JP5730043B2 - Resin molded body and manufacturing method thereof - Google Patents

Description

  The present invention relates to a resin molded body and a method for producing the same, and more specifically, enables a resin molded body with an internal foam to be fixed via a screw receiving material having a hollow hole in its thickness direction. Therefore, it is suitable for mounting a foam insulation panel.

  In recent years, resin foam panels have been attached to walls, floors, and ceilings for the purpose of maintaining comfortable indoor temperatures, increasing the air-conditioning effect, and improving sound absorption in buildings such as houses. The resin foam panel is directly fixed to the floor material of the building, the wall material, the pillar, the stud, the joist, and the structural plywood fastened to them by a nail or a screw.

  Since the insulation panel is made of foamed resin, it is compressed and pinched when nails or screws are driven in, so it cannot be firmly fixed, and especially when used under the floor, it is a repeated load for people to repeatedly step on it. As a result, the fixation may be loosened over time.

  For example, Patent Document 1 proposes a structure in which a foamed resin layer and a thermoplastic resin layer are integrally molded and fixed to a support leg with a screw through a screw hole penetrating in the thickness direction of the floor panel. . Moreover, in patent document 2, the fixing head for fixing the screw head concerning a soft material and the hard material is utilized using a two-stage screw as a fixing method of the heat insulation board which laminated | stacked the soft material and the hard material. Suggests a way to fix it.

JP 2010-163758 A Japanese Patent Laid-Open No. 11-14002

  In Patent Document 1, since the foamed resin layer having low compression rigidity is screwed in between, it is difficult to fix firmly and the screws are likely to loosen over time. Moreover, in patent document 2, you must use the thing with the same space | interval of the fixed head for fixing the screw head concerning the soft material of a two-stage screw, and a hard material with respect to the thickness of a soft material. Each time the thickness of the heat insulation board changes, there is an inconvenience that a corresponding two-stage screw must be prepared.

  In view of such technical problems, an object of the present invention is to provide a foam that can be easily and reliably fixed to a flooring, a wall material, a pillar, a stud, a joist, or a structural plywood using a conventional screw without slack. An object of the present invention is to provide an internal resin molded body and a method for producing the resin molded body.

A resin molded body according to the present invention for solving the above-mentioned problems is a resin molded body with a foam incorporated therein, the foam having a screw receiving material insertion hole penetrating in the thickness direction, and the screw having a hollow hole. A screw receiving material held in the receiving material insertion hole, the screw receiving material is provided with flanges at both ends, and these flanges form the surface material of the resin molded body together with the foam and the other resin wall Each screw hole is welded to the inner surface of the wall and the hollow hole of the screw receiving member has a stepped portion projecting to the inner surface. The head of the screw inserted into the hollow hole is caught by the stepped portion, so that the forward movement of the screw is suppressed. it is characterized in that that.

And the screw receiving material in the said structure has a substantially cylindrical trunk | drum, and it is suitable for the said trunk | drum to be formed with the rotation stopper which protruded radially.

The method for producing a resin molded body according to the present invention is a method for molding a resin molded body in which a foam is embedded, and a step of arranging two molten thermoplastic resin sheets between a pair of split molds, A step of inserting a screw receiving material having a hollow hole in which at least a part of its inner diameter is reduced by a stepped portion into a screw receiving material insertion hole formed so as to penetrate the foam in the thickness direction ; A step of disposing a foam in which a screw receiving material is inserted between two thermoplastic resin sheets, the thermoplastic resin sheet and the foam are fused by mold clamping, and the two thermoplastic resin sheets are bonded to the outer periphery of the foam In which a foam is internally attached and a flange provided on a screw receiving material is welded to the inner surface of one resin wall and the inner surface of the other resin wall which form the surface material of the resin molded body together with the foam. With features That.

