JP6764748B2 - Manufacturing method of resin laminate - Google Patents

Description

The present invention relates to a method for producing a resin laminate.

Conventionally, resin laminates have been used for various purposes such as automobiles, building materials, sports and leisure. The resin laminate has a structure in which a foamed structure containing one or more foams made of foamed resin is covered with a skin material sheet.
Among such resin laminates, those having protrusions or recesses are known. For example, Patent Document 1 describes a deck board (an example of a resin laminate) in which a hook accommodating portion for accommodating and holding a hook is formed. According to Reference 1, in the concave fitting recess of the hook accommodating portion, the hook is securely fitted by making the width dimension on the inlet side in the depth direction smaller than the width dimension on the back side in the depth direction. It is said that it can be held in the joint recess.

Japanese Patent No. 5779888

Conventionally, the foam in the portion of the resin laminate having irregularities formed on the surface tends to have a large dimensional variation because it is difficult for beads to enter the mold during molding. Therefore, the skin material sheet covering the foam is formed so as to secure a predetermined gap between the foam and the foam in consideration of the dimensional variation of the foam in the portion where the unevenness is formed. Further, in the portion of the resin laminate in which irregularities are formed on the surface, the molten resin sheet is not evenly formed along the molding surface of the mold during molding of the skin material sheet, and the corners of the irregularities tend to be thin. For these reasons, the rigidity of the portion of the resin panel on which the surface is formed tends to decrease locally.

From this point of view, an object of the present disclosure is to prevent a local decrease in rigidity of the resin laminate.

One aspect of the present disclosure is a method for producing a resin laminate in which a foam is covered with a skin material, wherein convex portions or concave portions are formed in the resin laminate to form corner portions.
The manufacturing method is
A step of arranging a pair of molten resin sheets in front of a first dividing die having a first forming surface and a second dividing die having a second forming surface, respectively.
A step of pressing the pair of molten resin sheets against the first forming surface of the first dividing die and the second forming surface of the second dividing die, respectively.
A step of arranging the foam between the pair of molten resin sheets pressed against the first forming surface and the second forming surface, and
The process of molding the first split mold and the second split mold, and
With
The first forming surface is provided with a mold concave portion or a mold convex portion for forming a convex portion or a concave portion of the resin laminate.
The volume of the portion of the foam arranged in the step of arranging the foam facing the molten resin sheet pressed against the concave portion of the mold or the convex portion of the mold is the pair of the foam after the mold is compacted. The volume defined between the molten resin sheets is larger than the volume of the portion facing the molten resin sheet pressed against the mold concave portion or the mold convex portion.
This is a method for manufacturing a resin laminate.

In the method for manufacturing the resin laminate, the mold concave portion or the mold convex portion may have an undercut shape.

In the method for manufacturing the resin laminate, the recess of the resin laminate may be a portion for fitting another member.

It is possible to prevent a local decrease in rigidity of the resin laminate.

A perspective view of the resin panel of the first embodiment and an enlarged fracture view of a part thereof. The hook accommodating portion of the resin panel of the first embodiment, and the perspective enlarged view of the hook. An enlarged plan view of a part of the hook accommodating portion of the resin panel of the first embodiment. FIG. 3 is an enlarged cross-sectional view taken along the line AA of FIG. The figure explaining the process of molding the skin material of the resin panel of 1st Embodiment. The figure explaining the process of molding the skin material of the resin panel of 1st Embodiment. The figure which shows the molding process about a part of the hook accommodating part of the resin panel of 1st Embodiment in order. The figure which shows the molding process about a part of the hook accommodating part of the resin panel of 1st Embodiment in order. The figure which shows the molding process about a part of the hook accommodating part of the resin panel of 1st Embodiment in order. The figure which shows the process at the time of welding the foam | foam which concerns on the modification of 1st Embodiment to a molten resin sheet. The figure which shows the molding process about a part of the resin panel of 2nd Embodiment in order.

(1) First Embodiment Hereinafter, a resin panel 1 (an example of a resin laminate), which is an embodiment of the present invention, and a foam 2 contained in the resin panel 1 will be described. The resin panel 1 of the present embodiment is provided with a hook accommodating portion 10 (described later) for attaching a hook.

