JP6681569B2

JP6681569B2 - Foam structure, resin panel

Info

Publication number: JP6681569B2
Application number: JP2016025826A
Authority: JP
Inventors: 福田　達也; 達也福田; 丹治　忠敏; 忠敏丹治; 岩崎　健司; 健司岩崎; 良介大木
Original assignee: Kyoraku Co Ltd
Current assignee: Kyoraku Co Ltd
Priority date: 2016-02-15
Filing date: 2016-02-15
Publication date: 2020-04-15
Anticipated expiration: 2036-02-15
Also published as: JP2017144574A

Description

本発明は、発泡体を含む発泡構造体、及び、当該発泡構造体を表皮材シートで覆う樹脂製パネルに関する。 The present invention relates to a foam structure including a foam, and a resin panel that covers the foam structure with a skin material sheet.

従来から、樹脂製パネルが、自動車用、建材用、スポーツ・レジャー用等、多用途に用いられてきた。樹脂製パネルは、芯材の両方の面を表皮材シートで覆うサンドイッチ構造を有し、サンドイッチパネルとも呼称される。 Conventionally, resin panels have been used for various purposes such as automobiles, building materials, sports and leisure. The resin panel has a sandwich structure in which both surfaces of the core material are covered with a skin material sheet, and is also called a sandwich panel.

従来、樹脂製パネルにおいて、芯材となる樹脂発泡体に金属製の補強材をインサートしたものが知られている。例えば引用文献１には、直線状の溝部が設けられる発泡体を当該溝部において割断して得られる第１の芯材及び第２の芯材が、それぞれ補強材の一方及び他方から嵌合されている発泡構造材が記載されている。 BACKGROUND ART Conventionally, a resin panel in which a metal reinforcing material is inserted into a resin foam body serving as a core material is known. For example, in Patent Document 1, a first core material and a second core material obtained by cutting a foam having a linear groove portion at the groove portion are fitted from one side and the other side of a reinforcing material, respectively. The foamed structural material is described.

特開２０１４−１２８９３８号公報JP, 2014-128938, A

従来の発泡構造体は、補強材を境にして芯材が第１の芯材と第２の芯材とに分割して構成されているため、第１の芯材と第２の芯材を補強材に組み付けるときの組み付け誤差（位置ずれ）に起因して、発泡構造体における芯材の寸法誤差が生ずる場合がある。発泡構造体において芯材の寸法誤差が大きい場合、芯材の寸法誤差に起因して樹脂製パネルの外観不良等の悪影響がある。 In the conventional foamed structure, since the core material is divided into the first core material and the second core material with the reinforcing material as a boundary, the first core material and the second core material are separated from each other. A dimensional error of the core material in the foam structure may occur due to an assembly error (positional deviation) when assembled to the reinforcing material. When the dimensional error of the core material is large in the foam structure, the dimensional error of the core material has an adverse effect such as a poor appearance of the resin panel.

よって、本開示は、発泡体に補強材が装着された発泡構造体において、発泡体の寸法精度を向上させることを目的とする。 Therefore, an object of the present disclosure is to improve the dimensional accuracy of a foam in a foam structure in which a reinforcing material is attached to the foam.

本開示の一観点は、互いに対向しつつ直線状に延伸する第１板および第２板と、第１板および第２板を連結する連結板と、を含む補強材と、前記補強材を収容するための直線状の収容部と、当該収容部を挟んで形成された第１発泡部および第２発泡部と、を有する発泡体と、を備えた発泡構造体である。前記収容部は、第１発泡部と第２発泡部を連結する連結部と、第１発泡部および第２発泡部の少なくともいずれか一方の発泡部から他方の発泡部に向けて突出する突出部と、を有し、前記突出部の少なくとも一部が、前記補強材の第１板と第２板の間に介在している。 One aspect of the present disclosure includes a reinforcing member including a first plate and a second plate that linearly extend while facing each other, and a connecting plate that connects the first plate and the second plate, and the reinforcing member is accommodated. A foamed structure including a linear accommodating portion for carrying out, and a foamed body having a first foamed portion and a second foamed portion formed with the accommodating portion sandwiched therebetween. The accommodating portion has a connecting portion that connects the first foaming portion and the second foaming portion, and a protruding portion that protrudes from at least one foaming portion of the first foaming portion and the second foaming portion toward the other foaming portion. And at least a part of the protrusion is interposed between the first plate and the second plate of the reinforcing member.

前記発泡構造体において、前記補強材の長手方向において前記補強材の移動を規制するための突起をさらに備えてもよい。 The foam structure may further include a protrusion for restricting movement of the reinforcing material in the longitudinal direction of the reinforcing material.

前記発泡構造体において、前記収容部は、前記発泡体の第１側面に形成された第１開口と、第１側面に対向する前記発泡体の第２側面に形成された第２開口と、を有してもよい。 In the foam structure, the accommodation portion includes a first opening formed in a first side surface of the foam body and a second opening formed in a second side surface of the foam body facing the first side surface. You may have.

前記発泡構造体において、前記収容部は、前記発泡体の第１側面に形成された第１開口と、第１側面に対向する前記発泡体の第２側面に形成された第２開口と、前記第１開口および前記第２開口の少なくともいずれか一方の開口の近傍に形成され、前記補強材の長手方向において前記補強材の移動を規制するための突起と、をさらに備えてもよい。 In the foam structure, the accommodation portion includes a first opening formed in a first side surface of the foam body, a second opening formed in a second side surface of the foam body facing the first side surface, and A protrusion that is formed in the vicinity of at least one of the first opening and the second opening and that restricts movement of the reinforcing material in the longitudinal direction of the reinforcing material may be further provided.

前記発泡構造体において、前記収容部には、前記突出部の長手方向の一端に隣接して、前記発泡体のおもて面と裏面とを貫通する貫通口が形成されていてもよい。 In the foam structure, a through-hole may be formed in the accommodation portion, adjacent to one end in the longitudinal direction of the protrusion, and penetrating the front surface and the back surface of the foam.

前記発泡構造体において、前記発泡体は、平坦面を有する平坦部と、前記平坦面から隆起している隆起部と、を備え、前記発泡体の平面視において、前記収容部の少なくとも一部が前記隆起部と重なっていてもよい。 In the foam structure, the foam includes a flat portion having a flat surface, and a raised portion that is raised from the flat surface, and in the plan view of the foam, at least a part of the housing portion is It may overlap with the raised portion.

前記発泡構造体において、前記突出部は、前記発泡体の第１発泡部と第２発泡部を連結しない部位において形成されていてもよい。 In the foam structure, the protrusion may be formed in a portion of the foam that does not connect the first foam part and the second foam part.

本開示の別の観点は、前記発泡構造体と、前記発泡構造体のおもて面および裏面を覆う樹脂シートと、を備えた樹脂製パネルである。 Another aspect of the present disclosure is a resin panel including the foam structure and a resin sheet that covers a front surface and a back surface of the foam structure.

本開示に係る発泡構造体によれば、発泡体に補強材が装着される場合において、発泡体の寸法精度を向上させることができる。 According to the foam structure of the present disclosure, the dimensional accuracy of the foam can be improved when the reinforcing material is attached to the foam.

実施形態の樹脂製パネルの斜視図及びその一部の拡大破断図。The perspective view of the resin panel of embodiment, and the one part enlarged fracture view. （ａ）は実施形態の発泡体のおもて側から見た斜視図、（ｂ）は実施形態の発泡体の裏側から見た斜視図。(A) is the perspective view seen from the front side of the foam of embodiment, (b) is the perspective view seen from the back side of the foam of the embodiment. 実施形態の補強材の斜視図。The perspective view of the reinforcement material of an embodiment. 実施形態の発泡体の平面図。The top view of the foam of an embodiment. 図４に示す発泡体のＣＬ部を拡大して示す図。The figure which expands and shows the CL part of the foam shown in FIG. 図４の矢視Ａから見た矢視図。The arrow view seen from the arrow A of FIG. 図４に示すＢ−Ｂの断面図。Sectional drawing of BB shown in FIG. 図４に示すＣ−Ｃの断面図。Sectional drawing of CC shown in FIG. 図４に示すＤ−Ｄの断面図。Sectional drawing of DD shown in FIG. 図４に示すＥ−Ｅの断面図。Sectional drawing of EE shown in FIG. 実施形態の発泡体を成形する工程を説明する図。The figure explaining the process of shape | molding the foam of embodiment. 実施形態の発泡体を成形する工程を説明する図。The figure explaining the process of shape | molding the foam of embodiment. 実施形態の発泡体に補強材を装着する手順を説明する図。The figure explaining the procedure which equips the foam of embodiment with a reinforcing material. 実施形態の発泡体に補強材を装着する手順を説明する図。The figure explaining the procedure which equips the foam of embodiment with a reinforcing material. 実施形態の樹脂製パネルの成形方法を示す図。The figure which shows the molding method of the resin-made panel of embodiment. 実施形態の樹脂製パネルの成形方法を示す図。The figure which shows the molding method of the resin-made panel of embodiment. 実施形態の発泡体の変形例を示す図。The figure which shows the modification of the foam of embodiment.

