JP5406498B2 - Panel and method for manufacturing the panel - Google Patents

Description

  The present invention relates to a panel having a panel main body formed hollow and a resin foam filled in the panel main body, and a method for manufacturing the panel.

  For example, a panel of the above type that is widely used as a flooring material laid in an automobile luggage compartment, an interior material installed in a vehicle interior, an interior material for a building, or a partition wall has been known (patents). Reference 1). The panel body of such a panel is filled with foam, and the foam is welded to the inner surface of the panel body to increase the rigidity of the entire panel, so this panel can be used for many purposes. Can do.

  In a conventional panel, a panel body having a hollow interior is made of resin, and when the panel body made of resin is manufactured, a molded foam is loaded into the panel body, and the foam is It is manufactured by welding to the inner surface of the panel body by the heat of the panel body. Such a panel body is made of, for example, polypropylene, and as the foam, a material compatible with the panel body, for example, a foam of polypropylene resin is used. However, the end material is generated at the time of molding such a foam, and this disadvantageously increases the cost of the panel.

  Therefore, as a method for manufacturing a panel at a lower cost, a method for manufacturing a panel by injecting a liquid foaming raw material into a panel body having a hollow interior and foaming the foaming raw material in the panel main body can be considered.

  However, even when a panel is manufactured by such a method, depending on the foaming raw material and the material of the panel main body, the inner surface of the panel main body and the foam cannot be firmly bonded, and the finished panel has sufficient rigidity. There is a risk that it will not be able to be increased. For example, when using a panel body made of polypropylene or polyethylene and injecting a foaming raw material into the panel body and filling the panel body with polyurethane foam, the polyurethane foam in the panel body is replaced by a panel. It cannot be firmly bonded to the inner surface of the main body. When a large external force is applied to such a panel, a gap is formed between the inner surface of the panel body and the foam, so that the rigidity of the panel should be considered when the foam is filled in the panel body. It cannot be increased.

  Therefore, conventionally, when using a foam and a panel main body having poor adhesion as described above, before injecting the foaming raw material into the panel main body, the tip of the nozzle is inserted into the panel main body, The primer was sprayed from the nozzle, the primer was applied to the inner surface of the panel body, the adhesion of the surface was improved, and then the foaming raw material was injected into the panel body to foam it. . If it does in this way, the foam in a panel main body can be firmly joined to the inner surface of a panel main body via a primer, and the rigidity of a panel can be improved.

  However, when a primer is applied to the inner surface of the panel main body, a lot of time is required to dry the primer, so that the manufacturing process of the panel becomes complicated and the cost of the panel increases.

JP 2006-334801 A

  An object of the present invention is to provide a panel of the type described at the beginning, which eliminates the above-mentioned conventional drawbacks, and a method for manufacturing the panel.

The present invention relates to a panel main body made of a resin reinforced with fibers and having a hollow interior and at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat joined to the inner surface thereof. A panel comprising a foam formed by foaming a foaming material injected into the panel body is proposed.

  In this case, the fiber for reinforcing the resin is advantageously composed of at least one of glass fiber, carbon fiber, wood fiber, aramid fiber, nylon fiber and polyethylene terephthalate fiber.

  The resin constituting the panel body is advantageously made of polyolefin or polylactic acid, and the foam is advantageously made of polyurethane foam.

  Further, it is advantageous that the panel body is composed of at least the first and second panel body base materials obtained by extruding a resin blended with a fiber as a reinforcing agent and molded by at least a blow molding method. It is.

  Further, the present invention is a panel which is made of a resin reinforced with fibers and has a hollow interior, and at least one of a nonwoven fabric, a woven fabric, a glass fiber mat and an aramid fiber mat is bonded to the inner surface. A method of manufacturing a panel in which a foaming raw material is injected into the main body, the foaming raw material is foamed in the panel body, and a resin foam is filled in the panel body is proposed.

  According to the present invention, since at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is joined to the inner surface of the panel body, the foam filled in the panel body is a nonwoven fabric, a woven fabric. By the anchor effect of at least one of the cloth, the glass fiber mat, and the aramid fiber mat, the panel is firmly bonded to the inner surface of the panel body, thereby sufficiently increasing the rigidity of the panel. In addition, since the panel body is made of a resin reinforced with fibers, the rigidity and impact resistance of the panel body are enhanced, and the rigidity and strength of the entire panel are remarkably improved. Even when the panel is heated to a high temperature, the rigidity of the panel body can be kept high.

  Embodiments of the present invention will be described below in detail with reference to the drawings.

