JP7078848B2 - Resin panel and its manufacturing method - Google Patents

Description

The present invention relates to a resin panel that can be used for building applications, in-vehicle applications, furniture applications, etc., and a method for manufacturing the same.

Patent Document 1 discloses a method of manufacturing a resin panel by welding a foamed structure in which a core material and a reinforcing material are integrated to a resin sheet and then molding a mold.

Japanese Unexamined Patent Publication No. 2014-128938

In the method of Patent Document 1, air remains between the foamed structure and the resin sheet, and as a result, swelling due to the residual air is formed on the surface of the resin panel, and the rigidity is lowered due to poor welding. There may be a problem of doing so.

The present invention has been made in view of such circumstances, and provides a resin panel capable of suppressing the generation of residual air.

According to the present invention, the panel is made of a resin and includes a resin wall, a core material, and a reinforcing member. The core material and the reinforcing member are surrounded by the resin wall, and the reinforcing member is air. The reinforcing member has a flow path, an adjacent portion adjacent to the core material, and a protruding portion protruding from the side surface of the core material, and the air flow path extends from the adjacent portion to the protruding portion. A resin panel is provided in which the air flow path communicates with the outside of the air flow path at both the adjacent portion and the projecting portion.

In the present invention, the air between the resin sheet and the core material can be evacuated through the first opening, the air flow path, and the second opening, so that the generation of residual air can be suppressed.

Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with each other.
Preferably, the reinforcing member is a resin panel having a first opening communicating with the air flow path at the adjacent portion.
Preferably, it is the resin panel described above, and the first opening is a resin panel provided so as not to come into contact with the resin wall.
Preferably, it is the resin panel described above, and the first opening is a resin panel provided on the side surface of the reinforcing member.
Preferably, it is the resin panel described above, and the first opening is a resin panel provided at a position facing the core material.
The resin panel described above is preferably a resin panel in which a gap between the reinforcing member and the core material is provided at a portion where the first opening is provided.
Preferably, it is the resin panel described above, and the first opening is a resin panel provided at a plurality of locations in the circumferential direction of the reinforcing member.
Preferably, it is the resin panel described above, wherein the surface of the core material is provided with a groove communicating with the air flow path.
Preferably, it is the resin panel described above, and the grooves are provided in a grid pattern.
Preferably, it is the resin panel described above, wherein the reinforcing member is a resin panel having a second opening communicating with the air flow path in the protruding portion.
Preferably, it is the resin panel described above, and the second opening is a resin panel provided on the end face of the reinforcing member.
Preferably, in the resin panel described above, a plurality of the reinforcing members are provided at intervals, the plurality of the reinforcing members are connected to each other by a connecting member, and the connecting member is the core material. The second side surface is a resin panel facing the first side surface, which is arranged along the second side surface of the above.
The resin panel described above is preferably a resin panel having no holes in the resin wall.
According to another aspect of the present invention, the resin panel comprises a resin wall, a core material, and a reinforcing member, and the core material and the reinforcing member are surrounded by the resin wall and the reinforcing member is provided. The member is inserted into an insertion hole provided in the core material, the core material has a front surface and a back surface facing each other, and the core material has a front surface side locking portion and a locking portion. The back surface side locking portion is provided, the front surface side locking portion locks the reinforcing member from the front surface side, and the back surface side locking portion locks the reinforcing member from the back surface side. A resin panel is provided which is locked and the front surface side locking portion and the back surface side locking portion are alternately provided side by side along the longitudinal direction of the insertion hole.
According to still another aspect of the present invention, the method for manufacturing a resin panel includes a hanging step, an inserting step, and a mold clamping step, and in the hanging step, between the first and second molds. The first and second resin sheets are hung down, the core material and the reinforcing member are arranged between the first and second resin sheets in the insert step, and the first and second molds are molded in the mold clamping step. Tightened, the reinforcing member has an air flow path, the reinforcing member has an adjacent portion adjacent to the core material, and a projecting portion protruding from the side surface of the core material, and the air flow path is described. A method is provided in which the air flow path is provided from the adjacent portion to the protruding portion, and the air flow path communicates with the outside of the air flow path at both the adjacent portion and the protruding portion.

