, and the liner Since the bonding point between the member and the core can be displaced, a highly rigid plate-like member having a desired molded shape can be obtained.

In the plate member according to claim 6, a liner member having a corrugated core is interposed between the plate members having a single-layer corrugated core structure so as to partially have a double corrugated core structure. By reinforcing it, a plate member having high rigidity can be obtained at a desired location.

In the method for forming a plate-like member according to any one of claims 7 to 9, the method for manufacturing the plate-like member is simplified by forming a temporary assembly including the liner member and the double corrugated core in advance. .

In the method for manufacturing a plate-like member according to claim 10, a step of forming a first temporary assembly including a liner member and a corrugated core; Laminating an adhesive on the core to form a second temporary assembly, and forming a preliminary assembly by facing the corrugated cores of the second temporary assembly and the first temporary assembly. The method for manufacturing a plate-like member, which includes a step, a step of thermocompression-bonding the pre-assembly, and a step of solidifying the adhesive, makes the method of manufacturing a plate-like member simpler.

In the vehicle plate-shaped member according to claim 11, by providing a corrugated core as a reinforcing member to form a double corrugated core structure, the rigidity is increased, and a skin material is attached to the liner member. Thereby, the appearance is also excellent.

According to the twelfth aspect of the present invention, a molded member having a necessary rigidity is obtained in the runner member and the double corrugated center in order to maintain a desired member shape by displacing an adhesion point. In addition, since the skin material is attached to the liner member, the appearance is excellent.

In the vehicle plate member according to claims 13 to 15,
Between the plate-like members of the single-layer corrugated core structure, a liner member having a corrugated core is interposed and reinforced so as to have a partially double corrugated core structure. A high plate-like member can be obtained, and the appearance is excellent because the skin material is attached to the liner member.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of a plate-shaped member according to the present invention, FIG. 2 is an exploded view of the plate-shaped member, and FIG. FIG. 4 is a front view showing a state before the press of the heating press machine to be molded;
The figure is a front view showing the heating press machine during the heating press, and FIG.
The figure is a perspective view showing a plate-like member obtained by hot press molding, FIG. 5 (a) is an enlarged sectional view of FIG. 5, and FIG.
6 (a) and 6 (b) are perspective views showing a liner material used for a roof trim of an automobile, and FIG.
FIG. 7 (a) is an enlarged cross-sectional view of FIG. 7, and FIG. 7 is a perspective view showing a liner material used for a roof trim of a sunroof specification vehicle.
(A) is an enlarged cross-sectional view of FIG. 7, FIG. 8 is a perspective view showing a liner material used for a roof trim of a T-bar roof specification vehicle, and FIG. 8 (a) is an enlarged cross-sectional view of FIG. FIG. 9 is an exploded perspective view showing another embodiment of the plate member according to the present invention. FIG. 10 is a perspective view showing an assembly of the corrugated cardboard base material shown in FIG. The figure is an enlarged sectional view of FIG. 10: Paper-type corrugated cardboard, 12, 14, 52, 54 ... Single-corrugated cardboard, 12a, 14a, 52a, 54a ... Corrugated core, 12b, 14b, 54b, 58
…… Corrugated cardboard liner, 16,20 …… Thermoplastic resin, 18a, 2
2a: crests, 24, 60: thermoplastic film, 28: decorative liner, 30: molded cardboard base material, 36: opening, 42: double corrugated core, 44: single layer Corrugated core, 122…
... male type, 124 ... female type, 126 ... heating means

 ──────────────────────────────────────────────────続 き Continuation of the front page (56) References Japanese Utility Model Showa 60-168923 (JP, U) Japanese Utility Model Showa 53-92081 (JP, U) Japanese Utility Model Showa 53-93366 (JP, U) Japanese Utility Model Showa 54- 2912 (JP, U)

Claims (15)