  ADVANTAGE OF THE INVENTION According to this invention, the resin molding which equipped the foam which can be fixed to a flooring, a wall material, a pillar, a stud, a joist, or a structural plywood easily and reliably without using a slack can be obtained. .

It is a fragmentary sectional view of a resin fabrication object concerning an embodiment of the present invention. It is a perspective view of the screw receiving material which concerns on embodiment of this invention. (A) is a top view of the screw receiving material which concerns on embodiment of this invention, (b) is the fragmentary sectional view in the bb line | wire shown to (a), (c) is shown to (a). It is the fragmentary sectional view in line cc, (d) is a bottom view. It is a figure which shows the state by which the molten resin sheet was arrange | positioned between the division molds with the shaping | molding apparatus which concerns on embodiment of this invention. It is a figure which shows the state which is making the outer frame of a division mold contact the side surface of a molten resin sheet in the shaping | molding apparatus which concerns on embodiment of this invention. It is a figure which shows the state which is shaping the molten resin sheet in the shaping | molding apparatus which concerns on embodiment of this invention. It is a figure which shows the state which clamped the division mold in the shaping | molding apparatus which concerns on embodiment of this invention. In the molding apparatus which concerns on embodiment of this invention, it is a figure which shows the state which opened the split mold.

An embodiment of a resin molded body 100 according to the present invention will be described below in detail with reference to the drawings.
As shown in FIG. 1, the resin molded body 100 includes a foam 122 having a screw receiving material insertion hole 121, a resin wall 124 fused to the entire outer surface 123 of the foam 122, and a screw receiving material insertion hole 121. And a screw receiving member 125 held on the surface.

  The peripheral edges of the resin wall 124 composed of one resin wall 124a and the other resin wall 124b are formed with edges 127A and 127B that are curved toward the resin wall facing each other, and end peripheral surfaces 128 of the edges 127A and 127B. The peripheral walls 129 are configured by abutting each other. The screw receiving material insertion hole 121 of the foam 122 penetrates in the thickness direction of the foam 122, and the screw receiving material 125 is held in the screw receiving material insertion hole 121. Flange 104 is formed at both longitudinal ends of screw receiving member 125, flange 104a is fused to the inner surface of one resin wall 124a, and flange 104b is fused to the inner surface of the other resin wall 124b.

  The plurality of screw receiving member insertion holes 121 provided in the foam body 122 penetrates perpendicularly to the thickness direction of the foam body 122, and the diameter thereof is the same as or smaller than the diameter of the body portion 133 of the screw receiving material 125. Preferably, it may be created by molding in the manufacturing process of the foam 122 or may be created by secondary processing such as punching or cutting after manufacturing.

For the foam 122, thermoplastic resins such as polyolefin resin, polystyrene, polycarbonate, ABS resin, and mixtures thereof, and thermosetting resins such as phenol resin, melamine resin, epoxy resin, and polyurethane can be used. The expansion ratio or the thickness of the foam 122 may be determined from the viewpoint of heat insulation performance and soundproofing / sound absorption performance required in the specification application. For example, the expansion ratio is 5 to 50 times and the thickness is about 10 to 100 mm. .
As the foaming agent, any of physical foaming agents, chemical foaming agents and mixtures thereof may be used.
As physical foaming agents, inorganic physical foaming agents such as air, carbon dioxide, nitrogen gas, and water, and organic physical foaming agents such as butane, pentane, hexane, dichloromethane, dichloroethane, and their supercritical fluids are used. be able to.