  1 is an external perspective view of the panel 1, and FIG. 2 is a cross-sectional view taken along the line II-II of FIG. As shown in these drawings, the panel 1 of this example includes a hard panel body 2 having a hollow interior, a non-woven fabric 3 bonded to the entire inner surface of the panel body 2, and the inside of the panel body 2. And a resin foam 4 filled in the container. As will be described in detail later, the foam 4 is obtained by foaming a foaming raw material injected into the panel body 2.

  The panel body 2 is made of a resin reinforced with fibers. Here, the resin reinforced with fiber widely means a plastic reinforced with fiber, and in addition to fiber reinforced plastic (FRP) formed by reinforcing a thermosetting resin with fiber, For example, a fiber reinforced thermoplastic resin comprising a fiber having a length of 1 mm to 15 mm, preferably 4 mm to 12 mm as a reinforcing agent is included. Examples of such reinforcing fibers include glass fibers, carbon fibers, wood fibers such as kenaf and bamboo, aramid fibers, nylon fibers, and polyethylene terephthalate fibers. At least one of these fibers can be used. it can.

  The resin constituting the panel body 2 and the foamed body 4 can also be selected from those of suitable materials, but as the resin of the panel body 2 reinforced with fibers, polyolefin such as polypropylene and polyethylene, or polylactic acid When the panel body 2 is disposed, an advantage that it can be easily recycled or incinerated can be obtained. Moreover, when a polyurethane foam is used as the foam 4, since polyurethane is cheaper than other resins, an advantage that the cost of the panel 1 can be reduced is obtained. Thus, it is particularly advantageous if the resin of the panel body 2 reinforced with fibers is made of polyolefin or polylactic acid and the foam 4 is made of polyurethane foam. However, in the conventional panel, as described above, when the panel body and the foam made of such a material are used, the foam in the panel body does not firmly join the inner surface of the panel body, which causes the rigidity of the panel. There was a risk that it could not be raised as expected. For this reason, conventionally, it has been necessary to apply a primer to the inner surface of the panel main body before injecting the foaming raw material into the panel main body.

  However, since the nonwoven fabric 3 is bonded to the inner surface of the panel body of the panel 1 of this example, the foam 4 foamed in the panel body 2 is firmly bonded to the nonwoven fabric 3 due to the anchor effect of the nonwoven fabric 3, As a result, the foam 4 is firmly fixed to the panel body 2. For this reason, even when a large external force is applied to the panel 1, there is no gap between the inner surface of the panel body 2 and the foam 4, and the rigidity of the panel 1 is effectively increased. Can do. Moreover, in order to firmly bond the foam 4 to the inner surface of the panel body 2, it is not necessary to apply a primer to the inner surface of the panel body 2, and therefore a step of drying the primer when manufacturing the panel 1 is unnecessary. For this reason, the manufacturing process of the panel 1 can be simplified and the cost of the panel 1 can be reduced.

  In the panel 1 shown in FIG. 2, the nonwoven fabric 3 is bonded to the inner surface of the panel body 2. However, even if a woven fabric, a glass fiber mat, or an aramid fiber mat is bonded to the entire inner surface of the panel body 2, The same effects as described above can be achieved. Moreover, when the glass fiber mat is bonded to the inner surface of the panel body 2, the rigidity of the panel 1 is bonded. When the aramid fiber mat is bonded to the inner surface of the panel body 2, the impact strength of the panel 1 is bonded. It can be higher than the case. Two or more of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat can be bonded to the inner surface of the panel body 2. Thus, at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is joined to the inner surface of the panel body 2.

  As described above, by joining at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat to the inner surface of the panel body 2, the panel body 2 made of polyolefin or polylactic acid which is not inherently adhesive. And the polyurethane foam 4 filled therein can be used, whereby the panel body 2 can be easily disposed of, and the cost of the panel 1 can be reduced.

  Further, as described above, since the panel body 2 is made of resin reinforced with fibers, its rigidity and impact resistance are improved, and the rigidity of the panel body at high temperatures is also improved. In particular, when glass fiber, carbon fiber, or wood fiber is used as the fiber that reinforces the resin, the rigidity of the panel body 2 can be greatly improved, so that the panel body 2 can be thinned and reduced in weight. In particular, when an aramid fiber, a nylon fiber or a polyethylene terephthalate fiber is used as a fiber for reinforcing this resin, the impact strength of the panel body 2 can be improved.

  Next, a specific example of the manufacturing method of the panel 1 in which the resin foam 4 is filled in the panel main body 2 as shown in FIG. 2 will be clarified. In this case, the case where the nonwoven fabric 3 is bonded to the inner surface of the panel body 2 will be described here, but the same applies to the case where a woven fabric, a glass fiber mat or an aramid fiber mat is bonded to the inner surface of the panel body 2. 1 can be manufactured.