(57) [Claims] 1. A corrugated core having substantially the same shape is adhered to one side surface of a liner member by a heat welding film to form a pair of single-plate members, and the corrugated cores of these single-plate members are fitted to each other. A plate-shaped member having a corrugated core, wherein a closed cross-section is formed between the corrugated cores. 2. A first and a second corrugated core having first and second liner members spaced apart from each other at a predetermined interval and arranged substantially in parallel, and a plurality of corrugated bent portions having substantially the same shape. And the first and second corrugated cores are fitted together to form a closed cross-section, and are bonded via a thermoplastic resin at least in a part of the fitted portion,
The first corrugated core is bonded to the first liner member near its crest, and the second corrugated core is bonded to the second liner member near its crest. A plate-shaped member having a corrugated core. 3. A first and second corrugated core having a first and second liner members spaced apart from each other at a predetermined interval and arranged substantially in parallel, and a plurality of wavy bent portions having substantially the same shape. Wherein the first and second corrugated cores are fitted to each other to form a closed cross-section, and are adhered to each other via a thermoplastic resin at a first adhesion point, The first core is located at the second bonding point near the crest of the first core.
The second corrugated core is adhered to the second liner member at a third adhesion point near the crest of the second corrugated core, and the first, second, and third adhesion points are: A plate having a corrugated core formed into an at least partially three-dimensionally bent shape, wherein the plate is displaced to an adhesion point that retains the shape according to a desired forming shape during hot pressing Shaped member. 4. A first corrugated structure in which a first and a second liner members are spaced apart from each other at a predetermined interval and arranged substantially in parallel, and a crest portion is interposed between the liner members. A first section comprising a core, first and second liner members extending from the first section at a distance substantially equal to the predetermined distance and extending from the first section, and disposed between the liner members. A first corrugated core extending from the first section, and a second corrugated core having a plurality of corrugated bent portions having substantially the same shape as the corrugated core. The corrugated cores are fitted to each other and bonded at least at a part of the fitting portion via a thermoplastic resin, and the first corrugated core is bonded to the first liner member near the crest thereof. , The second waveform center is the second line A plate-like member having a corrugated core, comprising a knurl member and a second section bonded near a crest portion thereof. 5. A first corrugated structure in which first and second liner members are spaced apart from each other at a predetermined interval and arranged substantially in parallel, and a crest portion is interposed between the liner members. A first section comprising a core, first and second liner members extending from the first section at a distance substantially equal to the predetermined distance and extending from the first section, and disposed between the liner members. A first corrugated core extending from the first section, and a second corrugated core having a plurality of corrugated bent portions having substantially the same shape as the corrugated core. The corrugated cores are fitted with each other via a thermoplastic resin at least at a second bonding point which is a part of the fitted portion, and the first corrugated core is connected to the first liner member. And the third bonding point near the crest And glued,
The second corrugated core is composed of the second liner member and a second section bonded at a fourth bonding point near a crest of the second liner member, and the first, second, third, and third sections are formed. (4) A plate-like member having a corrugated core, wherein the bonding point is displaced to a bonding point which maintains a desired shape according to a desired molding shape during hot pressing. 6. A first and a second liner members which are spaced apart from each other at a predetermined interval and are arranged substantially in parallel, and are interposed between these liner members with their crests as first adhesion points. A first section composed of a first corrugated core; first and second liner members extending from the first section at a distance substantially equal to the predetermined distance and extending from the first section at intervals substantially in parallel with each other; A first corrugated core disposed between the first corrugated core and extending from the first section; and a plurality of corrugated bent portions having substantially the same shape as the corrugated core, wherein the first corrugated core and the first liner member are provided. And a third liner member interposed between the corrugated core and the first liner member.
