JP6997374B2 - Resin panel - Google Patents

Description

The present invention relates to a resin panel and a manufacturing method.

Patent Document 1 discloses a resin panel formed by incorporating a spacer member made of a foam of a thermoplastic resin in a hollow portion.

Japanese Unexamined Patent Publication No. 2000-218682

By the way, for example, a hole portion not found in the hollow resin molded body may be provided in the spacer member. In such a case, sink marks may occur on the surface of the resin molded product, resulting in poor appearance.

The present invention has been made in view of such circumstances, and provides a resin panel capable of suppressing the occurrence of sink marks on a resin molded body.

According to the present invention, a resin panel including a hollow resin molded body and a spacer member, wherein the spacer member is arranged in the resin molded body and has a penetrating or non-penetrating hole portion, and the spacer is provided. A resin panel is provided in which the front surface and the back surface of the member are in close contact with the resin molded body so that the hole portion does not become a closed space.

As a result of investigating the cause of sink marks in the resin molded body, when the spacer member has a hole, the spacer member comes into close contact with the resin molded body around the hole, and the inside of the hole becomes a closed space. It was found that sink marks occur due to the contraction of the air inside. Then, based on this finding, it was found that it is possible to suppress the occurrence of sink marks in the resin molded body by constructing the resin panel so that the holes do not become a closed space, and the present invention has been completed. It was.

Hereinafter, various embodiments of the present invention will be illustrated.
Preferably, it is the resin panel described above, wherein the spacer member is a resin panel provided with an air escape path communicating with the hole portion.
Preferably, it is the resin panel described above, wherein a gap is provided between the outer peripheral side surface of the spacer member and the resin molded body, and the air escape path is connected from the hole to the gap. Is.
Preferably, the resin panel according to the above description, wherein the resin molded body is provided with an air-opening through hole connecting the inside and the outside of the resin molded body, and the air escape path is the air-opening through hole portion. It is a resin panel that connects to the holes.
Preferably, it is the resin panel described above, wherein the spacer member is provided with a groove connected to the hole portion on the surface thereof, and the groove constitutes the air escape path.
Preferably, it is the resin panel described above, wherein the spacer member is provided with a communication hole connected to the hole portion, and the communication hole constitutes the air escape path.
Preferably, the resin panel according to the above description is provided with an air-open through hole connecting the inside and the outside of the resin molded body, and the air-open through hole is provided at a position facing the hole. It is a resin panel provided.
Preferably, in the resin panel described above, the surface of the resin molded body has a stepped shape, the spacer member also has a stepped shape following the stepped shape, and the stepped shape faces the hole portion. It is a resin panel provided at the position where it is used.
Preferably, it is the resin panel described above, and the hole portion is a resin panel provided so as to penetrate the spacer member.
Preferably, it is the resin panel described above, and the hole portion is a resin panel provided so as not to penetrate the spacer member.
According to another aspect of the present invention, it is a method for manufacturing a resin panel including a hanging step, an inserting step, and a mold clamping step, and in the hanging step, a first method is provided between the first and second molds. The 1st and 2nd resin sheets are hung down, the spacer member is fixed to the 1st resin sheet in the insert process, the 1st and 2nd molds are molded in the mold clamping step, and the spacer member is formed into a hole. A method is provided that comprises a portion and is configured such that the hole is not a closed space.
Preferably, it is the method described above, wherein the spacer member is provided with an air escape path communicating with the hole.