  FIG. 3 is a cross-sectional view showing an example of a method of filling the foam body 4 in the panel body 2 as shown in FIG. First, as shown to (a) of FIG. 3, the panel main body 2 by which the nonwoven fabric 3 was joined to the inner surface and the inside was formed hollow is prepared. As described above, the panel body 2 is made of a highly rigid resin reinforced with fibers.

Next, as shown in FIG. 3B, the tip of the nozzle 5 is inserted into the hole formed in the panel body 2, and the liquid foaming raw material is injected into the panel body 2 from the tip of the nozzle 5. The foaming raw material is foamed in the panel main body 2, and the panel main body 2 is filled with, for example, polyurethane foam. Chemical reaction type polyurethane foaming by mixing two liquids is performed. At this time, due to the anchor effect of the nonwoven fabric 3, the foam 4 in the panel body 2 is firmly bonded to the inner surface of the panel body 2 via the nonwoven fabric 3. After injecting the foaming raw material into the panel main body 2, the nozzle 5 is extracted, and the hole into which the nozzle 5 is inserted is closed with a softened resin as necessary.

  As described above, a panel made of a resin reinforced with fibers and having a hollow interior, and at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat is bonded to the inner surface. A foaming raw material is injected into the main body, the foaming raw material is foamed in the panel body, and a panel in which a resin foam is filled in the panel body can be manufactured. A panel main body made of a resin reinforced with fibers, and having an interior that is hollow, and at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat joined to the inner surface; and the panel body A panel comprising a foam formed by foaming the foaming material injected into the inside is obtained.

  4 and 5 are cross-sectional views showing an example of a method for manufacturing the panel body 2 in which the nonwoven fabric 3 is bonded to the inner surface, as shown in FIG.

  First, a thermoplastic resin blended with fibers as a reinforcing agent having a length of, for example, 1 mm to 15 mm, preferably 4 mm to 12 mm, is extruded by an extruder (not shown) and shown in FIG. A sheet-like first panel main body base 2A is manufactured. At that time, the nonwoven fabric 3A is joined to one surface of the first panel body base material 2A extruded from the extruder. At this time, the anchor effect of the heated first panel body base material 2A and the nonwoven fabric 3A is obtained. Thus, the two can be firmly joined. It is also possible to join the non-woven fabric 3A to one surface of the first panel body base 2A with an adhesive.

  The first panel main body 2A thus manufactured is placed on the first mold 12 as shown in FIG. 4A in a state where the first panel main body 2A is heated and softened. At this time, the non-woven fabric 3A firmly bonded to the first panel main body 2A faces the opposite side to the first mold 12 so that the first panel main body 2A is first molded. Place on mold 12.

  In the first mold 12 shown here, a hollow chamber 14 is defined in the inside thereof, and a plurality of suction holes 16 are formed in the wall portion constituting the molding surface 15, and through the suction holes 16, The hollow chamber 14 communicates with the outside. After placing the first panel body base material 2A on the first mold 12, the air in the hollow chamber 14 is sucked through the exhaust port 17 formed in the first mold 12, The air in the hollow chamber is exhausted to the outside. Thus, the first panel main body 2A is molded into a shape along the molding surface 15 of the first molding die 12, as shown in FIG. The first panel body base 2A is vacuum formed.

  Next, as shown in FIG. 5A, a sheet-like second panel heated and softened between the first mold 12 and the second mold 18 located above the first mold 12 is provided. The main body base material 2B is disposed. The second panel main body 2B is also made of a thermoplastic resin in which reinforcing fibers having a length of 1 mm to 15 mm, preferably 4 mm to 12 mm, for example, are blended. The second panel body base material 2B is manufactured in the same manner as the first panel body base material 2A, and the nonwoven fabric 3B is firmly bonded to one surface thereof. The second panel body substrate 2B is disposed between the first mold 12 and the second mold 18 so that the nonwoven fabric 3B faces the first mold 12.

  The second molding die 18 also has a hollow chamber 20 defined therein, and a plurality of suction holes 22 are formed in a wall portion constituting the molding surface 21, and the hollow chamber 20 is formed via the suction holes 22. And the outside communicates. The second mold 18 is lowered as shown in FIG. 5B, the molds 12 and 18 are clamped, and the edge portions of the first and second panel body bases 2A and 2B. Are joined together.

