JP5678406B2 - Resin panel and manufacturing method thereof - Google Patents

Description

  The present invention relates to a resin panel used for a cargo floor panel (a lid panel or a luggage board of an automobile luggage compartment) or a car interior such as a rear parcel shelf or a panel-like building article such as an interior wall partition or a door, and the like. It relates to a manufacturing method.

  Resin hollow molding for interior parts such as decorative panels used in vehicles, etc., with an air layer such as a heat insulating material or a sound absorbing material as an intermediate member of interior parts by seat blow molding, and a reinforcing material such as a steel pipe or a frame A resin panel in which a foam and a reinforcing material are housed in a hollow part of a hollow double wall structure and a molding method thereof are described in Japanese Patent Application Laid-Open Nos. 2008-247003 and 2006-334801. Yes.

JP 2008-247003 A JP 2006-334801 A

  Since the resin molded product described in the above-mentioned Patent Document 1 inserts a reinforcing material together with a foam during the blow molding, a plurality of interior members are provided in the resin hollow molded product. Interior placement and positioning between molds is not easy, the molding accuracy is reduced, the interior member is not fully packed, the backlash does not occur, and the interior does not shrink like a metal reinforcement In the case of members, problems such as increased deformation due to molding shrinkage of resin hollow molded articles have been pointed out.

  Moreover, the resin molded product described in the above-mentioned Patent Document 2 is a reinforcing material formed on a foamed body made of a pre-molded thermoplastic resin as an interior material to be installed at the time of blow molding of the resin molded product. In order to prevent deformation of the foam due to the relationship between the foam that shrinks after blow molding and the reinforcing material that does not shrink, the foam housing Reinforcing material is arranged with play against. For this reason, when inserting at the time of blow molding, or in the process of blow molding, there is a problem that the reinforcing material disposed on the foam causes a misalignment or causes a great cause of molding failure.

Accordingly, the present invention is positioned in the interior material to be decorated is able to accurately, and to obtain a resin panel does not cause deformation due to rattle and molding shrinkage.

The resin panel according to the present invention for achieving the above object is
A resin panel of a hollow double wall structure comprising a front wall, a back wall, and a peripheral wall connecting the front wall and the back wall,
Place a molten parison or resin sheet between the split molds,
A parison or resin sheet is molded along the mold cavity by vacuum or compressed air,
Then, the core material is fitted to both sides of one reinforcing material, and the core material on both sides is connected to each other via the one reinforcing material and arranged in the cavity of the mold. Clamp the mold,
Weld the inner surface of the melted parison or resin sheet and the outer surface of the interior material,
In the hollow part of the hollow double wall structure, the interior material is covered with the front wall formed of the parison or the resin sheet, and the surface of the interior material is covered with the parison or the resin sheet. The back surface of the interior material is covered with the back wall, and the periphery of the interior material is covered with the surrounding wall formed by welding the parisons or the resin sheets. Is.

According to the present invention, it is possible to position the interior material to be decorated is able to accurately obtain the resin panel never deforms by rattle and molding shrinkage.

1 is an overall perspective view of a resin panel according to the present invention and an enlarged cutaway view of a part thereof. It is AA sectional drawing of FIG. It is a fragmentary perspective view which shows the fitting aspect of a foam and a reinforcing material in the resin-made panels shown in FIG. 1 and FIG. It is a perspective view which shows the other example of the fitting aspect of a foam and a reinforcing material. It is a perspective view which shows the further another example of the fitting aspect of a foam and a reinforcing material. It is a perspective view which shows the further another example of the fitting aspect of a foam and a reinforcing material. It is a perspective view which shows the aspect which fits the reinforcing material of a square pipe shape to a foam. It is sectional drawing of the foam shown in FIG. It is a perspective view of the aspect which each fitted the circular pipe-shaped reinforcement material to the both sides and its intermediate part to the foam. It is a side view which shows the other example of the aspect which fitted the circular pipe-shaped reinforcement material to the foam. It is sectional drawing of the aspect which fitted the circular pipe-shaped reinforcement material to the both-sides intermediate part of a foam. It is sectional drawing of the aspect which fitted the H-shaped reinforcement material to the both-sides intermediate part of a foam. It is a perspective view of the aspect which fitted the H-shaped reinforcement material to the both sides of the foam, and the circular pipe-shaped reinforcement material in the intermediate part. It is sectional drawing which shows the blow molding aspect of the resin panels which concern on this invention. It is sectional drawing which shows the state which advanced to the next process from the state of FIG. It is a general | schematic side view which shows the example which used the resin-made panels which concern on this invention as a cargo floor panel (the cover panel or luggage board of a motor vehicle luggage compartment) of a motor vehicle.

