JP6016073B2 - Laminated panel - Google Patents

Description

  The present invention relates to a laminated panel, and more particularly to a laminated panel in which a core material is sandwiched between two resin skin sheets.

  Conventionally, various types of resin panels have been used for vehicle parts and building materials. When the resin panel is required to be lightweight, it is preferable to mold the resin panel hollow. Such a hollow resin panel can be manufactured using a blow molding method suitable for producing a hollow molded body.

  On the other hand, a resin panel may require higher strength in addition to lightness. In this case, in the manufacture of a hollow resin panel using a blow molding method, if a core material such as a foam can be inserted into the extruded parison from below, a resin panel with higher strength can be obtained while maintaining light weight. be able to. However, in blow molding, in order to inflate the parison satisfactorily, it is generally performed to close the lower end of the parison in advance, and it is not easy to insert the core material into the hollow resin panel.

  Therefore, a sandwich panel having a sandwich structure in which a core material is sandwiched between two skin material sheets has been proposed (see, for example, Patent Document 1).

  In Patent Document 1, as shown in FIG. 2 of Patent Document 1, a thin resin panel (100) (the numbers in parentheses indicate the reference numerals described in Patent Document 1. The same applies hereinafter). The core material (122), the two resin skin sheets (124) laminated with the foamed resin core material (122) interposed therebetween, and the metal reinforcement held by the foamed resin core material (122) Plate (125). A curved edge (127) is formed on one side of each of the two skin material sheets (124), and the peripheral wall (128) is abutted against each other by abutting the end peripheral surfaces (128) of the edge (127). 129).

  According to the thin resin panel (100), the entire foamed resin core material (122) can be covered with the two skin material sheets (124). Further, the foamed resin core material (122) and the skin material sheet (124) are made of the same resin material (for example, polyolefin resin), so that the foamed resin core material (122) and the skin material sheet (124) are formed. Can be joined by heat welding. Thereby, the integral sheet resin panel (100) reinforced with the foamed resin core material (122) can be obtained.

  By the way, the material which comprises a laminated panel may be regulated by a regulation by the use of a laminated panel. For example, when a laminated panel is used for a partition wall of public transportation or public facilities, the material used for the laminated panel may be required to have flame retardancy and heat resistance. In such a case, the core material needs to be made of a material having flame resistance or heat resistance (for example, expanded polystyrene).

JP 2011-235447 A

  However, in the thin resin panel (100) of Patent Document 1, for example, a polyolefin-based resin is used for the skin sheet (124), and flame resistance is imparted to the foamed resin core (122). When foamed polystyrene is used for this, the compatibility of thermal welding between the foamed resin core material (122) and the skin material sheet (124) becomes worse. In this case, even if the foamed resin core material (122) is pressed against the skin sheet (124) and heated / cooled, the foamed resin core material (122) cannot be joined to the skin material sheet (124). . If the foamed resin core material (122) is not joined to the skin material sheet (124), the foamed resin core material (122) moves between the two skin material sheets (124). The material (122) may be damaged. In addition, since the foamed resin core material (122) and the skin material sheet (124) are not integrated, the strength of the thin resin panel (100), particularly against bending, may be reduced.

  This invention is made | formed in view of such a situation, The objective is to fix a core material to a skin material sheet, even if the material of a core material is a material which is not heat-welded to a skin material sheet. It is possible to provide a laminated panel capable of preventing damage to the core material and lowering of panel strength.

The present invention is grasped by the following composition.
The laminated panel of the present invention is composed of a panel body formed by two facing resin skin sheets, and a material that is not thermally welded to the skin sheet, and the two skin materials are formed when the panel body is molded. A laminated panel having a core material sandwiched between the sheets, and having a fixing member held by the core material, the area of the core material contacting the skin material sheet is the same as that of the skin material sheet. The fixing member is larger than an area of the fixing member in contact, and the fixing member is made of a thermoplastic resin that can be thermally welded to the skin material sheet, and is thermally welded to the skin material sheet when the panel body is molded. It is fixed to the panel body.

  With this configuration, the core member can be fixed to the skin material sheet by thermally welding the fixing member held by the core material to the skin material sheet. Therefore, even if the core material is a material that is not thermally welded to the skin material sheet, the core material can be positioned between the two skin material sheets, and the core material and the skin material sheet can be integrated.

  In the above invention, the fixing member is fitted into a hole, recess or notch provided in the core member and is held by the core member.

  With this configuration, the fixing member can be easily held by the core member by fitting the fixing member into the hole, recess or notch of the core member.

  In the above invention, the fixing member is fitted to an outer peripheral portion of the core member and is held by the core member.

  With this configuration, the fixing member can be easily held by the core material by fitting the fixing member to the outer peripheral portion of the core material.