  Immediately after the first and second molds 12 and 18 are clamped as described above, the tip of the blow pin 24 made of a hollow thin tube is placed between the first and second panel body bases 2A and 2B. And air is pumped through the blow pin 24 into the space between the first and second panel body bases 2A and 2B. In this way, air is pumped into the space between the first and second panel body bases 2A and 2B, and at the same time, through the exhaust port 23 formed in the second mold 18, the second mold 18 The air in the hollow chamber 20 is sucked and the air is discharged to the outside. Even when the air in the hollow chamber 20 of the second mold 18 is sucked and the air is pumped between the first and second panel body base materials 2A and 2B, the first mold 12 The air in the hollow chamber 14 is continuously sucked. In this way, the first and second panel body base materials 2A and 2B are in close contact with the molding surface 15 of the first molding die 12 and the molding surface 21 of the second molding die 18, respectively. 2nd panel main body base materials 2A and 2B are shape | molded by the shape along the molding surfaces 15 and 21 of the 1st and 2nd shaping | molding die 12 and 18. FIG.

  Next, after the blow pin 24 is extracted from the first panel body base 2A, the first and second molds 12 and 18 are separated from each other, and the molded product is removed from the mold. Subsequently, if the edge of the molded product is trimmed, the panel body 2 constituted by the first and second panel body base materials 2A and 2B is completed, and the first and second panel body bases are formed on the inner surface thereof. A nonwoven fabric 3 made of nonwoven fabrics 3A and 3B joined to the surfaces of the materials 2A and 2B is joined. Thus, the panel main body 2 shown in FIG. 3A is completed, and the panel 1 can be manufactured by filling the foamed body 4 therein as described above. The hole of the 2nd panel main body base material 2A with which the blow pin 24 was fitted may close this, and the above-mentioned nozzle 5 can also be inserted in this hole.

  Moreover, the panel main body 2 can also be manufactured as follows.

  As shown in FIG. 6A, the sheet-like first and second panel body base materials 2A and 2B configured in the same manner as in the example shown in FIGS. These are heated and softened, and the first and second panel body base materials 2A and 2B are formed into first and second molds 12 and 18 configured in the same manner as the molds shown in FIGS. The nonwoven fabrics 3A and 3B are arranged so as to face each other. Next, as shown in FIG. 6 (b), the second mold 18 is lowered and the molds 12 and 18 are clamped to join the edges of these base materials 2A and 2B to each other.

  As described above, immediately after the first and second molds 12 and 18 are clamped, the tip of the blow pin 24 is inserted between the first and second panel body bases 2A and 2B, and the blow pin 24 is inserted. Then, air is pumped between the first and second panel body base materials 2A and 2B. At the same time, the air in the hollow chambers 14 and 20 is discharged to the outside through the exhaust ports 17 and 23 formed in the first and second molds 12 and 18. At this time, since a large number of suction holes 16 and 22 are also formed in the wall portions forming the molding surfaces 15 and 21 of the first and second molding dies 12 and 18, the first and second panel main bodies are formed. As shown in FIG. 6C, the base materials 2A and 2B are vacuum-formed by the first and second forming dies 12 and 18 and simultaneously blow-molded. After that, exactly as in the method shown in FIGS. 4 and 5, the first and second molds 12 and 18 are separated and the molded product is taken out of the mold. In this way, the panel body 2 shown in FIG. 3A can be manufactured.

  According to the method shown in FIG. 6, since the first and second panel body base materials 2A and 2B are blow-molded simultaneously with the vacuum forming, the first and second panel body base materials 2A and 2B can be more accurately formed. The first and second molding dies 12 and 18 can be brought into close contact with the molding surfaces 15 and 21. Further, since the first and second panel body base materials 2A and 2B are overlapped with each other and the panel body base materials 2A and 2B are heated, the panel body base materials 2A and 2B are heated separately. Compared with the case where it does, a manufacturing man-hour can be reduced. At this time, even if the first and second panel body base materials 2A and 2B are superposed and heated, the nonwoven fabrics 3A and 3B exist between the base materials 2A and 2B. The panel body base materials 2A and 2B are not joined by the action of heat.

  The second mold 18 shown in FIG. 6 has a trim blade 25 protruding around the molding surface 15 and when the first and second molds 12 and 18 are clamped, The trim blade 25 is configured to trim the edge portions of the first and second panel body base materials 2A and 2B. The mold shown in FIGS. 4 and 5 can be configured in the same manner.

  Also, as shown in FIG. 6B, when the tip of the blow pin 24 is inserted between the first and second panel body base materials 2A and 2B, the blow pin 24 is softened to the first panel base material. 2A can be broken through, but the nonwoven fabric 3A bonded to the substrate 2A may not be broken through. Also in such a case, since the nonwoven fabrics 3A and 3B have air permeability, air can be pumped between the first and second panel body base materials 2A and 2B without any trouble. This is the same when the method shown in FIGS. 4 and 5 is performed.