  The resin panel according to the present invention is formed by fitting a reinforcing material into a core material made of a thermoplastic resin, which is preliminarily molded in a hollow portion of a hollow double wall structure into a shape substantially the same as the space in the hollow portion. The interior is made of an interior material that is integrated with a reinforcing material. Here, the interior material in which the core material and the reinforcing material are integrated is a state in which the reinforcing material is closely fitted to the core material, and is further in a tightly fitted state. Is a stationary state that cannot be removed carelessly. For this reason, in the interior material according to the present invention, the shrinkage of the core material is absorbed so as to bite into the reinforcing material in the relationship between the blow molding process and the core material that shrinks thereafter and the reinforcing material that does not shrink, There is no inconvenience that the core material is deformed.

  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 for decoration or the like may be attached to the surface of the front wall 2 over the peripheral wall 4. In the hollow portion 5 of the hollow double-wall structure, a reinforcing material 7 is fitted into a core material 6 made of a foam of a thermoplastic resin that is preliminarily molded in the same shape as the space in the hollow portion 5. An interior material 8 in which 6 and the reinforcing material 7 are integrated is provided. The core material 6 may have an appropriate structure such as a honeycomb structure (not shown).

  The reinforcing member 7 is a long shape having the same length as the end of the core member 6 and has a fitting groove 9 extending in the length direction (so-called H-type extrusion reinforcement). These end portions are press-fitted and fitted into the fitting grooves 9 of the reinforcing material 7 to form a single interior material 8 in which the core material 6 and the reinforcing material 7 are integrated. In the embodiment shown in FIG. 1 and FIG. 2, the interior material 8 that is housed in the hollow portion 5 of the hollow double wall structure is connected to each other via the reinforcing material 7 between the plurality of core materials 6 and 6. It's one thing. The reinforcing material 7 is made of metal such as aluminum or hard plastic. In addition to the H-type extrusion reinforcement, the reinforcing material 7 may be any appropriate shape as long as it has a C shape, a U-shape, a square pipe shape, a circular pipe shape, or the like that can be fitted and integrated with the core material 6. .

  When the reinforcing material 7 is an H-type extrusion reinforcement, as shown in FIG. 3, the end of the core material 6 is press-fitted into the fitting groove 9 of the H-type extrusion reinforcement. As shown in A), the fitting groove 9 of the H-type extrusion reinforcement is formed with hook-like portions 10 at both ends or one end thereof, and the core material 6 is formed with the engaging groove 11 of the hook-like portion 10. Then, the coupling state of the core material 6 press-fitted into the fitting groove 9 of the reinforcing material 7 is firmly maintained. Further, as shown in FIG. 3B, a large number of ridges 12 are formed in the longitudinal direction in the fitting groove 9 of the H-type extrusion reinforcement, and the end portion of the core material 6 is lowered by one step. The same applies to the case where the stepped portion 13 is formed. As shown in FIG. 3C, if the notch 14 is provided at the end of the core member 6, even if the reinforcing member 7 is a normal H-type extrusion reinforcement, it is formed in the fitting groove 9 of the reinforcing member 7. The bonded state of the press-fitted core material 6 can be held firmly. As shown in FIG. 3D, an interior material in which an engaging step 15 that is one step lower is formed at the end of the core 6 so that the core 6 and the reinforcing material 7 that is an H-type extrusion reinforcement are on the same plane. 8 can be configured.

  As shown in FIG. 4, the resin panel 1 according to the present invention connects two core materials 6 and 6 with a reinforcing material 7 that is an H-type extrusion reinforcement, and extrudes each end of the core materials 6 and 6. Interior material 8 having a configuration in which reinforcements 7 and 7 which are reinforcements are fitted, and an interior material in which U-shaped reinforcements 16 and 16 are fitted to both ends of one core material 6 as shown in FIG. Further, as shown in FIG. 6, interior material 8 having a configuration in which reinforcing members 7 and 7 which are H-type extrusion reinforcements are fitted to both ends of one core material 6 as shown in FIG. Can do.