（１）実施形態の樹脂製パネル
図１に、実施形態の樹脂製パネル１００の斜視図及びその一部の拡大破断図を示す。
図１に示すように、実施形態に係る樹脂製パネル１００の外形は、おもて面および裏面をそれぞれ構成する熱可塑性樹脂の樹脂シートである表皮材シートＳＡ，ＳＢによって、発泡構造体１を両側から挟み込むようにしたサンドイッチ構造となっている。
図１に示すように、実施形態の樹脂製パネル１００には、平坦部分から隆起する左右一対の隆起部１２５Ｌ，１２５Ｒが形成されている。 (1) Resin Panel of Embodiment FIG. 1 shows a perspective view of a resin panel 100 of the embodiment and an enlarged cutaway view of a part thereof.
As shown in FIG. 1, the outer shape of the resin panel 100 according to the embodiment is such that the foam structure 1 is formed by the skin material sheets SA and SB which are resin sheets of a thermoplastic resin forming the front surface and the back surface, respectively. It has a sandwich structure that is sandwiched from both sides.
As shown in FIG. 1, the resin panel 100 of the embodiment is formed with a pair of left and right raised portions 125L and 125R that are raised from a flat portion.

実施形態の樹脂製パネル１００において、表皮材シートＳＡ，ＳＢは、その樹脂材料を限定せず、発泡樹脂でもよいし、非発泡樹脂でもよいが、樹脂製パネル１００の剛性を確保するために非発泡樹脂から形成されることが好ましい。例えば、成形性を考慮して、表皮材シートＳＡ，ＳＢは、主材料であるポリプロピレン（ＰＰ）にポリスチレン（ＰＳ）とスチレンエチレンブチレンスチレンブロック共重合体樹脂（ＳＥＢＳ）を混合させてもよい。
表皮材シートＳＡ，ＳＢ及び発泡体２は、剛性及び強度を増加させる目的で、ガラスフィラーを混入した樹脂材料を用いて成形するようにしてもよい。
ガラスフィラーとしては、ガラス繊維、ガラスクロスやガラス不織布などのガラス繊維布、ガラスビーズ、ガラスフレーク、ガラスパウダー、ミルドガラスなどが挙げられる。ガラスの種類としては、Ｅガラス、Ｃガラス、Ａガラス、Ｓガラス、Ｄガラス、ＮＥガラス、Ｔガラス、クオーツ、低誘電率ガラス、高誘電率ガラスなどが挙げられる。
なお、ガラスフィラーに限らず、剛性を上げるためのタルク、炭酸カルシウム、珪灰石（Wollastonite）、マグネシウム系材料等の無機フィラー、カーボンファイバー等を混入させてもよい。 In the resin panel 100 of the embodiment, the skin material sheets SA and SB are not limited to the resin material, and may be foamed resin or non-foamed resin. However, in order to secure rigidity of the resin panel 100, It is preferably formed of a foamed resin. For example, in consideration of moldability, the skin material sheets SA and SB may be made by mixing polystyrene (PS) and styrene-ethylene-butylene-styrene block copolymer resin (SEBS) into polypropylene (PP) which is a main material.
The skin material sheets SA, SB and the foam 2 may be molded using a resin material mixed with a glass filler for the purpose of increasing rigidity and strength.
Examples of the glass filler include glass fiber, glass fiber cloth such as glass cloth and glass nonwoven fabric, glass beads, glass flakes, glass powder, and milled glass. Examples of types of glass include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, quartz, low dielectric constant glass, and high dielectric constant glass.
In addition to the glass filler, talc, calcium carbonate, wollastonite, an inorganic filler such as a magnesium-based material, carbon fiber or the like for increasing the rigidity may be mixed.

（２）実施形態の発泡構造体
次に、図２〜１０を参照して実施形態の発泡構造体１について説明する。
図２の（ａ）は、実施形態の発泡構造体１の主要部である発泡体２のおもて側から見た斜視図であり、図２の（ｂ）は発泡体２の裏側から見た斜視図である。図３は、発泡体２に組み込まれる補強材３の斜視図である。図４は、発泡体２の平面図である。図５は、図４に示す発泡体２のＣＬ部を拡大して示す図である。図６は、図４の矢視Ａから見た矢視図である。図７〜１０は、それぞれ、図４に示すＢ−Ｂ、Ｃ−Ｃ、Ｄ−Ｄ、Ｅ−Ｅの断面図である。 (2) Foamed Structure of the Embodiment Next, the foamed structure 1 of the embodiment will be described with reference to FIGS.
2A is a perspective view seen from the front side of the foam body 2 which is the main part of the foam structure 1 of the embodiment, and FIG. 2B is seen from the back side of the foam body 2. FIG. FIG. 3 is a perspective view of the reinforcing material 3 incorporated in the foam 2. FIG. 4 is a plan view of the foam 2. 5: is a figure which expands and shows the CL part of the foam body 2 shown in FIG. FIG. 6 is a view from the arrow A of FIG. 7 to 10 are cross-sectional views of BB, CC, DD, and EE shown in FIG. 4, respectively.

先ず図２の（ａ）を参照すると、発泡構造体１は、発泡体２と、発泡体２に対して局部的に装着されて剛性および強度を確保するための補強材３と、を有する。
発泡構造体１の全体形状は、図１に示した樹脂製パネル１００から表皮材シートＳＡ，ＳＢを取り除いたものであるため、図１の樹脂製パネル１００の全体形状と同様の形状となっている。すなわち、発泡構造体１は、平坦面であるおもて面２Ｔおよび裏面２Ｂを有する平坦部２３と、おもて面２Ｔから隆起している左右一対の隆起部２５Ｌ，２５Ｒ（以下、総称して、あるいは個々に「隆起部２５」ともいう。）と、を備える。
発泡体２の平坦部２３の厚さは、樹脂製パネル１００としての目標厚さ、さらには、樹脂製パネル１００の目標となる剛性および強度を確保するために適宜決定され、特に限定されるものではない。 First, referring to FIG. 2A, the foam structure 1 includes a foam 2 and a reinforcing member 3 locally attached to the foam 2 to secure rigidity and strength.
The overall shape of the foam structure 1 is the same as the overall shape of the resin panel 100 of FIG. 1 because the skin material sheets SA and SB are removed from the resin panel 100 shown in FIG. There is. That is, the foamed structure 1 includes a flat portion 23 having a front surface 2T and a back surface 2B, which are flat surfaces, and a pair of left and right raised portions 25L and 25R that are raised from the front surface 2T (hereinafter, collectively referred to as Or individually referred to as "raised portion 25").
The thickness of the flat portion 23 of the foam 2 is appropriately determined in order to secure the target thickness of the resin panel 100, and further the target rigidity and strength of the resin panel 100, and is not particularly limited. is not.

発泡体２は例えば熱可塑性樹脂を用いて成形される。その樹脂材料は限定しないが、例えば、ポリプロピレン、ポリエチレン等のポリオレフィンや、ポリアミド、ポリスチレン、ポリ塩化ビニル等のアクリル誘導体のいずれか、又は２種類以上の混合物を含む。発泡体２は発泡構造体１の体積に占める割合が大きいため、軽量化のために発泡剤を用いて発泡させた発泡樹脂で構成されている。発泡体２となる発泡樹脂の発泡倍率は、例えば１０〜６０倍の範囲であり、代表的には３０倍である。なお、発泡倍率とは、発泡前の混合樹脂の密度を、発泡後の発泡樹脂の見かけ密度で割った値である。 The foam 2 is molded using, for example, a thermoplastic resin. The resin material is not limited, but includes, for example, a polyolefin such as polypropylene or polyethylene, an acrylic derivative such as polyamide, polystyrene, or polyvinyl chloride, or a mixture of two or more kinds. Since the foam 2 has a large proportion in the volume of the foam structure 1, it is made of a foam resin foamed with a foaming agent for weight reduction. The foaming ratio of the foamed resin that becomes the foam 2 is, for example, in the range of 10 to 60 times, and is typically 30 times. The expansion ratio is a value obtained by dividing the density of the mixed resin before foaming by the apparent density of the foamed resin after foaming.

