KR20190125472A - Resin panel and manufacturing method, structure and manufacturing method - Google Patents

Abstract

[Problem] Provided are a structure, a resin panel, and a method for producing the same, which can protect the side edges of the member to be protected. According to the present invention, there is provided a resin panel including a panel portion, wherein the panel portion includes a hollow resin molded body, a spacer member, and a reinforcement member, and the spacer member and the reinforcement member are disposed in the resin molded body. And the reinforcing member includes an upper arm, a lower arm, and a connecting portion, wherein the upper arm and the lower arm are connected by the connecting portion at positions displaced from the center in the respective width directions, and the spacer member is provided on an upper surface. And a lower surface opposing the upper surface, and a connecting surface connecting the upper and lower surfaces, wherein the reinforcing member is made of a resin disposed such that the upper arm and the lower arm are positioned on the upper surface side and the lower surface side, respectively. A panel is provided.

Description

Resin panel and manufacturing method, structure and manufacturing method

TECHNICAL FIELD This invention relates to a resin panel, its manufacturing method, a structure, and its manufacturing method.

Patent Document 1 discloses a laminate and a method for producing the laminate, which can increase the strength and can suppress the occurrence of deformation after molding regardless of the size. Here, in patent document 1, in order to raise intensity | strength, H-shaped steel is used as a reinforcement member.

Patent Literature 2 discloses a technique for heat-welding a skin material, which is a cloth having a fluff in the outward direction, to a surface wall in order to give the panel a decorative effect or to improve the hand feel on a resin panel used as a deck board or the like. have.

Japanese Laid-Open Patent Publication 2008-247003 Japanese Patent Laid-Open No. 10-235720

However, the H-shaped steel described in Patent Document 1 cannot protect the side edge of the member to be reinforced because of its shape.

Moreover, in the resin panel of patent document 2, the skin material is not formed in this wall, and the resin molded object is exposed. When such a resin panel is installed in a vehicle, there is a problem that an abnormal sound occurs with vibration of the vehicle or the like.

Moreover, in patent document 1, since H type steel is inserted in resin in order to improve rigidity, it becomes heavier as H type steel.

This invention is made | formed in view of such a situation, and it is providing the resin panel which can protect the side edge of a member to be protected, and its manufacturing method.

Moreover, this invention provides the resin panel which can suppress generation | occurrence | production of an abnormal sound.

In addition, the present invention provides a structure and a method of manufacturing the same, which can realize weight reduction and ensure rigidity as compared with the case of using H-shaped steel.

(1st invention)

According to this invention, it is a resin panel provided with a panel part, The said panel part is provided with a hollow resin molded object, a spacer member, and a reinforcement member, The said spacer member and the said reinforcement member are arrange | positioned in the said resin molded body, The said reinforcement member Has an upper arm, a lower arm, and a connecting portion, wherein the upper arm and the lower arm are connected by the connecting portion at positions deviated from the center in the respective width directions, and the spacer member has an upper surface and the upper surface. There is provided a resin panel having a lower surface facing the upper surface and a connecting surface connecting the upper and lower surfaces, wherein the reinforcing member is disposed such that the upper arm and the lower arm are positioned on the upper surface side and the lower surface side, respectively. .

The panel part which concerns on this invention is equipped with a hollow resin molded object, a spacer member, and a reinforcement member. The spacer member and the reinforcing member are disposed in the resin molded body. The reinforcing member includes an upper arm, a lower arm, and a connecting portion. The upper arm and the lower arm are connected by the connecting portion at positions displaced from the center in the respective width directions. The spacer member has an upper surface, a lower surface facing the upper surface, and a connecting surface connecting the upper and lower surfaces. The reinforcing member is arranged such that the upper arm and the lower arm are located on the upper surface side and the lower surface side, respectively. Thereby, the side edge (connection surface) of the spacer member which is a member to be protected can be protected.

Hereinafter, various embodiment of this invention is illustrated. Embodiments shown below can be combined with each other.

Preferably, the connecting portion is configured to connect the upper arm and the lower arm at respective edges of the upper arm and the lower arm.

Preferably, the connecting portion is configured to be inclined with respect to the lower arm.

Preferably, the spacer member is sandwiched by the upper arm and the lower arm, so that the reinforcing member is attached to the spacer member.

Preferably, the upper surface of the spacer member has an upper surface side mounting structure, the lower surface of the spacer member has a lower surface side mounting structure, and the upper surface side mounting structure is configured to be capable of mounting the upper arm, The lower surface side mounting structure is configured to be capable of mounting the lower arm, and is different in shape from the upper surface side mounting structure.

Preferably, the spacer member has a base and a protrusion, the protrusion protrudes in the width direction of the base, and the reinforcing member has the upper arm and the lower arm formed on an upper surface side of each of the protrusion and the protrusion. It is arranged to be located on the lower surface side.

Preferably, a side protector is formed on the side of the base to protect the side of the protrusion.

Preferably, the resin panel includes a pair of the panel portions, and the pair of panel portions are connected via a hinge portion.

Preferably, the pair of panel portions are connected to the resin molded bodies by a skin material, and the hinge portion is formed by the resin and the skin material compressed at the connection location.

Preferably, the pair of panel portions are formed to be thinner than the thickness of the resin molded body at the other place at the thickness of the resin molded body at the connecting place.

In another aspect, a drooping step, an insert step, and a mold clamping step are provided, wherein the first and second resin sheets are dropped between the first and second molds in the drooping step, and the insert step includes the first structure. Or a second resin sheet, and the mold fastening step molds the first and second molds, wherein the structure includes a spacer member and a reinforcement member, and the spacer member and the reinforcement member are provided in the first and second molds. It is arrange | positioned between 2 resin sheets, The said reinforcement member is equipped with an upper arm, a lower arm, and a connection part, The said upper arm and the said lower arm are connected by the said connection part in the position shifted from the center of each width direction, The spacer member has an upper surface, a lower surface opposing the upper surface, and a connecting surface connecting the upper and lower surfaces, and the reinforcing member is the upper And the lower arm is when each of the upper surface side and the is provided a method of manufacturing a resin-made panel, which is configured to be placed on the side.

(2nd invention)

According to the present invention, the skin wall surface material, the skin wall, the skin wall and the skin wall material are provided in this order, and the skin wall and the skin wall face each other at a distance, and connect the periphery of the skin wall and the skin wall. There is provided a resin panel having a peripheral wall, wherein the back wall side skin material is integrally molded with the back wall so as to cover a part of the back wall.

In the resin panel of this invention, the outer_wall side skin material is integrally molded by this wall so that the one part area | region of this wall may be covered. According to such a structure, generation | occurrence | production of an abnormal sound can be suppressed by forming the skin surface side surface material in the area which a resin panel abuts on a vehicle. In addition, by integrally molding the back wall skin material on the back wall, it is not necessary to attach the back wall skin material as a post-process after forming the resin molded body, and thus the production efficiency is high.

Hereinafter, various embodiment of this invention is illustrated. Embodiments shown below can be combined with each other.

Preferably, the two-wall side skin material is formed along at least one side edge of the resin panel.

Preferably, when the area | region in which the said back wall side skin material was formed in the said back wall was made into the coating area, and the area | region in which the back wall side skin material is not formed in the back wall as an exposed area | region, the said resin panel has the thickness in the said coating area being exposed Larger than the thickness in the area.

Preferably, the thickness in the covering area is configured to approximate the thickness in the exposing area as it moves away from the side edges.

Preferably, a reinforcing member is provided between the front wall and the back wall, and the reinforcing member is disposed so as to overlap in the covering area when one end thereof is viewed in plan view.

Preferably, the back wall skin material has first and second back wall skin materials, the resin panel has opposing first and second side edges, and the first and second back wall skin materials, respectively. It is formed along the first and second side edges, and the reinforcing members are disposed so that their one end and the other end respectively overlap in the first and second back wall skin materials when viewed in plan.

Preferably, a spacer member is provided between the front wall and the back wall, and the reinforcing member is supported by the spacer member.

Preferably, the back wall skin is formed to extend from the back wall to the peripheral wall.

Preferably, the back wall skin material is formed to abut on the skin wall skin material.

Preferably, the surface wall side skin material is integrally formed with the surface wall so as to cover the entire area of the surface wall.

According to another aspect of the present invention, there is provided a drooping step and a mold clamping step, in which the first and second resin sheets are dropped between the first and second molds, and the first mold and the first resin sheet are provided. A skin wall side skin sheet is disposed therebetween, and a skin wall skin sheet is disposed between the second mold and the second resin sheet, and the skin wall skin sheet overlaps in an area of a part of the cavity of the second mold when viewed in plan view. It is arrange | positioned so that it may be carried out, and the manufacturing method of the resin panel which mold-fastens a 1st and a 2nd metal mold in the said mold clamping process is provided.

Preferably, the two wall side skin sheet is formed along at least one side edge of the second mold cavity.

Preferably, the second mold has a placement area in which the back wall skin sheet is disposed and a non-location area in which the back wall skin sheet is not arranged, and the cavity of the second mold has a depth at the placement area. Deeper than the depth in the unlocated region.

Preferably, the depth in the placement area is configured to get closer to the depth in the non- placement area as it moves away from the side edges.