  As shown in FIGS. 1 to 3, the screw receiving member 125 is provided with a hollow hole 105 penetrating in the length direction and having a stepped portion 103 in the middle. The step portion 103 is for adjusting the screwing amount when the screw is screwed. When the screw 107 inserted into the hollow hole 105 is screwed, the head portion of the screw 107 is located at the position of the step portion 103. The portion 108 is caught by the protruding portion of the stepped portion, and further advancement of the screw is prevented. The hole diameter of the hollow hole 105 is changed with the step portion 103 as a boundary. The diameter of the screw insertion port 132 side is larger than the diameter of the head portion 108 of the screw 107, and the other is the screw portion 109 of the screw 107. The diameter is larger than the diameter and smaller than the diameter of the head 108. In the screw receiving material 125 shown in FIGS. 1 to 3, the step portion 103 is described as being formed continuously around the entire inner surface of the hollow hole 105 of the screw receiving material 125. The forward movement of the screw 107 only has to be suppressed by being caught, and a plurality can be intermittently formed in the circumferential direction of the inner surface of the hollow hole 105.

  An anchor hole 130 is provided in the flange 104 of the screw receiving member 125. When the inner wall of the resin wall 124 melted in the manufacturing process described later enters the anchor hole 130 and solidifies, the resin wall 124 and the screw are fixed. It is possible to increase the welding strength of the receiving material 125 and prevent the screw receiving material 125 from rotating when the screw 107 is screwed together. Furthermore, it is also possible to obtain the same effect by providing the surface of the flange 104 in place of the anchor hole 130 with a textured surface or a fine uneven shape.

  Further, as shown in FIG. 2, the outer surface of the screw receiving member 125 is a thin plate or triangular section arranged in the same direction as the hollow hole 105, and the distance from the central axis CL to the apex of the hollow hole 105 is the screw receiving A plurality of rotation stoppers 131 larger than the diameter of the material insertion hole 121 are provided, and rotation stoppers 131a, b, c, d projecting radially from the body portion 133 of the screw receiving material 125 when inserted into the screw receiving insertion hole 121. There is an effect of preventing the screw receiving member 125 from rotating in the screw receiving member insertion hole 121 when the foam member 122 bites into the floor member 106 with the screw 107.

  On the other hand, the material of the resin wall 124 is formed by a thermoplastic resin sheet formed from an olefin resin such as polypropylene, engineering plastics, or the like. More specifically, as will be described later, the resin wall 124a and the resin wall 124b are formed by dripping molten thermoplastic resin sheets P1 and P2, and the thermoplastic resin sheets P1 and P2 are drawn down. It is preferable to use a resin material having a high melt tension from the viewpoint of preventing variation in thickness due to neck-in, etc., while high fluidity in order to improve transferability to the mold and followability. It is preferable to use a resin material.

  More specifically, it is a polyolefin (eg, polypropylene, high density polyethylene) which is a homopolymer or copolymer of olefins such as ethylene, propylene, butene, isoprene, pentene, methylpentene, etc. Measured according to JIS K-7210 at a test temperature of 230 ° C. and a test load of 2.16 kg) of 3.0 g / 10 min or less, more preferably 0.3 to 1.5 g / 10 min, or acrylonitrile butadiene Amorphous resin such as styrene copolymer, polystyrene, high-impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), and MFR at 200 ° C. (test temperature according to JIS K-7210) Measured at 200 ° C. and a test load of 2.16 kg) is 3.0 to 60 g / 10 Min, more preferably 30 to 50 g / 10 min and a melt tension at 230 ° C. (using a melt tension tester manufactured by Toyo Seiki Seisakusho Co., Ltd., a preheating temperature of 230 ° C., an extrusion rate of 5.7 mm / min, and a diameter of 2.095 mm) The strand is extruded from an orifice having a length of 8 mm and the tension when the strand is wound around a roller having a diameter of 50 mm at a winding speed of 100 rpm) is 50 mN or more, preferably 120 mN or more.

  Further, in order to prevent the thermoplastic resin sheets P1 and P2 from being cracked by impact, it is preferable that a hydrogenated styrene thermoplastic elastomer is added in an amount of less than 30 wt%, preferably less than 15 wt%. . Specifically, a styrene-ethylene / butylene-styrene block copolymer, a styrene-ethylene / propylene-styrene block copolymer, a hydrogenated styrene-butadiene rubber and a mixture thereof are suitable as the hydrogenated styrene-based thermoplastic elastomer. The styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to JIS K-7210) is 1.0 to 10 g / 10. Minute, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more.

