JP5946305B2 - 中空構造板の製造方法及び製造装置 - Google Patents
中空構造板の製造方法及び製造装置 Download PDFInfo
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
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- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Description
この中空構造板の製造方法では、前記成形シートを、中空凸部の先端部のみ加熱し、その他の部分は冷却することができる。
また、前記一体化する工程では、前記成形シートの幅方向両端部を、幅方向中心部よりも高熱量で加熱してもよい。
更に、前記一体化する工程により得た中間体の温度に基づいて、前記成形シートの加熱温度を調節することもできる。
この中空構造板の製造装置では、前記熱風発生機の前記成形シートに形成された各中空凸部と整合する位置に、熱風吹出口が設けられていてもよい。その場合、前記熱風吹出口をスリット状とすることができる。
また、前記熱風発生機は、前記成形シートの幅方向で加熱温度が分割制御可能となっていてもよい。ここで、「分割制御可能」とは、幅方向の位置によって、加熱温度などを個別に変更し、制御できることをいう。
更に、この中空構造板の製造装置には、2枚の成形シートを一体化して得られた中間体の温度を測定する温度測定器と、前記中間体の温度に基づいて、前記成形シートの加熱温度を調節する加熱温度調節部とを設けることができる。
先ず、本発明の第1の実施形態に係る中空構造板の製造方法について説明する。図1は本発明の実施形態に係る中空構造板の製造方法を示すフローチャート図であり、図2はその際使用する製造装置の概念図である。また、図3は本実施形態の製造方法により製造される中空構造板の構成を模式的に示す断面図であり、図4はその成形シート2の一形態を示す斜視図である。
図3に示すように、本実施形態の製造方法により得られる中空構造板1は、図4に示す錐台形状の中空凸部2aが千鳥状に形成された2枚の成形シート2が、その中空凸部2a同士を突き合わされて熱融着されている。また、この中空構造板1では、2枚の成形シート2からなる中間体3の両面に、必要に応じて面材4などが積層されている。
本実施形態の中空構造板1では、成形シート2における開口部から仮想される水平面と中空凸部2aとがなす角度(傾斜角)θが、45°〜80°であることが好ましい。傾斜角θが45°未満の場合、面材4との総接着面積が小さくなるため、得られた中空構造板1に荷重をかけた際に接着部が剥がれやすくなり、強度低下を招く。一方、傾斜角θが80°を超えると、真空成形した際に、成形シート2の厚さが薄くなりすぎて中空凸部2a側面がフィルム化し、十分な強度が得られないことがある。
本実施形態の中空構造板1の目付けは、特に限定されるものではないが、500〜3500g/m2とすることが好ましい。中空構造板1の目付けが500g/m2未満の場合、成形シート2の厚さが薄くなりすぎて中空凸部2a側面がフィルム化し、強度や剛性が低下することがあり、また、目付けが3500g/m2を超えると、質量が増加し、用途によっては軽量性が損なわれることがあるからである。
シート成形工程では、真空成形により、熱可塑性樹脂シートの一方の面に錐台形状の中空凸部2aを千鳥状に形成して、成形シート2を作製する。このシート成形工程は、例えば、図2に示すように、減圧チャンバー11内に、表面に円錐台形状又は角錐台形状のピン12aが複数突設されている1組の成形ローラー12が、その回転軸が相互に平行になるように配置されている真空成形装置(真空成形部10)により実施することができる。
熱風加熱工程では、熱風発生機22によって、ステップS1により形成した成形シート2の中空凸部2aの先端部を、選択的に、熱融着可能な温度まで熱風加熱する。このように、熱融着に関係する先端部のみを選択的に加熱することにより、中空凸部2aの変形を防止しつつ、中空凸部2a同士を確実に熱融着することができる。
熱融着工程では、前述した温度傾斜加熱工程で加熱された2枚の成形シート2を、その中空凸部2a同士を突き合わせて熱融着し、一体化する。この熱融着工程は、例えば、図2に示すように、真空成形部10のローラー12とロール径が同等で、表面に複数のピン21aが複数突設されている1組のローラー21が、回転軸が相互に平行になるように配置されている熱融着部20により実施することができる。
面材積層工程では、前述した熱融着工程で作製した中間体3の両面に、面材4を積層する。ここで使用する面材4としては、前述した成形シート2と同様に、熱可塑性樹脂シートを使用することができる。その材質は、熱可塑性樹脂であれば特に限定されるものではなく、例えば、ポリエチレン(PE)、ポリプロピレン(PP)及びポリカーボネート(PC)などを使用することができる。また、面材4の厚さは、特に限定されるものではなく、中間体3の厚さ及び中空構造板1の厚さに応じて適宜設定することができる。
次に、本発明の参考形態に係る中空構造板の製造方法について説明する。図7は本参考形態の中空構造板の製造方法において使用する製造装置の概念図である。なお、図7においては、図2に示す製造装置の構成要素と同じものには同じ符号を付し、その詳細な説明は省略する。前述した第1の実施形態では、図2に示す真空成形部10と熱融着部20とが独立して設けられている装置を使用しているが、本発明はこれに限定されるものではない。