Preferably, an insert step is provided between the drooping step and the mold fastening step, wherein the insert step welds the insert member to the first or second resin sheet, wherein the insert member is supported by the spacer member. The reinforcement member is arrange | positioned so that the one end may overlap in a two-wall side skin sheet, when it sees in plan view.

(Third invention)

According to the present invention, a front wall, a spacer member, a back wall, and a plate member are provided, and the plate member is disposed between at least one of the front wall and the spacer member and between the back wall and the spacer member. Is formed so as to cover a part of the front wall side facing surface or the rear wall facing surface of the spacer member, and the front wall and the spacer member are fixed to each other in the surface wall side exposed area not covered by the plate member, The spacer members are provided with structures that are fixed to each other in an exposed side wall side area not covered by the plate member.

The structure according to the present invention includes a front wall, a spacer member, a back wall, and a plate member. The plate member is disposed on at least one side between the front wall and the spacer member and between the back wall and the spacer member. The plate member is formed so as to cover a part of the front wall side facing surface or the rear wall side facing surface of the spacer member. Further, the surface wall and the spacer member are fixed to each other in the surface wall side exposed area not covered by the side plate member. The back wall and the spacer member are fixed to each other in the back wall exposed area not covered by the side plate member. For this reason, rigidity improves by operating a plate-shaped member and a spacer member as an integral structure.

Further, the first and second resin sheets are dropped between the first and second molds, and the insert member (member formed by sandwiching the spacer member by the front wall and the two wall side plate members) is provided with the first or second resin sheet. The structure can be produced by fastening the mold to the first and second molds, thereby facilitating the manufacture.

Hereinafter, various embodiment of this invention is illustrated. Embodiments shown below can be combined with each other.

Preferably, the plate member includes a front wall side plate member and a back wall side plate member, and the front wall, the front wall side plate member, the spacer member, the back wall side plate member, and the back wall in this order. And the surface wall side plate member is formed to cover a part of the surface wall side facing surface of the spacer member, and the surface wall and the spacer member are fixed to each other in the surface wall side exposed area not covered by the surface wall side plate member. And the back wall side plate member is formed to cover a part of the back wall side facing surface of the spacer member, and the back wall and the spacer member are fixed to each other in a back wall side exposed area not covered by the back wall side plate member. .

Preferably, the area of the area defined by the outer circumference of the plate member is at least 1/3 of the area of the front wall side facing surface or the back wall facing surface of the spacer member.

Preferably, the thickness of the plate member is 1/10 or less of the thickness of the spacer member.

Preferably, the spacer member has a convex portion in the front wall side exposed area and the back wall side exposed area, the front wall and the spacer member are fixed in the convex portion, and the back wall and the spacer member are in the convex portion. Is fixed.

Preferably, the plate member has an opening, and the convex portion is formed at a position corresponding to the opening.

Preferably, the plate member has a plurality of openings, and the convex portion is formed at a position corresponding to each of the plurality of openings.

Preferably, the opening portion of the front wall side plate member and the opening portion of the back wall side plate member are formed at positions facing each other.

Preferably, the opening portion and the convex portion have approximately the same planar shape.

Preferably, the heat resistance temperature of the plate member is higher than the heat resistance temperature of the spacer member.

Preferably, the spacer member is a foam.

Preferably, the plate member is a metal plate.

In another aspect, the method includes a drooping step, an insert step, and a mold clamping step, wherein the first and second resin sheets are dropped between the first and second molds in the drooping step, and the insert step includes removing the insert member. Fixed to the first or second resin sheet, and the first and second molds are mold-fastened in the mold clamping step, and the insert member is formed by sandwiching the spacer member by the front wall side plate member and the back wall side plate member. A method for producing is provided.

1A is a perspective view of the resin panel 90. FIG. 1B is a cross-sectional view of the surface passing through the points P1 to P3 in FIG. 1A.
FIG. 2A in FIG. 2 is a perspective view of the skin material 70 and the resin molded body 50 from FIG. 1. FIG. 2B is a cross-sectional view of a surface passing through points Q1 to Q3 in FIG. 2A.
3 is a partially enlarged view of the area X of FIG. 2.
4 is a diagram illustrating an example of the molding machine 1 that can be used in the method for manufacturing the resin panel 90.
FIG. 5 is an enlarged view of a cross section taken along line AA in FIG. 4 near the first and second molds 21 and 22 and the first and second resin sheets 23a and b. Here, FIG. 4 corresponds to the figure seen from the BB line cross section of FIG.
FIG. 6 is a diagram illustrating a state in which the first and second resin sheets 23a and b are suctioned under reduced pressure from the state of FIG. 5.
FIG. 7: is a figure which shows the state which fixed the spacer member 30 to the 1st resin sheet 23a.
8 is a cross-sectional view showing a state in which the first and second molds 21 and 22 are mold-fastened.
9 is an enlarged cross-sectional view of the periphery of the hinge portion 91 of the resin panel 90 taken out of the first and second molds 21 and 22.
FIG. 10: is a figure which shows the state which two panel parts 60 rotate by the hinge part 91. As shown in FIG.
FIG. 11: is a perspective view (cross-sectional perspective view in which one part was notched) of the resin panel 101 of 2nd Embodiment of this invention.
FIG. 12 is an enlarged view of a portion indicated by arrow X in FIG. 11.
FIG. 13 is a perspective view of a state in which the back wall 104 and the back wall skin 105 of the resin panel 101 of FIG. 11 are partially removed.
FIG. 14: is a block diagram of the molding machine which can be used for manufacture of the resin panel 101 of 2nd Embodiment of this invention.
15 is a cross-sectional perspective view taken along the line AA in FIG. 14.
It is AA sectional drawing in FIG.
FIG. 17 is an enlarged view of the region Y in FIG. 16.
It is sectional drawing corresponding to the AA cross section in FIG. 14 which shows a shaping process.
FIG. 19 is an enlarged view of the region Y in FIG. 18.
20 is a cross-sectional view corresponding to AA cross section in FIG. 14 showing an insert step.
It is sectional drawing corresponding to the AA cross section in FIG. 14 which shows a mold clamping process.
FIG. 22: is a longitudinal cross-sectional view corresponding to FIG. 14 which shows the state which is provided in the metal mold | die 131 in the state which the back side skin sheet 134 relaxed.
23A of FIG. 23 is a partially notched perspective view of structure 270. FIG. 23B is an enlarged view of the notched portion in FIG. 23A. FIG.
24 is a perspective view of five members constituting the structure 270 of the third embodiment of the present invention. In FIG. 24, the peripheral wall formed by the front wall 250F and the double wall 250R is omitted.
25A in FIG. 25 is a cross-sectional view of the plane defined by points P1 to P3 in FIG. 23A. FIG. 25B is a partially enlarged view of the region X of FIG. 25A.
FIG. 26 is a cross-sectional view of the plane defined by points Q1 to Q3 in FIG. 23A.
FIG. 27: is a perspective view which shows the state which pinched | opened the opening part 241 of the plate-shaped member 240 in the convex part 233 of the spacer member 230. As shown in FIG.
28 is a cross-sectional view corresponding to FIG. 25A of the insert member 260.
FIG. 29 is a cross-sectional view corresponding to FIG. 26 of the insert member 260.
30A and 30B of FIG. 30 are views for explaining the manufacturing method of the insert member 260.
31A to 31C of FIG. 31 are views showing the post-process of FIG.
32 is a diagram illustrating an example of a molding machine that can be used in the method of manufacturing the structure 270.
33 is an enlarged cross-sectional view of the vicinity of the first and second molds 221 and 222 and the first and second resin sheets 223a and b.
FIG. 34 is a diagram illustrating a state in which the first and second resin sheets 223a and b are suctioned under reduced pressure from the state of FIG. 33.
35 is a view showing a state where the spacer member 230 is fixed to the second resin sheet 223b.
36 is a cross-sectional view illustrating a state in which the first and second molds 221 and 222 are mold-fastened.
FIG. 37: is a top view which shows the plate member 240 which concerns on the modification 1 of 3rd Embodiment.
38 is a cross sectional view of a side surface of a plate-like member 240 according to Modification Example 2 of the third embodiment.
FIG. 39 is a cross-sectional view of a structure 270 according to Modification Example 3 of the third embodiment, and corresponds to FIG. 26.
40 is a partially enlarged view of a region Y in FIG. 39.

EMBODIMENT OF THE INVENTION Hereinafter, embodiment of this invention is described. Various characteristic matters shown in embodiment shown below can be combined with each other. In addition, the invention holds for each feature.

(First embodiment)

1. Resin panel (90)

As shown in FIGS. 1-3, the resin panel 90 which concerns on one Embodiment of this invention is equipped with the panel part 60. As shown in FIG. In this embodiment, a pair of panel part 60 is provided and they are connected through the hinge part 91. As shown in FIG. Specifically, in the pair of panel portions 60 which are disposed to face each other, the resin molded body 50 is connected by the skin material 70, and the hinge portion is compressed by the resin and the skin material 70 compressed at the connection location. 91 is formed. The skin material 70 is a nonwoven fabric, for example.

2. Panel

Next, the panel part 60 is demonstrated. In this embodiment, the panel part 60 is equipped with the hollow resin molded object 50, the spacer member 30, and the reinforcement member 40. As shown in FIG. Hereinafter, each element is demonstrated.