  Furthermore, the thermoplastic resin sheets P1 and P2 may contain an additive. Examples of the additive include inorganic fillers such as silica, mica, talc, calcium carbonate, glass fiber, and carbon fiber, and plasticizer. , Stabilizers, colorants, antistatic agents, flame retardants, foaming agents and the like. Specifically, silica, mica, glass fiber or the like is added in an amount of 50 wt% or less, preferably 10 to 30 wt% with respect to the molding resin.

  The screw receiving material 125 may be a thermoplastic resin such as polyolefin resin, polystyrene, polycarbonate, ABS resin, and a mixture thereof, or a thermosetting resin, but it is preferable that the screw receiving material 125 is firmly fused to the inner wall of the resin wall 124. In the manufacturing process described later, the surface of the flange 104 is softened and melted by the amount of heat of the thermoplastic resin sheet P, and can be firmly fixed by being welded to the thermoplastic resin sheet P and cooled. Therefore, a thermoplastic resin is preferable, and by using the same material as that of the resin wall 124, it is possible to fix the resin more firmly.

  Next, the manufacturing method of the resin molding 100 according to the present embodiment will be described in detail below. First, the manufacturing apparatus of the resin molding 100 is demonstrated below.

  As shown in FIG. 4, the molding device for the resin molded body 100 includes an extrusion device 12 and a mold clamping device 10 disposed below the extrusion device 12, and the molten heat extruded from the extrusion device 12. The resin wall 124 is formed by feeding the plastic resin sheet P to the mold clamping device 10 and molding the molten thermoplastic resin sheet P by the mold clamping device 10. Here, since the apparatuses for extruding each of the two thermoplastic resins and sending them to the mold clamping apparatus 10 are the same, only one of them will be described, and the other will be described with the same reference numerals. Omitted.

  The extruding device 12 is a conventionally known type, and a detailed description thereof is omitted. However, a cylinder 18 provided with a hopper 16, a screw (not shown) provided in the cylinder 18, and a screw are connected to the screw 18. The hydraulic motor 20, an accumulator 22 that communicates with the inside of the cylinder 18, and a plunger 24 provided in the accumulator 22, and a resin pellet introduced from the hopper 16 is screwed into the cylinder 18 by the hydraulic motor 20. The molten resin is melted and kneaded by the rotation of the resin, and the molten resin is transferred to the accumulator chamber 22 and stored in a certain amount. The plunger 24 is driven to feed the molten resin toward the T die 28, and through the extrusion slit 34, continuous heat A pair of rollers in which the plastic resin sheet P is extruded and spaced from each other 0 while clamped sent out downward by being suspended between the split mold blocks 32. Thereby, as will be described in detail later, the thermoplastic resin sheet P is disposed between the split molds 32 in a state of having a uniform thickness in the vertical direction (extrusion direction).

The extrusion capability of the extrusion device 12 is appropriately selected from the viewpoint of the size of the resin molded product to be molded, the draw-down of the thermoplastic resin sheet P, or the prevention of neck-in occurrence. More specifically, from a practical point of view, the extrusion amount of one shot in intermittent extrusion is preferably 1 to 10 kg, and the extrusion rate of the resin from the extrusion slit 34 is several hundred kg / hour or more, more preferably 700 kg / hour or more. Further, from the viewpoint of preventing the draw-down of the thermoplastic resin sheet P or the occurrence of neck-in, the extrusion process of the thermoplastic resin sheet P is preferably as short as possible, depending on the type of resin, MFR value, and melt tension value. In general, the extrusion process should be completed within 40 seconds, more preferably within 10 to 20 seconds. For this reason, the unit area and the amount of extrusion per unit time from the extrusion slit 34 of the thermoplastic resin are 50 kg / hour cm ² or more, more preferably 150 kg / hour cm ² or more.

