JP7064133B2 - Structure manufacturing method and panel - Google Patents

Description

The present invention relates to a method for manufacturing a structure and a panel.

Various methods for manufacturing a panel including a core material having an insert member and a foam molded body and a resin molded body formed on the surface of the core material have been proposed (see, for example, Patent Document 1). In Patent Document 1, the foamed molded product is formed by molding foamed beads. In the method for manufacturing a core material of Patent Document 1, the foamed molded product is fixed to the insert member by pushing the end portion of the foamed molded product into the concave portion of the insert member.

Japanese Patent No. 2014-128938

In addition to the method for manufacturing the core material in Patent Document 1 described above, a method for manufacturing the core material using a mold provided with, for example, a chuck that supports the insert member is also conceivable. Specifically, in this manufacturing method, after the insert member is attached to the chuck of the first split mold, the first and second split molds are closed, and the foam beads are placed in the filling space where the insert member is arranged. Fill and mold foam beads.

Here, in this manufacturing method, in the state where the first and second split dies are closed, the foamed beads may invade between the second split die and the insert member. The intrusion of the foamed beads between the second split mold and the insert member occurs, for example, due to manufacturing variations of the insert member or the like. In this way, if the foamed beads invade between the second split mold and the insert member, the core material becomes a defective product.

The present invention has been made in view of such circumstances, and an object of the present invention is to suppress the occurrence of defects in the structure.

According to the present invention, it is a method for manufacturing a structure, comprising a step of manufacturing the structure using the first and second split molds, which includes a mounting step, a first mold closing step, and a filling step. It has a molding step and a first mold opening step. In the mounting step, the insert member is attached to the first and second split molds, and in the first mold closing step, the first and second split molds are attached. By closing the mold, a filling space is formed in the first and second divided molds, the filling space is filled with foamed beads in the filling step, and the filling space is filled in the molding step. A foam molded body formed by molding foam beads is manufactured, and in the first mold opening step, the first and second split molds are opened, and the insert member has the first and second members. , The first and second members are attached to the first and second split molds, respectively, in the attachment step, and the first member and the second member are in contact with each other in a state where the molding step is completed. The method is provided.

According to the method for manufacturing a structure according to the present invention, the first and second members are attached to the first and second split molds, respectively, in the attachment step. As a result, the foamed beads are suppressed from entering between the first split mold and the first member, and the foamed beads are suppressed from entering between the second split mold and the second member. Ru. Therefore, according to the method for manufacturing a structure according to the present invention, it is possible to suppress the occurrence of defects in the structure.

Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with each other.
Preferably, in the method, the first and second split molds have first and second end faces, respectively, and the first and second members have first and second facing surfaces, respectively. In the mounting step, the first and second members are mounted on the first and second split molds so that the first and second facing surfaces abut on the first and second end faces.
Preferably, the method has a pressing step, the pressing step is performed after the filling step and before the molding step, and in the pressing step, the first and second divisions are performed. By pressing the mold, the foamed beads filled in the filling space are compressed.
Preferably, in the above method, the first member and the second member have first and second contact portions, and a first mold closing step is performed between the first contact portion and the second contact portion. The first gap is formed in the completed state, and the first gap is smaller than the diameter of the foamed beads filled in the filling space in the filling step, and the first contact portion and the second contact portion are formed. The portion is in contact with the portion when the pressing process is completed.
Preferably, in the method, the first contact portion has a concave portion, the second contact portion has a convex portion, and a first mold closing step is performed between the concave portion and the convex portion. The first gap is formed in the completed state, the convex portion is inserted into the concave portion in the state where the pressing process is completed, and the convex portion hits the concave portion in the state where the pressing process is completed. Contact.
Preferably, in the method, the convex portion has a side surface, the concave portion has an inner side surface, and the side surface faces the inner side surface in a state where the pressing process is completed, and the side surface and the inner surface are formed. A second gap is formed between the side surface and the side surface in a state where the pressing process is completed.
Preferably, in the method, the first and second split molds are provided with a regulating member, and the regulating member protrudes into the filling space in a state where the first mold closing step is completed, and the above-mentioned The regulating member is arranged at both ends in the longitudinal direction of the first and second members.
Preferably, in the method, the insert member is an elongated reinforcing member.
Preferably, in the method, the insert member is formed with a concave portion, the insert member has a hook portion, and in the filling step, the foamed molded product is filled in the concave portion. When the molding step is completed, the hooking portion is configured to be hooked on the foamed molded product.
Preferably, in the method, the insert member has a base portion and a flange portion, the concave portion is formed by the base portion and the flange portion, and the flange portion has the base portion. And the hooking portion is connected, and the hooking portion is configured to be convex toward the base portion.
Preferably, the method comprises a core material manufacturing step and a panel manufacturing step, and the core material manufacturing step includes the mounting step, the first mold closing step, the filling step, the molding step, and the first. It has a mold opening step, the panel manufacturing step has a shaping step, a second mold closing step, and a second mold opening step, and in the shaping step, the resin sheet is used in the third and fourth molds. It is shaped along the inner surface of the split mold, and in the second mold closing step, the third and fourth split molds are closed, and inside the resin molded body formed by the resin sheet and the inside of the resin molded body. A panel having the foamed molded body to be arranged is manufactured, and in the second mold opening step, the third and fourth divided molds are opened.
Preferably, in the method, the foam molded body is formed with a concave relief portion in a state where the molding step is completed, and the relief portion is formed in a portion provided with the restricting member in the molding step. In addition, the escape portion serves as an escape portion for an extra portion of the resin sheet in the second mold closing step.
Preferably, in the method, the relief portion is formed in a portion of the foam molded product provided on the peripheral edge of the first and second members.
Preferably, the panel comprises a core material and a resin molded body, wherein the core material has an insert member and a foam molded body, and the core material is arranged in the resin molded body. The insert member and the foam molded body are integrally molded, the insert member has first and second members, and the first and second members are in contact with each other, provided by a panel. Will be done.
Preferably, in the panel, the insert member is an elongated reinforcing member.
Preferably, in the panel, the insert member is formed with a concave portion, the insert member has a hook portion, the concave portion is filled with the foamed molded product, and the hook portion is formed. , It is configured to be hooked on the foam molded body.
Preferably, in the panel, the insert member has a base portion and a flange portion, the concave portion is formed by the base portion and the flange portion, and the flange portion has the base portion. And the hooking portion is connected, and the hooking portion is configured to be convex toward the base portion.

