JP5119315B2 - Manufacturing method of resin panel - Google Patents

Description

  [Technical Field] The present invention relates to the manufacture of resin panels used for interior parts for automobiles such as cargo floor panels (cover panels or luggage boards for automobile luggage compartments) or rear parcel shelves, interior wall partitions, doors and other panel-like building products. Regarding the method.

  Interior parts such as interior cosmetics such as parcel trays used for vehicles such as automobiles and aircraft, or decorative panels used for indoor walls, etc., and air such as heat insulating materials or sound absorbing materials as intermediate members of interior parts by seat blow molding A resin hollow molded article in which a reinforcing material such as a material having a layer, a steel pipe or a frame is arranged is described in JP-A-10-80982. Also, a resin hollow molded product in which a sheet-shaped parison is blow-molded to form a resin hollow molded product and a foam is embedded in the blow molding is described in Japanese Patent Application Laid-Open No. 2000-218682.

Japanese Patent Laid-Open No. 10-80982 JP 2000-218682 A

  The resin molded product described in Patent Document 1 inserts an intermediate member such as a foam or a reinforcing material at the time of blow molding. Also, the resin hollow molded product described in Patent Document 2 is pre- In the case where the molded foam is inserted at the time of blow molding and a reinforcing material is installed, a process of inserting the reinforcing material after molding is required.

  For this reason, when there are a plurality of intermediate members incorporated in the resin hollow molded product, it is not easy to place and position the intermediate members between the molds, the molding accuracy is reduced, or the intermediate member is packed. In the case of an intermediate member that does not rattle and does not shrink like a metal reinforcing material, problems such as increased deformation due to molding shrinkage of the hollow resin molded product have been pointed out.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for manufacturing a resin panel capable of accurately positioning a reinforcing material and preventing deformation due to rattling or molding shrinkage. And

  In order to achieve this object, the present invention has the following features.

The method for producing a resin panel according to the present invention is as follows.
Production of a resin panel having a front wall made of resin, a back wall, and a peripheral wall connecting the front wall and the back wall, wherein a reinforcing material and a pre-formed foam are embedded in the resin A method,
The foam, the foam is pre-molded in a shape that is interposed between the both ends of the reinforcing member and the peripheral wall,
An arrangement step of arranging the resin between the divided molds;
The reinforcing material and the foam are placed between the split molds so that the foam is located at both ends of the reinforcing material and clamped, and the reinforcing material and the foam are the resin. and decorated, and, forming step of forming a resin panel which the foam is interposed between the both ends of the reinforcing member and the peripheral wall,
It is characterized by having.

  According to the present invention, it is possible to accurately position the reinforcing material, and to prevent rattling and deformation due to molding shrinkage.

It is sectional drawing of the resin-made panels which concern on this invention. It is a whole perspective view same as the above. It is a perspective view which shows the aspect which arrange | positions a reinforcing material in the foam which consists of a preformed thermoplastic resin. It is sectional drawing which shows the blow molding aspect which incorporates the foam which has arrange | positioned the reinforcing material in resin-made panels.

  1 is a cross-sectional view of a resin panel according to the present invention, FIG. 2 is an overall perspective view of the same, FIG. 3 is a perspective view showing a mode in which a reinforcing material is disposed on a foam made of a pre-formed thermoplastic resin, and FIG. FIG. 5 is a cross-sectional view showing a blow-molded aspect in which a foam in which a reinforcing material is arranged in a resin panel is installed.

  As shown in FIGS. 1 and 2, the resin panel 1 according to the present invention includes a front wall 2, a back wall 3, and a peripheral wall 4 that connects the front wall 2 and the back wall 3. The resin panel 1 is hollow. It is a double wall structure, 5 is a hollow part. A skin material 6 for decoration or the like is attached to the surface of the front wall 2 over the peripheral wall 4.

  The peripheral wall 4 of the resin panel 1 has a welded portion 7 on the entire periphery thereof, and a foam 8 is housed in the hollow portion 5. The foam 8 is made of a thermoplastic resin that is preformed in substantially the same shape as the space in the hollow portion 5, and the foam 8 has accommodating portions 10, 10 for arranging the reinforcing members 9, 9. The reinforcing members 9 and 9 are arranged in the accommodating portions 10 and 10. The foam 8 is welded to the inner wall surface of the front wall 2 and the back wall 3 of the resin panel 1. For this reason, the reinforcing members 9 and 9 are securely held by the foam 8 so that the reinforcing members 9 and 9 can be positioned accurately, and the foam 8 and the reinforcing members 9 and 9 built in the hollow portion 5 are not loose. Can be prevented.

  The reinforcing members 9, 9 are long, and are made of metal or hard plastic having a shape such as a round pipe, a square pipe, or an H steel mold. As shown in FIG. 3, the reinforcing members 9, 9 are arranged to fit into the accommodating portions 10, 10 of the foam 8, but both end portions 9 a, 9 a (at least one end portion of the reinforcing members 9, 9). ) And the peripheral wall 4, a foam 8 is interposed, and 8a and 8a are the interposed portions.

  Thus, since the foam 8 is interposed between the end portions 9a, 9a of both the reinforcing members 9, 9, and the peripheral wall 4, the molding shrinkage can be reduced by the interposed portions 8a, 8a of the foam 8. It is possible to obtain the resin panel 1 that does not cause deformation due to the difference in contraction between the resin panel 1 and the reinforcing members 9, 9 by being absorbed.