(1-1) Resin panel 1 and foam 2
First, the configurations of the resin panel 1 of the present embodiment and the foam 2 contained in the resin panel 1 will be described with reference to FIGS. 1 to 4.
FIG. 1 is a perspective view of the front side of the resin panel 1 of the present embodiment and an enlarged fracture view of a part thereof. FIG. 2 is an enlarged perspective view of the hook accommodating portion 10 and the hook 20 of the resin panel 1 of the present embodiment. FIG. 3 is an enlarged plan view of a part of the hook accommodating portion 10 of the resin panel 1 of the present embodiment. FIG. 4 is an enlarged cross-sectional view taken along the line AA of FIG.

As shown in FIG. 1, the outer shape of the resin panel 1 according to the embodiment includes a front surface 1a and a back surface 1b which are flat surfaces, and a side wall surface 1c interposed between the front surface 1a and the back surface 1b. Consists of. The front surface 1a, the back surface 1b, and the side wall surface 1c are composed of a skin material sheet S made of a thermoplastic resin, and a foam 2 is contained therein. That is, the resin panel 1 has a structure in which the foam 2 is covered with the skin material sheet S of the thermoplastic resin.
On the front side of the resin panel 1, a hook accommodating portion 10 recessed from the front surface 1a is formed. The hook accommodating portion 10 is provided for accommodating the hook 20 (see FIG. 2).

In the resin panel 1 of the embodiment, the skin material sheet S to be the skin material sheet is not limited to the resin material, but is preferably formed of a non-foamed resin in order to secure the rigidity of the resin panel 1. For example, in consideration of moldability, the skin material sheet S may be made by mixing polystyrene (PS) and styrene ethylenebutylene styrene block copolymer resin (SEBS) with polypropylene (PP) as a main material.

In the resin panel 1 of the embodiment, the foam 2 is molded using, for example, a thermoplastic resin. The resin material is not limited, and includes, for example, any of polyolefins such as polypropylene and polyethylene, acrylic derivatives such as polyamide, polystyrene and polyvinyl chloride, or a mixture of two or more kinds. The foaming ratio of the foam 2 is not particularly limited, but is, for example, in the range of 1.5 to 60 times, typically 20 times or 30 times, preferably 10 to 45 times, and more preferably 15 times. ~ 35 times. The foaming 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.

Examples of the foaming agent that can be used for the foam 2 in the resin panel 1 of the embodiment include known physical foaming agents, chemical foaming agents, and mixtures thereof. For example, as the physical foaming agent, an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, and an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, and dichloroethane can be applied. Examples of the chemical foaming agent include azodicarboxylic amide (ADCA), N, N'-dinitrosopentamethylenetetramine, 4,4'-oxybis (benzenesulfonylhydrazide), and diphenylsulfone-3,3'-disulfonyl. Organic foaming agents such as hydrazide, p-toluenesulfonyl semicarbazide, trihydradinotriazine or azobisisobutyronitrile, citric acid, oxalic acid, fumaric acid, phthalic acid, malic acid, tartaric acid, cyclohexane-1,2-dicarboxylic acid , A mixture of polycarboxylic acids such as gyonoic acid, ethylenediamine tetraacetic acid, triethylenetetramine hexaacetic acid, and nitriloic acid and inorganic carbonate compounds such as sodium hydrogen carbonate, sodium hydrogen carbonate aluminum, potassium hydrogen carbonate, ammonium hydrogen carbonate, and ammonium carbonate. , Salts of polycarboxylic acids such as sodium dihydrogen citrate and potassium oxalate are mentioned as inorganic foaming agents.

The skin material sheet S 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 non-woven fabric, glass beads, glass flakes, glass powder, and milled glass. Examples of the type of glass include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, quartz, low dielectric constant glass, high dielectric constant glass and the like.
In addition to the glass filler, talc, calcium carbonate, wollastonite, an inorganic filler such as a magnesium-based material, carbon fiber, or the like may be mixed to increase the rigidity.

As shown in FIG. 2, the hook 20 housed in the hook accommodating portion 10 of the resin panel 1 includes a hook main body portion 22 and a connected member 24 connected to the hook main body portion 22. The hook main body 22 has a substantially J-shape, and is formed of, for example, metal or plastic. The fitted portion 22a of the hook main body portion 22 is a portion to be fitted by the fitting recess 13 of the hook accommodating portion 10.