  According to the laminated panel of the present invention, even if the core material is a material that is not thermally welded to the skin material sheet, the core material can be fixed to the skin material sheet, resulting in damage to the core material and a decrease in panel strength. Can be prevented.

It is a perspective view of the laminated panel of embodiment which concerns on this invention. It is the sectional view on the AA line of FIG. It is a perspective view of a core material and a fixing member. It is a side view of a shaping | molding apparatus. It is a figure explaining the effect | action of a split type | mold formwork. It is a figure which shows the process of shape | molding a sheet | seat made from a thermoplastic resin. It is a figure which shows the state which clamped the split mold. It is action | operation explanatory drawing of a fixing member, and is sectional drawing of the molded article of a laminated panel. It is a figure which shows the state which opened the split type | mold. It is a figure explaining a 1st modification and is a figure corresponding to FIG. It is a figure explaining a 2nd modification, and is a figure corresponding to FIG. It is a figure explaining a 3rd modification and is a figure corresponding to FIG. It is a figure explaining a 4th modification and is a figure corresponding to FIG.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments (hereinafter, embodiments) for carrying out the present invention will be described in detail with reference to the accompanying drawings. Note that the same number is assigned to the same element throughout the description of the embodiment.

First, the structure of the laminated panel of embodiment is demonstrated based on FIGS. 1-3.
As shown in FIG. 1, the laminated panel 10 according to the embodiment includes a panel main body 20, a core member 30 provided inside the panel main body 20, and a fixing member 40 held by the core member 30. The laminated panel 10 is used, for example, for various interior parts used for railway vehicles such as a retractable table provided on the back of the seat, various interior parts used for automobiles, airplanes, etc., electronic equipment, precision equipment, and the like. It is various housing parts or various materials used for construction, physical distribution, packaging, etc., and the use of the laminated panel 10 is arbitrary.

  The panel main body 20 is a resin molded body formed into a hollow shape by two facing resin skin sheets 21A and 21B. The planar shape of the panel body 20 is substantially rectangular in FIG. 1, but can be selected from various shapes such as a square, trapezoid, polygon, and circle.

  The two skin material sheets 21A and 21B are composed of a front surface skin material sheet 21A and a back surface skin material sheet 21B. Each of the skin material sheets 21 </ b> A and 21 </ b> B includes a substantially rectangular plane portion 22 and a lip 23 that is provided at the peripheral edge of the plane portion 22 and bends to the side surface of the core member 30. The peripheral edges of the edge 23 are abutted and thermally welded, so that the skin material sheets 21A and 21B are integrated. The heat-sealed lip 23 constitutes a peripheral wall 25 that serves as a side surface of the panel. Details of the material of the skin material sheets 21A and 21B will be described later.

  As shown in FIG. 2, the core member 30 is loaded into the panel body 20 by being sandwiched between the two skin material sheets 21 </ b> A and 21 </ b> B when the panel body 20 is molded. In the present embodiment, the core material 30 is restricted by the use of the laminated panel 10, and the material of the core material 30 is made of a material that is not thermally welded to the skin material sheets 21 </ b> A and 21 </ b> B. For this reason, the core material 30 is sandwiched between the two skin material sheets 21A and 21B when the panel body 20 is molded, but is not thermally welded to the skin material sheets 21A and 21B.

  In the present invention, the “material that is not heat-welded to the skin material sheet” means that the material of the skin material sheet is poorly compatible with heat welding, and even if heated and cooled in contact with the skin material sheet, A material that is not bonded, and includes a material that is easily peeled off from the skin material sheet even if it is temporarily bonded. Details of the material of the core material 30 will be described later.

  As shown in FIG. 3, a plurality of (here, five) substantially circular holes 31 are provided in the core member 30. The plurality of holes 31 are regularly arranged in the core member 30 at regular intervals, and each penetrates in the thickness direction of the core member 30.

  A plurality of (here, five) fixing members 40 are provided in accordance with the number of the plurality of holes 31. Each fixing member 40 is formed in a substantially cylindrical shape, and is held by the core member 30 by being fitted into the hole 31 of the core member 30. In addition, the cross-sectional shape of the fixing member 40 and the hole 31 can be selected from various shapes such as an ellipse, a quadrangle, and a polygon in addition to a circle. Further, the size, number, and arrangement of the fixing member 40 and the holes 31 are not particularly limited to the example shown in FIG. 3 and are arbitrary.

  The length of the fixing member 40 in the axial direction is set to the same size as the thickness of the core member 30. For this reason, in a state where the fixing member 40 is fitted in the hole 31, the two end surfaces 41 in the axial direction of the fixing member 40 are located on the substantially same plane as the surface of the core member 30 and are exposed. The fixing member 40 is made of a resin material that can be thermally welded to the skin sheets 21A and 21B (see FIG. 2), and the two end surfaces 41 in the axial direction of the fixing member 40 are formed on the panel body 20 (FIG. 2). (Refer to FIG. 2) and heat-welded to the inner surface of the skin material sheets 21A and 21B (see FIG. 2). Thereby, the fixing member 40 fixes the core material 30 to the panel main body 20 (refer FIG. 2).