It is a perspective view of the resin panel 1 which concerns on 1st Embodiment of this invention. It is a perspective view seen from the opposite side of FIG. 3A is a cross-sectional view of a surface of the resin panel 1 of FIG. 1 passing through the center in the width direction, and FIG. 3B is a front view of FIG. 3A. 4A is an enlarged view of the region A in FIG. 3A, and FIG. 4B is an enlarged view of the region B in FIG. 3B. It is a perspective view of the spacer member 3 provided with a hole 3a and a groove 3b. 6A is a cross-sectional view of a surface of the spacer member 3 of FIG. 5 passing through the center in the width direction, and FIG. 6B is a front view of FIG. 6A. It is sectional drawing enlarged view when the position of the spacer member 3 of FIG. 4B is displaced and attached. It is a figure which shows an example of the molding machine 10 which can be used in the manufacturing method of a resin panel 1. FIG. 8 is an enlarged view of the vicinity of the molds 21 and 22 in FIG. It is a figure which shows the state which the 1st and 2nd resin sheets 23a, 23b were sucked under reduced pressure from the state of FIG. It is a figure showing the state in which the spacer member 3 was welded to the 1st resin sheet 23a. It is sectional drawing which shows the state which the 1st and 2nd molds 21 and 22 are molded. 13A is a perspective view of the spacer member 3 of the resin panel 1 of the second embodiment of the present invention, and FIG. 13B is a cross-sectional view of a surface of the spacer member 3 of FIG. 13A passing through the center in the width direction. 14A is a perspective view of the spacer member 3 of the resin panel 1 of the third embodiment of the present invention, and FIG. 14B is a cross-sectional view of a surface of the spacer member 3 of FIG. 14A passing through the center in the width direction. 15A is a perspective view of the resin panel 1 of the fourth embodiment of the present invention, and FIG. 15B is a cross-sectional view of a surface of the resin panel 1 of FIG. 15A passing through the center in the width direction. 16A is a perspective view of the spacer member 3 of the resin panel 1 of the fourth embodiment of the present invention, and FIG. 16B is a cross-sectional view of a surface of the spacer member 3 of FIG. 16A passing through the center in the width direction.

Hereinafter, embodiments of the present invention will be described. The various features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each characteristic item.

1. 1. First Embodiment 1-1. Resin panel 1
As shown in FIGS. 1 to 6, the resin panel 1 according to the embodiment of the present invention is a panel covered with a rectangular resin molded body 2 in a plan view.

The resin panel 1 includes a hollow resin molded body 2 and a spacer member 3, and the spacer member 3 is arranged in the resin molded body 2. The front surface and the back surface of the spacer member 3 are in close contact with the resin molded body 2. In one example, the spacer member 3 is made of foam. The skin material 6 is integrally molded on the resin molded body 2. The skin material 6 is, for example, a non-woven fabric.

The resin molded body 2 includes a front wall 2f and a back wall 2r. The front wall 2f and the back wall 2r face each other with a gap. The periphery of the front wall 2f and the back wall 2r is connected by the peripheral wall 2s. The skin material 6 is provided so as to cover the back wall 2r and the peripheral wall 2s. The entire surface of the back wall 2r except the exposed area 2r1 is covered with the skin material 6. Half of the peripheral wall 2s on the back wall 2r side is covered with the skin material 6.

The spacer member 3 is provided with a hole portion 3a that penetrates the spacer member 3. The back wall 2r includes a pillar portion 2r2 protruding in a columnar shape in the hole portion 3a in the exposed region 2r1. The tip of the pillar portion 2r2 is welded to the front wall 2f. In the hole portion 3a, a space is formed around the pillar portion 2r2.

When the hole 3a of the spacer member 3 is a closed space, when the air in the hole 3a is cooled and contracted, a sink mark is generated in the resin molded body 2 at the portion facing the hole 3a, and the appearance of the resin molded body 2 is formed. Prone to failure. In the present embodiment, a groove 3b is provided as an air escape path 5 communicating with the hole 3a so that the hole 3a does not become a closed space.

A gap 4 is provided between the outer peripheral side surface of the spacer member 3 and the resin molded body 2, and the groove 3b is provided so as to connect from the hole 3a to the gap 4. Immediately after molding, the temperature of the air in the gap 4 tends to be lower than the temperature of the air in the hole 3a. Therefore, in the gap 4, the air is less likely to shrink than in the hole 3a. Therefore, by connecting the hole 3a and the gap 4 with the groove 3b, the pressure drop in the hole 3a is reduced.

The groove 3b of the spacer member 3 may have a cross section through which air can pass, and its width and depth are not particularly limited. The groove 3b may be linear or curved. Further, the cross-sectional shape of the groove 3b is not particularly limited, and may be a triangle, a quadrangle, a semicircle, or the like.

The depth of the groove 3b of the spacer member 3 in the state of being arranged in the resin panel 1 is, for example, 0.1 to 3.0 mm, preferably 0.5 to 2.0 mm, and specifically, for example, for example. It is 0.1, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0 mm, and may be within the range between any two of the numerical values exemplified here.

As will be described later, the spacer member 3 is welded to the resin sheets 23a and 23b, and the surface is retracted by being melted at the time of this welding. If the depth of the groove 3b before welding the spacer member 3 to the resin sheets 23a and 23b is insufficient, the groove 3b may disappear at the time of welding and the hole 3a may become a closed space.