目付が400g/m2の2枚の成形シート2を、熱融着部20よりも手前に設置された120℃の加熱槽30を通過させて、予備加熱した。その後、その中空凸部2aに、熱融着部20内に回転可能に配置され、オイルを循環させることにより温度が40℃に保持されている1組の成形ローラー21(ピン構成:高さ6mm、最小直径(先端部)2mm、最大直径(底部)6mm、傾斜角度約72°)のピン21aを挿入した。
ドライヤー式熱風発生機22の設定温度を、成形シートの幅方向中央部を260℃とし、両端部を280℃とした以外は、前述した実施例1と同様の方法及び条件で、中空凸部2a同士を熱融着した。その結果、全面において中空凸部2aの熱融着状態が良好で、十分な接着強度を有する中間体3を、長時間に亘って安定して製造することができた。
目付が400g/m2の2枚の成形シート2を、熱融着部20よりも手前に設置された120℃の加熱槽30を通過させて、予備加熱した。その後、その中空凸部2aに、熱融着部20内に回転可能に配置され、オイルを循環させることにより温度が40℃に保持されている1対の成形ローラー21(ピン構成:高さ6mm、最小直径(先端部)2mm、最大直径(底部)6mm、傾斜角度約72°)のピン21aを挿入した。
加熱装置の設定温度を、成形シート2の幅方向全域に亘って280℃とした以外は、前述した比較例1と同様の方法及び条件で、中空凸部2a同士を熱融着した。その結果、幅方向両端部は良好に熱融着していたが、幅方向中央部では中空凸部2aが歪み、熱融着部において中空凸部2aに変形が生じた。また、開始から数分という短時間の間に、加熱装置の幅方向中央部付近の鉄鋼製熱ブロック(中空凸部2aが接触する部分)に、成形シート2に由来する溶融樹脂が蓄積し、その一部が中間体3の熱融着部分に付着していた。その結果、製造される中間体3に、形状不良及び接着不良が発生した。
目付が400g/m2の2枚の成形シート2を、熱融着部20よりも手前に設置された120℃の加熱槽30を通過させて、予備加熱した。その後、その中空凸部2aに、熱融着部20内に回転可能に配置され、オイルを循環させることにより温度が40℃に保持されている1対の成形ローラー21(ピン構成:高さ6mm、最小直径(先端部)2mm、最大直径(底部)6mm、傾斜角度約72°)のピン21aを挿入した。
2 成形シート
2a 凸部
3 中間体
4 面材
5 熱可塑性樹脂シート
10 真空成形部
11 減圧チャンバー
12、21、23 ローラー
12a、21a ピン
13 ダイ
20 熱融着部
22 熱風発生機
22a ノズル
22b 熱風吹出口
30 加熱槽
41 温度測定器
42 加熱温度調節部
Claims (9)
- 真空成形により、熱可塑性樹脂シートの一方の面に錐台形状の中空凸部を千鳥状に形成して、成形シートを得る工程と、
2枚の成形シートを加熱した後、その中空凸部同士を突き合わせて熱融着し、一体化する工程と、を有し、
該一体化する工程では、前記成形シートの中空凸部の先端部を、選択的に熱風加熱し、かつ、複数のピンが千鳥状に形成されると共に、冷却又は温度調節機能を有する1組のローラーを使用し、該ローラーのピンを各成形シートの中空凸部に挿入し、前記成形シートを冷却しつつ、各中空凸部の頂点部分の少なくとも一部を内側から押圧することを特徴とする中空構造板の製造方法。 - 前記成形シートは、中空凸部の先端部のみ加熱され、その他の部分は冷却されることを特徴とする請求項1に記載の中空構造板の製造方法。
- 前記一体化する工程では、前記成形シートの幅方向両端部を、幅方向中心部よりも高熱量で加熱する請求項1又は2に記載の中空構造板の製造方法。
- 前記一体化する工程により得た中間体の温度に基づいて、前記成形シートの加熱温度を調節することを特徴とする請求項1〜3のいずれか1項に記載の中空構造板の製造方法。
- 減圧チャンバー内に成形ローラーが回転可能に配置され、熱可塑性樹脂シートの一方の面に錐台形状の中空凸部を千鳥状に形成する真空成形部と、
前記真空成形部で成形された2枚の成形シートを加熱した後、中空凸部同士を突き合わせて熱融着し、一体化する熱融着部と、
複数のピンが千鳥状に形成されると共に、冷却又は温度調節機能を有する1組のローラーと、を有し、
前記熱融着部には、前記成形シートの中空凸部の先端部を、選択的に熱風加熱する熱風発生機が設けられ、
前記ローラーのピンを各成形シートの中空凸部に挿入し、前記成形シートを冷却しつつ、各中空凸部の頂点部分の少なくとも一部を内側から押圧する中空構造板の製造装置。 - 前記熱風発生機は、前記成形シートに形成された各中空凸部と整合する位置に、熱風吹出口が設けられていることを特徴とする請求項5に記載の中空構造板の製造装置。
- 前記熱風吹出口がスリット状であることを特徴とする請求項6に記載の中空構造板の製造装置。
- 前記熱風発生機は、前記成形シートの幅方向で加熱温度が分割制御可能となっていることを特徴とする請求項5〜7のいずれか1項に記載の中空構造板の製造装置。
- 2枚の成形シートを一体化して得られた中間体の温度を測定する温度測定器と、
前記中間体の温度に基づいて、前記成形シートの加熱温度を調節する加熱温度調節部と、
を有することを特徴とする請求項5〜8のいずれか1項に記載の中空構造板の製造装置。
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