  By feeding the thermoplastic resin sheet P sandwiched between the pair of rollers 30 by the rotation of the pair of rollers 30 downward, the thermoplastic resin sheet P can be stretched and thinned, and extruded thermoplastic. By adjusting the relationship between the extrusion speed of the resin sheet P and the feed speed of the thermoplastic resin sheet P by the pair of rollers 30, it is possible to prevent the occurrence of drawdown or neck-in. It is possible to reduce the restrictions on the type, in particular the MFR value and the melt tension value, or the extrusion rate per unit time.

  As shown in FIG. 4, the extrusion slit 34 provided in the T die 28 is arranged vertically downward, and the continuous thermoplastic resin sheet P extruded from the extrusion slit 34 is suspended from the extrusion slit 34 as it is, It is sent vertically downward. The extrusion slit 34 can change the thickness of the continuous thermoplastic resin sheet P by making the interval variable.

  The pair of rollers 30 will be described. In the pair of rollers 30, the rotation axes of the pair of rollers 30 are arranged substantially horizontally in parallel with each other, one is the rotation drive roller 30A, and the other is driven to rotate. The roller 30B. More specifically, as shown in FIG. 4, the pair of rollers 30 are arranged so as to be line-symmetric with respect to the thermoplastic resin sheet P extruded in a form that hangs downward from the extrusion slit 34.

The diameter of each roller and the axial length of the roller may be appropriately set according to the extrusion speed of the thermoplastic resin sheet P to be molded, the length and width of the sheet in the extrusion direction, the type of resin, and the like. As will be described later, from the viewpoint of smoothly feeding the thermoplastic resin sheet P downward by rotation of the roller with the thermoplastic resin sheet P sandwiched between the pair of rollers 30, the diameter of the rotational drive roller 30A Is preferably slightly larger than the diameter of the driven roller 30B. The diameter of the roller is preferably in the range of 50 to 300 mm, and the thermoplastic resin sheet P wraps around the roller even when the roller curvature is too large or too small in contact with the thermoplastic resin sheet P. It causes a malfunction.
On the other hand, the mold clamping device 10 is also a conventionally known type like the extrusion device 12, and detailed description thereof will be omitted, but the two divided molds 32A and 32B and the molds 32A and 32B are melted. And a mold driving device that moves between an open position and a closed position in a direction substantially perpendicular to the supply direction of the thermoplastic resin sheet P.

  As shown in FIG. 4, the two divided molds 32 </ b> A and 32 </ b> B are arranged with the cavities 116 facing each other, and the cavities 116 are arranged so as to face substantially vertically. Concavities and convexities 119 are provided on the surface of each cavity 116 according to the outer shape and surface shape of a molded product formed based on the molten thermoplastic resin sheet P.

  In each of the two divided molds 32A and 32B, a pinch-off part 118 is formed around the cavity 116. The pinch-off part 118 is formed in an annular shape around the cavity 116, and the opposing molds 32A and 32B are formed. Protrusively toward. As a result, when the two divided molds 32A and 32B are clamped, the tip portions of the respective pinch-off portions 118 come into contact with each other and parting around the peripheral edges of the two molten thermoplastic resin sheets P1 and P2 It welds so that line PL may be formed.

  A mold 33A is slidably fitted on the outer periphery of the mold 32A so as to be slidable in a sealed state, and the mold 33A can be moved relative to the mold 32A by a mold moving device (not shown). . More specifically, the mold frame 33A can be brought into contact with the side surface of the thermoplastic resin sheet P1 disposed between the molds 32A and 32B by projecting toward the mold 32B with respect to the mold 32A. is there. Similarly, a mold 33B is provided for the mold 32B.