  In the present invention, the “resin material that can be thermally welded to the skin material sheet” refers to a resin material that is heated and cooled in contact with the skin material sheet to join the skin material sheet. Details of the material of the fixing member 40 will be described later.

Next, the material of the component of the laminated panel 10 (refer FIG. 1) is demonstrated in detail.
The skin material sheets 21A and 21B are made of, for example, a sheet formed of polypropylene, engineering plastics, olefin resin, or the like. More specifically, in order to manufacture the laminated panel 10 by integral molding, or to form the skin material sheets 21A and 21B by dripping a molten thermoplastic resin sheet, the material of the skin material sheets 21A and 21B It is preferable to use a resin material with a high melt tension that can suppress variations in thickness due to drawdown, neck-in, etc., while a resin material with high fluidity is used to improve the transferability to the mold and followability. It is preferable to use it.

  More specifically, the material of the skin material sheets 21A and 21B is a crystalline polyolefin resin (for example, a homopolymer or copolymer of olefins such as ethylene, propylene, butene, isoprene pentene, and methyl pentene). Polypropylene, high-density polyethylene), and MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg in accordance with JIS K-7210) is 3.0 g / 10 min or less, more preferably Amorphous resins such as those of 3 to 1.5 g / 10 minutes, or acrylonitrile / butadiene / styrene copolymer, polystyrene, high impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), etc. MFR at 200 ° C. (Test temperature 200 ° C. according to JIS K-7210, Melt tension (measured at a load of 2.16 kg) is 3.0 to 60 g / 10 min, more preferably 30 to 50 g / 10 min and at 230 ° C. (remaining heat temperature using a melt tension tester manufactured by Toyo Seiki Seisakusho Co., Ltd.) This shows the tension when a strand is extruded from an orifice having a diameter of 2.095 mm and a length of 8 mm at 230 ° C. and an extrusion speed of 5.7 mm / min, and the strand is wound on a roller having a diameter of 50 mm at a winding speed of 100 rpm. It is formed using 50 mN or more, preferably 120 mN or more.

  In addition, in order to prevent cracking due to impact, the hydrogenated styrene-based thermoplastic elastomer is added to the material of the skin material sheets 21A and 21B in a range of less than 30 wt%, preferably less than 15 wt%. preferable. Specifically, styrene-ethylene / butylene-styrene block copolymer, styrene-ethylene / propylene-styrene block copolymer, hydrogenated styrene-butadiene rubber and mixtures thereof are suitable as hydrogenated styrene thermoplastic elastomers. The styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured according to JIS K-7210 at a test temperature of 230 ° C. and a test load of 2.16 kg) is 1.0 to 10 g / It should be 10 minutes, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more.

  Furthermore, the material of the skin material sheets 21A and 21B may contain an additive. Examples of the additive include inorganic fillers such as silica, mica, talc, calcium carbonate, glass fiber, and carbon fiber, and plasticizers. , 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 30 to 40 wt%, based on the molding resin.

  On the other hand, the material of the core member 30 can be selected from various materials such as various synthetic resin materials, various metal materials, or combinations of these materials. The core 30 may include a paper honeycomb which is a structure in which hexagonal cylindrical cells are continuously formed. However, in the present embodiment, the core member 30 is restricted by the material and is made of a material that is not thermally welded to the skin material sheets 21A and 21B (a material having non-thermal weldability).

  For example, when the laminated panel 10 (see FIG. 1) is used as an interior part for a vehicle, the core 30 can prevent the spread of a fire and suppress the generation of toxic gas when a fire occurs in the vehicle. The composition by a new material may be calculated | required. Especially in public transportation, the composition of such materials may be stipulated by law.

  In such a case, the core material 30 is constituted by a thermosetting resin foam having flame resistance and heat resistance such as a phenol resin foam, and the skin sheets 21A and 21B are made of styrene resin (for example, polystyrene) or It may be composed of an amorphous resin such as a modified polyphenylene ether resin. Further, when the skin material sheets 21A and 21B are made of a crystalline resin such as polyolefin resin (eg, polypropylene, polyethylene), a styrene resin foam is used to improve the flexural strength at high temperatures (40 to 80 ° C.). (For example, foamed polystyrene) and non-crystalline resins such as modified polyphenylene ether resin foams. Since the crystalline thermoplastic resin, the amorphous thermoplastic resin, and the thermosetting resin have poor compatibility with each other, the skin material sheets 21A and 21B made of the crystalline thermoplastic resin or the amorphous thermoplastic resin are amorphous. The core material 30 made of a thermosetting thermoplastic resin or a thermosetting resin or the core material 30 made of a crystalline thermoplastic resin or a thermosetting resin is made of a material that is not thermally welded.