1A is a perspective view of the panel 1, and FIG. 1B is a cross-sectional view taken through the three points X shown in FIG. 1A. FIG. 2A is a perspective view of the core material 1b, and FIG. 2B is an enlarged view of the relief portion 1e shown in the region A. 3A is a perspective view of the insert member 1d, FIG. 3B is a cross-sectional view of the second member D2 of the insert member 1d, and FIG. 3C is a cross-sectional view of the first member D1 of the insert member 1d. It is a perspective view of the mold 2 for a core material. It is a perspective view of the 1st division mold 2a. It shows a state in which the first member D1 is attached to the first split mold 2a. It is a perspective view of the 2nd division mold 2A. It shows a state in which the second member D2 is attached to the second split mold 2A. FIG. 9A shows a state in which the opening / closing portion 2g protrudes toward the second split mold 2A, and FIG. 9B is an enlarged view of the region B shown in FIG. 9A. It shows the state where the mounting process of the core material manufacturing process is completed. It shows a state in which the first mold closing process of the core material manufacturing process is completed. It is an enlarged view which shows the region C of FIG. 11 in the state which the filling process of the core material manufacturing process is completed. It shows the state where the molding process of the core material manufacturing process is completed. It is an enlarged view of the convex portion 9d and the concave portion d7 in the state shown in FIG. It is explanatory drawing of various configurations used in a panel manufacturing process. It shows the state where the shaping process of the panel manufacturing process is completed. It shows the state where the pasting process of the panel manufacturing process is completed. It shows a state in which the second mold closing process of the panel manufacturing process is completed.

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.

<Structure related to the core material manufacturing process of the embodiment>
In the manufacturing method according to the embodiment, the core material 1b is manufactured using the core material mold 2 (see FIG. 4), and then the panel 1 is manufactured using the panel mold 22. As shown in FIGS. 1A and 1B, the panel 1 has a core material 1b and a resin molded body 1a. The surface of the core material 1b is covered with the resin molded body 1a. That is, the core material 1b is arranged inside the resin molded body 1a. The core material 1b has an insert member 1d and a foam molded body 1c.

The insert member 1d can be made of, for example, metal, reinforced plastic, or the like. The insert member 1d is a long member. That is, the insert member 1d is a skeleton that improves the load bearing capacity of the panel 1, and has a function of reinforcing the panel 1. As shown in FIGS. 3A to 3C, the insert member 1d has a pair of flange portions d1 and a base portion d2. Each flange portion d1 is formed with a facing surface d4 that contacts the inner surface of the resin molded body 1a. The substrate portion d2 is provided between one flange portion d1 and the other flange portion d1. One flange portion d1 is connected to one end of the base portion d2, and the other flange portion d1 is connected to the other end of the base portion d2. A pair of concave portions d3 are formed on the insert member 1d. The concave portion d3 is formed by a pair of flange portions d1 and a base portion d2. The concave portion d3 is filled with the foam molded body 1c. The foam molded body 1c is formed by molding foam beads. As shown in FIG. 2B, a relief portion 1e is formed in the foam molded body 1c. The relief portion 1e is formed in a concave shape.