  Further, the resin panel 1 according to the present invention can be fitted with a square pipe-shaped reinforcing member 17 as shown in FIG. That is, as shown in FIG. 7A, a protrusion 18 that engages with the reinforcing member 17 in the shape of a square pipe is provided on one end side in the fitting groove 9 of the core member 6 and is shorter than the protrusion 18 on the other end side. As shown in FIG. 7B, one end of a square pipe-shaped reinforcing member 17 is engaged with the projection 18 and pushed into the fitting groove 9 as shown in FIG. The core material 6 and the square pipe-shaped reinforcing material 17 are integrated by engaging. In addition, it can also be set as the structure which fixes the square-pipe-shaped reinforcement 17 by carrying out the back fitting of the stop piece 20 by making the other end side of the fitting groove | channel 9 open.

  In the embodiment shown in FIG. 7, the U-shaped reinforcing members 16, 16 are fitted to both ends of the core member 6 as shown in FIG. 8, and both ends of the core member 6 and the middle thereof as shown in FIG. It can be set as the structure which fitted the circular pipe-shaped reinforcement material 21 to each part, and in this aspect, as shown in FIG. 10, the engagement protrusion 22 provided in the both ends of the part which fits the reinforcement material 21 is shown. The reinforcing material 21 is fitted to and integrated with each other. In this embodiment, as shown in FIG. 11, U-shaped reinforcing members 16 and 16 are fitted to both ends of the core material 6, and both ends of the core material 6 are connected to H as shown in FIG. It is good also as a structure which fitted the reinforcing materials 7 and 7 which are type | mold extrusion reinforcements, Furthermore, as shown in FIG. 13, the reinforcement material 7 which is H type | mold extrusion reinforcements as shown in FIG. Various appropriate modes such as a configuration in which the U-shaped reinforcing members 16 and 16 are fitted to each other can be adopted.

  The resin panel 1 according to the present invention is blow-molded in the manner shown in FIGS. 14 and 15. That is, the melted parison 24 extruded from the resin extrusion head 23 is disposed between the divided molds 25 and 25, and the parison 24 is molded along the mold cavities 26 and 26 by vacuum or compressed air. Next, the reinforcing material 7 is fitted into the core material 6 made of a thermoplastic resin that is preliminarily molded in the same shape as the space in the hollow portion 5, and the interior material 8 in which the core material 6 and the reinforcing material 7 are integrated is obtained. Placed in the cavity 26 of one mold 25, the mold is clamped, the inner surface of the molten parison 24 and the outer surface of the interior material 8 are welded, and the interior material 8 in which the core material 6 and the reinforcing material 7 are integrated. Is obtained. 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). 14 and 15, 27 is a vacuum chamber, 28 is a ventilation contact surface, and 29 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 forming the core member 6 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.

  In the case where a skin material is applied to the surface of the resin panel 1, the skin material is a knitted fabric, a woven fabric, or a nonwoven fabric obtained by processing natural fibers, regenerated fibers, semi-synthetic fibers, synthetic fibers, and fibers made of blends thereof. Or a resin sheet comprising a thermoplastic elastomer (TPE) such as polyvinyl chloride (PVC), a thermoplastic polyurethane elastomer (TPU) or a thermoplastic polyolefin elastomer (TPO), or a thermoplastic resin such as a polyethylene polyolefin resin, and a laminate thereof. It can be appropriately selected from the sheet.

  The main use of the resin panel 1 according to the present invention is a cargo floor panel (a cover panel or a luggage board of an automobile luggage compartment) 31 of an automobile 30 as shown in FIG. 16, but an interior for an automobile such as a rear parcel shelf. In addition to being suitable as a product, it is highly versatile, such as a panel-like building article such as an interior wall partition or a door as a building article.