It is a perspective view of the resin panel 1 of the 1st Embodiment of this invention. It is a perspective view of the state in which a part of the resin wall 2 of the resin panel 1 of FIG. 1 is removed. It is an enlarged view near the protrusion 5b of FIG. It is a block diagram (cross-sectional view about the mold 21, 31 and the resin sheet 23, 33) which can be used for manufacturing the resin panel 1 of one Embodiment of this invention. It is sectional drawing which shows the hanging process in the cross section which passes through the center of the opening 5d and is parallel to the side surface 3a. It is sectional drawing which shows the shaping process and the insert process in the same cross section as FIG. It is sectional drawing which shows the mold clamping process in the same cross section as FIG. It is a perspective view of the state where the reinforcing member 5, 6 and the core material 3 are supported by the support device 8. It is a perspective view of the main part of a support device 8. It is an enlarged view near the protrusions 5b and 6b of FIG. 11A to 11B are cross-sectional views of the protruding portions 5b and 6b with the insertion portions 8a and 8b inserted, respectively. It is a perspective view of the state where the reinforcing members 5 and 6 are inserted in the core material 3. It is an enlarged view of the vicinity of the reinforcing member 5 of FIG. It is a perspective view of the state which removed the reinforcing member 5 from FIG. 15A to 15B are a plan view and a front view of FIG. 14, respectively, and FIG. 15C is a sectional view taken along the line BB in FIG. 15A. 12 is a perspective view of the reinforcing members 5 and 6 and the connecting member 7 in FIG. 12. 17A to 17B are enlarged views of the vicinity of the protrusions 5b and 6b of FIG. It is an enlarged cross-sectional view in the vicinity of the opening 5d of FIG. 8 in the cross section passing through the center of the opening 5d and parallel to the side surface 3a. FIG. 3 is a cross-sectional view taken along the line AA in FIG. It is a perspective view of the molds 21 and 31. It is a perspective view of the separation block 21c1 and the slide core 21c in the state that the slide core 21c is in the mold clamping position. It is a perspective view of the separation block 21c1 and the slide core 21c in the state that the slide core 21c is in the retracted position. 23A to 23C are views corresponding to FIGS. 15A to 15C for the resin panel 1 of the second embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. 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. Structure of Resin Panel of First Embodiment As shown in FIGS. 1 to 3, the resin panel 1 of the first embodiment of the present invention includes a panel portion 1a and protrusions 1b and 1c. The panel portion 1a has a plate shape, and the projecting portions 1b and 1c project from the side surface of the panel portion 1a. The resin panel 1 is covered with a resin wall 2. It is preferable that the resin wall 2 has no holes. Further, it is preferable that the resin wall 2 has no holes formed at the time of completion of molding, rather than having holes formed at the time of completion of molding closed by post-processing or another member. If there is a hole in the resin wall 2, water or dust may enter the inside of the resin panel 1. Further, if the hole is closed by post-processing or another member, the hole may be reopened due to an impact or the like, so the resin wall 2 is formed by a molding method in which the hole is not formed in the resin wall 2. It is preferable to have.

As shown in FIG. 2, the core material 3 and the reinforcing members 5 and 6 are arranged inside the resin panel 1. The reinforcing members 5 and 6 are provided so as to project from the side surface 3a of the core material 3. The core material 3 has a function of improving the strength of the resin panel 1 and is composed of a foam or the like. Reinforcing members 5 and 6 are adjacent to the core material 3. The reinforcing members 5 and 6 are made of a material having a higher rigidity than the core material 3 (eg, non-foamed resin or metal) to further improve the strength of the resin panel 1 or form a portion protruding from the core material 3. It is provided for the purpose of doing things such as The reinforcing members 5 and 6 preferably have an elongated shape, have a portion having a constant cross-sectional shape along the longitudinal direction thereof, and have a length ratio to a width of 10 or more. The reinforcing members 5 and 6 are preferably in the shape of a pipe having a round cross section, but may have a shape such as a square cross section, an H shape in a cross section, or a C shape in a cross section.

The reinforcing members 5 and 6 have adjacent portions 5a and 6a adjacent to the core material 3 and protruding portions 5b and 6b protruding from the side surface of the core material 3. As shown in FIGS. 11 and 16 to 17, the shapes of the adjacent portions 5a and 6a are the same, but the cross-sectional shapes of the protruding portions 5b and 6b are different. Therefore, the protruding portions 1b and 1c of the resin panel 1 also have different cross-sectional shapes. The protrusions 1b and 1c can be used to attach the resin panel 1 to another member, but the protrusions 1b and 1c also have different cross-sectional shapes to prevent the resin panel 1 from being attached in the opposite direction. be able to. In the present embodiment, the protruding portion 5b has an oval cross section, and the protruding portion 6b has a circular cross section.