The mold driving device is the same as the conventional one, and the description thereof is omitted. However, the two divided molds 32A and 32B are respectively driven by the mold driving device and are divided into two in the open position. Two molten thermoplastic resin sheets P can be arranged between the molds 32A and 32B, and the pinch-off portions 118 of the two divided molds 32A and 32B come into contact with each other in the closed position. The annular pinch-off portions 118 are in contact with each other so that a sealed space is formed in the two divided molds 32A and 32B. Regarding the movement of the molds 32A and 32B from the open position to the closed position, the closed position, that is, the position where the pinch-off portions 118 abut each other is between the two continuous thermoplastic resin sheets P1 and P2 in the molten state. The molds 32A and 32B are driven at the same distance from the two thermoplastic resin sheets P1 and P2 and moved toward the positions by the mold driving device.
Note that the extrusion device and the pair of rollers for one continuous thermoplastic resin sheet P1 and the extrusion device and the pair of rollers for the other continuous thermoplastic resin sheet P2 are arranged symmetrically with respect to this closed position. Has been.

As shown in FIG. 6, a vacuum suction chamber 80 is provided inside the divided mold 32 </ b> A, and the vacuum suction chamber 80 communicates with the cavity 116 </ b> A through the suction hole 82, and the suction hole 82 is opened from the vacuum suction chamber 80. By sucking through, the thermoplastic resin sheet P1 is adsorbed toward the cavity 116A and shaped into a shape along the outer surface of the cavity 116A. More specifically, the outer surface 117 of the thermoplastic resin sheet P1, which is the material of the one resin wall 124a, is shaped by the unevenness 119 provided on the outer surface 123 of the cavity 116A. The thermoplastic resin sheet P2 is shaped similarly.
On the other hand, a conventionally known blow pin (not shown) is applied to the divided mold 32B so that when the molds 32A and 32B are clamped, blowing pressure can be applied from within the sealed space formed by both molds. ) Is installed.

A method for manufacturing the resin molded body 100 using the molding apparatus 10 for the resin molded body 100 having the above configuration will be described below with reference to the drawings.
A foam 122 having a screw receiving material insertion hole on the inner surface 120 is molded in advance, and a screw receiving material 125 is prepared.

More specifically, the production of the foam 122 will be described. For example, a polyolefin resin is supplied to an extruder (not shown), kneaded while being heated and melted, and then a predetermined amount of foaming agent is added. Further, the mixture is kneaded to obtain a foamed molten resin, and the foamed molten resin is filled into an accumulator (not shown) while maintaining the resin temperature suitable for foaming and a pressure at which the foamed molten resin does not start foaming. Next, by pushing the ram (not shown) of the accumulator with the gate at the die tip of the extrusion head open, the foamed molten resin is opened to the low pressure region, and the foamed cylindrical parison is formed. . For example, this cylindrical parison is disposed between a pair of molds, the pair of molds are clamped, and the foam 122 can be molded by applying pressure from the inside.
The foam 122 may be formed by a known manufacturing method using polystyrene foam beads.

  Next, the screw receiving material 125 is inserted into the screw receiving material insertion hole 121 provided in the foam 122 and integrated as the interior body 140.

  Next, in FIG. 4, a predetermined amount of the melt-kneaded thermoplastic resin is stored in the accumulator 22, and the stored thermoplastic resin is discharged from the extrusion slits 34 provided at predetermined intervals on the T die 28. In this case, the thermoplastic resin swells and is extruded at a predetermined extrusion speed with a predetermined thickness so as to hang downward into a molten sheet.

  Subsequently, the pair of rollers 30 is moved to the open position, and the gap between the pair of rollers 30 arranged below the extrusion slit 34 is expanded from the thickness of the thermoplastic resin sheet P, thereby being extruded in a molten state. The lowermost part of the thermoplastic resin sheet P is smoothly supplied between the pair of rollers 30. In addition, the timing which expands the space | interval of the rollers 30 from the thickness of the sheet | seat P made from a thermoplastic resin may be performed at the time of the completion | finish of secondary shaping | molding for every one shot not after an extrusion start.