<Resin molded body 50>

The resin molded body 50 is a hollow molded body. In the present embodiment, the resin molded body 50 includes a front wall 50F, a back wall 50R facing the front wall 50F, and a connecting wall 50C connecting the front wall 50F and the back wall 50R. . The front wall 50F, the back wall 50R, and the connecting wall 50C are formed of resin. In addition, the thickness of the front wall 50F, the back wall 50R, and the connecting wall 50C is preferably 1/10 or less of the thickness of the spacer member 30 described later. In this embodiment, the spacer member 30 and the reinforcement member 40 are arrange | positioned in the resin molding 50, and the pair of panel part 60 is connected by 50F of surface walls. In addition, the pair of panel parts 60 is formed in the thickness of the resin molded object 50 in the connection location thinner than the thickness of the resin molded body 50 in other places.

<Spacer member 30>

In this embodiment, the spacer member 30 is a foam. As shown in FIG. 2 and FIG. 3, the spacer member 30 has an upper surface 31, a lower surface 32 facing the upper surface 31, and a connecting surface connecting the upper surface 31 and the lower surface 32 ( 33c).

The spacer member 30 has a base 37 and a protrusion 33. The protruding portion 33 protrudes in the width direction of the base 37. The base 37 has a first upper surface 31a and a first lower surface 32a opposite to the first upper surface 31a. The protrusion part 33 has the 2nd upper surface 31b and the 2nd lower surface 32b which opposes the 2nd upper surface 31b. The first upper surface 31a and the second upper surface 31b are connected by the upper side wall 33a. In addition, the first lower surface 32a and the second lower surface 32b are connected by the lower upper wall 33b. Thus, in this embodiment, the upper surface 31 is comprised by the 1st upper surface 31a and the 2nd upper surface 31b, and the lower surface 32 is formed by the 1st lower surface 32a and the 2nd lower surface 32b. It is composed.

In this embodiment, the connection surface 33c connects the 2nd upper surface 31b and the 2nd lower surface 32b. Moreover, the upper surface side mounting structure 34 comprised by the 1st upper surface 31a, the 2nd upper surface 31b, and the upper side wall 33a so that attachment of the upper arm 41 mentioned later is comprised. Moreover, the lower surface side mounting structure 35 comprised by the 1st lower surface 32a, the 2nd lower surface 32b, and the lower side wall 33b so that attachment of the lower arm 42 mentioned later is comprised. In addition, the lower surface side mounting structure 35 is a shape different from the upper surface side mounting structure 34. In the example of FIG. 3, the lower side wall 33b is located in the inner side of the base 37 rather than the upper side wall 33a.

In addition, in this embodiment, the base 37 of the spacer member 30 is provided with the side surface protection part 38 which protrudes to the protrusion part 33 side in both sides. As a result, both side surfaces of the protrusion 33 are protected. On the other hand, it is preferable that the side protection part 38 is formed in at least one side surface.

<Reinforcing member 40>

In this embodiment, the reinforcing member 40 is a metal member. The reinforcing member 40 includes an upper arm 41, a lower arm 42, and a connecting portion 43. The upper arm 41 and the lower arm 42 are connected by the connection part 43 in the position shift | deviated from the center of each width direction. In this embodiment, the connection part 43 is comprised so that the upper arm 41 and the lower arm 42 may be connected to each edge of the lower arm 42. And the reinforcing member 40 is arrange | positioned so that the upper arm 41 and the lower arm 42 may be located in the upper surface 31 side and the lower surface 32 side, respectively. Here, the structure 65 is constituted by the spacer member 30 and the reinforcing member 40.

In addition, the connecting portion 43 is configured such that the lower arm 42 is inclined with respect to the connecting portion 43. For example, the angle θ formed by the lower arm 42 and the connecting portion 43 is configured in a tapered TP shape such that 90.5 to 135 degrees. Angle (theta) becomes like this. Preferably it is 91-125 degree | times, More preferably, it is 91.5-115 degree | times, More preferably, it is 92-105 degree | times. Specifically, for example, 90.5, 91, 91.5, 92, 92.5, 93, 93.5, 94, 94.5, 95, 96, 97, 98, 99, 100, 105, 110, 115, 120, 125, 130, 135 degrees Here, you may exist in the range between any two of the illustrated numerical value.

In the present embodiment, when viewed from the side, the distance D2 from the root of the lower arm 42 to the tip of the lower arm 42 is the distance from the root of the lower arm 42 to the tip of the upper arm 41. It is comprised larger than (D1). In addition, the upper side 41a and the lower side 42a are formed in the front-end | tip of the upper arm 41 and the lower arm 42, respectively. And the upper side 41a is abutted on the 2nd upper surface 31b and the upper side wall 33a in the state which interposed the protrusion part 33 between the upper arm 41 and the lower arm 42, and the lower arm 42 ) Is abutted on the second lower surface 32b and the lower upper wall 33b to attach the reinforcing member 40 to the spacer member 30. This attachment prevents the reinforcing member 40 from being removed from the spacer member 30 by at least a part of the protrusion 33 being press-fitted into the upper arm 41 and the lower arm 42.

In this embodiment, the upper arm 41 is attached to the upper surface side mounting structure 34, and the lower arm 42 is attached to the lower surface side mounting structure 35. As shown in FIG. As a result, the spacer member 30 is sandwiched between the upper arm 41 and the lower arm 42, so that the reinforcing member 40 is attached to the spacer member 30. In the present embodiment, the reinforcing member 40 has the upper arm 41 and the lower arm 42 on the upper surface 31 (the second upper surface 31b) side of the protrusion 33 and on the lower surface of the protrusion 33 ( 32) (second lower surface 32b).

With this configuration, the first upper surface 31a is covered by the upper arm 41, the second lower surface 32b is covered by the lower arm 42, and the connecting surface 33c is connected by the connecting portion 43. Covered. As described above, in the present embodiment, when the reinforcing member 40 is viewed from the upper arm 41 and the lower arm 42, the connecting portion 43 is connected to the connecting surface 33c at a position separated from the center CL. It is configured to cover.

As shown in FIG. 3, in this embodiment, the upper arm 41 and the lower arm 42 are complementary to the upper surface side mounting structure 34 and the lower surface side mounting structure 35, respectively. In other words, the upper surface side mounting structure 34 and the lower surface side mounting structure 35 become shapes corresponding to the upper arm 41 and the lower arm 42 which differ from each other in length, respectively. As a result, the reinforcing member 40 can be mounted in the reverse direction, and the taper TP can be physically prevented from occurring in the reverse direction.

3. Configuration of Molding Machine 1

Next, the molding machine 1 which can be used for implementation of the manufacturing method of the resin panel 90 of one Embodiment of this invention is demonstrated using FIG. 4 and FIG. 5 is a cross-sectional view (ie, a cross-sectional view seen from the upper side of FIG. 4) passing through the A-A line of FIG. 4, and FIG. 4 is a view corresponding to the plane passing through the B-B line of FIG. 5.

The molding machine 1 includes a resin supply device 2, a T die 18, and first and second molds 21 and 22. The resin supply device 2 includes a hopper 12, an extruder 13, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T die 18 are connected via a connecting pipe 27. Hereinafter, each structure is explained in full detail.

<Hopper 12, extruder 13>

The hopper 12 is used to inject the raw material resin 11 into the cylinder 13a of the extruder 13. Although the form of raw material resin 11 is not specifically limited, Usually, it is a pellet form. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer and mixtures thereof. The raw material resin 11 is injected into the cylinder 13a from the hopper 12 and then heated in the cylinder 13a, thereby melting to become molten resin. Moreover, it conveys toward the front-end | tip of the cylinder 13a by rotation of the screw arrange | positioned in the cylinder 13a. The screw is disposed in the cylinder 13a and conveyed while kneading the molten resin by the rotation. A gear device is formed at the base end of the screw, and the screw is driven to rotate by the gear device. The number of screws arrange | positioned in the cylinder 13a may be one, or two or more may be sufficient as it.

<Accumulator 17, T die 18>

The foamed resin obtained by melt-kneading the raw material resin and the blowing agent 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 therein, and the molten resin 11a can be stored in the cylinder 17a. Then, by moving the piston 17b after the predetermined amount of the foamed resin is stored in the cylinder 17a, the foamed resin is extruded and dripped from the slit provided in the T die 18 through the connecting pipe 27 to be dripped. The resin sheets 23a and 23b are formed.

<1st and 2nd metal molds 21 and 22>

The first and second resin sheets 23a and 23b are introduced between the first and second molds 21 and 22. As shown in FIG. 7, the 1st metal mold | die 21 is formed with many pressure reduction suction holes (not shown), the 1st resin sheet 23a is vacuum-pressure-sucked and the cavity 21b of the 1st metal mold 21 is carried out. It is possible to shape | mold in the shape along (). The cavity 21b has the shape which has the recessed part 21c, and the pinch-off part 21d is formed so that the recessed part 21c may be enclosed. The second mold 22 is formed with a plurality of pressure reducing suction holes (not shown), and the second resin sheet 23b is suctioned under reduced pressure to be shaped into a shape along the cavity 22b of the second mold 22. It is possible. The cavity 22b has the shape which has the recessed part 22c, and the pin 24 is formed in the recessed part 22c. And the pinch-off part 21d is formed so that the recessed part 22c may be enclosed. Here, the pressure reduction suction hole is a very small hole, one end of which communicates with the inner surfaces of the cavities 21b and 22b through the first and second molds 21 and 22, and the other end is connected to the pressure reduction device.