Therefore, the depth of the groove 3b at the stage before welding the spacer member 3 to the resin sheets 23a and 23b is preferably 1.0 mm or more, for example, 1.0 to 3.0 mm, specifically. For example, it is 1.0, 1.5, 2.0, 2.5, 3.0 mm, and may be within the range between any two of the numerical values exemplified here. In this case, by setting the melting depth at the time of welding to less than 1.0 mm (preferably 0.9 mm or less), it is possible to prevent the groove 3b from disappearing, and the air escape path 5 is maintained even after welding. be able to.

Further, as shown in FIGS. 1 to 6, the hollow resin molded body 2 has a stepped shape 2d, and the spacer member 3 also has a stepped shape 3d that follows the shape of the resin molded body 2. The step shapes 2d and 3d are provided at positions facing the hole 3a. In such a case, if the positional relationship between the hollow resin molded body 2 and the spacer member 3 deviates from the original position as shown in FIG. 7 as compared with FIG. 4B, a hole is formed during the welding process between the spacer member 3 and the resin sheet 23a. Since the amount of air trapped in the portion 3a may be large, sink marks may easily occur on the surface of the resin panel 1. Therefore, the present invention is particularly useful when the hollow resin molded body 2 and the spacer member 3 have steps of the same shape.

1-2. Configuration of Molding Machine Next, using FIGS. 8 to 9, a molding machine 10 that can be used for carrying out the method for manufacturing the resin panel 1 according to the embodiment of the present invention will be described.

The molding machine 10 includes a resin supply device 14, a T-die 18, and first and second molds 21 and 22. The resin supply device 14 includes a hopper 12, an extruder 13, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27. Hereinafter, each configuration will be described in detail.

<Hopper 12, extruder 13>
The hopper 12 is used to charge the raw material resin 11 into the cylinder 13a of the extruder 13. The form of the raw material resin 11 is not particularly limited, but is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as a polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, an ethylene-propylene copolymer and a mixture thereof. The raw material resin 11 is charged into the cylinder 13a from the hopper 12 and then heated in the cylinder 13a to be melted into a molten resin. Further, it is conveyed toward the tip of the cylinder 13a by the rotation of the screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and the molten resin is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device.

<Accumulator 17, T-die 18>
The raw material resin is extruded from the resin extrusion port of the cylinder 13a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b slidable inside the cylinder 17a, and the molten resin 11a can be stored in the cylinder 17a. Then, by moving the piston 17b after a predetermined amount of the foamed resin is stored in the cylinder 17a, the foamed resin is pushed out from the slit provided in the T-die 18 through the connecting pipe 27 and hung down to be the first and second. The resin sheets 23a and 23b are formed.

<Molds 21 and 22>
The resin sheets 23a and 23b are guided between the molds 21 and 22. The mold 21 is provided with a large number of vacuum suction holes (not shown), and the resin sheet 23a can be suctioned under reduced pressure to form a shape along the cavity 21b of the mold 21. .. The cavity 21b has a shape having a recess 21c, and a pinch-off portion 21d is provided so as to surround the recess 21c. The cavity 21b is provided with a pillar portion 21a having a shape corresponding to the pillar portion 2r2. The mold 22 is provided with a large number of vacuum suction holes (not shown), and the resin sheet 23b can be suctioned under reduced pressure to form a shape along the cavity 22b of the mold 22. .. The cavity 22b has a shape having a recess 22c, and a pinch-off portion 22d is provided so as to surround the recess 22c. The cavity 22b is provided with a recess 22a having a shape corresponding to the step shape 2d. Here, the decompression suction hole is a very small hole, one end of which is communicated to the inner surface of the cavities 21b and 22b through the inside of the mold 21 and 22, and the other end is connected to the decompression device. Further, the pinch-off portion 21d of the mold 21 is provided with a mounting portion (not shown) for mounting the skin material 6.

1-3. Method for Manufacturing Resin Panel 1 Next, a method for manufacturing the resin panel 1 according to the first embodiment of the present invention will be described with reference to FIGS. 9 to 12. The method of the present embodiment includes a hanging step, a shaping step, an insert step, and a mold clamping step. Hereinafter, it will be described in detail.

(1) Hanging step In the hanging step, as shown in FIG. 9, after the skin material 6 is attached to the mold 21, the foamed resin in a molten state is extruded from the slit of the T die 18 between the molds 21 and 22. The resin sheets 23a and 23b formed by hanging are hung. In the present embodiment, since the direct vacuum forming using the resin sheets 23a and 23b extruded from the T die 18 as they are is performed, the resin sheets 23a and 23b may be cooled to room temperature and solidified before molding. No, the solidified resin sheets 23a and 23b are not heated before molding.

(2) Forming Step Next, as shown in FIG. 10, the skin material 6 and the resin sheet 23a are sucked under reduced pressure by the mold 21, and shaped into a shape along the cavity 21b of the mold 21. The resin sheet 23b is sucked under reduced pressure to form a shape along the cavity 22b of the mold 22. The timing of shaping the resin sheets 23a and 23b may be different. For example, the resin sheet 23b may be shaped after the insert step, or the resin sheet 23b may be shaped in the mold clamping step. Further, the resin compositions 23a and 23b may be shaped in the mold clamping step without being shaped in advance. At the time of shaping, the resin sheets 23a and 23b first come into contact with the pinch-off portions 21d and 22d. The longer the time that the resin sheets 23a and 23b are in contact with the molds 21 and 22, the lower the temperature of the resin sheets 23a and 23b. Prone. Therefore, immediately after molding, the temperature of the air in the gap 4 between the resin molded body 2 and the spacer member 3 tends to be low.

(3) Insert step In the insert step, as shown in FIG. 11, the spacer member 3 is welded to the resin sheet 23a. The spacer member 3 is arranged between the resin sheets 23a and 23b using a jig (not shown), and is welded to the resin sheet 23a by moving toward the resin sheet 23a. The jig supports the spacer member 3 by sucking the spacer member 3 with a suction cup or the like provided on the jig.

In the present embodiment, since the spacer member 3 is a foam, the spacer member 3 is welded to the resin sheet 23a by melting the foam by the heat of the resin sheet 23a. After that, the jig is retracted to the right in the figure.

The timing of arranging the spacer member 3 between the resin sheets 23a and 23b is not limited, and the spacer member 3 may be arranged between the resin sheets 23a and 23b in the hanging step or the shaping step. Further, the spacer member 3 may be welded to the resin sheet 23b first.

(4) Die-clamping process In the mold-clamping process, the molds 21 and 22 are mold-clamped as shown in FIG. Since the skin material 6 receives pressure while being sandwiched between the resin sheet 23a and the mold 21, the skin material 6 is welded to the resin sheet 23a. As a result, a molded body having a shape along the cavities 21b and 22b of the molds 21 and 22 can be obtained.

Then, the molded body is taken out from the molds 21 and 22, and the burr 26 on the outer side of the pinch-off portions 21d and 22d is removed to obtain the resin panel 1 shown in FIG.

Immediately after the mold clamping step, the air in the hole 3a becomes hot. When the molded body is taken out from the molds 21 and 22, the molded body is gradually cooled, and the air in the hole 3a is also cooled. If the hole 3a is a closed space, the inside of the hole 3a is in a reduced pressure state, and sink marks are likely to occur in the resin molded body 2. On the other hand, in the present embodiment, since the hole 3a is configured so as not to be a closed space, sink marks are suppressed from occurring in the resin molded body 2.

2. 2. Second Embodiment The resin panel 1 of the second embodiment of the present invention will be described with reference to FIG.

In the present embodiment, as shown in FIG. 13, the hole 3a of the spacer member 3 does not penetrate from the front surface to the back surface. Even when the spacer member 3 is provided with such a hole 3a, sink marks are suppressed from being generated in the resin molded body 2 by the same action as in the first embodiment.

3. 3. Third Embodiment The resin panel 1 of the third embodiment of the present invention will be described with reference to FIG.

In the present embodiment, as shown in FIG. 14, the spacer member 3 is provided with a communication hole 3c as an air escape path 5 communicating with the hole 3a so that the hole 3a does not become a closed space. A gap 4 is provided between the outer peripheral side surface of the spacer member 3 and the resin molded body 2, and the communication hole 3c is provided so as to connect from the hole portion 3a to the gap 4. Even in such a form, the occurrence of sink marks on the resin molded body 2 is suppressed by the same action as in the first embodiment.

4. Fourth Embodiment The resin panel 1 of the fourth embodiment of the present invention will be described with reference to FIGS. 15 to 16.

In the present embodiment, as shown in FIGS. 15 to 16, the resin molded body 2 is provided with an air-opening through hole 2a connecting the inside and the outside of the resin molded body 2 and is provided as an air escape path 5. The groove 3b is configured to connect from the hole 3a to the open through hole 2a to the atmosphere. Even in such a form, the occurrence of sink marks on the resin molded body 2 is suppressed by the same action as in the first embodiment.

The air-opening through hole 2a can be formed by a method such as inserting a pin into at least one of the resin sheets 23a and 23b. The air-opening through hole 2a is preferably formed in the mold clamping step, but may be formed in a step earlier than that. Further, the atmospheric open through hole 2a may be formed after the molded body is taken out from the molds 21 and 22. By forming the air-opening through hole 2a before the air in the hole 3a is sufficiently cooled, it is possible to prevent the space in the hole 3a from being depressurized. Further, the atmospheric open through hole 2a may be closed after the air in the hole portion 3a is sufficiently cooled.

5. Other Embodiment By providing an atmospheric open through hole 2a separately from the air escape path 5 and connecting the atmospheric open through hole 2a and the gap 4, the hole 3a and the atmospheric open through hole 2a can be indirectly connected through the gap 4. It may be configured in. In this case, it is possible to make it easier for the air in the hole 3a to escape.

Further, an atmospheric open through hole 2a may be provided at a position facing the hole 3a. In this case, it is possible to prevent the hole 3a from becoming a closed space without providing the air escape path 5.

The spacer member 3 may be fixed to the resin sheets 23a and 23b by a method other than welding.

1: Resin panel 2: Resin molded body 2a: Open-air through hole 2d: Step shape 2f: Front wall 2r: Back wall 2r1: Exposed area 2r2: Pillar part 2s: Peripheral wall 3: Spacer member 3a: Hole part 3b: Groove 3c: Communication hole 3d: Step shape 4: Gap 5: Air escape path 6: Skin material 10: Molding machine 11: Raw material resin 11a: Molten resin 12: Hopper 13: Extruder 13a: Cylinder 14: Resin supply device 17: Accumulator 17a: Cylinder 17b: Piston 18: T-die 21: First mold 21a: Pillar part 21b: Cavity 21c: Recessed portion 21d: Pinch-off part 22: Second mold 22a: Recessed part 22b: Cavity 22c: Recessed part 22d: Pinch-off part 23a: 1st resin sheet 23b: 2nd resin sheet 25: Connecting pipe 26: Burr 27: Connecting pipe

Claims (9)

A resin panel provided with a hollow resin molded body and a spacer member.
The spacer member is arranged in the resin molding and has a penetrating or non-penetrating hole.
The front surface and the back surface of the spacer member are in close contact with the resin molded body.
The hole is configured so that it does not become a closed space .
There is a step shape on the surface of the resin molded body, and there is a step shape.
The spacer member also has a step shape that follows the step shape.
A resin panel in which the stepped shape is provided at a position facing the hole . The resin panel according to claim 1.
The spacer member is a resin panel provided with an air escape path communicating with the hole. The resin panel according to claim 2.
A gap is provided between the outer peripheral side surface of the spacer member and the resin molded body.
The air escape path is a resin panel that connects from the hole to the gap. The resin panel according to claim 2 or 3.
The resin molded body is provided with an air-opening through hole that connects the inside and the outside of the resin molded body.
The air escape path is a resin panel that connects the hole to the open through hole for the atmosphere. The resin panel according to any one of claims 2 to 4.
The spacer member has a groove on the surface connected to the hole.
A resin panel in which the groove constitutes the air escape path. The resin panel according to any one of claims 2 to 4.
The spacer member is provided with a communication hole connected to the hole portion.
A resin panel in which the air escape path is formed by the communication holes. The resin panel according to any one of claims 1 to 6.
The resin molded body is provided with an air-opening through hole that connects the inside and the outside of the resin molded body.
A resin panel in which the atmospheric open through hole is provided at a position facing the hole. The resin panel according to any one of claims 1 to 7 .
The hole is a resin panel provided so as to penetrate the spacer member. The resin panel according to any one of claims 1 to 7 .
The hole is a resin panel provided so as not to penetrate the spacer member.

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