As shown in FIGS. 3A to 3C, the insert member 1d is composed of two members. Specifically, the insert member 1d includes a first member D1 and a second member D2. The first member D1 and the second member D2 are combined. The first member D1 has a flange portion d1 and a first contact portion d6. The second member D2 has a flange portion d1, a base portion d2, and a second contact portion d8. The first contact portion d6 is in contact with the second contact portion d8. Specifically, the first contact portion d6 has a concave portion d7, and the second contact portion d8 has a convex portion d9. The convex portion d9 has a side surface s2 and a front end surface s3. The tip surface s3 of the convex portion d9 is in contact with the inner surface s1 of the concave portion d7. The relief portion 1e is formed on the peripheral edge of the first member D1 and the peripheral edge of the second member D2. The first facing surface corresponds to the facing surface d4 of the flange portion d1 of the first member D1, and the second facing surface corresponds to the facing surface d4 of the flange portion d1 of the second member D2.

In the embodiment, the insert member 1d will be described as being a long reinforcing member, but the present invention is not limited to this embodiment. The insert member 1d does not have to be long, and the insert member 1d may be a member that does not have a function of reinforcing the panel 1. For example, the insert member 1d may be a resin tapping member to which a fixing member such as a bolt is fixed, and further, the first member D1 and the second member D2 not only come into contact with each other, but also the first member. D1 and the second member D2 may be configured to be engageable.

The core material mold 2 includes a first split mold 2a and a second split mold 2A. The first split mold 2a has a cavity 2b, a regulating member 2e, an opening / closing portion 2g, an ejector 2h, and a holding portion 3. Further, the first end surface 2i is formed on the first split mold 2a. The second split mold 2A includes a core 2B and a regulating member 2C. Further, the second split mold 2A includes a core 2B and a regulating member 2C. A second end surface 2E is formed on the second split mold 2A. Further, as shown in FIG. 11 described later, in a state where the first split mold 2a and the second split mold 2A are closed, between the first split mold 2a and the second split mold 2A. Is formed with a filling space Sp.

As shown in FIGS. 5 and 6, the first member D1 of the insert member 1d can be attached to the inner surface of the cavity 2b. A regulating member 2e, an opening / closing portion 2g, an ejector 2h, and a holding portion 3 are provided on the inner surface of the cavity 2b. The holding portion 3 has a function of holding the first member D1. Further, the holding portion 3 has a leaf spring. When the first member D1 is attached to the holding portion 3, the first member D1 is urged to the inner surface of the cavity 2b, and as a result, the first member D1 is attached to the cavity 2b. The cavity 2b is formed in a concave shape so that foamed beads can be filled.

The regulating member 2e has a function of preventing the insert member 1d from being displaced in the longitudinal direction of the insert member 1d. In a state where the insert member 1d is attached to the first split mold 2a, the regulating member 2e is arranged at both ends of one of the flange portions d1 of the pair of flange portions d1 of the insert member 1d. The regulating member 2e is fixed to the first end surface 2i. The regulating member 2e protrudes into the filling space Sp. Therefore, when the foamed beads are molded in the filling space Sp, the relief portion 1e described with reference to FIG. 2B described above is formed on the foamed molded body 1c.

The opening / closing portion 2g is configured to be movable in a direction parallel to the second split mold 2A side from the first split mold 2a side. As shown in FIGS. 9A and 9B, when the opening / closing portion 2g moves and the opening / closing portion 2g protrudes from the first end surface 2i, the bead supply hole Ho of the first split mold 2a is opened, and the foamed beads enter the filling space Sp. Be supplied. The ejector 2h has a function of pushing out the core material 1b formed in the filling space Sp. The ejector 2h is configured to be movable in a direction parallel to the second split mold 2A side from the first split mold 2a side.