  Next, the pair of rollers 30 are moved close to each other and moved to the closed position, the interval between the pair of rollers 30 is narrowed to sandwich the thermoplastic resin sheet P, and the thermoplastic resin sheet P is moved downward by the rotation of the rollers. Send it out.

  Next, as shown in FIG. 4, the thermoplastic resin sheet P having a uniform thickness in the extrusion direction is disposed between the divided molds 32 </ b> A and 32 </ b> B disposed below the pair of rollers 30. Thereby, the thermoplastic resin sheet P is positioned in a form that protrudes around the pinch-off portion 118.

The above process is performed for each of the two thermoplastic resin sheets P1 and P2, and the thermoplastic resin sheet P2 that is the material of the upper surface skin sheet 124A and the thermoplastic material that is the material of the lower surface skin sheet 124B. The resin sheet P1 is disposed between the divided molds 32A and 32B in a state of being spaced apart from each other.
In this case, the two thermoplastic resin sheets P1 and P2 are arranged between the divided molds 32A and 32B by adjusting the distance between the extrusion slits 34 or the rotational speed of the pair of rollers 30 independently of each other. It is possible to adjust the thickness when being applied.

  Next, as shown in FIG. 5, the mold 33A is made of the thermoplastic resin facing the mold 32A toward the thermoplastic resin sheet P1 which is the material of the lower surface skin sheet 124B with respect to the mold 32A. The sheet P1 is moved until it hits the outer surface 117 of the sheet P1. Similarly, the mold 33B is moved until it contacts the outer surface 117 of the thermoplastic resin sheet P2.

  Next, as shown in FIG. 5 and FIG. 6, the mold 116A includes the cavity 116A, the inner peripheral surface 102 of the mold 33A, and the outer surface 117 of the thermoplastic resin sheet P1 facing the mold 32A. The thermoplastic resin sheet P1 is pressed against the cavity 116A by being sucked from the vacuum suction chamber 80 through the suction hole 82 through the one sealed space 84, so that the thermoplastic resin has a shape along the uneven surface of the cavity 116A. The sheet P1 is shaped. The thermoplastic resin sheet P2 is similarly sucked and shaped.

  Next, as shown in FIG. 6, the preformed interior body 140 is placed between the divided molds 32 and pressed against the thermoplastic resin sheet P <b> 1 to be welded. The interior body 140 is adsorbed by, for example, using a known adsorption type manipulator and placing it between the split molds 32 while adsorbing and holding the side surface of the interior body 140 and welding it to the thermoplastic resin sheet P1. The type manipulator may be detached from the interior body 140 and retracted from between the split molds 32.

  Next, as shown in FIG. 7, the thermoplastic resin sheets P1 and P2 are sucked and held with the molds 33A and 33B contacting the outer surfaces 117 of the thermoplastic resin sheets P1 and P2 held in their positions. However, the molds 32A and 32B are moved toward each other until the respective annular pinch-off portions 118A and B contact each other. In this case, the contact position in the mold clamping direction between the pinch-off portions 118A and 118B is between the two thermoplastic resin sheets P1 and P2 that are spaced apart from each other. As shown in FIG. By contacting B with each other, the two thermoplastic resin sheets P1 and P2 are welded and fixed to each other's peripheral edge portions 126, and the inner body 140 is arranged inside, so that the peripheral edge of the thermoplastic resin sheet is arranged. While forming the sealed peripheral wall 129, the lower surface side skin material sheet 124b and the upper surface side skin material sheet 124a are welded to the interior body 140, respectively.

  Next, the thermoplastic resin sheets P1 and P2 are pressurized through the second sealed space 86 formed inside by the mold 32A and the mold 32B, and the thermoplastic resin from the mold 32A side through the first sealed space 84. The manufactured sheet P1 is continuously sucked. Similarly, the thermoplastic resin sheet P2 is sucked.