  On the other hand, if the core material is composed of a polyolefin resin foam (for example, foamed polypropylene) and the skin material sheet is composed of a polyolefin resin (for example, polypropylene or polyethylene), both the core material and the skin material sheet are polyolefins. Since it is comprised with a system resin, the compatibility of heat welding is good and a core material can be heat-welded to a skin material sheet. However, in this case, the required flame retardancy and heat resistance cannot be imparted to the core material.

  In addition, when the core material 30 is composed of a resin foam, any of a physical foaming agent, a chemical foaming agent and a mixture thereof may be used as the foaming agent. 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.

  In addition, styrene resin foams and phenolic resin foams are generally more difficult to increase the expansion ratio than foams such as polyolefin resins (for example, polypropylene), and the mass increases accordingly. For this reason, when the core material 30 is composed of a styrene resin foam or a phenol resin foam, a hollow portion may be provided in the core material 30 for weight reduction.

  The fixing member 40 is selected from resin materials that can be heat-welded to the skin material sheets 21A and 21B (resin material having heat-weldability), and is preferably made of the same thermoplastic resin as the skin material sheets 21A and 21B. . For example, when the skin material sheets 21A and 21B are made of a polyolefin resin, the fixing member 40 is also made of a polyolefin resin.

Next, a forming apparatus used for manufacturing the laminated panel 10 will be described with reference to FIG.
As shown in FIG. 4, the shaping | molding apparatus 50 has extrusion apparatus 51A, 51B and the mold clamping apparatus 52 arrange | positioned under extrusion apparatus 51A, 51B. In the molding apparatus 50, molten thermoplastic resin sheets 26A and 26B made of the thermoplastic resin extruded from the extrusion apparatuses 51A and 51B are fed to the mold clamping apparatus 52, and the mold clamping apparatus 52 makes a molten thermoplastic resin sheet. Sheets 26A and 26B are formed. The thermoplastic resin sheet 26A and the thermoplastic resin sheet 26B are materials molded into the front surface skin sheet 21A (see FIG. 1) and the back surface skin sheet 21B (see FIG. 1), respectively. .

  Since the extrusion apparatus 51A and the extrusion apparatus 51B are the same, in the following description, only the extrusion apparatus 51A corresponding to the thermoplastic resin sheet 26A will be described, and the extrusion apparatus 51B corresponding to the thermoplastic resin sheet 26B. Description of is omitted. In the molding apparatus 50, “A” is added to the reference numerals of the elements corresponding to the thermoplastic resin sheet 26A, and “B” is added to the reference numerals of the elements corresponding to the thermoplastic resin sheet 26B.

  The extruding device 51A is a well-known extruding device, and detailed description thereof is omitted. However, a cylinder 55A provided with a hopper 53A, a screw (not shown) provided in the cylinder 55A, and a hydraulic pressure coupled to the screw. The motor 56A, an accumulator 57A that communicates with the cylinder 55A, and a plunger 58A provided in the accumulator 57A. In the extrusion device 51A, the resin pellets introduced from the hopper 53A are melted and kneaded in the cylinder 55A by the rotation of the screw by the hydraulic motor 56A, and the molten resin is transferred to the accumulator 57A and stored in a certain amount. Then, the molten resin in the accumulator 57A is sent to the T die 61A by driving the plunger 58A, and is extruded as a continuous thermoplastic resin sheet 26A having a predetermined length through the extrusion slit 62A. The extruded thermoplastic resin sheet 26A is sent downward while being pinched by a pair of rollers 63A arranged at intervals, and is suspended between the split dies 65A and 65B. Accordingly, the thermoplastic resin sheet 26A is disposed between the split dies 65A and 65B in a state having a uniform thickness in the vertical direction (extrusion direction).

The extrusion capability of the extrusion apparatus 51A is appropriately determined from the viewpoint of the size of the skin material sheet 21A (see FIG. 1) to be molded, or the prevention of drawdown or neck-in occurrence of the thermoplastic resin sheet 26A. More specifically, from a practical point of view, the extrusion rate of one shot in intermittent extrusion is preferably 1 to 10 kg, and the extrusion rate of the resin from the extrusion slit 62A is several hundred kg / hour or more, more preferably 700 kg / hour or more. Further, from the viewpoint of preventing the thermoplastic resin sheet 26A from being drawn down or preventing neck-in, the extrusion process of the thermoplastic resin sheet 26A is preferably as short as possible and depends on the type of resin, MFR value, and melt tension value. However, in general, the extrusion process should be completed within 40 seconds, more preferably within 10-20 seconds. For this reason, the extrusion amount per unit time and unit time from the extrusion slit 62A of the thermoplastic resin is 50 kg / hour / cm ² or more, more preferably 150 kg / hour / cm ² or more.