The portion where the core material 3 and the adjacent portions 5a and 6a are covered with the resin wall 2 is the panel portion 1a, and the portions where the protruding portions 5b and 6b are covered with the resin wall 2 are the protruding portions 1b and 1c. The diameters of the adjacent portions 5a and 6a are larger than the diameters of the protruding portions 5b and 6b. As a result, the reinforcing members 5 and 6 are stably held. In addition, in this specification, "diameter" means the diameter of a circumscribed circle. The adjacent portions 5a and 6a are inserted into the insertion holes 3d and 3e provided in the core material 3. The reinforcing members 5 and 6 are preferably fixed to the core material 3, and the core material 3 is welded to the resin wall 2 to fix the reinforcing members 5 and 6 and the core material 3.

As shown in FIGS. 14 to 15, the core material 3 includes a front surface 3i and a back surface 3j facing each other. The front surface 3i and the back surface 3j are provided with a front surface side locking portion 3k and a back surface side locking portion 3l. The front surface side locking portion 3k locks the reinforcing member 5 inserted through the insertion hole 3d from the front surface 3i side, and the back surface side locking portion 3l is the reinforcing member inserted through the insertion hole 3d. 5 is locked from the back surface 3j side. The front surface side locking portion 3k and the back surface side locking portion 3l are provided alternately side by side along the longitudinal direction of the insertion hole 3d. With such a configuration, the reinforcing member 5 is stably held in the insertion hole 3d. As shown in FIG. 15A, the front surface side locking portion 3k and the back surface side locking portion 3l do not overlap in a plan view, and the front surface side locking portion 3k and the back surface side locking portion 3l A through hole of 3 m is provided between them. Further, in the front view of FIG. 15B, the insertion hole 3d is sandwiched between the front surface side locking portion 3k and the back surface side locking portion 3l. Further, as shown in FIG. 15B, the inner surfaces of the front surface side locking portion 3k and the back surface side locking portion 3l are arcuate, respectively, and have a shape along the outer surface of the adjacent portion 5a.

In addition, one or both of the front surface side locking portion 3k and the back surface side locking portion 3l may be configured to press the reinforcing member 5. That is, the front surface side locking portion 3k may press the reinforcing member 5 toward the back surface 3j, and the back surface side locking portion 3l presses the reinforcing member 5 toward the front surface 3i. You may do so. In this case, the reinforcing member 5 is more stably held in the insertion hole 3d. Such a configuration can be obtained by inserting the reinforcing member 5 into the insertion hole 3d while the reinforcing member 5 is pressed by one or both of the front surface side locking portion 3k and the back surface side locking portion 3l. ..

In FIG. 14, the front surface side locking portion 3k and the back surface side locking portion 3l are provided so as to project from the front surface 3i and the back surface 3j, respectively. As a result, the wall thickness of the front surface side locking portion 3k and the back surface side locking portion 3l is increased, so that the reinforcing member 5 is held more stably. Further, as shown in FIGS. 6 to 7, the front surface side locking portion 3k and the back surface side locking portion 3l are melted and compressed at the time of the resin panel 1, and the front surface 3i and the back surface side locking portion 3l are formed. It is almost flush with the back surface 3j. At the time of compression, the rigidity of the front surface side locking portion 3k and the back surface side locking portion 3l is increased, so that the reinforcing member 5 is held more stably.

The reinforcing member 6 is also held in the insertion hole 3e by the same configuration.