  FIGS. 4 to 6 show an example in which the panel body 2 is manufactured by vacuum molding and blow molding, and the panel body 2 is manufactured only by blow molding. It can also be manufactured. Air is pumped between the extrusion-molded first and second panel body bases, and the first and second panel body bases are formed along the molding surfaces of the first and second molding dies, respectively. It is molded into a different shape.

  As described above, the panel body 2 is obtained by molding at least the first and second panel body base materials 2A and 2B obtained by extruding a resin containing a fiber as a reinforcing agent by a blow molding method. As described above, when the first and second panel bodies are formed by extruding the resin in which the fibers are blended, the fibers in the resin are oriented in the extruding direction at the time of the extruding. Accordingly, when an integral hinge is formed on the panel, the oriented fibers in the panel body base materials 2A and 2B are broken at the hinge portion by arranging the hinge in a direction parallel to the extrusion direction. Therefore, the durability of the integral hinge can be improved. Normally, when an integral hinge is provided on a resin product reinforced with fibers, the hinge part is likely to break. However, by extruding the resin filled with the fibers as described above, the integra A hinge can be provided.

  Instead of manufacturing the panel body 2 with a nonwoven fabric by using both the vacuum forming method and the blow molding method, the panel body 2 can also be manufactured by an injection molding method. In this case, first, as shown in FIG. 7A, the non-woven fabric 3C is set on the molding surface of the first mold 30 and then, as shown in FIG. 7B, the first mold 30 and the second molding die 31 are clamped, and a molten thermoplastic resin in which fibers having a length of, for example, 1 mm to 8 mm, preferably 4 mm to 8 mm are blended is injected into the cavity 32. As a result, the first panel body base material 2C shown in FIG. 7C is molded, and the nonwoven fabric 3C is firmly bonded to one surface thereof.

  In exactly the same manner as described above, as shown in FIG. 8A, a second panel body base material 2D in which the nonwoven fabric 3D is firmly bonded to one surface is molded. Next, as shown in FIG. 8B, if the first and second panel body base materials 2C and 2D are aligned and the butted portion 33 is welded, the first and second panel body base materials 2C are obtained. , 2D, and the panel body 2 made of resin reinforced with fibers is completed. A nonwoven fabric 3 made of nonwoven fabrics 3C and 3D is firmly bonded to the inner surface. The panel 1 shown in FIG. 1 and FIG. 2 is completed by filling the inside of the panel body 2 with the foam as described above.

  As mentioned above, although the manufacture example of the panel main body formed by joining a nonwoven fabric to an inner surface was shown, the panel main body formed by joining a woven fabric, a glass fiber mat, or an aramid fiber mat to the inner surface can be manufactured in the same manner as described above. Is as described above.

It is an external appearance perspective view of a panel. It is II-II sectional drawing of FIG. It is sectional drawing which shows a mode when inject | pouring the raw material for foaming into a panel main body. It is sectional drawing which shows the method of manufacturing a panel main body. It is sectional drawing which shows the method of manufacturing a panel main body. It is sectional drawing which shows the other method of manufacturing a panel main body. It is sectional drawing which shows the further another method of manufacturing a panel main body. It is sectional drawing which shows the further another method of manufacturing a panel main body.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Panel 2 Panel main body 2A, 2B Panel main body base material 3 Nonwoven fabric 4 Foam

Claims (5)

A panel main body made of a resin reinforced with fibers and having a hollow interior , and at least one of a nonwoven fabric, a woven fabric, a glass fiber mat, and an aramid fiber mat joined to the inner surface ; and the panel A panel comprising a foam formed by foaming a foaming raw material injected into the main body. The panel according to claim 1, wherein the fiber that reinforces the resin includes at least one of glass fiber, carbon fiber, wood fiber, aramid fiber, nylon fiber, and polyethylene terephthalate fiber . The panel according to claim 1 or 2 , wherein the resin constituting the panel body is made of polyolefin or polylactic acid, and the foam is made of polyurethane foam . 4. The panel body according to claim 1, wherein the panel body is formed by molding at least a first and second panel body base materials obtained by extruding a resin blended with fibers as reinforcing agents by a blow molding method . Panel described in. A raw material for foaming in a panel body made of a resin reinforced with fibers and having a hollow interior and at least one of a nonwoven fabric, a woven fabric, a glass fiber mat and an aramid fiber mat joined to the inner surface Is injected, and the foaming raw material is foamed in the panel body, and the panel body is filled with a resin foam.

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