4. Manufacturing Method of Resin Panel 90

Here, the manufacturing method of the resin panel 90 of one Embodiment of this invention is demonstrated using FIGS. The method of this embodiment includes a drooping step, a shaping step, an insert step, and a mold fastening step. It will be described in detail below.

4. 1 dropping process

In a drooping process, as shown in FIG. 5, the structure 65 is arrange | positioned between the 1st and 2nd metal molds 21 and 22 using the jig 80 which is not shown in figure. In this embodiment, the structure 65 includes the spacer member 30 and the reinforcing member 40. The reinforcing member 40 includes an upper arm 41, a lower arm 42, and a connecting portion 43. The upper arm 41 and the lower arm 42 are connected by the connection part 43 in the position shift | deviated from the center of each width direction. The spacer member 30 includes an upper surface 31, a lower surface 32 facing the upper surface 31, and a connecting surface 33c connecting the upper surface 31 and the lower surface 32. And the reinforcing member 40 is arrange | positioned so that the upper arm 41 and the lower arm 42 may be located in the upper surface 31 side and the lower surface 32 side, respectively.

On the other hand, as shown in FIG. 2 and FIG. 4, in this embodiment, since the longitudinal direction of the reinforcing member 40 is disposed along the vertical direction, the reinforcing member ( 40) can be prevented from falling in the vertical direction.

Then, the first and second resin sheets 23a and 23b formed by extruding and dropping the foamed resin in the molten state from the slit of the T die 18 between the first and second molds 21 and 22 are dropped. . Here, the spacer member 30 and the reinforcement member 40 are disposed between the first and second resin sheets 23a and 23b. In this embodiment, since the direct vacuum molding which uses the 1st and 2nd resin sheets 23a and 23b extruded from the T die 18 is performed as it is, the 1st and 2nd resin sheets 23a and 23b are before shaping | molding. It is not cooled to room temperature and solidified, and the solidified first and second resin sheets 23a and 23b are not heated before molding. Here, in FIG. 5, the structure 65 is shown between the 1st and 2nd resin sheets 23a and 23b in a drooping process, In the drooping process, you may make the structure 65 stand by another place.

4. 2 shaping process

Subsequently, as shown in FIG. 6, the first and second resin sheets 23a and 23b are suctioned under reduced pressure by both the first and second molds 21 and 22, and the first and second molds 21, It is shaped into a shape along the cavity 21b of 22). At this time, the skin material 70 is pressed by the 1st metal mold | die 21 by the 1st resin sheet 23a, and is integrally molded with the 1st resin sheet 23a. Here, the skin material 70 is welded to the first resin sheet 23a or the resin of the first resin sheet 23a is permeated into the skin material 70 so that the skin material 70 is the first resin sheet 23a. It is integrally formed by not moving away from (). Moreover, the jig | tool 80 is set to a pair of structure 65 by this time. In the present embodiment, the jig 80 has a tapered TP shape corresponding to the tapered TP shape of the connecting portion 43 of the reinforcing member 40. Thereby, when arranging a pair of structures 65, the connection part 43 of the reinforcing member 40 is abutted with respect to the taper TP shape of the jig 80, and positioning of the structure 65 becomes easy. In addition, the jig 80 is supported by the support member 81. The spacer member 30 is supported by sucking the structure 65 (spacer member 30) by the suckers 82 formed at both ends of the support member 81.

4. 3 insert process

In the insert process, as shown in FIG. 7, the structure 65 is moved by the jig 80, and is welded to the 1st resin sheet 23a. Here, in this embodiment, since the spacer member 30 is a foam, a foam is melted by the heat of the 1st resin sheet 23a, and the spacer member 30 is welded to the 1st resin sheet 23a. Thereafter, the jig 80 is retracted in the right direction in the drawing. Here, in the present embodiment, since the reinforcing member 40 has a tapered TP shape, the additional effect that the retreat of the jig 80 becomes smooth is obtained.

4. 4 type fastening process

In the mold clamping step, as illustrated in FIG. 8, the first and second molds 21 and 22 are mold clamped. At this time, the first and second resin sheets 23a and 23b forming the front wall 50F of the pair of panel portions 60 are compressed by the pins 24 of the second mold 22, and the first And the thickness of the 2nd resin sheets 23a and 23b becomes thinner than the 1st and 2nd resin sheets 23a and 23b in other places. This corresponds to resin compressed at the connection point.

By this type of fastening, the first resin sheet 23a becomes the front wall 50F, and the second resin sheet 23b becomes the double wall 50R. Moreover, the connection wall 50C which connects the front wall 50F and the back wall 50R is formed by the 2nd resin sheet 23b around the pin 24. As shown in FIG. Moreover, the space SP (refer FIG. 9) is formed between the reinforcement member 40 and the connection wall 50C in the vicinity of the connection location of a pair of panel part 60. As shown in FIG. Thereby, the molded object of the shape along the cavities 21b and 22b of the 1st and 2nd metal molds 21 and 22 is obtained.

Then, the resin panel 90 is obtained by discharging the molded body from the first and second molds 21 and 22 and removing the burrs 26 outside the pinch-off portions 21d and 22d. Here, in this embodiment, the shape of one edge of the resin molded object 50 which comprises the resin panel 90 is designed by taper TP shape (shape prescribed | regulated by the pin 24), and the reinforcement member 40 is carried out. The tapered TP shape is set to the same taper angle (angle θ: FIG. 9) as the tapered TP shape of the resin molded body 50. Thereby, the reinforcement member 40 can be inserted in the vicinity (close to one edge) of one edge of the resin panel 90. With such a configuration, the contact area between the resin and the pin 24 corresponding to the connection wall 50C in the mold fastening step shown in FIG. 8 increases, so that the pressing force from the pin 24 against the resin can be made uniform. have.

5. Hinge section (91)

Next, the hinge part 91 of the resin panel 90 is demonstrated using FIG. 9 and FIG. As mentioned above, the surface wall 50F in the connection location of a pair of panel part 60 is formed by the 1st and 2nd resin sheets 23a and 23b compressed by the pin 24. As shown in FIG. As a result, the surface wall 50F of the pair of panel portions 60 becomes thinner than other locations at the connecting location. And a pair of panel part 60 is connected by the skin material 70 so that the surface wall 50F in a connection location may be covered. Thereby, as shown in FIG. 10, the skin material 70 and the surface wall 50F in a connection location can operate as the hinge part 91. As shown in FIG. Therefore, when the resin panel 90 of this embodiment is applied to an on-vehicle deck board, in addition to the aspect which opens two panel parts 60 together, one panel part 60 is bounded by the hinge part 91. ) Can only be opened.

<Others>

This invention can be implemented also in the following aspects.

The thickness or shape of the upper arm 41 and the lower arm 42 are different. And the upper surface side mounting structure 34 and the lower surface side mounting structure 35 of the shape (complementary) corresponding to such thickness or form are formed. Thereby, mounting of the reinforcement member 40 to the spacer member 30 in the reverse direction can be physically prevented.

A plurality of shapes of the upper arm 41 and the lower arm 42 having a thin board shape are formed, and the upper surface side mounting structure 34 and the lower surface side mounting structure 35 are formed by slits corresponding to the thin board shape. .

(2nd embodiment)

1. Structure of resin panel

As shown in FIGS. 11-13, the resin panel 101 of 2nd Embodiment of this invention is the front wall side skin material 102, the front wall 103, the back wall 104, and the double wall side skin material. 105 is provided in this order. The front wall 103 and the back wall 104 face each other with a gap. The periphery of the front wall 103 and the back wall 104 is connected by the peripheral wall 106. The back wall skin 105 is integrally formed with the back wall 104 to cover a part of the back wall 104.

The resin panel 101 has a pair of opposite side edges 101a. The pair of side edges 101a are spaced apart in the longitudinal direction of the resin panel 101. A pair of two wall side skin materials 105 are formed along each of the pair of side edges 101a. The surface side skin material 102 is integrally formed with the surface wall 103 so as to cover the entire area of the surface wall 103. The back wall skin 105 is formed so as to extend from the back wall 104 to the peripheral wall 106, and the back wall skin 105 and the front wall skin 102 are located in the vicinity of the front wall 103. You are facing.

When the area | region in which the back wall side skin material 105 was formed in the back wall 104 was made into the coating area | region R1, and the area | region in which the back wall side skin material 105 was not formed in the back wall 104 was made into the exposed area | region R2, In the panel 101, the thickness in the covering region R1 is larger than the thickness in the exposure region R2. In other words, the back wall skin 105 is formed to rise from the exposed region R2 of the back wall 104. The difference between the thicknesses of the covering region R1 and the exposed region R2 is, for example, 0.5 to 5 mm, preferably 1 to 3 mm, specifically, for example, 0.5, 1, 1.5, 2, 2.5. , 3, 3.5, 4, 4.5, and 5 mm, and may be in the range between any two of the numerical values illustrated here.