  In addition, it can also be set as the aspect which formed the cavity part which the foam 8 does not interpose between the at least one edge part of the reinforcing materials 9 and 9 and the surrounding wall 4 (not shown). As shown in FIG. 3, the accommodating portions 10 and 10 formed in the foam 8 are concave portions that are recessed from one surface of the foam 8 toward the other surface. It may be an insertion hole penetrating from one surface of the foam 8 toward the other surface (not shown).

  The resin panel 1 in which the foam 8 and the reinforcing materials 9 and 9 are housed is blow-molded in the manner shown in FIG. That is, the parison 12 in a molten state extruded from the resin extrusion head 11 is disposed between the divided molds 13 and 13, and the parison 12 is pressed against the mold cavities 14 and 14 by vacuum or compressed air, and then molded in advance. The foam 8 that has been molded and retained by holding the reinforcing members 9 and 9 in the housing portions 10 and 10 is placed in one cavity 14 so as to contact the inner surface of the sheet-like parison 12 and clamped. The parison 12 disposed in each of the cavities 14 and 14 is sandwiched by the pinch-off portions of the split molds 13 and 13 so that the welded portion 7 is formed on the entire circumference of the peripheral wall 4 of the resin panel 1 and in a molten state. The resin panel 1 is obtained in which the inner surface of the parison 12 and the outer surface of the foam 8 are welded, and the foam 8 in which the reinforcing materials 9 and 9 are disposed is housed in the hollow portion 5. In addition, this resin panel 1 can also be shape | molded in the aspect which blow-molds a pair of preformed resin sheet (not shown). In FIG. 4, 15 is a vacuum chamber, 16 is a ventilation contact surface, and 17 is a blow pin.

  In the present invention, blow molding is a method in which a cylindrical parison or a resin sheet obtained by extruding or pre-molding a plurality of resin sheets is overheated and melted, and placed between divided molds and clamped to obtain a desired shape. It refers to so-called direct blow molding or sheet blow molding for molding, and it does not matter whether air is blown or not.

  The thermoplastic resin constituting the front wall 2, the back wall 3 and the peripheral wall 4 of the resin panel 1 may be any one that can be blow-molded, such as polyethylene resin, polypropylene resin, ethylene-vinyl acetate copolymer, chloride. Engineering plastics such as vinyl resin, ABS resin (acrylonitrile-styrene-butadiene resin), polyamide resin, polystyrene resin, polyester resin, polycarbonate resin, and modified polyphenylene ether are suitable. Glass fiber, carbon fiber, calcium carbonate are used as appropriate. Fillers such as talc and mica can be added.

  The foam 8 is made of polyethylene, polypropylene, polystyrene, or the like, and is preferably made of the same material as the thermoplastic resin constituting the front wall, back wall, and surrounding wall panels. Moreover, fillers, such as glass fiber, carbon fiber, calcium carbonate, talc, and mica, can be appropriately added to the foam.

  The skin material 6 is a knitted fabric, a woven fabric, a non-woven fabric, or a polyvinyl chloride (PVC), a thermoplastic polyurethane elastomer (TPU) obtained by processing a natural fiber, a recycled fiber, a semi-synthetic fiber, a synthetic fiber and a blend thereof. ) Or a thermoplastic elastomer (TPE) such as a thermoplastic polyolefin elastomer (TPO), a resin sheet made of a thermoplastic resin such as a polyethylene polyolefin-based resin, and a laminate sheet thereof.

  The above-described embodiment is a preferred embodiment of the present invention, and the scope of the present invention is not limited to the above-described embodiment alone, and various modifications are made without departing from the gist of the present invention. Implementation is possible.

DESCRIPTION OF SYMBOLS 1 Resin panel 2 Front wall 3 Back wall 4 Peripheral wall 5 Hollow part 6 Skin material 7 Welding part 8 Foam 8a, 8a Interposition part 9, 9 Reinforcement material 9a, 9a Both ends 10, 10 Housing part 11 Resin extrusion Head 12 Parison 13, 13 Split mold 14, 14 Cavity 15 Vacuum chamber 16 Venting contact surface 17 Blow pin

Claims (5)

Production of a resin panel having a front wall made of resin, a back wall, and a peripheral wall connecting the front wall and the back wall, wherein a reinforcing material and a pre-formed foam are embedded in the resin A method,
The foam, the foam is pre-molded in a shape that is interposed between the both ends of the reinforcing member and the peripheral wall,
An arrangement step of arranging the resin between the divided molds;
The reinforcing material and the foam are placed between the split molds so that the foam is located at both ends of the reinforcing material and clamped, and the reinforcing material and the foam are the resin. and decorated, and, forming step of forming a resin panel which the foam is interposed between the both ends of the reinforcing member and the peripheral wall,
A method for producing a resin panel, comprising: The foam has an accommodating portion for accommodating the reinforcing material,
The method for producing a resin panel according to claim 1, wherein the reinforcing material is disposed in the housing portion, and the reinforcing material and the foam are disposed between the split molds.   The accommodating portion has a concave shape that is recessed from one surface of the foam toward the other surface, and the reinforcing material is fitted into the concave-shaped accommodating portion so that the reinforcing material is placed in the accommodating portion. The method for producing a resin panel according to claim 2, wherein the resin panel is arranged.   The accommodating portion has a hole shape penetrating from one surface of the foam to the other surface, and the reinforcing material is fitted into the accommodating portion having the hole shape so that the reinforcing material is disposed in the accommodating portion. The method for producing a resin panel according to claim 2.   The method for producing a resin panel according to any one of claims 1 to 4, wherein a gap is formed between the reinforcing material and the foam.

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