As shown in FIGS. 2 and 3, the hook accommodating portion 10 includes a first accommodating portion 12 accommodating the hook main body portion 22 of the hook 20 and a second accommodating portion 14 accommodating the connected member 24 of the hook 20. Be prepared.
A fitting recess 13 for fitting with the fitted portion 22a of the hook main body 22 and holding the hook 20 is formed between the first accommodating portion 12 and the second accommodating portion 14. The fitting recess 13 is formed by protrusions 16 and 18 protruding from the contact surface 10s with which the hook 20 is abutted in the hook accommodating portion 10 toward the front surface 1a.

As shown in the AA cross section of FIG. 4, the fitting recess 13 has a bottom surface 130 and a side wall surface 131 so that the fitted portion 22a of the hook 20 (indicated by a virtual line in FIG. 4) is accommodated. It has a concave shape consisting of 132. The depth of the fitting recess 13 may be set according to the shape and dimensions of the fitted portion 22a, but is, for example, about the same as the thickness of the fitted portion 22a.

Corner portions 133 and 134 are formed at the ends of the fitting recess 13, that is, between the side wall surfaces 131 and 132 and the front surface 1a. The corner portions 133 and 134 are located at the ends of the protruding portions 16 and 18, respectively, and project in the directions facing each other. That is, as shown in FIG. 4, since the width of the fitting recess 13 at the position near the front surface 1a is narrower than the width at the position near the bottom surface 130, the fitting recess 13 is once accommodated in the fitting recess 13. It is configured to hold the fitted portion 22a so that the fitted portion 22a does not easily come off from the fitting recess 13.

(1-2) Method for Molding Resin Panel 1 Next, a method for molding the resin panel 1 of the embodiment using a mold will be described with reference to FIGS. 5 and 6. 5 and 6 are diagrams for explaining the steps of molding the skin material sheet S of the resin panel 1 of the present embodiment, respectively. Note that FIGS. 5 and 6 show a cross section when the mold is cut with a cross section including the line AA of FIG. 3, respectively.

Referring to FIG. 5, the mold clamping device 70 is located between the open position and the closed position in a direction substantially orthogonal to the molten resin sheets P and P extruded vertically downward from the extruder (not shown). It has a pair of split molds 71A and 71B that can be moved. The pair of split dies 71A and 71B are arranged so that the corresponding forming surfaces 72A and 72B face each other. The forming surfaces 72A and 72B have a shape corresponding to the front surface 1a and the back surface 1b of the resin panel 1.

In each of the pair of split dies 71A and 71B, pinch-off portions 74A and 74B are formed in the vicinity of the upper and lower ends of the forming surfaces 72A and 72B corresponding to each. The pinch-off portions 74A and 74B are formed in an annular shape around the forming surfaces 72A and 72B, respectively, and project toward the opposing split dies 71B and 71A. As a result, when the pair of split dies 71A and 71B are molded, the tips of the pinch-off portions 74A and 74B come into contact with each other, and a parting line is formed on the peripheral edges of the molten resin sheets P and P. ing.

The pair of split dies 71A and 71B are provided with sliding portions 75A and 75B so as to be able to project from the forming surfaces 72A and 72B around the forming surfaces 72A and 72B. The sliding portions 75A and 75B are brought into 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 dies 71A and 71B are formed. It is provided to form a closed space between the forming surfaces 72A and 72B.

A vacuum chamber (not shown) is built in the pair of split dies 71A and 71B. The vacuum chamber is connected to a vacuum pump and a vacuum tank (neither shown). A communication passage (not shown) for vacuum suction is provided between the vacuum chamber and the forming surfaces 72A and 72B.

The pair of split molds 71A and 71B are driven by a mold driving device (not shown) so as to be movable between the open position and the closed position. In the open position, two continuous molten resin sheets P and P can be arranged between the pair of split dies 71A and 71B at intervals from each other. The two molten resin sheets P and P become the skin material sheet S in the resin panel 1 after molding. In the closed position, the pinch-off portions 74A and 74B of the pair of split dies 71A and 71B come into contact with each other.