In the covering region R1, a tapered region 101b and a flat region 101c are formed. The tapered region 101b is formed between the flat region 101c and the exposed region R2. According to this structure, since the thickness in the covering area | region R1 becomes close to the thickness in the exposed area | region R2 as it moves away from the side edge 101a, the step | step difference between the covering area | region R1 and the exposed area | region R2 is made. Formation is suppressed. In addition, the occurrence of rattling is suppressed by the flat region 101c contacting the vehicle or the like. The angle of the taper area | region 101b is 1-15 degrees, for example, 2-10 degrees is preferable, and specifically 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 , 11, 12, 13, 14, 15 degrees, and may be in the range between any two of the illustrated numerical values here.

The tapered region 101b may not be formed in the covering region R1, and a step may be formed between the covering region R1 and the exposed region R2. However, in this embodiment, when the wall surface skin 105 is integrally molded to the wall wall 104 in a state where the edge of the skin wall 105 is shifted from the step position due to manufacturing unevenness, the difference is noticeable. Since there is a outstanding problem, it is preferable to form the tapered region 101b.

It is preferable that the outer skin material 102 and the outer skin material 105 have a nonwoven fabric, respectively. It is preferable that a nonwoven fabric consists of resin fibers. It is preferable that the resin fiber is made of a resin having a higher Bicat softening point than the resin constituting the front wall 103, the back wall 104, and the peripheral wall 106. In this case, it is because deformation | transformation of the outer skin side material 102 and the outer skin side material 105 is suppressed at the time of manufacture.

A reinforcing member 108 is formed between the front wall 103 and the back wall 104. The reinforcing member 108 is made of metal (aluminum or the like) or hard plastic. The reinforcing member 108 is preferably a thin and long shape, the cross-sectional shape is constant along its longitudinal direction, and the ratio of the length to the width is 10 or more. The reinforcing member 108 is preferably a cross-sectional H shape, but may be other shapes.

As shown in FIG. 13, the reinforcement member 108 is arrange | positioned along the longitudinal direction of the resin panel 101. As shown in FIG. The reinforcement member 108 is arrange | positioned so that the one end 108a and the other end 108b may overlap in the covering area | region R1, respectively, when viewed in plan. One end 108a and the other end 108b of the reinforcing member 108 are preferably arranged to overlap the flat region 101c, respectively, when viewed in plan. According to such a structure, when the resin panel 101 is mounted in a vehicle etc. so that the coating area | region R1 formed in the both ends of the longitudinal direction of the resin panel 101 may contact | connect a vehicle etc., the resin panel 101 curves and deforms. Is suppressed. On the other hand, "when viewed from the plane" means the state when it sees from the direction perpendicular | vertical to the main surface of the back wall 104 by another expression.

The spacer member 107 is formed between the front wall 103 and the back wall 104. The spacer member 107 is a member for securing the space between the front wall 103 and the back wall 104, and is preferably made of foam. The reinforcing member 108 is preferably supported by the spacer member 107. In this embodiment, the two reinforcing members 108 are supported by the spacer member 107 divided into three.

2. Molding Machine (110)

Next, the molding machine 110 which can be used for implementation of the manufacturing method of the resin panel of 2nd Embodiment of this invention is demonstrated using FIG. The molding machine 110 includes a pair of resin sheet forming apparatus 120 and molds 121 and 131. Each resin sheet forming apparatus 120 includes a hopper 112, an extruder 113, an accumulator 117, and a T die 118. The extruder 113 and the accumulator 117 are connected via the connecting pipe 125. The accumulator 117 and the T die 118 are connected via a connecting pipe 127.

Hereinafter, each structure is explained in full detail.

<Hopper 112, extruder 113>

The hopper 112 is used to inject the raw material resin 111 into the cylinder 113a of the extruder 113. Although the form of raw material resin 111 is not specifically limited, Usually, it is a pellet form. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer and mixtures thereof. The raw material resin 111 is injected into the cylinder 113a from the hopper 112 and then heated in the cylinder 113a, thereby melting to become molten resin. Moreover, it conveys toward the front-end | tip of the cylinder 113a by rotation of the screw arrange | positioned in the cylinder 113a. The screw is disposed in the cylinder 113a and conveyed while kneading the molten resin by the rotation. A gear device is formed at the base end of the screw, and the screw is driven to rotate by the gear device. One may be sufficient as the number of the screws arrange | positioned in the cylinder 113a, and two or more may be sufficient as it.

<Accumulator 117, T die 118>

The molten resin is extruded from the resin extrusion port of the cylinder 113a and injected into the accumulator 117 through the connecting pipe 125. The accumulator 117 includes a cylinder 117a and a piston 117b slidable therein, and the molten resin can be stored in the cylinder 117a. After the molten resin is stored in the cylinder 117a by a predetermined amount, the piston 117b is moved so that the molten resin is extruded and dripped from the slit formed in the T die 118 through the connecting pipe 127 to be melted. 123 and 133 are formed.

<Die (121, 131)>

The resin sheets 123 and 133 are received between the molds 121 and 131. The molds 121 and 131 have cavities 121a and 131a, and pinch-off parts 121b and 131b are formed so as to surround the cavities 121a and 131a. Pressure reducing suction holes (not shown) are formed in the cavities 121a and 131a, and the resin sheets 123 and 133 are vacuum suctioned through the pressure reducing suction holes to cavities 121a and 131a of the molds 121 and 131. It is possible to shape into a shape along the inner surface of the. The pressure reduction suction hole is a very small hole, one end of which communicates with the inner surfaces of the cavities 121a and 131a through the molds 121 and 131, and the other end is connected to the pressure reduction device.

3. Manufacturing method of resin panel

Here, the manufacturing method of the resin panel of 2nd Embodiment of this invention is demonstrated using FIGS. 14-21. The method of this embodiment includes a drooping step, a shaping step, an insert step, and a mold fastening step. It will be described in detail below.

3-1. Drooping process

In the drooping step, as shown in FIGS. 14 to 17, the resin sheets 123 and 133 are dropped between the molds 121 and 131. The front wall side skin sheet 124 is disposed between the mold 121 and the resin sheet 123, and the back wall skin sheet 134 is disposed between the mold 131 and the resin sheet 133. The front wall side skin sheet 124 and the back wall skin sheet 134 are respectively fixed to the molds 121 and 131 by clips or the like (not shown). The front wall side skin sheet 124 is formed to cover the entire area of the cavity 121a of the mold 121. On the other hand, the back wall skin sheet 134 is disposed so as to overlap in a part of the cavity 131a of the mold 131 when viewed in plan. More specifically, the back wall side skin sheet 134 is formed along the side edge of the cavity 131a of the mold 131. As shown in FIG. 14, the two wall side skin sheets 134 may be arranged in a state extending in a straight line in the longitudinal cross-sectional view, or as shown in FIG. 22 in a loose state so as to be curved in the longitudinal cross-sectional view. do. By arranging the back wall skin sheet 134 to be a straight line, a technical effect of improving the positioning accuracy of the back wall skin sheet 134 or suppressing the occurrence of wrinkles in the back wall skin sheet 134 is obtained. . More specifically, a pair of two wall side skin sheets 134 are formed along a pair of side edges of the cavity 131a of the metal mold 131 facing each other. In addition, "viewing from a plane" means the state when it sees from a mold clamping direction by another expression here.

As shown in FIG. 17, when the area | region where the back wall skin sheet 134 is arrange | positioned is set to arrangement area | region S1, and the area | region where the back wall skin sheet 134 is not arrange | positioned as a non-arrangement area | region S2, an arrangement area The depth of the cavity 131a in S1 becomes deeper than the depth of the cavity 131a in the non-located region S2. According to such a structure, since resin of the resin sheet 133 becomes hard to be pressed by the back wall side skin sheet 134, the problem by which resin of the resin sheet 133 is pressed is suppressed. The difference between the thickness of the arrangement area S1 and the non-location area S2 is, for example, 0.5 to 5 mm, preferably 1 to 3 mm, and specifically, for example, 0.5, 1, 1.5, 2, It is 2.5, 3, 3.5, 4, 4.5 and 5 mm, and may be in the range between any two of the illustrated numerical value here. Arrangement area | region S1 and the non-arrangement area | region S2 correspond to the covering area | region R1 and the exposed area | region R2 of the resin panel 101, respectively.

A tapered region 131c and a flat region 131d are formed in the arrangement region S1. The tapered region 131c is formed between the flat region 131d and the non-arranged region S2. According to this structure, since the depth in the placement area S1 approaches the depth in the non-location area S2 as it moves away from the side edge of the cavity 131a, between the placement area S1 and the non-location area S2. It is suppressed that a step is formed in the gap. The tapered region 131c and the flat region 131d respectively correspond to the tapered region 101b and the flat region 101c of the resin panel 101. The angle of the taper area | region 131c is 1-15 degrees, for example, 2-10 degrees is preferable, For example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 , 11, 12, 13, 14, 15 degrees, and may be in the range between any two of the illustrated numerical values here.