And the second corrugated core are fitted with each other via a thermoplastic resin at a second bonding point which is at least a part of the fitted portion, and the first corrugated core is a third liner. The member is bonded at a third bonding point near the crest of the member, the third liner is bonded to the entire surface of the first liner, and the second corrugated core is connected to the third liner member. A second section bonded at a fourth bonding point near the crest, and the first, second, third, and fourth bonding points are formed into a desired molding shape during hot pressing. A plate-like member having a corrugated core formed into a desired shape, wherein the plate-like member is displaced to a bonding point that maintains the shape in response to the shape. 7. A temporary assembly of a single-plate corrugated member comprising a liner member and a corrugated core member is constituted as a pair, and the adhesive which is in a solid state at normal temperature and has adhesive properties at a predetermined melting temperature is provided. After being interposed between the pair of temporary assemblies, the corrugated cores of the pair of temporary assemblies are fitted to each other to form a closed cross section, and then the pair of temporary assemblies at a temperature equal to or higher than the predetermined melting temperature. Wherein the corrugated cores are bonded to each other by pressing at least one of the corrugated cores against the other, cured, and the adhesive is cured. 8. The method according to claim 7, wherein the adhesive is a thermoplastic resin. 9. The method according to claim 1, wherein said thermoplastic resin is polyethylene, polypropylene, polyvinyl chloride, polyvinyl acetate, polystyrene, ethylene propylene copolymer, ethylene vinyl acetate copolymer or hot melt. 9. A method for manufacturing a plate-shaped member having a corrugated core according to claim 8. 10. A first and second temporary assembly of a single-plate corrugated member comprising a liner member and a corrugated core member, which is in a solid state at normal temperature and has an adhesive property at a predetermined melting temperature. After bonding the adhesive to the corrugated core of the first temporary assembly, the corrugated cores of the first and second temporary assemblies are fitted together to form a closed cross-section to form a pre-assembled body. And forming a plate-like member by bonding the pre-assembly by pressing the one pre-assembly of the pre-assembly through the other temporary assembly at a temperature equal to or higher than the predetermined melting temperature. Curing the adhesive by curing the plate-shaped member having a corrugated core. 11. A first liner member and a second liner member which are spaced apart from each other at a predetermined interval and arranged substantially in parallel with each other,
The first and second corrugated cores are composed of a skin material adhered to the second liner member and first and second corrugated cores each having a plurality of corrugated bent portions having substantially the same shape. Are fitted to each other to form a closed cross-section, and at least a part of the fitted portion is adhered via a thermoplastic resin, and the first corrugated core is formed by the first liner member and its corrugated portion. A plate member for a vehicle having a corrugated core, wherein the corrugated core is bonded near the top and the second corrugated core is bonded to the second liner member near the corrugated portion. 12. A first and a second member having a skin material, first and second liner members spaced apart from each other at a predetermined interval and arranged substantially in parallel, and a plurality of wavy bent portions having substantially the same shape.
And the first and second corrugated cores are fitted together to form a closed cross-section, and are mutually bonded at a first bonding point via a thermoplastic resin, The first corrugated core is bonded to the first liner member at a second bonding point near the crest, and the second corrugated core is bonded to the second liner at a third bonding point near the crest. Adhered to the liner member, the first and second
And the third bonding point is, at the time of hot pressing, displaced to a bonding point that retains the shape according to a desired molding shape, and is bent at least partially three-dimensionally. A plate member for a vehicle, comprising a plate member formed into a shape. 13. A skin material, first and second liner members spaced apart from each other at a predetermined interval and arranged substantially in parallel with each other, and a crest portion between the liner members is used as a first bonding point. A first section including an interposed first corrugated core; first and second liner members extending from the first section at intervals substantially equal to the predetermined interval and substantially parallel to each other; A first corrugated core disposed between the liner members and extending from the first section; and a plurality of corrugated bent portions having substantially the same shape as the corrugated core. A second corrugated core interposed between the first liner member and a third liner member interposed between the corrugated core and the first liner member;
And the second corrugated core are fitted with each other via a thermoplastic resin at a second bonding point which is at least a part of the fitted portion, and the first corrugated core is a third liner. The member is bonded at a third bonding point near the crest of the member, the third liner is bonded to the entire surface of the first liner, and the second corrugated core is connected to the third liner member. A second section bonded at a fourth bonding point near the crest, and the first, second, third, and fourth bonding points are formed into a desired molding shape during hot pressing. A plate member for a vehicle, comprising a plate member bent at least partially three-dimensionally and formed into a desired shape, characterized in that the plate member is displaced to an adhesion point which maintains the shape in response to the change. 14. A vehicle roof trim having a sunroof opening, wherein the second section is provided around an opening of a plate member formed at a position corresponding to the sunroof opening. Item 14. The vehicle plate member according to item 13. 15. A vehicle roof trim having a T-bar roof opening, wherein the second section is provided around an opening of a plate-like member formed at a position corresponding to the T-bar roof opening. 14. The plate member for a vehicle according to claim 13, wherein: