JPH08258201A - Production of composite panel - Google Patents

Abstract

PURPOSE: To provide a composite panel producing method capable of omitting and simplifying a manufacturing process, not generating load in the manufacturing process even if a surface plate has unevenness such as a curved surface or a corner part, capable of distributing the various arrangements of ribs represented by a honeycomb in an ill-balanced state if necessary so as to be capable of corresponding to non-uniform load and high in the degree of freedom of planning. CONSTITUTION: A panel material 1 made of a synthetic resin wherein thin-walled ribs 3 are provided on the single surface of a surface plate 2 is integrally molded and a foamable resin is supplied to the gaps between the ribs 3 to be foamed to form a laminated structure.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a panel having ribs, and more particularly to a panel having high strength, high heat insulation and high sound insulation, and having a high degree of freedom in designing the shape of the panel surface and strength. The present invention relates to a method for manufacturing a composite panel made of synthetic resin, which is easy to manufacture and is obtained.

[0002]

2. Description of the Related Art Various types of panels having ribs have been proposed, and a typical example is a panel having a laminated structure in which two upper and lower face plates are joined to a rib having a honeycomb structure. Further, these panels include those having a void space between the ribs and those having a space filled with a filling material. A foam material is most often used for this filling material and is widely used for various purposes because of its high strength, heat insulation, sound insulation and light weight.

When manufacturing such a panel, a face plate and ribs are manufactured separately, a foaming resin is supplied to the spaces between the ribs, and the face plate and ribs are joined to form a panel. There is.

In particular, when the ribs are limited to honeycomb, one of the ways of making the ribs is to stack a number of corrugated sheets and, at that time, slice them at right angles to the corrugated sheets so that a gap is formed between the corrugated sheets. Then there is a method to cut out. Further, although there are ribs made of various thin materials such as paper honeycombs and thin metallic materials, the lack of strength due to the thin thickness is compensated by the high density of the honeycomb. To make such a honeycomb, for example, if the thin material is paper, first prepare a large number of papers in which paste is applied in stripes at equal intervals, align these stripes, and alternate stripes. There is a method of stacking so as to be staggered, cutting the stacked paper into strips, and spreading the sheets to form a honeycomb.

[0005]

However, if the face plate and the rib are separate, a joining process is required each time. In particular,
The thinner the rib, the more difficult the joining becomes. If the rib and the face plate are different materials, joining such as welding will be difficult. Further, in order to join, the rib-side joining surface and the face plate must have the same surface shape. Therefore, if the face plate has various irregularities such as a curved surface, it is difficult to make the joining surface on the rib side follow this curved surface by the method of slicing laminated corrugated plates or paper as described above, and the curved surface is It may be impossible if it is complicated. Furthermore, many of these conventional ribs have a uniform distribution, and it is difficult to make an arbitrary distribution. Therefore, when the load on the panel is uneven, it is not suitable to distribute the ribs following the unevenness.

In view of the above problems, the present invention has an object of simplifying and simplifying the manufacturing process, even if the face plate has irregularities such as curved surfaces and corners. The manufacturing of composite panels with a high degree of freedom in design, in which various arrangements of ribs typified by honeycomb can be distributed unbalanced as needed so that even loads can be accommodated To provide a method.

[0007]

In order to solve the above problems and to achieve the object, the invention according to claim 1 states that "a synthetic resin panel material 1 having a thin rib 3 on one surface of a face plate 2 is integrally formed. Molding, and supplying the foaming resin 20 to the voids 5 between the ribs 3 and 3 to foam the foaming resin 20 to form a laminated structure. "
Was the gist.