As shown in FIGS. 7 and 8, the second member D2 of the insert member 1d can be attached to the core 2B. The core 2B has a regulating member 2C and a holding portion 30. The function of the regulating member 2C is the same as the function of the regulating member 2e. The regulating member 2C is fixed to the second end surface 2E. Further, the function of the holding unit 30 is the same as that of the holding unit 3. When the second member D2 is attached to the holding portion 30, the second member D2 is urged to the core 2B, and as a result, the second member D2 is attached to the core 2B. The core 2B is inserted into the cavity 2b while the core material mold 2 is closed. In a state where the core material mold 2 is closed, the regulating member 2e is arranged at both ends of the other flange portion d1 of the pair of flange portions d1 of the insert member 1d.

<Core material manufacturing process of the embodiment>
The core material manufacturing process will be described with reference to FIGS. 10 to 14 and the like. The cross sections shown in FIGS. 10 to 14 do not pass through the holding portion 3 and the holding portion 30. Therefore, in FIGS. 10 and 11, the holding portion 3 and the holding portion 30 are shown by broken lines. The core material manufacturing process includes a mounting process, a first mold closing process, a filling process, a pressing process, a molding process, a first mold opening process, and a removing process. First, the first member D1 is attached to the holding portion 3 provided in the first split mold 2a, and the second member D2 is attached to the holding portion 30 provided in the second split mold 2A (mounting step). ). Next, as shown in FIGS. 10 and 11, the first split mold 2a and the second split mold 2A are closed to fill the space between the first split mold 2a and the second split mold 2A. A space Sp is formed (type 1 closing step). As shown in FIGS. 11 and 12, in a state where the first mold closing step is completed, a first gap L1 is formed between the first contact portion d6 and the second contact portion d8.

Next, the filling space Sp is filled with the foamed beads bi (filling step). Specifically, as shown in FIG. 9 described above, the opening / closing portion 2g protrudes from the first end surface 2i. As a result, as shown in FIG. 12, the foamed beads bi are supplied to the filling space Sp. Here, the first gap L1 is smaller than the diameter (average particle diameter) of the foamed beads bi. Therefore, the foamed beads bi are prevented from entering the first gap L1. Next, the second split die 2A further moves to the first split die 2a side (pressing step). As a result, the convex portion d9 of the second contact portion d8 is inserted into the concave portion d7 of the first contact portion d6. As described above, since the insert member 1d has the concave portion d7 and the convex portion d9, the movable range of the second split die 2A in the pressing process is widened. As a result, the foamed bead bi in the filling space Sp is pressed more reliably, and the filling density of the foamed bead bi in the filling space Sp is more reliably increased. In the state where the pressing process is completed, the side surface s2 of the convex portion d9 faces the inner side surface s1 of the concave portion d7, and the tip surface s3 of the convex portion d9 is in contact with the inner side surface s1 of the concave portion d7. A second gap L2 is formed between the side surface s2 and the inner side surface s1 in a state where the pressing process is completed (see FIG. 14). Although FIG. 14 shows a state in which the molding process is completed, the positional relationship between the concave portion d7 and the convex portion d9 in FIG. 14 is the same as the positional relationship between the concave portion d7 and the convex portion d9 in the state where the pressing process is completed. be.

Next, the foamed beads bi filled in the filling space Sp are heated and then cooled (molding step). As a result, as shown in FIGS. 13 and 14, the foam molded body 1c is formed in the core material mold 2. That is, the insert member 1d and the foam molded body 1c are integrally molded. The first split mold 2a is provided with a heating / cooling mechanism (not shown). The heating / cooling mechanism is configured to be able to supply high-temperature steam or cold water. The heat of the heating / cooling mechanism is transferred to the foamed beads of the filling space Sp through the surface of the cavity 2b. When high-temperature steam is supplied to the heating / cooling mechanism, the foamed beads in the filling space Sp are fused to each other. Then, when cold water is supplied to the heating / cooling mechanism, the fused foamed beads are solidified.

Next, the first split mold 2a and the second split mold 2A are opened (first mold opening step). After that, as the ejector 2h moves, the ejector 2h pushes the core material 1b, and the foamed molded body 1c is removed from the first split mold 2a (removal step).

<Structure relating to the panel manufacturing process of the embodiment>
The molding apparatus 100 shown in FIG. 15 is an apparatus for manufacturing a structure which is an integrally molded body. Specifically, the molding apparatus 100 is an apparatus for integrally molding the resin sheets P1 and P2 and the core material 1b. The molding device 100 includes an extrusion mechanism 10, a panel mold 22, a roller 20, and a moving mechanism 21. The extrusion mechanism 10 has a function of extruding the molten resin. The molding apparatus 100 includes two extrusion mechanisms 10. The panel mold 22 is provided on the lower side of the extrusion mechanism 10. The roller 20 feeds the resin sheets P1 and P2 extruded from the extrusion mechanism 10 to the panel mold 22. The moving mechanism 21 has a function of moving the roller 20.

The extrusion mechanism 10 includes a hopper 16, a cylinder 15, a screw (not shown), a motor 17, an accumulator 13, a T-die 11, and a plunger 14. The hopper 16 is a charging unit for resin pellets. The cylinder 15 is connected to the hopper 16, and a screw is provided in the cylinder 15. The motor 17 is connected to a screw provided in the cylinder 15. The accumulator 13 has a function of storing resin, and the accumulator 13 is connected to a cylinder 15 and a T-die 11. The plunger 14 has a function of pushing the resin in the accumulator 13 to the T-die 11.

The panel mold 22 has a third split mold a3 and a fourth split mold a4. The third split mold a3 has a cavity 24 and a pinch-off 26, and the fourth split mold a4 has a cavity 25 and a pinch-off 26. The cavity 24 is a portion where the resin sheet P1 hanging from the roller 20 is formed. The cavity 25 is a portion where the resin sheet P2 hanging from the roller 20 is formed. The pinch-off 26 is a convex portion that cuts the resin sheets P1 and P2.

<Panel manufacturing process of the embodiment>
The panel manufacturing process of the embodiment will be described with reference to FIGS. 16 to 18. First, a sheet forming process for manufacturing the resin sheets P1 and P2 will be described. The resin pellets charged into the hopper 16 reach the inside of the cylinder 15. The resin pellet of the cylinder 15 is melted by a screw to become a molten resin. The molten resin is supplied to the accumulator 13. The molten resin of the accumulator 13 is extruded from the T-die 11 by the extrusion action of the plunger 14. The resin sheets P1 and P2 extruded from the T die 11 hang down on the roller 20. The above series of flows is the sheet forming step.

Next, the resin sheets P1 and P2 are sent out from the inlet side to the outlet side of the roller 20 (delivery step). The resin sheet P1 that has passed through the roller 20 is shaped along the inner surface of the cavity 24 of the third split mold a3, and the resin sheet P2 that has passed through the roller 20 is formed on the inner surface of the cavity 25 of the fourth split mold a4. It is shaped along (shaping process). The third divided mold a3 is formed with a vacuum suction hole (not shown) that communicates with the cavity 24. The fourth divided mold a4 also has a vacuum suction hole (not shown) that communicates with the cavity 25. By vacuum suctioning the vacuum suction holes, the resin sheet P1 is shaped along the inner surface of the cavity 24 of the third split mold a3, and the resin sheet P2 is formed along the inner surface of the cavity 25 of the fourth split mold a4. Is shaped.

The manipulator holding the core material 1b presses the core material 1b against the resin sheet P1 (pasting step). Here, the core material 1b has a foam molded body 1c. The foamed molded product 1c of the core material 1b is welded to the resin sheet P1 by the heat of the resin sheet P1. As a result, the core material 1b is attached to the resin sheet P1. When the panel mold 22 is closed (second mold closing step), the resin sheets P1 and P2 are integrally molded with the core material 1b to become a resin molded body 1a. After that, the panel mold 22 is opened (second mold opening step), and the resin molded body 1a is taken out.

<Action and effect of the embodiment>
In the manufacturing method according to the embodiment, the first member D1 is attached to the first split mold 2a in the mounting step, and the second member D2 is mounted to the second split mold 2A in the mounting step. As a result, the foamed beads are suppressed from entering between the first split mold 2a and the first member D1, and the foamed beads penetrate between the second split mold 2A and the second member D2. Is suppressed. Therefore, in the manufacturing method according to the embodiment, it is possible to prevent defects from occurring in the core material 1b and the panel 1.
Further, in the manufacturing method according to the embodiment, the first member D1 and the second member D2 are in contact with each other in a state where the molding process is completed. Therefore, even if a load is applied to the core material 1b, the movement of the first member D1 and the movement of the second member D2 are restricted, and as a result, the deformation of the core material 1b is suppressed. That is, the deterioration of the load bearing capacity of the core material 1b and the load bearing capacity of the panel 1 is suppressed. Therefore, in the manufacturing method according to the embodiment, the insert member 1d is made of a plurality of members so that the intrusion of the foamed beads between the first and second split dies and the first and second members is suppressed. Even if the configuration is adopted, the deterioration of the load bearing capacity of the core material 1b and the load bearing capacity of the panel 1 is suppressed.

In the mounting step, the first member D1 is attached to the first split mold 2a so that the facing surface d4 abuts on the first end surface 2i of the first split mold 2a, and the second member D2 has the facing surface d4 second. It is attached to the second split mold 2A so as to abut on the second end surface 2E of the split mold 2A. As a result, it is suppressed in advance that a gap is generated between the first end surface 2i of the first division mold 2a and the facing surface d4 of the first member D1, and the second end surface 2E of the second division mold 2A It is suppressed in advance that a gap is generated between the second member D2 and the facing surface d4. As a result, the foamed beads are suppressed from entering between the first end surface 2i of the first split mold 2a and the facing surface d4 of the first member D1, and the foamed beads are the second of the second split mold 2A. Invasion between the two end faces 2E and the facing surface d4 of the second member D2 is suppressed. Therefore, in the manufacturing method according to the embodiment, it is possible to prevent defects from occurring in the core material 1b and the panel 1.

In the pressing step, the foamed beads filled in the filling space Sp are compressed by pressing the first split die 2a and the second split die 2A. As a result, unevenness in the distribution of the foamed beads filled in the filling space Sp is suppressed, and the density of the foamed molded product 1c after molding is improved. As a result, the strength of the foam molded product 1c is improved.

A first gap L1 is formed between the first contact portion d6 and the second contact portion d8 in a state where the first mold closing step is completed. Further, the first gap L1 is smaller than the diameter of the foamed beads filled in the filling space Sp in the filling step. Therefore, it is possible to prevent the foamed beads from invading the first gap L1.
Further, the first contact portion d6 and the second contact portion d8 are in contact with each other in a state where the pressing process is completed. Therefore, even if a load is applied to the core material 1b, the movement of the first member D1 is performed. And the movement of the second member D2 is restricted, and as a result, the deformation of the core material 1b is suppressed. That is, the deterioration of the load bearing capacity of the core material 1b and the load bearing capacity of the panel 1 is suppressed.

The first contact portion d6 has a concave portion d7, and the second contact portion d8 has a convex portion d9. A first gap L1 is formed between the concave portion d7 and the convex portion d9 in a state where the first mold closing step is completed. That is, the first gap L1 is formed in an uneven structure. Here, the gaps formed in the concave-convex structure are intricate as compared with the gaps formed between the pair of flat surfaces. Therefore, it is more surely prevented that the foamed beads invade the first gap L1.
Further, the convex portion d9 is inserted into the concave portion d7 in a state where the pressing process is completed. Therefore, even if an external force in the Z direction is applied to the convex portion d9 or the concave portion d7, the convex portion d9 and the concave portion d7 come into contact with each other, and the movement of the convex portion d9 and the concave portion d7 is restricted. As a result, the deformation of the core material 1b is suppressed.
Further, the convex portion d9 and the concave portion d7 are in contact with each other when the pressing process is completed. Specifically, the tip surface s3 of the convex portion d9 and the inner surface s1 of the concave portion d7 are in contact with each other in a state where the pressing process is completed. Therefore, even if a load is applied to the core material 1b, the movement of the first member D1 and the movement of the second member D2 are restricted, and as a result, the deformation of the core material 1b is suppressed. That is, the deterioration of the load bearing capacity of the core material 1b and the load bearing capacity of the panel 1 is suppressed.

A second gap L2 is formed between the side surface s2 of the convex portion d9 and the inner side surface s1 of the concave portion d7 in a state where the pressing process is completed. That is, when the pressing process is being carried out, at least one of the pair of side surfaces s2 and at least one of the pair of inner side surfaces s1 are separated from each other. When the pressing process is completed, a second gap L2 is formed between at least one of the pair of side surfaces s2 and at least one of the pair of inner side surfaces s1. Since at least one of the pair of side surfaces s2 and at least one of the pair of inner side surfaces s1 are separated from each other, sliding between the convex portion d9 and the concave portion d7 is suppressed. Therefore, the pressing process is smoothly carried out, and damage to the insert member 1d is suppressed.

The insert member 1d is a long reinforcing member. Since the panel 1 is provided with this reinforcing member, the load bearing capacity of the panel 1 is improved. Further, since the insert member 1d has a long shape, a wide range of the panel 1 is reinforced by the insert member 1d. Therefore, the panel 1 is less likely to be deformed such as distortion, and the strength of the panel 1 is improved.

The insert member 1d is formed with a concave portion d3. Here, since the space inside the concave portion d3 is narrow, it is difficult for the foamed beads to be filled in the concave portion d3. However, when the filling step is being carried out, the first member D1 and the second member D2 are separated from each other. Therefore, the width of the concave portion d3 when the filling step is carried out is wider than the width of the concave portion d3 when the pressing step and the molding step are carried out. Therefore, even if the insert member 1d has the concave portion d3, the foamed beads are uniformly filled in the concave portion d3.
Further, in the state where the molding step is completed, the hooking portion d5 is configured to be hooked on the foam molded body 1c. Therefore, the fixing between the foam molded body 1c and the insert member 1d becomes stronger.

The concave portion d3 is formed by a base portion d2 and a flange portion d1. A base portion d2 and a hook portion d5 are connected to the flange portion d1. The hook portion d5 is configured to be convex toward the base portion d2. Therefore, even if an external force is generated so as to pull out the foamed molded body 1c from the concave portion d3, the foamed molded body 1c is caught by the hooking portion d5, so that the foamed molded body 1c is prevented from coming off from the insert member 1d.

The regulating members 2e and 2C project into the filling space Sp in the first mold closing step, and the regulating members 2e and 2C are arranged at both ends in the longitudinal direction of the insert member 1d. As a result, it is possible to prevent the insert member 1d from being displaced in the longitudinal direction in the filling step and the molding step.

Since the restricting members 2e and 2C protrude into the filling space Sp in the first mold closing step, the foam molded body 1c is formed with a concave relief portion 1e in a state where the molding step is completed. The relief portion 1e serves as a relief place for an extra portion of the resin sheets P1 and P2 in the second mold closing step of the panel manufacturing process.
Here, the hardness of the insert member 1d is higher than the hardness of the foamed molded product 1c. Therefore, the resin sheets P1 and P2 on the surface of the insert member 1d are pressurized in the second mold closing step, so that the resin sheets P1 and P2 radiate from the surface side of the insert member 1d to the surface side of the foam molded body 1c. Therefore, if the relief portion 1e is not formed, the difference between the wall thickness of the resin sheets P1 and P2 on the surface of the insert member 1d and the wall thickness of the resin sheets P1 and P2 on the surface of the foamed molded product 1c is large. It may become. However, since the relief portion 1e is formed in the foam molded body 1c in the state where the molding step is completed, a part of the resin sheets P1 and P2 on the surface of the insert member 1d is formed in the relief portion 1e in the second mold closing step. Invade. As a result, it is possible to prevent the difference between the wall thickness of the resin sheets P1 and P2 on the surface of the insert member 1d and the wall thickness of the resin sheets P1 and P2 on the surface of the foamed molded product 1c from becoming large.

As described above, the resin sheets P1 and P2 on the surface of the insert member 1d are pressurized in the second mold closing step, so that the resin sheets P1 and P2 radiate from the surface side of the insert member 1d to the surface side of the foamed molded product 1c. Here, the resin sheets P1 and P2 on the surface of the insert member 1d move to the peripheral edge of the insert member 1d. Therefore, in the manufacturing method according to the embodiment, the relief portion 1e is formed in the portion of the foam molded body 1c provided on the peripheral edge of the insert member 1d. As a result, it is more reliably suppressed that the difference between the wall thickness of the resin sheets P1 and P2 on the surface of the insert member 1d and the wall thickness of the resin sheets P1 and P2 on the surface of the foamed molded product 1c becomes large.

1: Panel 1a: Resin molded body 1b: Core material 1c: Foamed molded body 1d: Insert member 1e: Relief part 2: Core material mold 2A: Second split mold 2B: Core 2C: Regulatory member 2E: Second End face 2a: First split mold 2b: Cavity 2e: Restricting member 2g: Opening and closing part 2h: Ejector 2i: First end face 3: Holding part 10: Extrusion mechanism 11: T-die 13: Accumulator 14: Plunger 15: Cylinder 16: Hopper 17: Motor 20: Roller 21: Moving mechanism 22: Panel mold 24: Cavity 25: Cavity 26: Pinch-off 30: Holding portion 100: Molding device D1: First member D2: Second member L1: First gap L2 : 2nd gap P1: Resin sheet P2: Resin sheet Sp: Filling space Ho: Bead supply hole bi: Foamed beads a3: 3rd division mold a4: 4th division mold d1: Flange part d2: Base part d3: Concave Part d4: Facing surface d5: Hooking part d6: First contact part d7: Concave d8: Second contact part d9: Convex part s1: Inner side surface s2: Side surface s3: Tip surface

Claims (17)