発泡構造体１では、補強材３が発泡体２の収容部２０に装着されている。
図３に示すように、補強材３は、互いに対向しつつ直線状に延伸する第１板３１および第２板３２と、第１板３１および第２板３２を連結する連結板３３と、を含む。図３に示す例では、補強材３の断面がＨ型形状となっている。補強材３が発泡体２に装着された状態では、補強材３の第１板３１および第２板３２のうち、連結板３３が接続されている面とは反対側の面が、それぞれ、発泡体２のおもて面２Ｔおよび裏面２Ｂの一部を構成する。
第１板３１の両端には第２板３２に向かって突出する突起３１１が設けられており、第２板３２の両端には第１板３１に向かって突出する突起３２１が設けられている。
補強材３の材料は特に限定するものではないが、樹脂製パネル１００の強度を確保するために、好ましくはアルミニウムなどの金属製あるいは硬質のプラスチック製である。補強材３は、例えば押出成形によって成形される。 In the foam structure 1, the reinforcing material 3 is attached to the housing portion 20 of the foam 2.
As shown in FIG. 3, the reinforcing member 3 includes a first plate 31 and a second plate 32 that linearly extend while facing each other, and a connecting plate 33 that connects the first plate 31 and the second plate 32. Including. In the example shown in FIG. 3, the reinforcing member 3 has an H-shaped cross section. In the state where the reinforcing material 3 is attached to the foam body 2, one of the first plate 31 and the second plate 32 of the reinforcing material 3 on the side opposite to the surface to which the connecting plate 33 is connected is foamed. It constitutes a part of the front surface 2T and the back surface 2B of the body 2.
Protrusions 311 protruding toward the second plate 32 are provided at both ends of the first plate 31, and protrusions 321 protruding toward the first plate 31 are provided at both ends of the second plate 32.
The material of the reinforcing material 3 is not particularly limited, but in order to secure the strength of the resin panel 100, it is preferably made of a metal such as aluminum or a hard plastic. The reinforcing material 3 is formed by, for example, extrusion molding.

図２および図４に示すように、発泡体２は、補強材３を収容するための直線状の収容部２０と、収容部２０を挟んで形成された第１発泡部２１および第２発泡部２２と、を有する。
図４および図６に示すように、収容部２０は、発泡体２の左側の第１側面２４Ｌに設けられた第１開口２００Ｌと右側の第２側面２４Ｒに設けられた第２開口２００Ｒに亘って形成されている。第１開口２００Ｌおよび第２開口２００Ｒ（以下、総称して、あるいは個々に「開口２００」ともいう。）は、補強材３を第１側面２４Ｌまたは第２側面２４Ｒから収容部２０内に挿入するために設けられている。 As shown in FIGS. 2 and 4, the foam body 2 includes a linear housing portion 20 for housing the reinforcing material 3, and a first foaming portion 21 and a second foaming portion 21 sandwiching the housing portion 20. 22 and.
As shown in FIGS. 4 and 6, the housing portion 20 extends over the first opening 200L provided on the left first side surface 24L of the foam body 2 and the second opening 200R provided on the right second side surface 24R. Is formed. The first opening 200L and the second opening 200R (hereinafter, also collectively or individually referred to as “opening 200”) insert the reinforcing material 3 into the housing portion 20 from the first side surface 24L or the second side surface 24R. It is provided for.

図２（ａ）に示すように、本実施形態の例では、直線状の収容部２０の両端付近に一対の隆起部２５Ｌ，２５Ｒが形成されている。言い換えれば、発泡体２の平面視において、収容部２０と隆起部２５Ｌ，２５Ｒが重なった状態となっている。隆起部２５Ｌ，２５Ｒは、樹脂製パネル１００の隆起部１２５Ｌ，１２５Ｒにそれぞれ対応して形成されている。 As shown in FIG. 2A, in the example of the present embodiment, a pair of raised portions 25L and 25R are formed near both ends of the linear accommodation portion 20. In other words, in the plan view of the foam body 2, the accommodation portion 20 and the raised portions 25L, 25R are in a state of overlapping. The raised portions 25L and 25R are formed corresponding to the raised portions 125L and 125R of the resin panel 100, respectively.

図４に示すように、補強材３を収容するための収容部２０は、対称構造となっている。
収容部２０の中央部分には、発泡体２のおもて面２Ｔおよび裏面２Ｂと直交する方向の補強材３の移動を規制するための突出部２０１，２０２が形成されている。突出部２０１，２０２の間には、発泡体２のおもて面２Ｔと裏面２Ｂを貫通する貫通口２０５が設けられている。突出部２０１，２０２の長手方向の両端の第１側面２４Ｌ側および第２側面２４Ｒ側には（つまり、突出部２０１，２０２の一端および他端に隣接して）、それぞれ、貫通口２０６Ｌおよび貫通口２０６Ｒ（以下、総称して、あるいは個々に「貫通口２０６」ともいう。）が設けられている。収容部２０の両端近傍には、連結部２０３Ｌ，２０３Ｒ（以下、総称して、あるいは個々に「連結部２０３」ともいう。）および突起２０４Ｌ，２０４Ｒ（以下、総称して、あるいは個々に「突起２０４」ともいう。）が形成されている。 As shown in FIG. 4, the accommodating portion 20 for accommodating the reinforcing material 3 has a symmetrical structure.
Protrusions 201 and 202 for restricting the movement of the reinforcing member 3 in the direction orthogonal to the front surface 2T and the back surface 2B of the foam body 2 are formed in the central portion of the housing portion 20. A through hole 205 that penetrates the front surface 2T and the back surface 2B of the foam 2 is provided between the protruding portions 201 and 202. On the first side face 24L side and the second side face 24R side at both ends in the longitudinal direction of the protrusions 201, 202 (that is, adjacent to one end and the other end of the protrusions 201, 202), the through-hole 206L and the through-hole are provided. A port 206R (hereinafter, also collectively or individually referred to as "through port 206") is provided. In the vicinity of both ends of the accommodating portion 20, connecting portions 203L and 203R (hereinafter collectively or individually referred to as “connecting portion 203”) and protrusions 204L and 204R (hereinafter collectively or individually referred to as “projection”). Also referred to as "204").

図６および図９に示すように、第１発泡部２１と第２発泡部２２を連結しない部位（すなわち、図４の収容部２０の長手方向で貫通口２０６Ｌ，２０５，２０６Ｒが設けられている部位）において、第１発泡部２１から第２発泡部２２に向けて突出部２０１が突出しており、第２発泡部２２から第１発泡部２１に向けて突出部２０２が突出している。突出部２０１と突出部２０２は、貫通口２０５を挟んで対向している。
図９に示すように、貫通口２０５は、補強材３が収容部２０に挿入されたときに補強材３の連結板３３が配置される。 As shown in FIGS. 6 and 9, a portion that does not connect the first foaming portion 21 and the second foaming portion 22 (that is, through holes 206L, 205, 206R are provided in the longitudinal direction of the housing portion 20 in FIG. 4). In the portion), the protruding portion 201 projects from the first foaming portion 21 toward the second foaming portion 22, and the protruding portion 202 projects from the second foaming portion 22 toward the first foaming portion 21. The protruding portion 201 and the protruding portion 202 are opposed to each other with the through hole 205 interposed therebetween.
As shown in FIG. 9, the through-hole 205 is provided with the connecting plate 33 of the reinforcing material 3 when the reinforcing material 3 is inserted into the housing portion 20.

図９に示すように、収容部２０の突出部２０１，２０２の厚さは第１発泡部２１，第２発泡部２２の厚さより小さく、それによって、おもて面２Ｔ側および裏面２Ｂ側には、貫通口２０５を挟んでそれぞれ溝ｇ１および溝ｇ２が形成されている。おもて面２Ｔ側の溝ｇ１および裏面２Ｂ側の溝ｇ２は、それぞれ、補強材３の第１板３１および第２板３２が配置される溝である。好ましくは、おもて面２Ｔ側の溝ｇ１の幅および裏面２Ｂ側の溝ｇ２の幅は、それぞれ補強材３の第１板３１の幅および第２板３２の幅と等しいか、またはそれより僅かに広くなっており、それによって補強材３が発泡体２に装着されたときの補強材３の幅方向の移動が規制される。
おもて面２Ｔ側の溝ｇ１の深さは補強材３の第１板３１の突起３１１を含めた厚みに等しく、裏面２Ｂ側の溝ｇ２の深さは補強材３の第２板３２の突起３１２を含めた厚みに等しいことが好ましい。それによって、補強材３が収容部２０に収容されたときに第１発泡部２１、収容部２０、および、第２発泡部２２がおもて面２Ｔ側および裏面２Ｂ側において同一平面となるため、樹脂製パネル１００が完成したときの外観が良好となる。 As shown in FIG. 9, the thickness of the projecting portions 201 and 202 of the housing portion 20 is smaller than the thickness of the first foaming portion 21 and the second foaming portion 22, so that the front surface 2T side and the back surface 2B side are formed. The groove g1 and the groove g2 are formed so as to sandwich the through hole 205. The groove g1 on the front surface 2T side and the groove g2 on the back surface 2B side are grooves in which the first plate 31 and the second plate 32 of the reinforcing member 3 are arranged, respectively. Preferably, the width of the groove g1 on the front surface 2T side and the width of the groove g2 on the back surface 2B side are equal to or larger than the width of the first plate 31 and the width of the second plate 32 of the reinforcing member 3, respectively. It is slightly wider, which restricts the movement of the reinforcing material 3 in the width direction when the reinforcing material 3 is attached to the foam 2.
The depth of the groove g1 on the front surface 2T side is equal to the thickness of the first plate 31 of the reinforcing member 3 including the protrusions 311. The depth of the groove g2 on the back surface 2B side is the same as that of the second plate 32 of the reinforcing member 3. It is preferably equal to the thickness including the protrusion 312. As a result, when the reinforcing member 3 is housed in the housing portion 20, the first foamed portion 21, the housing portion 20, and the second foamed portion 22 are flush with each other on the front surface 2T side and the back surface 2B side. The appearance when the resin panel 100 is completed is good.