  By feeding the thermoplastic resin sheet 26A sandwiched between the pair of rollers 63A downward, the thermoplastic resin sheet 26A can be stretched and thinned. That is, by adjusting the relationship between the extrusion speed of the extruded thermoplastic resin sheet 26A and the delivery speed of the thermoplastic resin sheet 26A by the pair of rollers 63A, the occurrence of drawdown or neck-in is prevented. Therefore, the restriction on the type of resin, in particular, the MFR value and the melt tension value, or the extrusion amount per unit time can be reduced.

  The extrusion slit 62A provided in the T-die 61A is arranged vertically downward, and the thermoplastic resin sheet 26A extruded from the extrusion slit 62A is sent vertically downward in a form that hangs down from the extrusion slit 62A. Yes. The extrusion slit 62A can change the thickness of the thermoplastic resin sheet 26A by making the interval variable.

  The pair of rollers 63A are arranged below the extrusion slit 62A in a state in which the respective rotation axes are substantially horizontal and aligned in parallel with each other. One of the pair of rollers 63A is a rotation driving roller, and the other is a rotation driven roller. More specifically, the pair of rollers 63A are arranged so as to be line-symmetric with respect to the thermoplastic resin sheet 26A extruded in a form that hangs downward from the extrusion slit 62A.

  The diameter of the roller 63A and the axial length of the roller 63A are the extrusion speed of the thermoplastic resin sheet 26A to be molded, the extrusion direction length of the thermoplastic resin sheet 26A, the width of the thermoplastic resin sheet 26A, the resin It is set as appropriate according to the type. However, from the viewpoint of smoothly feeding the thermoplastic resin sheet 26A downward by the rotation of the roller 63A in a state where the thermoplastic resin sheet 26A is sandwiched between the pair of rollers 63A, the diameter of the rotation driving roller is rotated. It is preferable to set it slightly larger than the diameter of the driving roller. Further, if the curvature of the roller 63A is too large or too small, the thermoplastic resin sheet 26A may be wound around the roller 63A. Therefore, the diameter of the roller 63A is preferably in the range of 50 to 300 mm.

  On the other hand, the mold clamping device 52 is a well-known mold clamping device, and has a mold driving device (not shown) and a molding die, although detailed description thereof is omitted. The mold driving device is a device that moves the split dies 65A and 65B in a direction substantially orthogonal to the feeding direction of the molten thermoplastic resin sheets 26A and 26B. The split dies 65A and 65B are opened and closed. Move between positions.

  The molding die is a split type, and includes a split die 65A and a split die 65B that fits the split die 65A. The split dies 65A and 65B are arranged with the cavities 66A and 66B facing each other, and the cavities 66A and 66B are arranged along the substantially vertical direction.

  In each of the split molds 65A and 65B, pinch-off portions 67A and 67B are formed around the cavities 66A and 66B, and the pinch-off portions 67A and 67B are formed in an annular shape around the cavities 66A and 66B. Projects toward the molds 65A and 65B. As a result, when clamping the split dies 65A and 65B, the tip portions of the pinch-off portions 67A and 67B come into contact with each other, and the two thermoplastic resin sheets 26A and 26B are formed with parting lines at their peripheral edges. So that it is heat-welded. Thereby, the surrounding wall 25 (refer FIG. 1) of a laminated panel is formed.

  Forms 68A and 68B are slidably fitted to the outer peripheral portions of the split dies 65A and 65B in a close state. The molds 68A and 68B can be moved relative to the split molds 65A and 65B by a mold moving device (not shown). More specifically, the molds 68A and 68B protrude inward from the split dies 65A and 65B, thereby the outer surfaces 28A and 26B of the thermoplastic resin sheets 26A and 26B disposed between the split dies 65A and 65B. 28B can be contacted.

  The split dies 65A and 65B are respectively driven by a mold driving device, and in the open position, the two thermoplastic resin sheets 26A and 26B are arranged between the split dies 65A and 65B, while in the closed position the split dies The pinch-off portions 67A and 67B of 65A and 65B are brought into contact with each other to form a sealed space in the split dies 65A and 65B. The closed position is set to an intermediate position between the thermoplastic resin sheets 26A and 26B (a position equidistant from both the thermoplastic resin sheets 26A and 26B). The extrusion device 51A and the pair of rollers 63A, and the extrusion device 51B and the pair of rollers 63B are arranged symmetrically with respect to the closed position.

  Moreover, vacuum suction chambers 71A and 71B are provided in the split dies 65A and 65B, respectively. The vacuum suction chambers 71A and 71B communicate with the cavities 66A and 66B through the suction holes 72A and 72B, and are made of thermoplastic resin by suction from the vacuum suction chambers 71A and 71B through the suction holes 72A and 72B. The sheets 26A and 26B are adsorbed in the cavities 66A and 66B. Thereby, the thermoplastic resin sheets 26A and 26B are shaped into shapes along the outer surfaces of the cavities 66A and 66B.