Next, the molding method of the resin panel 1 will be described.
First, as shown in FIG. 5, the molten resin sheets P and P are extruded vertically downward from the extruder and supplied between the forming surfaces 72A and 72B of the pair of split dies 71A and 71B. At this point, the pair of split dies 71A and 71B are in the open position.

Next, the sliding portions 75A and 75B around the forming surfaces 72A and 72B are projected, and the end surfaces thereof are brought into contact with the molten resin sheets P and P. As a result, a closed space is formed between the molten resin sheets P and P and the forming surfaces 72A and 72B of the pair of split dies 71A and 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 and P are pressed against the forming surfaces 72A and 72B of the pair of split dies 71A and 71B, respectively, and along the forming surfaces 72A and 72B as shown in FIG. It is shaped (formed) into a shape, that is, a substantially outer shape of the resin panel 1.

Next, the foam 2 assembled as described above is positioned between the pair of split dies 71A and 71B using a manipulator (not shown), and as shown in FIG. 6, one of the foams 2 is positioned from the side. It is inserted by pressing it against the split die (split die 71B in FIG. 6). As a result, the foam 2 is welded to one of the molten resin sheets P, and the foam 2 is arranged between the pair of molten resin sheets P pressed against the forming surfaces 72A and 72B.

After that, the pair of split dies 71A and 71B are moved from the open position to the closed position to perform mold clamping. As a result, the foam 2 that has been welded to one molten resin sheet 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 and 74B of the pair of split dies 71A and 71B, the peripheral edges of the pair of molten resin sheets P and P are welded to form a parting line PL.

Finally, the pair of split dies 71A and 71B are moved to the open position again, the molded resin panel 1 is separated from the forming surfaces 72A and 72B, and the burrs formed around the parting line PL are removed by a cutter or the like. Cut and remove. With the above, the resin panel 1 having a structure in which the foam 2 is covered with the skin material sheet S is completed.
In the above-mentioned molding method of the resin panel 1, the case where the molten resin sheet P is pressed against the forming surfaces 72A and 72B of the pair of split dies 71A and 71B by suction has been described, but this is not the case. The molten resin sheet P may be pressed against the forming surfaces 72A and 72B of the pair of split dies 71A and 71B by blowing a fluid such as air on the molten resin sheet P (blow molding).

(1-3) About molding of the fitting recess 13 of the hook accommodating portion 10 Next, referring to FIGS. 7A to 7C, in the molding process of the resin panel 1, the fitting recess 13 of the hook accommodating portion 10 The molding will be described in more detail. 7A to 7C are views showing the molding steps in order (that is, in the order of S1 to S5) for the fitting recess 13 of the hook accommodating portion 10 of the resin panel.

As shown in FIG. 7A, the split mold 71A is provided with a mold convex portion 73 protruding from the surrounding forming surface 72A corresponding to the concave fitting recess 13. The mold convex portion 73 has a convex shape including a top surface 730 corresponding to the bottom surface 130 of the fitting recess 13 and side wall surfaces 731 and 732 corresponding to the side wall surfaces 131 and 132 of the fitting recess 13, respectively. ..
Corner portions 733 and 734 corresponding to the corner portions 133 and 134 of the fitting recess 13 are formed between the side wall surfaces 731 and 732 and the forming surface 72A, respectively. As shown in FIG. 7A, the corners 733 and 734 have an undercut shape.

S1 of FIG. 7A shows a state in which the molten resin sheet P is supplied between the forming surface 72A provided with the mold convex portion 73 and the forming surface 72B (not shown in FIG. 7A). ..
In S2 of FIG. 7A, the molten resin sheet P was pressed against the forming surface 72A and the mold convex portion 73 by the suction described above, and was shaped (formed) along the shapes of the forming surface 72A and the mold convex portion 73. Indicates the state. At this time, as shown in the figure, the corner portions 733 and 734 of the mold convex portion 73 are portions where the surface shape changes significantly between the forming surface 72A and the side wall surfaces 731 and 732, and the corner portions 733 and 734 have a large change. Since the molten resin sheet P is not sufficiently sucked, the thickness of the molten resin sheet P becomes thinner than that of other portions. This is even more so because the corners 733 and 734 of the convex portion 73 of the mold have an undercut shape and are recessed inward from the side wall surfaces 731 and 732.