  Next, as shown in FIG. 8, the divided molds 32A and B are opened, the molded thin resin panel 100 is taken out, and the burr portions B outside the pinch-off portions 118A and B are cut and molded. Is completed.

  As described above, each time the molten resin is intermittently extruded in the primary molding, the sheet-like thin resin panel 100 can be molded one after another by repeating the above-described steps. The thermoplastic resin is intermittently extruded as a melted thermoplastic resin sheet P by extrusion molding, and the thermoplastic resin sheet P extruded by secondary molding (blow molding or vacuum molding) is molded using a mold. Is possible.

  FIG. 1 shows a state in which the resin molded body 100 manufactured as described above is used as a heat insulating lid in an underfloor storage or an underfloor inspection port used in a house. More specifically, FIG. The resin molded body is fixed by 107.

  More specifically, the resin molded body is fixed to the flooring material using the hollow hole 105 with the stepped portion 103 of the screw receiving material 125 of the resin molded body 100, so that the foam alone or the foam with the skin is directly fixed. As compared with the case where the screw is fixed to the floor material 106, the screw receiving member 125 having a shaft shape that is rigid in the tightening direction of the screw can be used to fix it more firmly and without slack.

P Thermoplastic resin sheet PL Parting line CL Center shaft 10 Mold clamping device 12 Extrusion device 16 Hopper 18 Cylinder 20 Hydraulic motor 22 Accumulator 24 Plunger 28 T die 30 Roller 32 Divided mold 33 Mold frame 34 Extrusion slit 80 Vacuum suction Chamber 82 Vacuum suction hole 84 First sealed space 86 Second sealed space 100 Resin molded body 102 Screw hole 103 Step portion 104 Flange 105 Hollow hole 106 Floor material 107 Screw 108 Head portion 109 Screw portion 116 Cavity 117 Outer surface 118 Pinch-off portion 119 Unevenness 121 Screw receiving material insertion hole 122 Foam 123 Outer surface 124 Resin wall 125 Screw receiving material 126 Peripheral portion 127 Edge 128 End peripheral surface 129 Peripheral wall 130 Anchor hole 131 Anti-rotation 132 Screw insertion port 133 Body 140 inner body

Claims (3)

In the resin molded body in which the foam is embedded, the foam has a screw receiving material insertion hole penetrating in the thickness direction, and a screw receiving material having a hollow hole and held in the screw receiving material insertion hole,
The screw receiving material is provided with flanges at both ends, and these flanges are welded to the inner surface of one resin wall and the inner surface of the other resin wall that form the surface material of the resin molded body together with the foam,
A resin having a stepped portion projecting from the inner surface of the hollow hole of the screw receiving member, and the head of the screw inserted into the hollow hole is caught by the stepped portion, so that the advancement of the screw is suppressed. Molded body.   The resin molded body according to claim 1, wherein the screw receiving member has a substantially cylindrical body portion, and a rotation stop projecting radially is formed on the body portion. A method of molding a resin molded body in which a foam is embedded, a step of arranging two molten thermoplastic resin sheets between a pair of split molds, a screw formed so as to penetrate the foam in the thickness direction A step of inserting a screw receiving material having a hollow hole having at least a part of the inner diameter reduced by a stepped portion into the receiving material insertion hole and having flanges at both ends; and a screw receiving material between the two thermoplastic resin sheets The step of arranging the inserted foam, the thermoplastic resin sheet and the foam are fused by mold clamping, the two thermoplastic resin sheets are fused on the outer periphery of the foam, and the foam is embedded and screw receiving A method for molding a resin molded body, comprising: a step of welding a flange provided on a material to one inner surface of the resin wall and the other inner surface of the resin wall, which form a surface material of the resin molded body together with the foam .

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