図９に示したように、補強材３が収容部２０に収容された状態では、突出部２０１および突出部２０２は、発泡体２の厚み方向において補強材３の第１板３１および第２板３２の間に介在している状態となる。そのため、補強材３が発泡体２に装着された後に、発泡体２のおもて面２Ｔおよび裏面２Ｂと直交する方向の補強材３の移動が、突出部２０１，２０２によって規制され、当該方向に補強材３が脱落することはない。 As shown in FIG. 9, when the reinforcing material 3 is accommodated in the accommodating portion 20, the protruding portion 201 and the protruding portion 202 have the first plate 31 and the second plate of the reinforcing material 3 in the thickness direction of the foam body 2. It is in the state of being interposed between 32. Therefore, after the reinforcement material 3 is attached to the foam body 2, the movement of the reinforcement material 3 in the direction orthogonal to the front surface 2T and the back surface 2B of the foam body 2 is restricted by the protrusions 201 and 202, and the direction is restricted. In addition, the reinforcing material 3 does not fall off.

なお、補強材３が収容部２０に収容された状態では、補強材３の第１板３１の突起３１１の先端と第２板３２の突起３１２の先端が突出部２０１および突出部２０２のそれぞれの表面に当接する。そのため、第１板３１の本体（突起３１１以外の部分）および第２板３２の本体（突起３２１以外の部分）と、突出部２０１および突出部２０２のそれぞれの表面との間には、間隙が形成される。 In the state where the reinforcing material 3 is accommodated in the accommodating portion 20, the tips of the protrusions 311 of the first plate 31 and the tips of the protrusions 312 of the second plate 32 of the reinforcing material 3 correspond to the protrusions 201 and 202, respectively. Contact the surface. Therefore, a gap is formed between the main body of the first plate 31 (the portion other than the protrusion 311) and the main body of the second plate 32 (the portion other than the protrusion 321) and the respective surfaces of the protrusion 201 and the protrusion 202. It is formed.

図５、図６および図１０に示すように、収容部２０には、第１側面２４Ｌおよび第２側面２４Ｒにおいて、補強材３が収容部２０に収容された後に補強材３の長手方向の移動を規制するための突起２０４が設けられている。すなわち、図１０に示すように、補強材３が収容部２０に収容された状態では、補強材３の第２板３２が突起２０４に当接し、それによって補強材３の外側（図１０の右側）への移動が規制される。
本実施形態の例では、突起２０４は、開口２００の開口の近傍に形成されている。 As shown in FIGS. 5, 6 and 10, in the housing portion 20, in the first side surface 24L and the second side surface 24R, the reinforcing material 3 is moved in the longitudinal direction after the reinforcing material 3 is housed in the housing portion 20. Is provided with a protrusion 204 for restricting. That is, as shown in FIG. 10, in the state where the reinforcing material 3 is accommodated in the accommodating portion 20, the second plate 32 of the reinforcing material 3 abuts on the protrusion 204, whereby the outside of the reinforcing material 3 (the right side of FIG. 10). ) Is restricted.
In the example of this embodiment, the protrusion 204 is formed near the opening of the opening 200.

図５、図７および図１０に示すように、収容部２０は、第１発泡部２１と第２発泡部２２を連結する連結部２０３を有している。連結部２０３は、補強材３を挟んで第１発泡部２１と第２発泡部２２を別体にせず、補強材３が収容部２０に収容される前後で発泡体２の一体構造を維持するために設けられている。収容部２０に連結部２０３が形成されているため、発泡体２に補強材３が収容される前後で、補強材３を境にして第１発泡部２１と第２発泡部２２の位置のずれが生じることがなく、発泡体２の寸法精度が高い。 As shown in FIGS. 5, 7, and 10, the housing portion 20 has a connecting portion 203 that connects the first foaming portion 21 and the second foaming portion 22. The connecting portion 203 does not separate the first foamed portion 21 and the second foamed portion 22 with the reinforcing material 3 interposed therebetween, and maintains the integrated structure of the foamed body 2 before and after the reinforcing material 3 is housed in the housing portion 20. It is provided for. Since the connecting portion 203 is formed in the housing portion 20, the displacement of the positions of the first foaming portion 21 and the second foaming portion 22 with the reinforcing material 3 as a boundary before and after the reinforcing material 3 is housed in the foam body 2. And the dimensional accuracy of the foam 2 is high.

本実施形態の発泡体２では、発泡体２の平面視において、収容部２０と隆起部２５が重なっているため、図１０に示すように、連結部２０３と隆起部２５は一体構造となっている。連結部２０３は、収容部２０の長手方向の両端近傍（すなわち、開口２００の近傍）に形成されて補強材３の第２板３２の両端を支持することで、安定的に補強材３を収容部２０に収容させることができる。つまり、図１０において、補強材３を突出部２０１，２０２および連結部２０３で（収容部２０の長手方向の異なる位置で）補強材３を、図１０の上方向および下方向の両方で支持することになるため、補強材３が収容部２０に収容された後に安定的に補強材３を支持することができる。 In the foam body 2 of the present embodiment, the housing portion 20 and the raised portion 25 are overlapped with each other in a plan view of the foam body 2, so that the connecting portion 203 and the raised portion 25 have an integral structure as shown in FIG. 10. There is. The connecting portion 203 is formed near both ends of the accommodating portion 20 in the longitudinal direction (that is, near the opening 200) and supports both ends of the second plate 32 of the reinforcing material 3 to stably accommodate the reinforcing material 3. It can be accommodated in the section 20. That is, in FIG. 10, the reinforcing material 3 is supported by the projecting portions 201 and 202 and the connecting portion 203 (at different positions in the longitudinal direction of the housing portion 20) in both the upward direction and the downward direction of FIG. Therefore, the reinforcing material 3 can be stably supported after being housed in the housing portion 20.

図５および図８に示すように、収容部２０には、突出部２０１，２０２の長手方向の一端に隣接して、発泡体２のおもて面２Ｔと裏面２Ｂとを貫通する貫通口２０６が形成されている。本実施形態の収容部２０の例では、突出部２０１，２０２の長手方向の両端と連結部２０３との間に貫通口２０６が形成されている。貫通口２０６を突出部２０１，２０２の長手方向の一端に隣接して設けることで、後述するように、第１開口２００Ｌまたは第２開口２００Ｒからの補強材３の突出部２０１，２０２への挿入が容易になる。 As shown in FIGS. 5 and 8, the accommodation portion 20 has a through-hole 206 adjacent to one end of the protrusions 201 and 202 in the longitudinal direction and penetrating the front surface 2T and the back surface 2B of the foam 2. Are formed. In the example of the housing portion 20 of the present embodiment, the through-hole 206 is formed between both ends of the protruding portions 201 and 202 in the longitudinal direction and the connecting portion 203. By providing the through-hole 206 adjacent to one end of the protrusions 201 and 202 in the longitudinal direction, as will be described later, the reinforcement member 3 is inserted into the protrusions 201 and 202 from the first opening 200L or the second opening 200R. Will be easier.

（３）発泡体の成形方法
次に、本実施形態の発泡体２の成形方法について、図１１Ａおよび図１１Ｂを参照して説明する。図１１Ａおよび図１１Ｂはそれぞれ、実施形態の発泡体２を成形する工程を説明する図である。
発泡体２は、図１１Ａ及び図１１Ｂに示す成形装置５０を使用してビーズ法型内発泡成形法によって成形される。図１１Ａの段階Ｓ１０に示すように、成形装置５０には対向して配置される型５１，５２が設けられる。型５１，５２はそれぞれ、空室５３，５４の一部を構成している。空室５３，５４には、冷却管４１，４２が配設されている。 (3) Molding Method of Foam Body Next, a molding method of the foam body 2 of the present embodiment will be described with reference to FIGS. 11A and 11B. FIG. 11A and FIG. 11B are views for explaining the process of molding the foam body 2 of the embodiment.
The foam 2 is molded by the bead method in-mold foam molding method using the molding device 50 shown in FIGS. 11A and 11B. As shown in step S10 of FIG. 11A, the molding apparatus 50 is provided with the molds 51 and 52 arranged to face each other. The molds 51 and 52 form a part of the vacant chambers 53 and 54, respectively. Cooling pipes 41 and 42 are arranged in the empty chambers 53 and 54.