As shown in FIGS. 11 and 17, the reinforcing members 5 and 6 have air flow paths 5c and 6c. The air flow paths 5c and 6c are provided from the adjacent portions 5a and 6a to the projecting portions 5b and 6b. The adjacent portions 5a, 6a and the protruding portions 5b, 6b are provided with openings 5d, 6d, 5e, 6e, respectively, which facilitates air bleeding during manufacturing. As shown in FIGS. 17 to 18, the adjacent portions 5a and 6a have a plurality of openings 5d and 6d (in the present embodiment, four at 90 degree intervals) in the circumferential direction (90 in the present embodiment). 4) are provided at intervals. At least one of them does not come into contact with the resin wall 2. This prevents the openings 5d and 6d from being blocked by the resin wall 2. Further, a gap 3f between the reinforcing members 5 and 6 and the core material 3 is provided at the portion where the openings 5d and 6d are provided. As a result, it is possible to prevent the openings 5d and 6d facing the core material 3 from being blocked. Further, as shown in FIGS. 13 to 14 and 18 to 19, the insertion hole 3d includes a narrow width portion 3g and a wide width portion 3h. The width of the insertion hole 3d in the wide portion 3h is wider than the width of the insertion hole 3d in the narrow portion 3g. That is, the wide portion 3h is recessed one step more than the narrow portion 3g. The gap 3f is provided in the wide portion 3h. The insertion hole 3e has a similar structure.

The narrow width portion 3g is provided at a portion where the front surface side locking portion 3k and the back surface side locking portion 3l are provided. The wide portion 3h is provided in a through hole 3m between the front surface side locking portion 3k and the back surface side locking portion 3l.

At the time of manufacturing, the air between the core material 3 and the resin sheet is discharged through the openings 5d and 6d, the air flow paths 5c and 6c, and the openings 5e and 6e. After the air is discharged, the openings 5e and 6e may be closed.

A groove 3b communicating with the openings 5d and 6d is provided on the surface of the core material 3, further facilitating air bleeding during manufacturing. Further, the grooves 3b are formed in a grid pattern, which further facilitates air bleeding during manufacturing. In the narrow width portion 3g, as shown in FIG. 19, an air flow path 4 is provided between the outer surface of the reinforcing member 5 and the inner surface of the insertion hole 3d. In the vicinity of the narrow width portion 3g, at the time of manufacture, the air between the core material 3 and the resin sheet has the grooves 3b, the air flow path 4, the openings 5d and 6d, the air flow paths 5c and 6c, and the openings 5e and 6e. It is discharged through.

As shown in FIGS. 2 and 16, a plurality of reinforcing members 5 and 6 (two in the present embodiment) are provided at intervals. The two reinforcing members 5 and 6 are connected to each other by the connecting member 7. The connecting member 7 is arranged along the side surface 3c of the core material 3. The side surfaces 3a and 3c face each other. The openings 5d and 6d penetrated in the vertical direction can be used to position the reinforcing members 5 and 6 when connecting the reinforcing members 5 and 6 to the connecting member 7. For example, the reinforcing members 5 and 6 can be positioned by inserting a pin into the openings 5d and 6d.

The resin wall 2 constituting the panel portion 1a includes a front wall 2a, a back wall 2b, and a peripheral wall 2c connecting them. The core material 3 and the adjacent portions 5a and 6a are sandwiched between the front wall 2a and the back wall 2b and surrounded by the peripheral wall 2c. The resin wall 2 constituting the projecting portions 1b and 1c includes a peripheral wall 2d and an end wall 2e. The peripheral surfaces of the protrusions 5b and 6b are surrounded by the peripheral wall 2d, and the end faces of the protrusions 5b and 6b are covered by the end wall 2e. The walls 2a to 2e are connected to each other, and the core material 3 and the reinforcing members 5 and 6 as a whole are surrounded by the resin wall 2. The core material 3 and the reinforcing members 5 and 6 are preferably completely surrounded by the resin wall 2, but a part thereof may be exposed.

Applications of the resin panel 1 include automobile headrests, chair backrests, partitions, side rails, and the like.

2. 2. Molding machine 10
Next, with reference to FIG. 4, a molding machine 10 that can be used for carrying out the method for manufacturing a resin panel according to an embodiment of the present invention will be described. The molding machine 10 includes a pair of resin sheet forming devices 20 and a pair of molds 21 and 31. Each resin sheet forming device 20 includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18. 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. The number of screws arranged in the cylinder 13a may be one or two or more.

<Accumulator 17, T-die 18>
The molten 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 molten resin 11a is stored in the cylinder 17a, the molten resin 11a is pushed out from the slit provided in the T die 18 through the connecting pipe 27 and hung down to be in a molten state. The resin sheets 23 and 33 are formed.

<Molds 21, 31>
The resin sheets 23 and 33 are hung between the molds 21 and 31. The molds 21 and 31 have cavities 21a and 31a, and pinch-off portions 21b and 31b are provided so as to surround the cavities 21a and 31a. Decompression suction holes (not shown) are provided in the cavities 21a and 31a, and the resin sheets 23 and 33 are decompressed and sucked through the decompression suction holes along the inner surfaces of the cavities 21a and 31a of the molds 21 and 31. It is possible to shape it into a different shape. The decompression suction hole is a very small hole, one end of which is communicated to the inner surface of the cavities 21a and 31a through the inside of the molds 21 and 31, and the other end is connected to the decompression device.

3. 3. Method for Manufacturing Resin Panel Here, a method for manufacturing a resin panel according to an embodiment of the present invention will be described with reference to FIGS. 4 to 22. 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.

3-1. In the hanging step, as shown in FIGS. 4 to 5, the resin sheets 23 and 33 are hung between the dies 21 and 31.

3-2. Shaped step In the shaping step, as shown in FIGS. 5 to 6, the resin sheets 23 and 33 are brought into contact with the pinch-off portions 21b and 31b, respectively, and vacuum suction is performed by the molds 21 and 31. The resin sheets 23 and 33 are shaped into a shape along the inner surface of the cavities 21a and 31a. The shaping step may be performed after the insert step. Further, it may be performed before the mold clamping step or at the same time as the mold clamping step. The shaping step may be omitted.

3-3. Insert step In the insert step, as shown in FIG. 6, the core material 3 and the reinforcing members 5 and 6 are arranged between the resin sheets 23 and 33. As shown in FIG. 8, the core material 3 and the reinforcing members 5 and 6 are arranged with high accuracy by supporting the core material 3 with the reinforcing members 5 and 6 and supporting the reinforcing members 5 and 6 with the support device 8.

As shown in FIG. 9, the support device 8 has elongated insertion portions 8a and 8b. As shown in FIGS. 10 to 11, the support device 8 supports the reinforcing members 5 and 6 by inserting the insertion portions 8a and 8b into the air flow paths 5c and 6c, respectively. The support device 8 includes diameter-expanded portions 8a2 and 8b2 on the root side of the insertion portions 8a and 8b. By bringing the reinforcing members 5 and 6 into contact with the enlarged diameter portions 8a2 and 8b2, the reinforcing members 5 and 6 can be positioned in the longitudinal direction of the reinforcing members 5 and 6. The length Lb of the insertion portion 8b in the longitudinal direction is longer than the length La of the insertion portion 8a in the longitudinal direction. Therefore, the tip of the insertion portion 8b is arranged so as to protrude from the tip of the insertion portion 8a. Therefore, after the insertion portion 8b is inserted into the air flow path 6c, the insertion portion 8a can be inserted into the air flow path 5c, which is excellent in workability.

The insertion portion 8a includes a pair of insertion pieces 8a1. As shown in FIG. 11A, the insertion portion 8a is configured to press the inner surface of the reinforcing member 5 by widening the distance between the pair of insertion pieces 8a1 in a state where the insertion portion 8a is inserted into the air flow path 5c. .. The pair of insertion pieces 8a1 are attached to the pair of linear sliders 8a3, and the distance between the pair of insertion pieces 8a1 changes as the pair of linear sliders 8a3 slides. When the reinforcing member 5 is supported in a state where the reinforcing member 5 faces in the horizontal direction as in the present embodiment, the reinforcing member 5 may come off from the support device 8, but according to the above configuration, the reinforcing member 5 Is securely fixed to the support device 8. Although the insertion portion 8b is composed of one rod in the present embodiment, it may have the same configuration as the insertion portion 8a. When the projecting portions 1b and 1c are projected from the side surface corresponding to the long side of the resin panel 1, if the reinforcing member 5 tries to support the reinforcing member 5 while facing the vertical direction, the resin panel 1 is inevitably A mold with a size corresponding to the long side of the mold is required, and the mold becomes large. On the other hand, in the present embodiment, since the reinforcing member 5 is supported in a state where the reinforcing member 5 faces in the horizontal direction, the metal is set so that the hanging direction of the resin sheets 23 and 33 is the long side direction of the resin panel 1. The mold can be designed. Therefore, the mold size can be reduced.

As shown in FIG. 11A, there is a gap between the pair of insertion pieces 8a1. As shown in FIG. 11B, there is also a gap between the inner surfaces of the insertion portion 8b and the protrusion 6b. Therefore, even if the insertion portions 8a and 8b are inserted into the air flow paths 5c and 6c, the air flow paths 5c and 6c are not blocked, so that air can be smoothly bleeded through the air flow paths 5c and 6c.