Next, the foam 2 is positioned between the pair of split dies 71A and 71B and pressed against the split dies 71B from the side, so that the foam 2 is divided into the dies 71B as shown in S3 of FIG. 7B. It is welded to the molten resin sheet P formed by.

After that, the pair of split dies 71A and 71B are moved from the open position to the closed position to perform mold clamping. When the pair of split dies 71A and 71B are molded and the distance between the pair of split dies 71A and 71B is narrowed, first, the surface 2s of the foam 2 is convex as shown in S4 of FIG. 7C. It comes into contact with the molten resin sheet P welded to the top surface 730 of the portion 73. Further, the distance between the pair of split dies 71A and 71B is narrowed, and the state when the mold clamping is completed is shown in S5 of FIG. 7C.

Here, in the molding method of the present embodiment, the foam 2 arranged between the pair of molten resin sheets P in S4 (or S3 in FIG. 7B) of FIG. 7C was pressed against the convex portion 73 of the mold. The portion facing the molten resin sheet P is a portion 2g of the foam 2 sandwiched between the surfaces PH and PL defined by the molten resin sheet P on the side wall surfaces 731 and 732 of the convex portion 73 of the mold. The volume of the portion 2g of the foam 2 is the molten resin sheet pressed against the mold convex portion 73 of the volume defined between the pair of molten resin sheets P after molding (that is, in S5). It is molded so as to be larger than the volume PA of the portion facing P (the portion sandwiched between the surfaces PH and PL). That is, the foam 2 is molded so that the volume of the portion 2 g of the foam 2 is larger than the volume PA.
By making the volume of the portion 2g of the foam 2 larger than the volume of the region PA, the surplus portion of the portion 2g of the foam 2 is effectively applied to the corners 733 and 734 of the convex portion 73 of the mold after the molding is performed. You can get in.

As shown in S4 of FIG. 7C, the foam 2 according to an example of the present embodiment does not have a concave shape corresponding to the convex portion 73 of the mold, and has a surface welded to the molten resin sheet P. The surface 2s on the opposite side is flat. As a result, the volume of the portion 2g of the foam 2 is larger than the volume of the region PA.

In the mold clamping of the pair of split molds 71A and 71B, since the foam 2 does not have a recess corresponding to the mold convex portion 73, the surplus portion of the foam 2 portion 2 g is the side wall surface of the mold convex portion 73. The foam 2 is deformed between the molten resin sheets P and P so as to wrap around 731 and 732 and fill the corners 733 and 734. As a result, as shown in S5 of FIG. 7C, a part of the foam 2 sufficiently enters the corners 733 and 734 of the convex portion 73 of the mold in which the molten resin sheet is thinner than the other portions. Therefore, it is possible to prevent a local decrease in rigidity at the corners 133 and 134 of the resin panel 1 after completion.

Since the fitting recess 13 of the resin panel 1 is a portion for fitting the hook 20 which is another member, the above-mentioned molding method is particularly effective. That is, as shown in FIG. 4, since the fitting recess 13 is configured to hold the fitted portion 22a of the hook 20 by the corner portions 133 and 134, when the hook 20 is repeatedly attached and detached, the fitted portion 22a Will repeatedly interfere with the corners 133 and 134. At this time, as described above, since the corner portions 133 and 134 of the present embodiment are sufficiently filled with the foam, plastic deformation is unlikely to occur even if there is repeated interference, and the holding function of the hook 20 is maintained for a long time. be able to.

(1-4) Deformation Example of First Embodiment In FIG. 7C, a case where the surface 2s on the side opposite to the surface welded to the molten resin sheet P in the foam 2 is flat is illustrated. The shape of the foam 2 is not limited to this.
FIG. 8 shows the foam 2A according to the displacement example, which has a shape different from that of the foam 2 of FIG. 7C. In FIG. 8, similarly to S3 in FIG. 7B, the foam 2A is arranged between the pair of molten resin sheets P pressed against the forming surfaces 72A and 72B of the pair of split dies 71A and 71B. Is shown. In the foam 2A shown in FIG. 8, the concave portion 2Ah is formed so as to face the convex portion 73 of the mold.