図１１Ａにおいて、段階Ｓ１０に示す状態から型５１，５２を閉じると、段階Ｓ１１に示すように型５１，５２による密閉空間５０ａが形成される。型５１，５２が閉じられた状態で、フィーダ４３，４４を通して発泡ビーズを充填する。充填される発泡ビーズの量は、例えば密閉空間５０ａの容積の１０５〜１１０％である。次に、図１１Ｂの段階Ｓ１２に示すように、蒸気注入口５５，５６より、空室５３，５４に蒸気（例えば蒸気圧３．０〜３．５kgｆ／cm²）を、例えば１０〜３０秒間注入する。蒸気は型に形成された細孔から発泡ビーズ内の気泡、個々間の空隙に入り込み、ビーズ相互を融着させる。その後、図１１Ｂの段階Ｓ１３に示すように、冷却水注入口５７，５８から冷却水を冷却管４１，４２に注入し、型５１，５２に噴霧して型５１，５２および発泡体２を冷して発泡体２を固化させる。次いで、図１１Ｂの段階Ｓ１４に示すように型を開けて発泡体２を取り出す。発泡体２はその後、例えば５０〜７０°Ｃの部屋に１２〜２４時間置いて養生させることで硬化を促進させ、ヒケ、変形を防止する。 In FIG. 11A, when the molds 51 and 52 are closed from the state shown in step S10, a sealed space 50a formed by the molds 51 and 52 is formed as shown in step S11. With the molds 51 and 52 closed, the foam beads are filled through the feeders 43 and 44. The amount of the expanded beads to be filled is, for example, 105 to 110% of the volume of the closed space 50a. Next, as shown in step S12 of FIG. 11B, steam (for example, steam pressure of 3.0 to 3.5 kgf / cm ² ) is supplied from the steam injection ports 55 and 56 to the vacant chambers 53 and 54 for, for example, 10 to 30 seconds. inject. The vapor enters the bubbles in the expanded beads and the voids between the individual through the pores formed in the mold, and fuses the beads to each other. Then, as shown in step S13 of FIG. 11B, cooling water is injected from the cooling water inlets 57 and 58 into the cooling pipes 41 and 42 and sprayed on the molds 51 and 52 to cool the molds 51 and 52 and the foam 2. Then, the foam 2 is solidified. Next, as shown in step S14 of FIG. 11B, the mold is opened and the foam 2 is taken out. Thereafter, the foam 2 is left in a room at 50 to 70 ° C. for 12 to 24 hours for curing to accelerate the curing and prevent sink marks and deformation.

なお、図４および図５に示したように、収容部２０の長手方向において、突出部２０１，２０２と連結部２０３の間に貫通口２０６を設けているのは、型５１，５２の開閉を可能とするためでもある。仮に、突出部２０１，２０２を図４，図５に示した状態よりも外側に延伸させて発泡体２の平面視で突出部２０１，２０２の一部が連結部２０３と重なった場合には、その突出部２０１，２０２の一部がアンダーカットとなり、型の開閉（型の開閉方向は、図４において紙面に直交する方向）ができなくなる。 As shown in FIGS. 4 and 5, the through-hole 206 is provided between the projecting portions 201 and 202 and the connecting portion 203 in the longitudinal direction of the housing portion 20 to open and close the molds 51 and 52. It is also to make it possible. If the protrusions 201 and 202 are extended outward from the state shown in FIGS. 4 and 5 and part of the protrusions 201 and 202 overlaps with the connecting portion 203 in a plan view of the foam body 2, Part of the protrusions 201 and 202 becomes an undercut, and it becomes impossible to open and close the mold (the opening and closing direction of the mold is a direction orthogonal to the paper surface in FIG. 4).

（４）発泡構造体の組み立て方法
次に、本実施形態の発泡構造体１の組み立て方法について、図１２Ａおよび図１２Ｂを参照して説明する。図１２Ａおよび図１２Ｂは、それぞれ、本実施形態の発泡体２に補強材３を装着（挿入）することで発泡構造体１を組み立てる手順を説明する図である。
図１２Ａに示すように、補強材３が装着されていない発泡体２（段階Ｓ１）に対して、第１側面２４Ｌの第１開口２００Ｌまたは第２側面２４Ｒの第２開口２００Ｒから、補強材３の先端が斜め下方となるようにして突出部２０１，２０２の端部に向けて補強材３を挿入する（段階Ｓ２）。 (4) Assembling Method of Foamed Structure Next, an assembling method of the foamed structure 1 of the present embodiment will be described with reference to FIGS. 12A and 12B. FIG. 12A and FIG. 12B are views for explaining a procedure for assembling the foam structure 1 by mounting (inserting) the reinforcing material 3 on the foam 2 of the present embodiment.
As shown in FIG. 12A, with respect to the foam body 2 (step S1) to which the reinforcing material 3 is not attached, the reinforcing material 3 is provided from the first opening 200L of the first side surface 24L or the second opening 200R of the second side surface 24R. The reinforcing member 3 is inserted toward the ends of the protrusions 201 and 202 so that the tip of the reinforcing member 3 is obliquely downward (step S2).

前述したように、突出部２０１，２０２の長手方向の一端に隣接して、発泡体２のおもて面２Ｔと裏面２Ｂとを貫通する貫通口２０６が形成されているため、段階Ｓ２において補強材３の先端を貫通口２０６に入り込ませ、補強材３の第１板３１および第２板３２をそれぞれ、突出部２０１，２０２によって形成されるおもて面２Ｔ側の溝ｇ１（図９参照）および裏面２Ｂ側の溝ｇ２（図９参照）に円滑に導入させることができる。補強材３の第１板３１および第２板３２をそれぞれ溝ｇ１および溝ｇ２に導入した後は、補強材３を挿入方向にさらに押し込む。このとき、前述したように、補強材３の第１板３１の本体（突起３１１以外の部分）および第２板３２の本体（突起３２１以外の部分）と、突出部２０１および突出部２０２のそれぞれの表面との間には、間隙が形成されているため、挿入抵抗が小さく、比較的小さい押し込み力で補強材３を収容部２０内に押し込むことができる。
最終的に、補強材３の先端が突起２０４に当接し、図１２Ｂの段階Ｓ３に示すように、補強材３の両端が、収容部２０の両端にある突起２０４間にセットされ、補強材３が収容部２０に収容される。
なお、収容部２０の長手方向における貫通口２０６の長さは、補強材３の挿入容易性の観点から適宜設定してもよい。 As described above, since the through-hole 206 that penetrates the front surface 2T and the back surface 2B of the foam 2 is formed adjacent to one end of the protrusions 201 and 202 in the longitudinal direction, the reinforcement is performed in step S2. The tip of the material 3 is inserted into the through hole 206, and the first plate 31 and the second plate 32 of the reinforcing material 3 are respectively formed by the protrusions 201 and 202, and the groove g1 on the front surface 2T side (see FIG. 9). ) And the groove g2 (see FIG. 9) on the back surface 2B side can be smoothly introduced. After introducing the first plate 31 and the second plate 32 of the reinforcing member 3 into the groove g1 and the groove g2, respectively, the reinforcing member 3 is further pushed in the insertion direction. At this time, as described above, the main body (the portion other than the protrusion 311) of the first plate 31 and the main body (the portion other than the protrusion 321) of the second plate 32 of the reinforcing member 3, the protruding portion 201, and the protruding portion 202, respectively. Since a gap is formed between the surface of the reinforcing member 3 and the surface of the reinforcing member 3, the reinforcing member 3 can be pushed into the accommodating portion 20 with a relatively small pushing force.
Finally, the tip of the reinforcing member 3 comes into contact with the protrusion 204, and both ends of the reinforcing member 3 are set between the protrusions 204 at both ends of the accommodating portion 20, as shown in step S3 of FIG. 12B. Are accommodated in the accommodation section 20.
The length of the through-hole 206 in the longitudinal direction of the housing portion 20 may be appropriately set from the viewpoint of easy insertion of the reinforcing material 3.

（５）樹脂製パネルの成形方法
次に、図１３および図１４を参照して、実施形態の樹脂製パネル１００を、金型を用いて成形する装置および方法について説明する。 (5) Molding Method of Resin Panel Next, an apparatus and a method for molding the resin panel 100 of the embodiment using a mold will be described with reference to FIGS. 13 and 14.

図１３を参照すると、型締装置７０は、押出装置（図示せず）から鉛直下方に押し出された溶融樹脂シートＰ，Ｐに対して略直交する方向に、開位置と閉位置との間で移動させられる一対の分割金型７１Ａ，７１Ｂを有する。一対の分割金型７１Ａ，７１Ｂは、各々に対応する形成面７２Ａ，７２Ｂを対向させた状態で配置される。形成面７２Ａは、発泡体２のおもて面２Ｔに対応した形状となっている。 Referring to FIG. 13, the mold clamping device 70 includes a mold clamping device 70 between an open position and a closed position in a direction substantially orthogonal to the molten resin sheets P, P extruded vertically downward from an extrusion device (not shown). It has a pair of split molds 71A and 71B that can be moved. The pair of split molds 71A and 71B are arranged with the forming surfaces 72A and 72B corresponding thereto facing each other. The formation surface 72A has a shape corresponding to the front surface 2T of the foam body 2.