3-4. Mold clamping step In the mold clamping process, as shown in FIG. 7, the molds 21 and 31 are molded. Molding is performed in a state where the reinforcing member 5 is supported by the support device 8. Therefore, the positioning of the reinforcing member 5 and the core material 3 can be suppressed. By fastening the molds 21 and 31, the resin sheets 23 and 33 are welded along the pinch-off portions 21b and 31b, and the resin sheets 23 and 33 are welded to the core material 3.

By the way, in order to fasten the molds 21 and 31 in a state where the reinforcing member 5 is supported by the support device 8, it is necessary to prevent the molds 21 and 31 from interfering with the insertion portions 8a and 8b. Interference can be prevented by providing the molds 21 and 31 with recesses for inserting the insertion portions 8a and 8b, but in that case, the end faces of the protrusions 5b and 6b are not covered with the resin wall 2.

Therefore, in order to prevent the interference between the molds 21 and 31 and the insertion portions 8a and 8b and to cover the end faces of the projecting portions 5b and 6b with the resin wall 2, the molds 21 and 31 are provided with the end portion of the reinforcing member 5. Slide cores 21c, 21d, 31c, 31d (hereinafter, "slide core 21c and the like") are provided at opposite positions. The slide cores 21c and 31c are provided with pinch-off portions corresponding to the ends of the protruding portions 5b. The slide cores 21d and 31d are provided with pinch-off portions corresponding to the ends of the protruding portions 6b. The slide cores 21c and 31c are mold-molded and the end faces of the protrusions 5b are covered with the resin wall 2, and the slide cores 21d and 31d are mold-molded and the end faces of the protrusions 6b are covered with the resin wall 2.

The slide core 21c and the like may be provided directly on the molds 21 and 31, but in the present embodiment, the slide core 21c and the like are provided on the separation blocks 21c1, 21d1, 31c 1, 31d1 separably provided on the molds 21 and 31. Is provided. According to such a configuration, it is possible to easily cope with the shape change of the protrusions 5b and 6b.

As shown in FIG. 22, the slide core 21c and the like are arranged at the retracted position when the molds 21 and 31 are clamped so that the slide core 21c and the like do not interfere with the insertion portions 8a and 8b. It has become. When the molds 21 and 31 are clamped in this state, the resin sheets 23 and 33 are found in the portions other than the ends of the protruding portions 5b and 6b (that is, the portions other than the portions where the slide core 21c and the like are provided). It is sandwiched and welded by the pinch-off portions 21b and 31b.

Then, after the insertion portions 8a and 8b are pulled out from the air flow paths 5c and 6c, the slide core 21c and the like are molded. As a result, the resin sheets 23 and 33 are also sandwiched and welded by the pinch-off portions such as the slide core 21c even at the ends of the protruding portions 5b and 6b. Since the slide core 21c and the like are arranged at the retracted position when the molds 21 and 31 are fastened, the resin sheets 23 and 33 are stretched by that amount. When the slide core 21c or the like is advanced to mold in this state, the resin sheets 23 and 33 are gradually loosened, and the slide core 21c and the like are molded with the resin sheets 23 and 33 loosened (at this time). The slide core 21c and the like are arranged at the mold clamping position shown in FIG. 21). The resin sheets 23 and 33 are stretched to cover the end faces of the protrusions 5b and 6b when the slide core 21c and the like are molded, but the slide core 21c and the like are molded with the resin sheets 23 and 33 loosened. Therefore, the resin sheets 23 and 33 are not excessively locally stretched, and the resin wall 2 is prevented from becoming extremely thin in the vicinity of the end faces of the protrusions 5b and 6b.

Air may be caught between the resin sheets 23 and 33 and the core material 3 when the molds 21 and 31 are clamped, and this air is introduced into the grooves 3b, the openings 5d and 6d, and the air flow path 5c. , 6c, and the openings 5e and 6e are discharged to the outside, so that air is suppressed from remaining between the resin sheets 23 and 33 and the core material 3. When the molds 21 and 31 are molded, the openings 5e and 6e are open to the outside because the slide core 21c and the like are not molded. Therefore, air bleeding is performed smoothly.