A method for manufacturing a structure, comprising a step of manufacturing the structure using the first and second split molds.
It has a mounting process, a first mold closing process, a filling process, a molding process, and a first mold opening process.
In the mounting step, the insert member is mounted on the first and second split dies.
In the first mold closing step, a filling space is formed in the first and second divided molds by closing the first and second divided molds.
In the filling step, the filling space is filled with foamed beads, and the filling space is filled.
In the molding step, a foamed molded product formed by molding the foamed beads filled in the filling space is manufactured.
In the first mold opening process, the first and second split molds are opened and the molds are opened.
The insert member has first and second members.
The first and second members are attached to the first and second split molds, respectively, in the mounting step, and the first member and the second member are in contact with each other in a state where the molding step is completed. There is a way. The method according to claim 1.
The first and second split molds have first and second end faces, respectively.
The first and second members have first and second facing surfaces, respectively.
In the mounting step, the first and second members are mounted on the first and second split molds so that the first and second facing surfaces abut on the first and second end faces. The method according to claim 1 or claim 2.
Has a pressing process,
The pressing step is performed after the filling step and before the molding step, and in the pressing step, the filling space is filled by pressing the first and second split dies. A method of compressing the foamed beads. The method according to claim 3.
The first member and the second member have first and second contact portions.
A first gap is formed between the first contact portion and the second contact portion in a state where the first mold closing step is completed.
The first gap is smaller than the diameter of the foamed beads filled in the filling space in the filling step.
A method in which the first contact portion and the second contact portion are in contact with each other in a state where the pressing process is completed. The method according to claim 4.
The first contact portion has a concave portion, and the second contact portion has a convex portion.
The first gap is formed between the concave portion and the convex portion in a state where the first mold closing step is completed.
A method in which the convex portion is inserted into the concave portion when the pressing process is completed, and the convex portion abuts on the concave portion when the pressing process is completed. The method according to claim 5.
The convex portion has a side surface, and the concave portion has an inner side surface.
The side surface faces the inner side surface in a state where the pressing process is completed.
A method in which a second gap is formed between the side surface and the inner surface surface in a state where the pressing process is completed. The method according to any one of claims 1 to 6.
Regulatory members are provided on the first and second split dies.
A method in which the restricting member protrudes into the filling space in a state where the first mold closing step is completed, and the restricting member is arranged at both ends in the longitudinal direction of the first and second members. The method according to any one of claims 1 to 7.
The method in which the insert member is a long reinforcing member. The method according to any one of claims 1 to 8.
The insert member has a concave portion, and the insert member has a hook portion.
In the filling step, the foamed molded product is filled in the concave portion.
A method in which the hooking portion is configured to be hooked on the foamed molded product in a state where the molding step is completed. The method according to claim 9.
The insert member has a base portion and a flange portion, and has a base portion and a flange portion.
The concave portion is formed by the base portion and the flange portion.
The base portion and the hook portion are connected to the flange portion, and the base portion and the hook portion are connected to the flange portion.
A method in which the hook portion is configured to be convex toward the substrate portion. The method according to any one of claims 1 to 10.
Equipped with a core material manufacturing process and a panel manufacturing process,
The core material manufacturing step includes the mounting step, the first mold closing step, the filling step, the molding step, and the first mold opening step.
The panel manufacturing step includes a shaping step, a second mold closing step, and a second mold opening step.
In the shaping step, the resin sheet is shaped along the inner surface of the third and fourth split dies.
In the second mold closing step, the third and fourth divided molds are closed, and a panel having the resin molded body formed by the resin sheet and the foam molded body arranged inside the resin molded body is formed. Manufactured and
In the second mold opening step, a method of opening the third and fourth split molds. The method according to claim 11, which cites claim 7.
In the foam molded body, a concave relief portion is formed in a state where the molding process is completed.
The method in which the relief portion is formed in a portion where the regulation member is provided in the molding step, and the relief portion serves as a relief place for an extra portion of the resin sheet in the second mold closing step. .. The method according to claim 12.
The method in which the relief portion is formed in a portion of the foam molded body provided on the peripheral edge of the first and second members. A panel comprising a core material and a resin molded body.
The core material has an insert member and a foam molded body, and the core material is arranged in the resin molded body.
The insert member and the foam molded body are integrally molded, and are integrally molded.
The insert member has first and second members.
The first and second members are abutting panels. The panel according to claim 14.
The insert member is a panel which is a long reinforcing member. The panel according to claim 14 or claim 15.
The insert member has a concave portion, and the insert member has a hook portion.
The concave portion is filled with the foam molded product, and the concave portion is filled.
The hook portion is a panel configured to be hooked on the foam molded body. The panel according to claim 16.
The insert member has a base portion and a flange portion, and has a base portion and a flange portion.
The concave portion is formed by the base portion and the flange portion.
The base portion and the hook portion are connected to the flange portion, and the base portion and the hook portion are connected to the flange portion.
The hook portion is a panel configured to be convex toward the substrate portion.

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