Here, the width L2 of the recess 2Ah is smaller than the distance L1 of the surfaces PH and PL defined by the molten resin sheets P on the side wall surfaces 731 and 732 of the mold convex portion 73 (L1 <L2). As a result, the volume of the portion 2Ag of the foam 2A (the portion of the foam 2 sandwiched between the surfaces PH and PL) is larger than the volume of the region PA (see FIG. 7C). In this case as well, as in the case of FIG. 7C, the surplus portion of the foam 2A is inserted into the corners 733 and 734 of the mold convex portion 73 whose molten resin sheet is thinner than the other portions. be able to.
In this modification, the concave portion 2Ah is only an example, and the volume of the foam portion before molding facing the molten resin sheet P pressed against the convex portion 73 of the mold faces the molten resin sheet P. The foam may be in any form as long as it is larger than the volume PA of the portion after molding.

(2) Second Embodiment Next, the second embodiment will be described with reference to FIG. In the first embodiment, the case where the concave portion (fitting concave portion 13) is formed on the surface of the resin panel 1 has been described, but in the present embodiment, the convex portion is formed on the surface of the resin panel 1. The case will be described.
FIG. 9 is a diagram showing sequentially the molding steps of a part of the resin panel of the second embodiment. FIG. 9S3a shows a state in which the foam 2B is arranged between the pair of molten resin sheets P pressed against the forming surfaces of the pair of split dies 71Aa and 71Ba, similarly to S3 of FIG. 7B. ing. S5a in FIG. 9 shows a state when mold clamping is completed, as in S5 in FIG. 7C.

The split mold 71Aa is formed with a mold recess 83 for forming a convex portion on the surface of the resin panel of the present embodiment. The forming surface of the split mold 71Ba is a flat surface like the split mold 71B of the first embodiment.
As shown in FIG. 9, the mold recess 83 includes a bottom surface 830, side wall surfaces 831 and 832, and corners 833 and 834 interposed between the bottom surface 830 and the side wall surfaces 831 and 832. The side wall surfaces 831 and 832 are curved, thereby forming an undercut shape from the side wall surfaces 831 and 832 to the corners 833 and 834.

Since the corners 833 and 834 are recessed in the mold recess 83 and the molten resin sheet P is difficult to be pressed, the thickness of the molten resin sheet P pressed by the corners 833 and 834 is the bottom surface 830 and the side. It becomes thinner than that pressed against the wall surfaces 831 and 832.

Here, the portion of the foam 2B arranged between the pair of molten resin sheets P in S3a of FIG. 9 facing the molten resin sheet P pressed against the mold recess 83 is a corner of the mold recess 83. It is a portion 2Bg of the foam 2 sandwiched between the surfaces PH and PL defined by the molten resin sheet P on the portions 833 and 834. The volume of the portion 2Bg of the foam 2B is the volume defined between the pair of molten resin sheets P after molding (that is, in S5a), and the molten resin sheet P is pressed against the mold recess 83. The foam 2B is molded so as to have a volume larger than the volume PA of the portion facing the surface (the portion sandwiched between the surfaces PH and PL). That is, in FIG. 9, the foam 2B is molded so that the volume of the portion 2g of the foam 2B is larger than the volume PA. Specifically, as shown in S3a of FIG. 9, the foam 2B according to the example of the present embodiment has a convex formation having a volume larger than the volume of the mold recess 83.
By making the volume of the portion 2Bg of the foam 2B larger than the volume PA, the surplus portion of the portion 2Bg of the foam 2B can be effectively inserted into the corners 833 and 834 of the mold recess 83 after the molding is performed. be able to.

In the mold clamping of the pair of split molds 71A and 71B, the foam 2B is formed between the molten resin sheets P and P so that the excess portion of the foam 2B fills the corners 833 and 834 of the mold recess 83. Deform. As a result, as shown in S5a of FIG. 9, one of the foams 2B is sufficiently formed in the corners 833 and 834 of the mold recess 83 in which the molten resin sheet is thinner than the other parts after molding. Since the portion is inserted, the local rigidity of the corner portion of the convex portion of the resin panel after completion (not shown; the portion formed corresponding to the corner portion 833, 834 of the mold recess 83) is reduced. Can be prevented.