  A method of manufacturing the laminated panel 10 (see FIG. 1) using the molding apparatus 50 described above will be described with reference to FIGS.

  First, in FIG. 4, a predetermined amount of melted and kneaded thermoplastic resin is stored in the accumulators 57A and 57B, and the stored thermoplastic resin is discharged from the extrusion slits 62A and 62B provided at predetermined intervals on the T dies 61A and 61B. Extrude intermittently at a predetermined extrusion rate per unit time. Thereby, the thermoplastic resin swells and hangs downward in a molten sheet shape, and is extruded at a predetermined extrusion speed with a predetermined thickness.

  Next, the rollers 63A and 63B are moved to the open position, and the gap between the pair of rollers 63A and the gap between the pair of rollers 63B is made wider than the thickness of the thermoplastic resin sheets 26A and 26B, thereby being extruded downward. The lowermost portions of the thermoplastic resin sheets 26A and 26B in the state are smoothly supplied between the pair of rollers 63A and the pair of rollers 63B. In addition, the timing at which the interval between the pair of rollers 63A and the interval between the pair of rollers 63B is wider than the thickness of the thermoplastic resin sheets 26A and 26B is not after the start of extrusion but when the secondary molding is completed for each one shot. You may go on. Next, the pair of rollers 63A and the pair of rollers 63B are moved closer to each other and moved to the closed position, the thermoplastic resin sheets 26A and 26B are sandwiched, and the thermoplastic resin sheet 26A is rotated by the rotation of the rollers 63A and 63B. , 26B are sent out downward.

  Next, the thermoplastic resin sheets 26A and 26B formed to have a uniform thickness in the extrusion direction are disposed between the split dies 65A and 65B. At this time, the sheets 26A and 26B made of the thermoplastic resin are positioned so as to protrude from around the pinch-off portions 67A and 67B. As described above, the thermoplastic resin sheet 26A, which is the material of the front side skin material sheet 21A (see FIG. 1), and the thermoplastic resin, which is the material of the back side skin material sheet 21B (see FIG. 1). The sheet 26B is disposed between the split dies 65A and 65B in a state of being spaced apart from each other. The spacing between the extrusion slits 62A and 62B or the rotation speed of the rollers 63A and 63B is individually adjusted with respect to the thermoplastic resin sheets 26A and 26B, respectively, so that they are arranged between the split dies 65A and 65B. The thickness of the thermoplastic resin sheets 26A and 26B can be individually adjusted.

  Next, as shown in FIG. 5, the mold 68A is moved from the split mold 65A until it contacts the outer surface 28A of the thermoplastic resin sheet 26A. Similarly, the mold 68B is moved from the split mold 65B until it contacts the outer surface 28B of the thermoplastic resin sheet 26B.

  Then, sealed spaces 75A and 75B formed by the cavities 66A and 66B, the inner peripheral surfaces 73A and 73B of the molds 68A and 68B, and the outer surfaces 28A and 28A of the thermoplastic resin sheets 26A and 26B are formed.

  As shown in FIG. 6, by sucking the sealed space 75A through the suction hole 72A communicating with the vacuum suction chamber 71A, the thermoplastic resin sheet 26A is pressed against the cavity 66A along the surface of the cavity 66A. The flat portion 22 and the edge 23 are formed by shaping the thermoplastic resin sheet 26A into the shape. The thermoplastic resin sheet 26B (see FIG. 5) is similarly shaped by vacuum suction. Next, the core material 30 in which the fixing member 40 is fitted is arranged between the split mold 65A and the split mold 65B (see FIG. 5).

  Then, as shown in FIG. 7, the thermoplastic resin sheets 26A and 26B are sucked and held in the state where the molds 68A and 68B that are in contact with the thermoplastic resin sheets 26A and 26B are held as they are. The split dies 65A and 65B are moved in a direction approaching each other until the annular pinch-off portions 67A and 67B come into contact with each other, and the split dies 65A and 65B are closed. At this time, since the contact position of the pinch-off portions 67A and 67B is set to an intermediate position between the pair of thermoplastic resin sheets 26A and 26B, the pair of thermoplastic resin sheets 26A and 26B is connected to the pinch-off portions 67A and 67B. By contact, the peripheral edge portions 29A and 29B are thermally welded to each other. Thereby, while the surrounding wall 25 is formed, the panel main body 20 is shape | molded by two skin material sheets 21A and 21B which oppose.

  At the same time, as shown in FIG. 8, by closing the split dies 65A and 65B, the core member 30 and the fixing member 40 are sandwiched between the thermoplastic resin sheets 26A and 26B. At this time, since the core member 30 is made of a material that is not thermally welded to the thermoplastic resin sheets 26A and 26B, the core material 30 is not thermally welded to the thermoplastic resin sheets 26A and 26B.