A honeycomb structure having a honeycomb structure is suitable for the "rib", and the honeycomb structure is not limited to a hexagonal structure and may be any polygonal structure. Of course, it does not have to have a honeycomb structure. The “molding” can be performed by an injection molding method, an injection compression molding method, or the like. As the “resin”, polypropylene, polyethylene, ABS resin, or other thermoplastic resin can be used. The "foaming resin" may be a thermoplastic resin such as polystyrene, polyethylene or polypropylene, or may be a thermosetting resin such as a phenol resin, a urea resin, a melanin resin or a polyurethane resin. . Further, these resins may be used in a non-foamed or pre-foamed state. The "foaming" can be performed by shielding the opening of the rib to which the foamable resin is supplied with a mold and heating this.

According to a second aspect of the present invention, "a synthetic resin panel material 1 having a thin rib 3 on one surface of a face plate 2 is integrally molded, and a foaming resin 20 is provided in a space 5 between the ribs 3 and 3. Then, the foamable resin 20 is foamed, and the opening 6 of the rib 3 is supplied.
To form a laminated structure by joining the single plate 10 to the above. " The “joining” may be performed by heat welding, vibration welding, adhesive bonding, or any other method.

The gist of the invention according to claim 3 is that in the means according to claim 2, "the plate surface of the veneer has irregularities".

The gist of the invention according to claim 4 is that the plate surface of the face plate has irregularities in the means according to claims 1 to 3.

The gist of the invention according to claim 5 is that in the means according to claims 1 to 4, "the rib is formed in an arrangement corresponding to the load strength".

[0013]

By the above means, the invention according to claim 1 does not require the step of joining the face plate and the rib. Further, since the ribs are manufactured by molding, particularly when this molding is injection compression molding, it is easy to manufacture a product having a thickness close to that of a paper honeycomb or the like.

According to the second aspect of the present invention, a face plate and a single plate are provided.
Although it is a composite panel composed of one plate material, only one plate material needs to be joined.

According to the invention of claim 3, in addition to the effect of claim 2, it becomes easy to make the height of the rib follow the unevenness of the single plate to be joined.

According to the invention described in claim 4, in addition to the effects of claims 1 to 3, it is possible to eliminate the difficulty of joining the face plate having irregularities and the ribs having different heights.

According to the invention of claim 5, in addition to the actions of claims 1 to 4, the mechanical strength of the composite panel can be made to have an arbitrary distribution.

[0018]

EXAMPLE First, a manufacturing process by the method for manufacturing a composite panel according to claim 5 will be described below. In addition, this embodiment is
An example of a method of manufacturing a composite panel according to claims 1, 2 and 4 is indirectly shown. Furthermore, this embodiment is a manufacturing method for manufacturing the composite panel 100 shown in FIG.

First, the composite panel 100 to be manufactured.
The structure of will be described first. As shown in FIG. 2, the composite panel 100 of FIG. 1 has a laminated structure in which a substantially rectangular synthetic resin panel material 1 and a single plate 10 sandwich a foamed body 20a.
The synthetic resin panel material 1 is made of polypropylene and has a rib 3 having a honeycomb structure on one surface of a face plate 2, and the other one surface is formed into a pillar portion 4 having four convex corners as shown in FIG. As a result, the plate surface is uneven. Also, rib 3
Is a thin wall having a thickness of about 1 mm, and a portion corresponding to the supporting column 4 is formed into a coarse density rib 3a, and a portion between the supporting columns 4 and 4 which is easily twisted is formed into a high density rib 3b.
A middle density rib 3c is formed in the central portion of the panel surrounded by, so that the face plate 2 as a whole is formed with a difference in strength. Furthermore, the foam 20a is made by foaming polystyrene.

Next, the manufacturing process will be sequentially described. First, the synthetic resin panel material 1 shown in FIGS. 3 and 4 is molded by injection compression molding. At the time of this molding, polypropylene having a molding temperature of 240 ° C. was used as a material, and it was injected into a mold having a mold opening of 20 mm, and then the pressing pressure was 10
It is compressed under the conditions of 0 kg / cm ² and a pressing speed of 20 mm / sec to obtain a desired synthetic resin panel material 1. After this synthetic resin panel material 1 is cured, it is released from the mold to obtain the synthetic resin panel material 1 having the sectional structure shown in FIG. Next, about 5% of pre-expanded beaded polystyrene is supplied into the voids of the honeycomb of the synthetic resin panel material 1. Then, as shown in FIG. 6, the opening 6 of the honeycomb is shielded by a mold, and steam at 110 ° C. is compressed to 0.8 atm.
Heat at kg / cm ² to foam.

The panel at this stage also serves as one embodiment of the composite panel 100 according to the first aspect. Finally, as shown in FIG. 7, the openings 6 of the honeycomb are formed.
Then, the polypropylene single plate 10 is bonded at a bonding temperature of 180 ° C.,
Bonding is performed by heat welding under the condition that the bonding time is 30 seconds to form a laminated structure.

The composite panel 100 can be used, for example, as a flooring material for an OA floor, and has a surface shape that can be freely designed, a required strength distribution, energy saving due to a heat insulating effect, a quiet office due to a sound insulating effect, and the like. Bring about realization. Furthermore, we will further expand the applications and improve the performance of various panels such as wall materials, concrete formwork, and heat insulation materials for refrigerators.

[0023]

As described above, according to the first aspect of the invention, the step of joining the face plate and the rib is not necessary, and the manufacturing process can be omitted. Further, since the ribs are manufactured by molding, in particular, by injection compression molding, it is possible to manufacture a thin paper honeycomb or the like, and it is possible to easily reduce the weight.

According to the second aspect of the present invention, a face plate and a single plate are provided.
Although it is a composite panel composed of one plate material, only one plate material needs to be joined, and the manufacturing process can be omitted.

According to the third aspect of the present invention, it becomes easy to make the height of the rib follow the unevenness of the single plate to be joined, which simplifies the manufacturing and increases the degree of freedom in designing the composite panel.

According to the fourth aspect of the present invention, the difficulty of joining the uneven face plate and the ribs having different heights to each other is eliminated, which simplifies the production and increases the degree of freedom in designing the composite panel.

According to the invention of claim 5, the mechanical strength of each part of the panel can be arbitrarily changed as required. In other words, it is possible to design the strength arbitrarily according to the load distribution and the strain distribution.

[Brief description of drawings]

FIG. 1 is a cutaway perspective view of a composite panel manufactured by a manufacturing method according to an embodiment.

2 is a cross-sectional view taken along the line AA of the composite panel shown in FIG.

FIG. 3 is a perspective view of a synthetic resin panel material used in the composite panel shown in FIG.

FIG. 4 is a perspective view of a synthetic resin panel material used for the composite panel shown in FIG. 1 as viewed from the rib side.

FIG. 5 is a partial cross-sectional view of a synthetic resin panel material showing one step of the manufacturing method of the embodiment.

FIG. 6 is a partial cross-sectional view of a synthetic resin panel material showing one step of the manufacturing method of the example.

FIG. 7 is a partial cross-sectional view of a composite panel showing one step of the manufacturing method of the example.

[Explanation of symbols]

 100 composite panel 1 synthetic resin panel material 2 face plate 3 ribs 4 pillars as irregularities 5 voids 6 openings 10 veneer 20 foam resin 20a foam

Claims (5)

[Claims] 1. A synthetic resin panel material having a thin rib on one surface of a face plate is integrally molded, and a foamable resin is supplied into a space between the ribs to foam the foamable resin to form a laminated structure. A method for manufacturing a composite panel, which comprises: 2. A synthetic resin panel material having a thin rib on one surface of a face plate is integrally molded, and a foamable resin is supplied into a space between the ribs to foam the foamable resin, A method for manufacturing a composite panel, which comprises forming a laminated structure by bonding a single plate to the opening. 3. The method of manufacturing a composite panel according to claim 2, wherein the plate surface of the single plate is uneven. 4. The method for manufacturing a composite panel according to claim 1, wherein the plate surface of the face plate is uneven. 5. The method for manufacturing a composite panel according to claim 1, wherein the ribs are formed in an arrangement corresponding to a load strength.