3-2. Shaping process

In the shaping step, as shown in FIGS. 18 to 19, the pressure reduction suction is performed by the molds 121 and 131 in a state in which the resin sheets 123 and 133 are brought into contact with the pinch-off portions 121b and 131b, respectively. 123 and 133 are shaped into shapes along the inner surfaces of the cavities 121a and 131a. At this time, the skin sheets 124 and 134 are pressed against the molds 121 and 131 by the resin sheets 123 and 133, respectively, and are integrally molded with the resin sheets 123 and 133. The skin sheets 124 and 134 are formed by the skin sheets 124 and 134 being welded to the resin sheets 123 and 133 or the resin of the resin sheets 123 and 133 soaked into the foamed skin sheets 124 and 134. The outer skin sheets 124 and 134 are integrally molded by keeping them away from the resin sheets 123 and 133.

3-3. Insert process

In the insert step, as shown in FIG. 20, the insert member 126 is welded to the resin sheet 123 or the resin sheet 133. The insert member 126 is constructed by supporting the reinforcing member 108 by the spacer member 107 made of foam, and the insert member 126 is formed on the resin sheet by melting the foam by the heat of the resin sheet 133. Welded. Although the insert member 126 may be welded to either the resin sheet 123 or the resin sheet 133, the resin sheet 123 may be formed by using a mold (eg, a cut sheet) through the skin sheet 124 disposed in the entire region of the cavity 121a. 121), it is harder to cool by the mold than the resin sheet 133. For this reason, it is preferable to weld the insert member 126 to the resin sheet 123 from a viewpoint of reliably welding the insert member 126 and preventing a fall. The insert member 126 is arranged such that one end 108a and the other end 108b of the reinforcing member 108 overlap in the skin sheet 134 when viewed in plan.

3-4. Type fastening process

In the mold clamping step, as illustrated in FIG. 21, mold clamping of the molds 121 and 131 is performed. Thereby, the resin panel 101 of the shape along the inner surface of the cavity formed by the pair of metal molds 121 and 131 is obtained. The outside of the pinch-off parts 121b and 131b becomes the burr 141. Thereafter, the molds 121 and 131 are opened, the resin panel 101 is taken out, and the burr 141 is removed, thereby obtaining the resin panel 101 shown in FIG. 11.

In a form in which the depth of the cavity 131a in the arrangement region S1 is equal to the depth of the cavity 131a in the non-positioning region S2, the resin of the resin sheet 133 is a double-walled skin sheet ( 134) and the reinforcement member 108 are sandwiched by the reinforcement member 108, and the resin excess easily occurs, and when the remaining resin shrinks, the resin rises onto the reinforcement member 108, so that the expansion that protrudes on the back wall 104 side easily occurs. In this embodiment, since the depth of the cavity 131a in the arrangement area S1 is deeper than the depth of the cavity 131a in the non-location area S2, the resin of the resin sheet 133 is hardly pressed, The problem is unlikely to occur.

(Third embodiment)

1. Structure 270

As shown to FIG. 23 and FIG. 24, the structure 270 which concerns on 3rd Embodiment of this invention is comprised by the front wall 250F, the spacer member 230, the back wall 250R, and the plate-shaped member 240. As shown in FIG. The plate member 240 is disposed on at least one side between the front wall 250F and the spacer member 230 and between the back wall 250R and the spacer member 230. In the present embodiment, the plate member 240 includes a front wall side plate member 240F and a back wall side plate member 240R. The plate member 240 is formed to cover part of the front wall side facing surface 231 or the rear wall facing surface 232 of the spacer member 230. Specifically, in the present embodiment, the surface wall side plate member 240F is formed to cover a part of the surface wall side opposing surface 231 of the spacer member 230. Further, the surface wall 250F and the spacer member 230 are fixed to each other in the surface wall side exposed area not covered by the surface wall side plate member 240F. The back wall side plate member 240R is formed to cover a part of the back wall side facing surface 232 of the spacer member 230. In addition, the back wall 250R and the spacer member 230 are fixed to each other in the back wall side exposed area not covered by the back wall plate member 240R. The heat resistance temperatures of the front wall side plate member 240F and the second wall side plate member 240R are higher than the heat resistance temperature of the spacer member 230, respectively. Details of this structure will be described later with reference to FIGS. 25 and 26. In addition, the thick line in a figure shows the parting line PL.

In this embodiment, the spacer member 230 is a foam. A plurality of convex portions 233 are formed on the front wall side facing surface 231 and the rear wall facing surface 232 of the spacer member 230, respectively. In this embodiment, the convex part 233 is formed in the surface wall side exposed area | region not covered by the front wall side plate-shaped member 240F, and the back wall side exposed area | region which is not covered by the two wall side plate-shaped member 240R. Here, the shape and number of the convex portions 233 are arbitrary and can be appropriately designed. It is preferable that the height of the convex part 233 is 0.1-5 mm, for example. Specifically, for example, it is 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5 mm, even if it is in the range between any two of the numerical values illustrated here. do. Here, polystyrene and polyethylene can be used as a raw material of the foam.

In addition, it is preferable that the thickness of the spacer member 230 is 5 mm or more. This thickness is 5-50 mm, for example, Preferably it is 10-30 mm, Specifically, for example, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50 mm, and may be in the range between any two of the numerical values shown here.

In addition, in this embodiment, the front wall side plate member 240F and the back wall side plate member 240R are comprised by the separate member mutually separated. In addition, the front wall side plate member 240F and the back wall side plate member 240R are metal plates. The heat resistance temperatures of the front wall side plate member 240F and the second wall side plate member 240R are higher than the heat resistance temperature of the spacer member 230. For example, the rigidity of the front wall side plate member 240F and the rear wall side plate member 240R is 200-500 kg under high temperature (for example, 80 degrees or more). In addition, the front wall side plate member 240F and the rear wall side plate member 240R have an opening portion 241. In addition, the convex portion 233 is formed at a position corresponding to the opening portion 241.

23B and 25B, in this embodiment, the opening part 241 of the front wall side plate-shaped member 240F and the opening part 241 of the back wall side plate-shaped member 240R are formed in the mutually opposing position. Further, the convex portion 233 of the front wall side facing surface 231 and the convex portion 233 of the two wall side facing surface 232 are formed at positions facing each other. Thereby, as shown in FIG. 24, the opening part 241 of the front wall side plate-shaped member 240F, the convex part 233 of the front wall side opposing surface 231, and the convex part of the back wall side opposing surface 232 ( 233 and the opening part 241 of the wall-side plate member 240R overlap when it sees from a plane. According to this structure, the symmetry of the structure 270 increases, and since the fixing part of the front side and the back side becomes the shortest distance, the intensity | strength of the structure 270 becomes large.

In this embodiment, the some opening part 241 is formed in the front wall side plate member 240F and the rear wall side plate member 240R, respectively. The convex portion 233 is formed at a position corresponding to each of the plurality of openings 241. In addition, in this embodiment, the opening part 241 and the convex part 233 have substantially the same planar shape. As a result, when the convex portion 233 is inserted into the opening portion 241, it is difficult to be pulled out. Then, the front wall side plate member 240F and the back wall side plate member 240R are brought close to the spacer member 230 from the front wall side facing surface 231 and the back wall facing surface 232 side of the spacer member 230, The insert member 260 (refer FIG. 33) is formed in the state which inserted the opening part 241 in the convex part 233 (refer FIG. 27-29).

In this embodiment, the area of the area | region defined by the outer periphery of the surface wall side plate-shaped member 240F and the rear wall side plate-shaped member 240R which opposes the spacer member 230 is respectively the surface wall side facing surface (of the spacer member 230). 231 and one-third to two-thirds of the area of the opposite wall side facing surface 232. (Area of area defined by outer periphery of surface wall side plate member 240F and rear wall side plate member 240R) / area of surface wall side facing surface 231 and spacer side facing surface 232 of spacer member 230. ) Is 0.3 to 1.5, preferably 0.5 to 1, more preferably 0.6 to 0.9. Specifically, it is 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, and may be in the range between any two of the illustrated numerical value here. On the other hand, in this embodiment, the area of the front wall side facing surface 231 and the back wall facing surface 232 of the spacer member 230 is the front wall side facing surface 231 and the back wall facing surface 232 of the spacer member 230. It is smaller than the area of).

Moreover, it is preferable that the thickness of the front wall side plate member 240F and the back wall side plate member 240R is 0.1-2 mm, respectively. Specifically, for example, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2 mm, where The range between any two of the illustrated numerical values may be sufficient.

In addition, the thickness of the front wall side plate member 240F and the rear wall side plate member 240R is preferably 1/10 to 1/2000 of the thickness of the spacer member 230. The values of (thickness of the front wall side plate member 240F or the rear wall side plate member 240R) / (thickness of the spacer member 230) are specifically 0.1, 0.05, 0.03, 0.025, 0.02, 0.015, It is 0.01 and 0.005, You may be in the range between any two of the illustrated numerical value here.

In addition, in this embodiment, the front wall 250F and the back wall 250R are shape | molded with resin.

2. Structure

Next, the structure of the structure 270 will be described with reference to FIGS. 25 and 26. As shown in FIG. 25B, the two plate members 240 are formed in a state where the convex portions 233 of the spacer member 230 fit the openings 241 of the front wall side plate member 240F and the rear wall side plate member 240R. ), The front wall 250F and the rear wall 250R are formed to be interposed therebetween. As a result, the surface wall 250F and the spacer member 230 are fixed in the convex portion 233 via the opening portion 241 of the surface wall-side plate member 240F. Moreover, the back wall 250R and the spacer member 230 are fixed by the convex part 233 through the opening part 241 of the back wall side plate-shaped member 240R. Such fixation is realized at the time of molding described later using FIGS. 32 to 36.

In addition, as shown in FIG. 26, the front wall 250F and the back wall 250R are each convex part through the opening part 241 of the front wall side plate member 240F and the back wall side plate member 240R, even from a different angle. 233 is fixed to the spacer member 230.

By this structure, rigidity is improved by operating the front wall side plate member 240F, the back wall side plate member 240R, and the spacer member 230 as an integral structure. In addition, since the heat-resistant temperature of the front wall side plate member 240F and the rear wall side plate member 240R is higher than that of the spacer member 230, the front wall side plate member 240F and the rear wall side plate member 240R are not formed. Compared with that, the stiffness under high temperature is improved. Moreover, compared with the case where one H-shaped steel is inserted into the resin, the embodiment of the present embodiment using the front wall side plate member 240F and the double wall side plate member 240R becomes high rigidity, and the structure 270 is thinned. Can contribute to

3. Manufacturing Method of Insert Member 260

Next, the manufacturing method of the insert member 260 is demonstrated. The insert member 260 is molded by the bead method in-mold foam molding method using the shaping | molding apparatus 290 shown to FIG. 30 and FIG. As shown in FIG. 30A, the molds 291 and 292 arrange | positioned opposingly are formed in the shaping | molding apparatus 290. FIG. The molds 291 and 292 constitute a part of the vacancy 293 and 294, respectively. Cooling tubes 281 and 282 are disposed in the vacancy 293 and 294. Moreover, the front wall side plate member 240F and the back wall side plate member 240R are arrange | positioned at the molds 291 and 292, respectively.

When the molds 291 and 292 are closed from the state shown in FIG. 30A, as shown in FIG. 30B, the cavity 290a which is a sealed space by the molds 291 and 292 is formed. The foam beads are filled through the feeders 283 and 284 while the molds 291 and 292 are closed. The amount of foam beads filled is, for example, 105 to 110% of the volume of the cavity 290a. Subsequently, as illustrated in FIG. 31A, steam (eg, vapor pressure of 3.0 to 3.5 kgf / cm 2) is injected into the vacancy 293 and 294 from the steam injection ports 295 and 296 for 10 to 30 seconds, for example. Steam enters the bubbles in the foam beads and the pores between the individual pores formed in the mold, and fuses the beads together. Thereafter, as shown in FIG. 31B, cooling water is injected into the cooling tubes 281 and 282 from the cooling water injection ports 297 and 298, and sprayed into the molds 291 and 292 to form the molds 291 and 292 and the spacer member ( The 230 is cooled to solidify the spacer member 230. Subsequently, as shown to FIG. 31C, a mold is opened and the spacer member 230 is taken out. Thereby, the insert member 260 which the convex part 233 of the spacer member 230 fits the some opening part 241 of the front wall side plate member 240F and the back wall side plate member 240R as shown in FIG. ) Is molded. The insert member 260 is then cured for 12 to 24 hours in a room at 50 to 70 ° C., for example, to accelerate curing and prevent shrinkage and deformation.

On the other hand, the spacer member 230, the front wall side plate member 240F, and the back wall side plate member 240R are separately prepared, and the front wall side plate member 240F and the back wall side plate member 240R with respect to the spacer member 230. ), The insert member 260 may be manufactured.

4. Configuration of Molding Machine 201

Next, the molding machine 201 which can be used for implementation of the manufacturing method of the foamed molded object of 3rd Embodiment of this invention is demonstrated using FIG. 32 and FIG. The molding machine 201 includes a resin supply device 202, a T die 218, and first and second molds 221 and 222. The resin supply device 202 includes a hopper 212, an extruder 213, and an accumulator 217. The extruder 213 and the accumulator 217 are connected via a connecting pipe 225. The accumulator 217 and the T die 218 are connected via a connecting pipe 227. Hereinafter, each structure is explained in full detail.

<Hopper 212, extruder 213>

The hopper 212 is used to inject the raw material resin 211 into the cylinder 213a of the extruder 213. Although the form of raw material resin 211 is not specifically limited, Usually, it is a pellet form. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer and mixtures thereof. The raw material resin 211 is injected into the cylinder 213a from the hopper 212 and then heated in the cylinder 213a to be melted to become molten resin. Moreover, it conveys toward the front-end | tip of the cylinder 213a by rotation of the screw arrange | positioned in the cylinder 213a. The screw is disposed in the cylinder 213a and conveyed while kneading the molten resin by the rotation. A gear device is formed at the base end of the screw, and the screw is driven to rotate by the gear device. One may be sufficient as the number of screws arrange | positioned in the cylinder 213a, and two or more may be sufficient as it.

<Accumulator 217, T die 218>

The foamed resin obtained by melt kneading the raw material resin and the blowing agent is extruded from the resin extrusion port of the cylinder 213a and injected into the accumulator 217 through the connecting pipe 225. The accumulator 217 includes a cylinder 217a and a piston 217b slidable therein, and the molten resin 211a can be stored in the cylinder 217a. Then, by moving the piston 217b after the predetermined amount of the foamed resin is stored in the cylinder 217a, the foamed resin is extruded and dripped from the slit formed in the T die 218 through the connecting pipe 227 to be first and second. Resin sheets 223a and 223b are formed.

<1st and 2nd metal mold | die (221, 222)>

The first and second resin sheets 223a and 223b are introduced between the first and second molds 221 and 222. As shown in FIG. 33, many pressure reduction suction holes (not shown) are formed in the 1st metal mold | die 221, the 1st resin sheet 223a is pressure-reduced, and the cavity 221b of the 1st metal mold 221 is carried out. It is possible to shape | mold in the shape along (). The cavity 221b has a shape having a recessed portion 221c, and a pinch-off portion 221d is formed to surround the recessed portion 221c. A plurality of pressure reducing suction holes (not shown) are formed in the second mold 222, and the second resin sheet 223b is suctioned under reduced pressure to be shaped into a shape along the cavity 222b of the second mold 222. It is possible. The cavity 222b has a shape having a recess 222c, and a pinch-off portion 221d is formed to surround the recess 222c.

5. Manufacturing Method of Structure 270

Here, the manufacturing method of the foamed molded object of one Embodiment of this invention is demonstrated using FIGS. 32-36. The method of this embodiment includes a drooping step, an insert step, and a mold clamping step. It will be described in detail below.

5. 1 dropping process

In the drooping step, as shown in FIG. 33, the insert member 260 is disposed between the first and second molds 221 and 222. Here, in this embodiment, the insert member 260 is comprised by the front wall side plate-shaped member 240F and the back wall side plate-shaped member 240R between the spacer members 230. In addition, in this embodiment, since the opening part 241 of the front wall side plate-shaped member 240F and the rear wall side plate-shaped member 240R is inserted in the convex part 233 of the spacer member 230, the insert member 260 is stable. do. Then, the first and second resin sheets 223a and 223b formed by extruding and dripping the foamed resin in the molten state from the slit of the T die 218 between the first and second molds 221 and 222 are received. . In this embodiment, direct vacuum molding using the first and second resin sheets 223a and 223b extruded from the T die 218 is performed as it is, so that the first and second resin sheets 223a and 223b are formed before molding. It is not cooled to room temperature and solidified, and the solidified first and second resin sheets 223a and 223b are not heated before molding. Here, although the insert member 260 is shown between the 1st and 2nd resin sheets 223a and 223b in the drooping process, the insert member 260 may be made to stand by another place in the drooping process.

5. 2 insert process

Next, as shown in FIG. 35, the first and second resin sheets 223a and 223b are suctioned under reduced pressure by both of the first and second molds 221 and 222, and the first and second molds 221 and 222. It shapes to the shape along the cavity 221b of (). Then, the insert member 260 is inserted between the first and second molds 221 and 222 to move in the direction of the second resin sheet 223b. And as shown in FIG. 35, the insert member 260 adheres to the 2nd resin sheet 223b by making the 2nd resin sheet 223b and the insert member 260 contact. Here, in this embodiment, the fixation includes the welding of a resin in a molten state and another resin (foam). In addition, you may fix the insert member 260 and the 1st resin sheet 223a first.

5. 3 type fastening process

At this process, as shown in FIG. 36, the 1st and 2nd metal mold | die 221, 222 is clamped by die. By this type of fastening, the first resin sheet 223a becomes the front wall 250F and the second resin sheet 223b becomes the double wall 250R. And the molded object of the shape along the cavity 221b, 222b of the 1st and 2nd metal mold | die 221, 222 is obtained. At this time, since the 1st and 2nd resin sheets 223a and 223b are high temperature, it contacts with the spacer member 230 via the opening part 241 of the front wall side plate member 240F and the back wall side plate member 240R. Thus, the front wall 250F and the back wall 250R are firmly fixed to the spacer member 230, respectively. In addition, in this embodiment, the area of the area | region defined by the outer periphery of the front wall side plate member 240F and the back wall side plate member 240R is the front wall side facing surface 231 and the back wall facing surface ( Since it is smaller than the area of 232, the front wall 250F and the back wall 250R are also fixed to the spacer member 230 in the region T and the region B, respectively. On the other hand, such fixation is also realized in the end region in the left and right directions in Fig. 25A. That is, in this embodiment, the surface wall side exposed area | region which is not covered by the surface wall side plate-shaped member 240F is the part in which the convex part 233 was formed among the surface wall side opposing surfaces 231 of the spacer member 230, and in the figure. It is an area including the areas T and B. In addition, the back wall side exposed area | region not covered by the back wall side plate-shaped member 240R is the part in which the convex part 233 was formed among the back wall side opposing surfaces 232 of the spacer member 230, and the area | region T in the figure. , B).