In the method of the present embodiment, since air can be discharged through the above path, it is not necessary to separately provide a hole for bleeding air. Therefore, it is possible to manufacture the resin panel 1 covered with the resin wall 2 having no holes.

Through the above steps, a resin panel 1 having a shape along the inner surface of the cavity formed by the molds 21, 31 and the slide core 21c and the like can be obtained. The outside of the pinch-off portion becomes the burr 41. After that, the resin panel 1 shown in FIG. 1 is obtained by opening the molds 21 and 31, taking out the resin panel 1, and removing the burrs 41.
4. Second Embodiment The second embodiment of the present invention will be described with reference to FIG. 23. This embodiment is similar to the first embodiment, and the main difference is the difference in the structure of the core material 3. Hereinafter, the differences will be mainly described.

In the present embodiment, as shown in FIG. 23A, the position of the end portion 3k1 of the front surface side locking portion 3k and the position of the end portion 3l1 of the back surface side locking portion 3l coincide with each other in a plan view. Even in such a form, the same action and effect as in the first embodiment can be obtained.

5. Other Embodiments-In the above embodiment, in the adjacent portions 5a and 6a, the air flow paths 5c and 6c communicate with the outside through the openings 5d and 6d provided on the side surfaces of the reinforcing members 5 and 6, but the reinforcing members When the cross sections 5 and 6 have an H-shaped cross section or a C-shaped cross section, the air flow paths 5c and 6c may communicate with the outside through the gap between the reinforcing members 5 and 6 and the core material 3. Further, the openings 5d and 6d may be provided on the end faces on the adjacent portions 5a and 6a of the reinforcing members 5 and 6.
The openings 5d and 6d may have a shape that allows air to flow, and may be slits or the like instead of small holes.
-In the above embodiment, the openings 5e and 6e are provided on the end faces of the protrusions 5b and 6b, but may be provided at different positions of the protrusions 5b and 6b. For example, the openings 5e and 6e can be provided at a portion overlapping the slide core 21c and the like. Since this portion is not covered with the resin sheet at the time when the molds 21 and 31 are molded, the openings 5e and 6e may be blocked by the resin sheet even if the openings 5e and 6e are provided at this position. do not have.
In the above embodiment, the insertion portion 8a is configured to press the inner surface of the reinforcing member 5 by widening the distance between the pair of insertion pieces 8a1, but another configuration allows the diameter of the circumscribed circle of the insertion portion 8a to be changed. It may be increased. For example, in a state where the insertion portion 8a is inserted into the air flow path 5c, a protruding piece may protrude from the side surface of the insertion portion 8a to press the inner surface of the reinforcing member 5.
-The core material 3 can be omitted if it is not needed. In this case, the reinforcing members 5 and 6 may be fixed by adhering or welding the reinforcing members 5 and 6 to the resin wall 2.
-The adjacent portions 5a and 6a may be adjacent along the side surface of the core material 3 instead of being inserted into the insertion holes 3d and 3e provided in the core material 3. When the core material 3 is composed of a plurality of core materials and the reinforcing members 5 and 6 have an H-shaped cross section, the two core materials may be connected by using the reinforcing members.
-In the above embodiment, the reinforcing members 5 and 6 are connected by the connecting member 7, but the reinforcing members 5 and 6 may not be connected. Further, the number of reinforcing members may be one or three or more.
-In the above embodiment, as shown in FIG. 18, four openings 5d are provided in the vertical and horizontal directions, but the openings 5d may be provided in an oblique direction. The opening provided in the oblique direction has an advantage that it is difficult to come into contact with any of the resin sheets 23 and 33 and the core material 3.