一対の分割金型７１Ａ，７１Ｂの各々において、各々に対応する形成面７２Ａ，７２Ｂの上下端近傍には、ピンチオフ部７４Ａ，７４Ｂが形成されている。このピンチオフ部７４Ａ，７４Ｂはそれぞれ、形成面７２Ａ，７２Ｂのまわりに環状に形成され、対向する分割金型７１Ｂ，７１Ａに向かって突出する。これにより、一対の分割金型７１Ａ，７１Ｂを型締する際、それぞれのピンチオフ部７４Ａ，７４Ｂの先端部が当接し、溶融樹脂シートＰ，Ｐの周縁にパーティングラインＰＬが形成されるようになっている。 In each of the pair of split molds 71A and 71B, pinch-off portions 74A and 74B are formed near the upper and lower ends of the corresponding forming surfaces 72A and 72B. The pinch-off portions 74A and 74B are annularly formed around the forming surfaces 72A and 72B, respectively, and project toward the facing split molds 71B and 71A. As a result, when the pair of split molds 71A and 71B are clamped, the tip ends of the pinch-off portions 74A and 74B come into contact with each other so that the parting line PL is formed on the peripheral edges of the molten resin sheets P and P. Has become.

一対の分割金型７１Ａ，７１Ｂには、形成面７２Ａ，７２Ｂの周囲において、形成面７２Ａ，７２Ｂから突出可能に摺動部７５Ａ，７５Ｂが設けられている。摺動部７５Ａ，７５Ｂは、形成面７２Ａ，７２Ｂから突出した状態において、その端面を溶融樹脂シートＰ，Ｐに接触させ、それによって溶融樹脂シートＰ，Ｐと一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂとの間に密閉空間を形成するために設けられている。 The pair of split molds 71A, 71B are provided with sliding portions 75A, 75B around the forming surfaces 72A, 72B so as to project from the forming surfaces 72A, 72B. The sliding portions 75A and 75B have their end surfaces in contact with the molten resin sheets P and P in a state of protruding from the forming surfaces 72A and 72B, whereby the molten resin sheets P and P and the pair of split molds 71A and 71B. It is provided to form a closed space between the forming surfaces 72A and 72B.

一対の分割金型７１Ａ，７１Ｂには、真空チャンバ（図示せず）が内蔵されている。真空チャンバは、真空ポンプおよび真空タンク（いずれも図示せず）と接続されている。真空チャンバと形成面７２Ａ，７２Ｂの間には、真空吸引のための連通路（図示せず）が設けられている。 A vacuum chamber (not shown) is built in the pair of split molds 71A and 71B. The vacuum chamber is connected to a vacuum pump and a vacuum tank (neither is shown). A communication passage (not shown) for vacuum suction is provided between the vacuum chamber and the forming surfaces 72A and 72B.

一対の分割金型７１Ａ，７１Ｂは、金型駆動装置（図示せず）によって、開位置と閉位置の間を移動可能となるように駆動される。開位置では、一対の分割金型７１Ａ，７１Ｂの間に、２枚の連続した溶融樹脂シートＰ，Ｐが、互いに間隔を隔てて配置可能となっている。２枚の溶融樹脂シートＰ，Ｐは、成形後に、樹脂製パネル１００における表皮材シートＳＡ，ＳＢとなる。閉位置では、一対の分割金型７１Ａ，７１Ｂのピンチオフ部７４Ａ，７４Ｂが当接する。 The pair of split molds 71A and 71B are driven by a mold driving device (not shown) so as to be movable between an open position and a closed position. At the open position, two continuous molten resin sheets P, P can be arranged at a distance between the pair of split molds 71A, 71B. The two molten resin sheets P, P become the skin material sheets SA, SB in the resin panel 100 after molding. At the closed position, the pinch-off portions 74A and 74B of the pair of split molds 71A and 71B are in contact with each other.

次に、樹脂製パネル１００の成形方法について説明する。
先ず、図１３に示したように、押出装置から溶融樹脂シートＰ，Ｐが鉛直下方に押し出され、一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂの間に供給される。この時点で、一対の分割金型７１Ａ，７１Ｂは開位置にある。 Next, a method of molding the resin panel 100 will be described.
First, as shown in FIG. 13, the molten resin sheets P, P are extruded vertically downward from the extruder and supplied between the forming surfaces 72A, 72B of the pair of split molds 71A, 71B. At this point, the pair of split molds 71A and 71B are in the open position.

次に、形成面７２Ａ，７２Ｂの周囲にある摺動部７５Ａ，７５Ｂを突出させて、その端面を溶融樹脂シートＰ，Ｐに接触させる。これにより、溶融樹脂シートＰ，Ｐと一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂとの間に密閉空間が形成される。そして、真空チャンバと形成面７２Ａ，７２Ｂの間に設けられた連通路によって、密閉空間内の空気を吸引する。この吸引により、２枚の溶融樹脂シートＰ，Ｐがそれぞれ、一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂに押圧させられ、図１４に示すように、形成面７２Ａ，７２Ｂに沿った形状、すなわち、樹脂製パネル１００の略外形に賦形（形成）される。 Next, the sliding portions 75A and 75B around the forming surfaces 72A and 72B are projected to bring their end faces into contact with the molten resin sheets P and P. As a result, a sealed space is formed between the molten resin sheets P, P and the forming surfaces 72A, 72B of the pair of split molds 71A, 71B. Then, the air in the closed space is sucked by the communication passage provided between the vacuum chamber and the forming surfaces 72A and 72B. By this suction, the two molten resin sheets P, P are pressed against the forming surfaces 72A, 72B of the pair of split molds 71A, 71B, respectively, and along the forming surfaces 72A, 72B as shown in FIG. The shape, that is, the outer shape of the resin panel 100 is shaped (formed).

次に、マニピュレータ（図示せず）を用いて一対の分割金型７１Ａ，７１Ｂの間で発泡構造体１を位置決めし、図１４に示すように、側方より一方の分割金型（図１４では、分割金型７１Ｂ）に押し付けるようにして挿入する。これにより、発泡構造体１が一方の溶融樹脂シートＰに溶着される。 Next, the foam structure 1 is positioned between the pair of split molds 71A and 71B using a manipulator (not shown), and as shown in FIG. , And insert it by pressing it against the split mold 71B). As a result, the foam structure 1 is welded to the one molten resin sheet P.

その後、一対の分割金型７１Ａ，７１Ｂを開位置から閉位置まで移動させて、型締する。これにより、一方の溶融樹脂シートＰ（図面右側）に対して溶着されていた発泡構造体１は、他方の溶融樹脂シートＰ（図面左側）に対しても溶着される。さらに、一対の分割金型７１Ａ，７１Ｂのピンチオフ部７４Ａ，７４Ｂにおいて、一対の溶融樹脂シートＰ，Ｐの周縁が溶着させられ、パーティングラインＰＬが形成される。 Then, the pair of split molds 71A and 71B are moved from the open position to the closed position, and the molds are clamped. As a result, the foamed structure 1 welded to one of the molten resin sheets P (right side in the drawing) is also welded to the other molten resin sheet P (left side in the drawing). Further, in the pinch-off portions 74A, 74B of the pair of split molds 71A, 71B, the peripheral edges of the pair of molten resin sheets P, P are welded to form a parting line PL.

最後に、一対の分割金型７１Ａ，７１Ｂを再び開位置に移動させ、成形した樹脂製パネル１００を形成面７２Ａ，７２Ｂから離間させ、パーティングラインＰＬまわりに形成されたバリを、カッター等で切断して除去する。以上で、表皮材シートＳＡ、発泡構造体１、樹脂シートＳＢが積層された樹脂製パネル１００が完成する。 Finally, the pair of split molds 71A and 71B are moved to the open position again, the molded resin panel 100 is separated from the forming surfaces 72A and 72B, and burrs formed around the parting line PL are cut by a cutter or the like. Cut and remove. As described above, the resin panel 100 in which the skin material sheet SA, the foam structure 1 and the resin sheet SB are laminated is completed.

以上、本発明の実施形態について詳細に説明したが、本発明の発泡構造体および樹脂製パネルは上記実施形態に限定されず、本発明の主旨を逸脱しない範囲において、種々の改良や変更をしてもよいのは勿論である。 Although the embodiments of the present invention have been described in detail above, the foamed structure and the resin panel of the present invention are not limited to the above embodiments, and various improvements and changes are made without departing from the gist of the present invention. Of course, it is okay.

以下、上述した実施形態の変形例について述べる。 Hereinafter, modified examples of the above-described embodiment will be described.

（変形例１）
上述した実施形態では、収容部２０の両端に第１側面２４Ｌの第１開口２００Ｌ、および、第２側面２４Ｒの第２開口２００Ｒが形成されている場合について説明したが、この限りではない。第１開口２００Ｌまたは第２開口２００Ｒのいずれか一方が形成されていれば、補強材３の収容部２０に対する挿入が容易となる。
また、収容部２０の両端が開口していなくもよい。例えば、突出部２０１，２０２の一端に隣接する貫通口２０６Ｌ，２０６Ｒのいずれか一方において、収容部２０の長手方向の開口量を長くとることで、貫通口２０６Ｌ，２０６Ｒのいずれか一方から補強材３を突出部２０１，２０２に挿入することができる。 (Modification 1)
In the above-described embodiment, the case where the first opening 200L of the first side surface 24L and the second opening 200R of the second side surface 24R are formed at both ends of the housing portion 20 has been described, but the present invention is not limited to this. If either the first opening 200L or the second opening 200R is formed, the reinforcement member 3 can be easily inserted into the housing portion 20.
Further, both ends of the housing portion 20 do not have to be open. For example, in one of the through holes 206L and 206R adjacent to one end of the protrusions 201 and 202, by increasing the opening amount in the longitudinal direction of the housing portion 20, the reinforcing material is provided from either of the through holes 206L and 206R. 3 can be inserted into the protrusions 201, 202.