  On the other hand, since the fixing member 40 is made of a material that is thermally welded to the thermoplastic resin sheets 26A and 26B, the two end surfaces 41 of the fixing member 40 are at the boundary surfaces with the thermoplastic resin sheets 26A and 26B. It is firmly heat-welded to the thermoplastic resin sheets 26A and 26B. Therefore, the two end surfaces 41 of the fixing member 40 held by the core member 30 are thermally welded to the thermoplastic resin sheets 26A and 26B so as to connect the thermoplastic resin sheets 26A and 26B. As a result, the core material 30 is fixed to the thermoplastic resin sheet 26A (front surface side skin material sheet 21A) and the thermoplastic resin sheet 26B (back surface side skin material sheet 21B) via the fixing member 40. Is done.

  As a means for arranging the core member 30 between the split dies 65A and 65B, for example, a well-known adsorption manipulator can be used. That is, the core material 30 is disposed between the split molds 65A and 65B while adsorbing and holding the side surface of the core material 30 with the suction type manipulator, and then the suction type manipulator is detached from the core material 30 and between the split molds 65A and 65B. Try to unplug.

  Next, as shown in FIG. 9, the split dies 65A and 65B are opened, the molded laminated panel 10 is taken out, and the burr portions 76 outside the pinch-off portions 67A and 67B are cut. This completes the molding.

  As described above, each time the molten resin is intermittently extruded in the primary molding, the sheet-shaped laminated panel 10 can be molded one after another by repeating the steps shown in FIGS. That is, the thermoplastic resin is intermittently extruded as a thermoplastic resin sheet 26A, 26B in a molten state by primary molding (extrusion molding), and the thermoplastic resin sheet 26A, extruded by secondary molding (vacuum molding). 26B can be molded using split dies 65A and 65B. The one and / or the other thermoplastic resin sheets 26A, 26B are not limited to those formed by extrusion by directly introducing them between molds, but are formed by extrusion molding in advance. After cutting a sheet made into a predetermined size, it may be reheated to be in a molten state.

The effects of the laminated panel 10 described above will be described.
According to the laminated panel 10, the core member 30 can be fixed to the skin material sheets 21A and 21B by thermally welding the fixing member 40 held by the core material 30 to the skin material sheets 21A and 21B. For example, even if the core material 30 is composed of a flame-retardant styrene resin foam or a phenol resin foam, and the skin sheets 21A and 21B are composed of a polyolefin resin, the fixing member 40 is composed of a polyolefin resin. The core material 30 can be fixed to the skin material sheets 21A and 21B by heat-welding them to the skin material sheets 21A and 21B. Thereby, while being able to position the core material 30 between the two skin material sheets 21A and 21B, the core material 30 and the skin material sheets 21A and 21B can be integrated.

  Therefore, according to the laminated panel 10, even if the material of the core material 30 is a material that is not thermally welded to the skin material sheets 21A and 21B, the core material 30 can be fixed to the skin material sheets 21A and 21B. 30 damage and a decrease in strength of the laminated panel 10 can be prevented.

  Moreover, the fixing member 40 can be easily held by the core member 30 by fitting the fixing member 40 into the hole 31 of the core member 30.

(Modification of the embodiment)
Next, modified examples of the fixing member 40 and its holding structure will be described with reference to FIGS. In addition, the same code | symbol is attached | subjected to the site | part which is common in the laminated panel 10 of embodiment mentioned above, and the overlapping description is abbreviate | omitted.

(First modification)
In the above-described laminated panel 10 (see FIG. 2), the core member 30 is provided with the hole 31, and the fixing member 40 is fitted into the hole 31, but the fixing member is also provided in the recess provided in the core member. You may fit. For example, as shown in FIG. 10, in the first modification, a circular recess 32 is provided in the core member 30C, and a cylindrical fixing member 40C is fitted into the recess 32, whereby the fixing member 40C is fixed to the core member 30C. It was made to hold. One end surface 41 in the axial direction of the fixing member 40C is exposed while being positioned substantially on the same plane as the surface of the core member 30C in a state where the fixing member 40C is fitted in the recess 32. The exposed end surface 41 is thermally welded to the inner surfaces of the skin material sheets 21A and 21B (see FIG. 2) when the panel body 20 (see FIG. 2) is molded.

  According to this first modification, the same operational effects as those of the laminated panel 10 of the above-described embodiment can be obtained. Furthermore, since the end surface 41 can be aligned with the surface of the core member 30C by applying the fixing member 40C to the bottom of the recess 32, the positioning of the fixing member 40C is facilitated.