1: Resin panel 1a: Panel part 1b: Protruding part 1c: Protruding part 2: Resin wall 2a: Front wall 2b: Back wall 2c: Peripheral wall 2d: Peripheral wall 2e: End wall 3: Core material 3a: Side surface 3b: Groove 3c: Side surface 3d: Insertion hole 3e: Insertion hole 3f: Gap 3g: Narrow width part 3h: Wide width part 3i: Front surface 3j: Back surface 3k: Front surface side locking part 3l: Back surface side locking part 3m: Through hole 5: Reinforcing member 5a: Adjacent part 5b: Protruding part 5c: Air flow path 5d: Opening 5e: Opening part 6: Reinforcing member 6a: Adjacent part 6b: Protruding part 6c: Air flow path 6d: Opening 6e: Opening 7: Connecting member 8: Support device 8a: Insertion part 8a1: Insertion piece 8a2: Diameter expansion part 8a3: Linear slider 8b: Insert part 8b2: Diameter expansion part 10: Molding machine 11: Raw material resin 11a: Molten resin 12: Hopper 13: Extruder 13a: Cylinder 17: Accumulator 17a: Cylinder 17b: Piston 18: T-die 20: Resin sheet forming device 21: Mold 21a: Cavity 21b: Pinch-off part 21c: Slide core 21c1: Separation block 21d: Slide core 21d1: Separation block 23: Resin sheet 25: Connecting tube 27: Connecting tube 31: Mold 31a: Cavity 31b: Pinch-off part 31c: Slide core 31c1: Separation block 31d: Slide core 31d1: Separation block 33: Resin sheet 41 :Bari

Claims (14)

It ’s a resin panel,
Equipped with a resin wall, core material, and reinforcing member,
The core material and the reinforcing member are surrounded by the resin wall, and the core material and the reinforcing member are surrounded by the resin wall.
The reinforcing member has an air flow path and has an air flow path.
The reinforcing member has an adjacent portion adjacent to the core material and a protruding portion protruding from the side surface of the core material.
The air flow path is provided from the adjacent portion to the protruding portion.
The air flow path communicates with the outside of the air flow path at both the adjacent portion and the projecting portion .
The reinforcing member is a resin panel provided with a first opening communicating with the air flow path at the adjacent portion . The resin panel according to claim 1 .
The first opening is a resin panel provided so as not to come into contact with the resin wall. The resin panel according to claim 1 or 2.
The first opening is a resin panel provided on the side surface of the reinforcing member. The resin panel according to claim 3 .
The first opening is a resin panel provided at a position facing the core material. The resin panel according to claim 3 or 4.
A resin panel in which a gap is provided between the reinforcing member and the core material at a portion where the first opening is provided. The resin panel according to any one of claims 3 to 5.
The first opening is a resin panel provided at a plurality of locations in the circumferential direction of the reinforcing member. The resin panel according to any one of claims 1 to 6 .
A resin panel provided with a groove communicating with the air flow path on the surface of the core material. The resin panel according to claim 7 .
The groove is a resin panel provided in a grid pattern. The resin panel according to any one of claims 1 to 8 .
The reinforcing member is a resin panel having a second opening in the protruding portion communicating with the air flow path. The resin panel according to claim 9 .
The second opening is a resin panel provided on the end face of the reinforcing member. The resin panel according to any one of claims 1 to 10 .
A plurality of the reinforcing members are provided at intervals.
The plurality of the reinforcing members are connected to each other by a connecting member, and the plurality of reinforcing members are connected to each other.
The connecting member is arranged along the second side surface of the core material.
The second side surface is a resin panel facing the first side surface. The resin panel according to any one of claims 1 to 11 .
A resin panel with no holes in the resin wall. It ’s a resin panel,
Equipped with a resin wall, core material, and reinforcing member,
The core material and the reinforcing member are surrounded by the resin wall, and the core material and the reinforcing member are surrounded by the resin wall.
The reinforcing member is inserted into an insertion hole provided in the core material.
The core material comprises a front surface and a back surface facing each other.
The core material includes a front surface side locking portion and a back surface side locking portion.
The front surface side locking portion locks the reinforcing member from the front surface side.
The back surface side locking portion engages the reinforcing member from the back surface side.
A resin panel in which the front surface side locking portion and the back surface side locking portion are provided alternately side by side along the longitudinal direction of the insertion hole. It is a manufacturing method of resin panels.
Equipped with a hanging process, an insert process, and a mold clamping process,
In the hanging step, the first and second resin sheets are hung between the first and second molds.
In the insert step, a core material and a reinforcing member are arranged between the first and second resin sheets, and the core material and the reinforcing member are arranged.
In the mold clamping step, the first and second molds are molded and molded.
The reinforcing member has an air flow path and has an air flow path.
The reinforcing member has an adjacent portion adjacent to the core material and a protruding portion protruding from the side surface of the core material.
The air flow path is provided from the adjacent portion to the protruding portion.
A method in which the air flow path communicates with the outside of the air flow path at both the adjacent portion and the protruding portion.

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