（変形例２）
上述した実施形態では、連結部２０３と突起２０４が一体構造となっている例を説明したが、この限りではない。連結部２０３と突起２０４は別体であってもよい。例えば、図５の平面図において、連結部２０３と突起２０４の間に、おもて面２Ｔと裏面２Ｂを貫通する貫通口が形成されていてもよい。
なお、上述した実施形態のように、連結部２０３と突起２０４を一体構造とすることで、補強材３の端面を第１発泡部２１および第２発泡部２２の両方で支持する構成となるため、安定的に補強材３を収容させることができる。 (Modification 2)
In the above-described embodiment, the example in which the connecting portion 203 and the protrusion 204 are integrated has been described, but the present invention is not limited thereto. The connecting portion 203 and the protrusion 204 may be separate bodies. For example, in the plan view of FIG. 5, a through hole penetrating the front surface 2T and the back surface 2B may be formed between the connecting portion 203 and the protrusion 204.
Note that, as in the above-described embodiment, the end surface of the reinforcing member 3 is supported by both the first foaming portion 21 and the second foaming portion 22 by integrally forming the connecting portion 203 and the protrusion 204. Therefore, the reinforcing material 3 can be stably accommodated.

（変形例３）
上述した実施形態では、突起２０４Ｌ，２０４Ｒがそれぞれ第１開口２００Ｌ，第２開口２００Ｒの近傍に形成されている場合について説明したが、この限りではない。突起２０４Ｌ，２０４Ｒの少なくとも一方は、収容部２０の長手方向において、図５に示した位置より内側（つまり、突出部２０１，２０２側）に設けてもよい。その場合、補強材３の第２板３２が突起２０４Ｌおよび／または突起２０４Ｒに当接するように、補強材３の長手方向の長さが設定される。 (Modification 3)
In the above-described embodiment, the case where the protrusions 204L and 204R are formed near the first opening 200L and the second opening 200R, respectively, has been described, but the present invention is not limited to this. At least one of the protrusions 204L and 204R may be provided inside the position shown in FIG. 5 (that is, on the side of the protrusions 201 and 202) in the longitudinal direction of the housing portion 20. In that case, the length of the reinforcing member 3 in the longitudinal direction is set such that the second plate 32 of the reinforcing member 3 contacts the protrusions 204L and / or the protrusions 204R.

（変形例４）
上述した実施形態では、断面がＨ型形状となっている補強材３を発泡体に装着する場合について説明したが、補強材の形状はその限りではない。
図１５に、実施形態の変形例に係る発泡体２Ａを示す。図１５において、上側の図は図５に相当する平面図を示し、下側の図は上側の図のＦ−Ｆの断面図を示している。
図１５において、変形例に係る補強材３Ａは、互いに対向しつつ直線状に延伸する第１板３１Ａおよび第２板３２Ａが連結板３３Ａによって連結され、その断面がコの字状（あるいはＵの字状）をなしている。
図１５に示すように、第１発泡部２１と第２発泡部２２を連結しない部位（すなわち、図１５の突出部２０１Ａの長手方向で貫通口２０５Ａ，２０６が設けられている部位）において、第１発泡部２１から第２発泡部２２に向けて突出部２０１Ａが突出している。この変形例では、第２発泡部２２から第１発泡部２１に向けて突出する突出部は存在しない。 (Modification 4)
In the above-described embodiment, the case where the reinforcing material 3 having an H-shaped cross section is attached to the foam has been described, but the shape of the reinforcing material is not limited thereto.
FIG. 15 shows a foam body 2A according to a modified example of the embodiment. In FIG. 15, the upper diagram shows a plan view corresponding to FIG. 5, and the lower diagram shows a cross-sectional view taken along line F-F of the upper diagram.
In FIG. 15, in a reinforcing member 3A according to a modification, a first plate 31A and a second plate 32A that linearly extend while facing each other are connected by a connecting plate 33A, and the cross section thereof has a U shape (or U shape). It is shaped like a letter.
As shown in FIG. 15, at the portion where the first foamed portion 21 and the second foamed portion 22 are not connected (that is, the portion where the through holes 205A and 206 are provided in the longitudinal direction of the protrusion 201A of FIG. 15), The projecting portion 201A projects from the first foaming portion 21 toward the second foaming portion 22. In this modification, there is no protruding portion that protrudes from the second foam portion 22 toward the first foam portion 21.

図１５に示すように、突出部２０１Ａの厚さは第１発泡部２１の厚さより小さく、それによって、おもて面２Ｔ側および裏面２Ｂ側には溝ｇ１Ａおよび溝ｇ２Ａが形成されている。おもて面２Ｔ側の溝ｇ１Ａおよび裏面２Ｂ側の溝ｇ２Ａには、それぞれ、補強材３Ａの第１板３１Ａおよび第２板３２Ａが配置される。
このような構成によっても、補強材３Ａが発泡体２Ａに収容された状態では、突出部２０１Ａは、発泡体２Ａの厚み方向において補強材３Ａの第１板３１Ａおよび第２板３２Ａの間に介在している状態となる。そのため、補強材３Ａが発泡体２Ａに装着された後に、発泡体２Ａのおもて面２Ｔおよび裏面２Ｂと直交する方向の補強材３Ａの移動が突出部２０１Ａによって規制され、当該方向に補強材３Ａが脱落することはない。さらに、上述した実施形態と同様に、第１発泡部２１と第２発泡部２２を連結する連結部２０３が設けられているため、発泡体２Ａに補強材３Ａが収容される前後で、補強材３Ａを境にして第１発泡部２１と第２発泡部２２の位置のずれが生じることがなく、発泡体２Ａの寸法精度が高い。 As shown in FIG. 15, the thickness of the projecting portion 201A is smaller than the thickness of the first foaming portion 21, whereby the groove g1A and the groove g2A are formed on the front surface 2T side and the back surface 2B side. The first plate 31A and the second plate 32A of the reinforcing member 3A are arranged in the groove g1A on the front surface 2T side and the groove g2A on the back surface 2B side, respectively.
Even with such a configuration, when the reinforcing material 3A is housed in the foam 2A, the protrusion 201A is interposed between the first plate 31A and the second plate 32A of the reinforcing material 3A in the thickness direction of the foam 2A. It will be in the state of doing. Therefore, after the reinforcement member 3A is attached to the foam body 2A, the protrusion 201A restricts the movement of the reinforcement member 3A in the direction orthogonal to the front surface 2T and the back surface 2B of the foam body 2A, and the reinforcement member 3A is moved in that direction. 3A will not fall out. Further, as in the above-described embodiment, since the connecting portion 203 that connects the first foaming portion 21 and the second foaming portion 22 is provided, the reinforcing material is provided before and after the reinforcing material 3A is housed in the foam body 2A. The positional difference between the first foamed portion 21 and the second foamed portion 22 does not occur at the boundary of 3A, and the dimensional accuracy of the foamed body 2A is high.

（変形例５）
上述した実施形態の発泡構造体１は、樹脂製パネル１００の形状に応じて隆起部２５Ｌ，２５Ｒが形成されているが、この例に限られない。発泡構造体の形状は、樹脂製パネルの形状に応じて適宜設計される。例えば、発泡構造体は、平坦部のみで構成されていてもよい。平坦部のみで構成されていても、連結部２０３によって第１発泡部２１と第２発泡部２２が連結している限り、補強材３を境にして第１発泡部２１と第２発泡部２２の位置のずれが生じることがなく、発泡体２の寸法精度が高いという効果が発揮される。 (Modification 5)
In the foam structure 1 of the above-described embodiment, the raised portions 25L and 25R are formed according to the shape of the resin panel 100, but the present invention is not limited to this example. The shape of the foam structure is appropriately designed according to the shape of the resin panel. For example, the foam structure may be composed of only flat portions. Even if the first foaming part 21 and the second foaming part 22 are connected to each other by the connecting part 203, the first foaming part 21 and the second foaming part 22 are separated by the reinforcing material 3 as long as the first foaming part 21 and the second foaming part 22 are connected by the connecting part 203. There is no displacement of the position, and the effect that the dimensional accuracy of the foam 2 is high is exhibited.