Although each embodiment of the present invention has been described in detail above, the method for producing a resin laminate according to the present invention is not limited to each of the above embodiments, and various improvements and modifications are made without departing from the gist of the present invention. Of course, you may do.

In the first embodiment described above, a method of using a mold having a convex portion of the mold for molding a resin panel having a concave portion formed on the flat surface will be described, and in the second embodiment, the flat surface will be formed. A method of using a mold having a mold recess for molding a resin panel having a convex portion has been described. However, the shape of the concave portion of the resin panel and the corresponding convex portion of the mold, and the shape of the convex portion of the resin panel and the corresponding concave portion of the mold are merely examples, and the appearance and function of the resin panel can be improved. Various forms can be taken depending on the situation. For example, the upper surface of the convex portion of the resin panel and / or the bottom surface of the concave portion of the resin panel may be curved rather than flat, and the convex portion and / or the side wall surface of the concave portion of the resin panel may have a step. It may be formed.

In each of the above-described embodiments, the case where the convex portion of the mold and the concave portion of the mold have an undercut shape has been described, but this is not the case. When the convex portion or the concave portion of the mold has an undercut shape, the corner portion of the convex portion or the concave portion of the mold is located deeper than when there is no undercut shape, so that the molten resin is pressed. The sheet tends to be thin, but even in that case, according to the molding method of the present invention, the corner portion is filled with the foamed resin by the surplus portion of the foam before molding, and the local decrease in rigidity is prevented. ..
Since the mold convex portion and the mold concave portion shown in FIGS. 7 and 9, respectively, have a relatively shallow undercut shape, there is no problem in mold clamping and mold opening of the split molds 71A and 71B, but there is a problem. If there is, you may take measures such as dividing one of the molds so as not to hinder the mold clamping and mold opening.

1 ... Resin panel (example of resin laminate)
1a ... Front surface 1b ... Back surface 1c ... Side wall surface S ... Skin material sheet 2, 2A, 2B ... Foam 2g, 2Ag, 2Bg ... Foam part 2Ah ... Recess 10 ... Hook accommodating part 10s ... Contact surface 12 ... 1st accommodating portion 13 ... Fitting recess 130 ... Bottom surface 131, 132 ... Side wall surface 133, 134 ... Corner portion 14 ... 2nd accommodating portion 16, 18 ... Protruding portion 20 ... Hook 22 ... Hook body portion 22a ... Fitted Part 24 ... Connected member 70 ... Mold clamping device 71A, 71B, 71Aa, 71Ba ... Split mold 72A, 72B ... Forming surface 73 ... Mold convex part 730 ... Top surface 731,732 ... Side wall surface 733, 734 ... Corner 74A, 74B ... Pinch-off part 75A, 75B ... Sliding part 83 ... Mold recess 830 ... Bottom surface 831,832 ... Side wall surface 833,834 ... Corner P ... Molten resin sheet PL, PH ... Surface PA ... Volume

Claims (3)

It is a method of manufacturing a resin laminate in which a foam is covered with a skin material, and a convex portion or a concave portion is formed in the resin laminate to form a corner portion.
The manufacturing method is
A step of arranging a pair of molten resin sheets in front of a first dividing die having a first forming surface and a second dividing die having a second forming surface, respectively.
A step of pressing the pair of molten resin sheets against the first forming surface of the first dividing die and the second forming surface of the second dividing die, respectively.
A step of arranging the foam between the pair of molten resin sheets pressed against the first forming surface and the second forming surface, and
The process of molding the first split mold and the second split mold, and
With
The first forming surface is provided with a mold concave portion or a mold convex portion for forming a convex portion or a concave portion of the resin laminate.
The volume of the portion of the foam arranged in the step of arranging the foam facing the molten resin sheet pressed against the concave portion of the mold or the convex portion of the mold is the pair of the foam after the mold is compacted. The volume defined between the molten resin sheets is larger than the volume of the portion facing the molten resin sheet pressed against the mold concave portion or the mold convex portion.
A method for manufacturing a resin laminate. The mold concave portion or the mold convex portion has an undercut shape.
The method for producing a resin laminate according to claim 1. The recessed portion of the resin laminate is a portion for fitting another member.
The method for producing a resin laminate according to claim 1 or 2.

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