(Second modification)
In the second modification, as shown in FIG. 11, a semicircular cutout 33 is provided on the side surface of the core material 30 </ b> D, and a cylindrical fixing member 40 </ b> D is fitted into the cutout 33 so The fixing member 40 </ b> D is held by the. In a state in which the fixing member 40D is fitted in the notch 33, one end surface 41 in the axial direction of the fixing member 40D is positioned substantially on the same plane as the surface of the core member 30D. This end surface 41 is heat-welded to the inner surfaces of the skin material sheets 21A and 21B (see FIG. 2) when the panel body 20 (see FIG. 2) is molded.

  According to the second modification, the same operational effects as those of the laminated panel 10 of the embodiment described above can be obtained. Furthermore, since only the notch 33 is provided in the core material 30D, the core material 30D can be easily formed.

(Third Modification)
In the third modification, as shown in FIG. 12, the fixing member 40E is formed in a frame shape, and the frame-shaped fixing member 40E is fitted to the outer periphery of the core material 30E, so that the fixing member 40E is the core material. 30E. The width of the fixing member 40E (the width in the panel thickness direction) is set to the same size as the thickness of the core member 30E. For this reason, in a state where the fixing member 40E is fitted to the core member 30E, the two annular end faces 42 of the fixing member 40E are positioned on substantially the same plane as the surface of the core member 30E. The two end faces 42 of the fixing member 40E are thermally welded to the inner surfaces of the skin material sheets 21A and 21B (see FIG. 2) when the panel body 20 (see FIG. 2) is molded. Thereby, the fixing member 40E fixes the core material 30E to the panel main body 20 (refer FIG. 2).

  According to the third modification, the same operational effects as those of the laminated panel 10 of the embodiment described above can be obtained. Moreover, the fixing member 40E can be easily held by the core material 30E by fitting the fixing member 40E to the outer peripheral portion of the core material 30E. Furthermore, since the core member 30E is completely surrounded by the fixing member 40E, the core member 30E can be positioned more reliably. In addition, since it is not necessary to process a hole or the like in the core material 30E, the processing cost of the core material 30E can be reduced.

(Fourth modification)
In the fourth modification, as shown in FIG. 13, the fixing member 40F is formed in an L shape, and the fixing member 40F is fitted into the four corners of the core member 30F, thereby fixing the fixing member. 40F was held by the core material 30F. The width of the fixing member 40F (the width in the panel thickness direction) is set to the same size as the thickness of the core member 30F. For this reason, in a state where the fixing member 40F is fitted to the corner portion of the core member 30F, the two L-shaped end surfaces 43 of the fixing member 40F are positioned on substantially the same plane as the surface of the core member 30F. The two end surfaces 43 of each fixing member 40F are thermally welded to the inner surfaces of the skin material sheets 21A and 21B (see FIG. 2) when the panel body 20 (see FIG. 2) is molded. Thereby, the fixing member 40F fixes the core member 30F to the panel body 20 (see FIG. 2).

  According to the fourth modification, it is possible to obtain the same operational effects as those of the laminated panel 10 of the embodiment described above. Furthermore, since it is not necessary to process a hole or the like in the core material 30F as in the third modification, the processing cost of the core material 30F can be reduced.

  As mentioned above, although this invention was demonstrated using embodiment, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiments. Further, it is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

  For example, in the embodiment and the first to fourth modifications, the core materials 30, 30C to F and the fixing members 40 and 40C to F are shown. However, the core material and the fixing member according to the present invention are those implementations. A form and the 1st-4th modification may be combined suitably.

DESCRIPTION OF SYMBOLS 10 Laminated panel 20 Panel main body 21A, B Skin material sheet 30 Core material 30C-F Core material 31 Hole 32 Recess 33 Notch 40 Fixing member 40C-F Fixing member

Claims (4)

A panel body formed by two facing resin skin sheets, and a core that is made of a material that is not thermally welded to the skin sheet and is sandwiched between the two skin sheets when the panel body is molded A laminated panel having a material,
A fixing member held by the core material;
The area of the core material in contact with the skin material sheet is larger than the area of the fixing member in contact with the skin material sheet,
The fixing member is made of a thermoplastic resin that can be thermally welded to the skin material sheet, and is thermally welded to the skin material sheet when the panel body is molded, and fixes the core material to the panel body. Laminated panel.   2. The laminated panel according to claim 1, wherein the fixing member is fitted into a hole, a recess, or a notch provided in the core member and is held by the core member.   The laminated panel according to claim 1, wherein the fixing member is fitted to an outer peripheral portion of the core member and is held by the core member.   When the skin sheet is made of a crystalline thermoplastic resin or an amorphous thermoplastic resin and the skin sheet is made of a crystalline thermoplastic resin, the core material is made of an amorphous thermoplastic resin or a thermosetting resin. The laminated panel according to any one of claims 1 to 3, wherein when the material sheet is made of an amorphous thermoplastic resin, the core material is made of a crystalline thermoplastic resin or a thermosetting resin.

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