なお、上述した実施形態の発泡構造体１のように、発泡体２の平面視において、補強材３の収容部２０の少なくとも一部が隆起部２５と重なっている場合、従来の方法、すなわち、別体の第１発泡部２１と第２発泡部２２を補強材３に両側から組み付ける方法を採ることが困難である。そのため、隆起部２５を平坦部２３と別体とする等の、形状精度の低下および／またはコストの増加を招来する別の方法を採らざるを得ない。それに対して、本発明を発泡構造体１に適用することで、発泡体２の平面視において、補強材３の収容部２０の少なくとも一部が隆起部２５と重なっている位置に、補強材３の収容部２０を設定することができるという利点がある。 As in the foam structure 1 of the above-described embodiment, when at least a part of the housing portion 20 of the reinforcing member 3 overlaps the raised portion 25 in the plan view of the foam body 2, a conventional method, that is, It is difficult to adopt a method of assembling the first foamed portion 21 and the second foamed portion 22 which are separate bodies from the both sides of the reinforcing material 3. Therefore, there is no choice but to adopt another method such as a method in which the raised portion 25 is separated from the flat portion 23, which leads to a decrease in shape accuracy and / or an increase in cost. On the other hand, by applying the present invention to the foam structure 1, in the plan view of the foam 2, at least a part of the accommodating portion 20 of the reinforcement 3 overlaps with the raised portion 25, and the reinforcement 3 There is an advantage that the accommodation section 20 can be set.

隆起部が形成された発泡構造体であっても、補強材の位置は所望の位置に設定してよい。例えば、発泡体の平面視において、必ずしも補強材の収容部の少なくとも一部が隆起部と重なっていなくてもよい。言い換えれば、本発明を適用することで、平坦部と隆起部を備えた発泡構造体において、補強材を所望の位置に設定することができ、設計自由度が向上する。 The position of the reinforcing material may be set to a desired position even in the foamed structure having the raised portion. For example, in a plan view of the foam, at least a part of the accommodating portion for the reinforcing material does not have to overlap the raised portion. In other words, by applying the present invention, the reinforcing material can be set at a desired position in the foam structure having the flat portion and the raised portion, and the degree of freedom in design is improved.

（変形例６）
上述した実施形態では、突出部２０１および突出部２０２が発泡体２の第１発泡部２１と第２発泡部２２を連結しない部位において形成されている場合について説明したが、この限りではない。例えば、図５に示す平面図では、突出部２０１，２０２と連結部２０３とが貫通口２０６を挟んで離間しているが、両者を平面視で重複させてもよい。例えば、発泡体２の板厚が厚い場合には、おもて面または裏面に近い部分に連結部を形成し、板厚方向の中央に突出部を形成することができる。 (Modification 6)
In the above-described embodiment, the case where the protruding portion 201 and the protruding portion 202 are formed in a portion of the foam body 2 that does not connect the first foamed portion 21 and the second foamed portion 22 has been described, but the present invention is not limited thereto. For example, in the plan view shown in FIG. 5, the projecting portions 201 and 202 and the connecting portion 203 are separated from each other with the through-hole 206 in between, but they may be overlapped in a plan view. For example, when the foam 2 has a large plate thickness, it is possible to form the connecting portion in a portion close to the front surface or the back surface and form the projecting portion in the center in the plate thickness direction.

１…発泡構造体
２…発泡体
２Ｔ…おもて面（平坦面）
２Ｂ…裏面
２１…第１発泡部
２２…第２発泡部
２０…収容部
２０１，２０２…突出部
ｇ１，ｇ２…溝
２０３Ｌ，２０３…連結部
２０４Ｌ，２０４Ｒ…突起
２０５…貫通口
２０６Ｌ，２０６Ｒ…貫通口
２４Ｌ…第１側面
２００Ｌ…第１開口
２４Ｒ…第２側面
２００Ｒ…第２開口
２３…平坦部
２５Ｌ，２５Ｒ…隆起部
３…補強材
３１…第１板
３２…第２板
３３…連結板
４１，４２…冷却管
４３，４４…フィーダ
５０…成形装置
５０ａ…密閉空間
５１，５２…型
５３，５４…空室
５５，５６…蒸気注入口
５７，５８…冷却水注入口
７０…型締装置
７１Ａ，７１Ｂ…分割金型
７２Ａ，７２Ｂ…形成面
７４Ａ，７４Ｂ…ピンチオフ部
７５Ａ，７５Ｂ…摺動部
ＳＡ，ＳＢ…表皮材シート
１００…樹脂製パネル
１２５Ｌ，１２５Ｒ…隆起部
Ｐ…溶融樹脂シート 1 ... Foamed structure 2 ... Foamed body 2T ... Front surface (flat surface)
2B ... back surface 21 ... 1st foaming part 22 ... 2nd foaming part 20 ... accommodating part 201, 202 ... projecting part g1, g2 ... groove 203L, 203 ... connecting part 204L, 204R ... projection 205 ... penetration hole 206L, 206R ... penetration Mouth 24L ... 1st side surface 200L ... 1st opening 24R ... 2nd side surface 200R ... 2nd opening 23 ... Flat part 25L, 25R ... Ridge part 3 ... Reinforcement material 31 ... 1st board 32 ... 2nd board 33 ... Connection board 41 , 42 ... Cooling pipes 43, 44 ... Feeder 50 ... Molding device 50a ... Closed space 51, 52 ... Mold 53, 54 ... Vacancy 55, 56 ... Steam injection port 57, 58 ... Cooling water injection port 70 ... Mold clamping device 71A , 71B ... Split molds 72A, 72B ... Forming surface 74A, 74B ... Pinch-off part 75A, 75B ... Sliding part SA, SB ... Skin material sheet 100 ... Resin panel 125L, 125R Ridges P ... molten resin sheet

Claims

In the foam structure in which the reinforcing material is attached to the foam,
A reinforcing member including a first plate and a second plate that linearly extend while facing each other, and a connecting plate that connects the first plate and the second plate,
A foam having a linear accommodating portion for accommodating the reinforcing material, and a first foaming portion and a second foaming portion formed with the accommodating portion interposed therebetween,
Equipped with
The accommodating portion is
A connecting portion that connects the first foaming portion and the second foaming portion,
A protruding portion protruding from at least one of the first foaming portion and the second foaming portion toward the other foaming portion,
At least a part of the protruding portion is interposed between the first plate and the second plate of the reinforcing member ,
Characterized in that it further comprises a protrusion for restricting movement of the reinforcing member in the longitudinal direction of the reinforcing member.
Foam structure.

The accommodation portion has a first opening formed on a first side surface of the foam body and a second opening formed on a second side surface of the foam body facing the first side surface. ,
The foam structure according to claim 1 .

In the foam structure in which the reinforcing material is attached to the foam,
A reinforcing member including a first plate and a second plate that linearly extend while facing each other, and a connecting plate that connects the first plate and the second plate,
A foam having a linear accommodating portion for accommodating the reinforcing material, and a first foaming portion and a second foaming portion formed with the accommodating portion interposed therebetween,
Equipped with
The accommodating portion is
A connecting portion that connects the first foaming portion and the second foaming portion,
A protruding portion protruding from at least one of the first foaming portion and the second foaming portion toward the other foaming portion,
At least a part of the protruding portion is interposed between the first plate and the second plate of the reinforcing member,
The housing portion includes a first opening formed on a first side surface of the foam body, and a second opening formed on a second side surface of the foam body facing the first side surface.
A protrusion that is formed in the vicinity of at least one of the first opening and the second opening and that restricts the movement of the reinforcing material in the longitudinal direction of the reinforcing material. To do
Foam structure .

In the accommodation portion, a through-hole penetrating the front surface and the back surface of the foam is formed adjacent to one end in the longitudinal direction of the protruding portion.
The foamed structure according to claim 1 .

In the foam structure in which the reinforcing material is attached to the foam,
A reinforcing member including a first plate and a second plate that linearly extend while facing each other, and a connecting plate that connects the first plate and the second plate,
A foam having a linear accommodating portion for accommodating the reinforcing material, and a first foaming portion and a second foaming portion formed with the accommodating portion interposed therebetween,
Equipped with
The accommodating portion is
A connecting portion that connects the first foaming portion and the second foaming portion,
A protruding portion protruding from at least one of the first foaming portion and the second foaming portion toward the other foaming portion,
At least a part of the protruding portion is interposed between the first plate and the second plate of the reinforcing member,
The foam includes a flat portion having a flat surface, and a raised portion protruding from the flat surface,
In a plan view of the foam, at least a part of the housing portion is overlapped with the raised portion,
Foam structure .

In the foam structure in which the reinforcing material is attached to the foam,
A reinforcing member including a first plate and a second plate that linearly extend while facing each other, and a connecting plate that connects the first plate and the second plate,
A foam having a linear accommodating portion for accommodating the reinforcing material, and a first foaming portion and a second foaming portion formed with the accommodating portion interposed therebetween,
Equipped with
The accommodating portion is
Connection portions formed near both ends in the longitudinal direction to connect the first foamed portion and the second foamed portion,
A protruding portion protruding from at least one of the first foaming portion and the second foaming portion toward the other foaming portion,
At least a part of the protruding portion is interposed between the first plate and the second plate of the reinforcing member,
The projecting portion is formed in a portion that does not connect the first foaming portion and the second foaming portion of the foam.
Foam structure .

A resin panel comprising: the foam structure according to any one of claims 1 to 6; and a resin sheet that covers a front surface and a back surface of the foam structure.