DESCRIPTION OF SYMBOLS 1 Resin panel 2 Front wall 3 Back wall 4 Peripheral wall 5 Hollow part 6 Core material 7 Reinforcement material which is H-type extrusion reinforcement 8 Interior material 9 Fitting groove 10 Hook-shaped part 11 Engaging groove 12 Many mountain-shaped fine Groove
DESCRIPTION OF SYMBOLS 13 Engagement step 14 Notch 15 Engagement step 16 U-shaped reinforcement 17 Square pipe-shaped reinforcement 18 Protrusion 19 Protrusion 20 Stopping piece 21 Circular pipe-shaped reinforcement 22 Engagement protrusion 23 Resin extrusion head 24 Parison 25 Split mold 26 Cavity 27 Vacuum chamber 28 Venting contact surface 29 Blow pin 30 Car 31 Cargo floor panel

Claims (7)

A resin panel of a hollow double wall structure comprising a front wall, a back wall, and a peripheral wall connecting the front wall and the back wall,
Place a molten parison or resin sheet between the split molds,
A parison or resin sheet is molded along the mold cavity by vacuum or compressed air,
Then, the core material is fitted to both sides of one reinforcing material, and the core material on both sides is connected to each other via the one reinforcing material and arranged in the cavity of the mold. Clamp the mold,
Weld the inner surface of the melted parison or resin sheet and the outer surface of the interior material,
Wherein the hollow portion of the hollow double-walled structure, the interior material is said parison or surface of the interior material in the resin sheet formed Table wall is covered, it is formed in the parison or the resin sheet The back surface of the interior material is covered with the back wall, and the periphery of the interior material is covered with the surrounding wall formed by welding the parisons or the resin sheets. Resin panel. A resin panel of a hollow double wall structure comprising a front wall, a back wall, and a peripheral wall connecting the front wall and the back wall,
In the hollow portion of the hollow double wall structure, an interior material in which the core material and the reinforcing material are integrated by being fitted with a reinforcing material is incorporated,
The reinforcing member has a long fitting groove into which an end of the core member is press-fitted, and the reinforcing member and the core member are coupled to the fitting groove or the end of the core member. A holding part for holding
The resin panel according to claim 1, wherein the holding portion includes a hook-shaped portion formed at least at one end of the fitting groove. A resin panel of a hollow double wall structure comprising a front wall, a back wall, and a peripheral wall connecting the front wall and the back wall,
In the hollow portion of the hollow double wall structure, an interior material in which the core material and the reinforcing material are integrated by being fitted with a reinforcing material is incorporated,
The reinforcing member has a long fitting groove into which an end of the core member is press-fitted, and the reinforcing member and the core member are coupled to the fitting groove or the end of the core member. A holding part for holding
The resin panel according to claim 1, wherein the holding portion includes a plurality of narrow grooves formed in the fitting groove. A resin panel of a hollow double wall structure comprising a front wall, a back wall, and a peripheral wall connecting the front wall and the back wall,
In the hollow portion of the hollow double wall structure, an interior material in which the core material and the reinforcing material are integrated by being fitted with a reinforcing material is incorporated,
The reinforcing member has a long fitting groove into which an end of the core member is press-fitted, and the reinforcing member and the core member are coupled to the fitting groove or the end of the core member. A holding part for holding
The resin panel, wherein the holding portion has a notch for holding the joined state of the reinforcing material and the core material at an end of the core material. A resin panel of a hollow double wall structure comprising a front wall, a back wall, and a peripheral wall connecting the front wall and the back wall,
In the hollow part of the hollow double wall structure, a reinforcing material is fitted into a core material, and an interior material in which the core material and the reinforcing material are integrated is incorporated,
A resin panel, wherein both ends of the reinforcing member in the longitudinal direction are fitted to the core member. In the method of manufacturing a resin panel having a front wall, a back wall, and a hollow double wall structure comprising a peripheral wall connecting the front wall and the back wall,
Place a molten parison or resin sheet between the split molds,
A parison or resin sheet is molded along the mold cavity by vacuum or compressed air,
Then, one of the interior material in which the core on both sides by the core member is fitted is integrated by connecting with each other through one of the reinforcing material on opposite sides of the reinforcing material is placed in a mold cavity Mold clamping
A method for producing a resin panel, comprising: welding an inner surface of a molten parison or resin sheet and an outer surface of the interior material. Manufacture of a resin panel having a hollow double wall structure comprising a front wall, a back wall, and a peripheral wall connecting the front wall and the back wall, and an interior material in which a core material and a reinforcing material are integrated. In the method
Place a molten parison or resin sheet between the split molds,
A parison or resin sheet is molded along the mold cavity by vacuum or compressed air,
Next, the both ends of the reinforcing material in the longitudinal direction are fitted to the core material, and the interior material in which the core material and the reinforcing material are integrated is placed in a cavity of a mold and clamped,
A method for producing a resin panel, comprising: welding an inner surface of a molten parison or resin sheet and an outer surface of the interior material.

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