The structure 270 is obtained by taking out the molded bodies from the first and second molds 221 and 222 and removing the burrs 228.

As described above, in the present embodiment, the first and second resin sheets 223a and 223b are dropped between the first and second molds 221 and 222 in the drooping step, and the insert member ( 260 is fixed to the first or second resin sheets 223a and 223b, and the structure 270 can be formed by mold-fastening the first and second molds 221 and 222 in the mold fastening process. Becomes easy. In addition, by using the front wall side plate member 240F and the double wall side plate member 240R as reinforcing members, it is possible to contribute to weight reduction compared to the case where H-shaped steel is used.

<Modification 1>

Next, modified example 1 of one embodiment is demonstrated using FIG. As shown in FIG. 37, the slit 242 may be formed in the plate member 240. In this case, it is preferable to form a convex portion having a shape corresponding to the slit 242 in the spacer member 230. In the modification 1, the front wall 250F, the back wall 250R, and the spacer member 230 are adhered through the slit 242.

<Modification 2>

As shown in FIG. 38, the punching pin 243 may be formed in the plate member 240, and the punching pin 243 may be inserted into the spacer member 230. As shown in FIG. Thereby, the plate member 240 can be fixed to the spacer member 230. In this case, it is preferable to form a convex portion having a shape corresponding to the hole 244 formed by the punching pin 243 in the spacer member 230. In the modification 2, the front wall 250F, the back wall 250R, and the spacer member 230 are adhered through the hole 244.

<Modification 3>

As shown in FIG. 39 and FIG. 40, the plate member 240 in which the opening part 241 or the slit 242 is not formed can be used. In this case, the area of the plate-shaped member 240 is made smaller than the area of the back wall side facing surface 232 and the back wall facing surface 232 of the spacer member 230. As a result, the surface wall 250F and the back wall 250R and the spacer member 230 adhere to each other in the regions T and B. On the other hand, such fixation is also realized in the end region in the left and right directions in Fig. 25A.

<Others>

This invention can be implemented also in the following aspects.

The height of the convex portion 233 of the spacer member 230 is made larger than the thickness of the plate member 240. This makes it difficult for the plate member 240 to be removed from the spacer member 230, and the stability of the insert member 260 is improved.

The spacer member 230 and the plate member 240 are adhered with a special adhesive agent.

The front wall 250F, the rear wall 250R, and the spacer member 230 are adhered with an adhesive.

The plate member 240 is formed of heat-resistant plastic (polyimide, polybutylene terephthalate, polypropylene, diallyl phthalate, or the like).

Another member is formed between the above-mentioned members, and it is set as the structure of 6 or more layers.

A structure of four or more layers is used as the insert member.

1 ： Molding Machine
2: resin supply device
11: Raw material balance
11a ： Resin
12 hopper
13: extruder
13a ： Cylinder
17: Accumulator
17a ： Cylinder
17b ： piston
18 ： T die
21 ： the first mold
21b ： cavity
21c ： Golden part
21d ： Pinch off part
22 ： second mold
22b ： cavity
22c ： Convex part
22d ： Pinch off part
23a ： 1st resin sheet
23b ： 2nd resin sheet
24 ： Pin
25 ： Connector
26 ： Bur
60 ： Panel part
30 ： Spacer member
31 ： Top
31a ： First upper surface
31b ： 2nd upper surface
32 ：
32a: The first lower surface
32b ： The second lower surface
33 ： protrusion
33a ： Upper wall
33b ： lower wall
33c ： Connecting surface
34 ： Top side mounting structure
35 ： Rear side mounting structure
37 ： Contribution
38 ： Side protection part
40 ： Reinforcement member
41 ： Upper arm
42 ： Lower arm
41a ： Upper tide
42a ： Lower basin
43 ： Connection
50 ： Resin molding
50F ： Surface
50R ： This wall
50C ： Connecting wall
60 ： Panel part
65 ： Structure
70 ： Skin material
80 ： Jig
81 ： Support
82 ： Sucker
90 ： Resin panel
91 ： Hinge part
101 ： Resin panel
101a ： side edge
101b: Taper area
101c ： flat area
102 ： Surface material
103 ： Surface
104 ： This wall
105 ： Side wall skin
106 ： Perimeter wall
107 ： Spacer member
108 ： Reinforcement member
108a ： Once
108b ： The other end
110 ： Molding machine
111 ： Raw resin
112 hopper
113 ： Extruder
113a ： Cylinder
117 ： Accumulator
117a ： Cylinder
117b ： Piston
118 ： T die
120 ： Resin sheet forming device
121 ： Mold
121a ： cavity
121b: Pinch off part
123 ： Resin sheet
124 ： Surface side skin sheet
125 ： Connector
126 ： Insert member
127 ： Connector
131 ： Mold
131a ： cavity
131b: Pinch off part
131c: Taper area
131d ： flat area
133 ： Resin sheet
134 ： Back side skin sheet
141 ： Bur
R1: Cover area
R2: Exposure area
S1: Placement area
S2: Unallocated Area
201 ： Molding Machine
202 ： Resin supply device
211 ： Raw material balance
211a: Molten resin
212 hoppers
213 ： Extruder
213a ： Cylinder
217: Accumulator
217a ： Cylinder
217b ： Piston
218 ： T die
221 ： 1st mold
221b ： cavity
221c: Concave part
221d ： Pinch off part
222 ： 2nd mold
222b ： cavity
222c: Convex part
222d ： Pinch off part
223a: First resin sheet
223b: Second resin sheet
225 ： Connector
227 ： Connector
228: Bur
230: Spacer member
231 ： Surface side facing surface
232 ： This wall side facing surface
233 ： Convex part
240: plate-shaped member
240F: Surface side plate member
240R: Double wall side plate member
241 ： Opening department
242 ： Slit
243 ： Punching pin
244 ： Hole
250F: Surface
250R: Two walls
260 ： Insert member
270 ： Structure
PL ： Parting line

Claims (39)

As a resin panel provided with a panel part,
The panel portion includes a hollow resin molded body, a spacer member, and a reinforcing member,
The spacer member and the reinforcing member are disposed in the resin molded body,
The reinforcing member has an upper arm, a lower arm, and a connecting portion,
The upper arm and the lower arm are connected by the connecting portion at positions displaced from the center of the respective width directions,
The spacer member has an upper surface, a lower surface facing the upper surface, and a connecting surface connecting the upper and lower surfaces,
And the reinforcing member is disposed such that the upper arm and the lower arm are located on the upper surface side and the lower surface side, respectively. The method of claim 1,
And the connecting portion is configured to connect the upper arm and the lower arm at respective edges of the upper arm and the lower arm. The method according to claim 1 or 2,
And said connecting portion is configured to be inclined with respect to said lower arm. The method according to any one of claims 1 to 3,
The spacer member is sandwiched by the upper arm and the lower arm, so that the reinforcing member is attached to the spacer member. The method according to any one of claims 1 to 4,
The upper surface of the spacer member has an upper surface side mounting structure,
The lower surface of the spacer member has a lower surface side mounting structure,
The upper surface side mounting structure is configured to mount the upper arm,
The said lower surface side mounting structure is comprised so that the said lower arm is mountable, and is a resin panel which is different from the said upper surface side mounting structure. The method according to any one of claims 1 to 5,
The spacer member has a base and a protrusion,
The protrusion protrudes in the width direction of the base,
And the reinforcing member is disposed such that the upper arm and the lower arm are located on the upper surface side of the protrusion and the lower surface side of the protrusion, respectively. The method of claim 6,
The resin panel which is provided with the side surface protection part which protects the side surface of the said projection part in the side surface of the said base part. The method according to any one of claims 1 to 7,
The resin panel has a pair of the panel portion,
The panel panel made of a resin connected to the pair of panel portions via a hinge portion. The method of claim 8,
The pair of panel portions are connected to the resin molded bodies by a skin material,
The resin panel in which the said hinge part is formed by the resin and the said skin material compressed at the said connection location. The method according to claim 8 or 9,
The said panel part is a resin panel in which the thickness of the said resin molding in the said connection part is formed thinner than the thickness of the said resin molding in another place. Including a drooping step, an insert step, and a mold clamping step,
In the drooping step, the first and second resin sheets are dropped between the first and second molds,
In the insert process, the structure is fixed to the first or second resin sheet,
In the mold fastening process, the first and second molds are fastened to each other.
The structure has a spacer member and a reinforcing member,
The spacer member and the reinforcing member are disposed between the first and second resin sheets,
The reinforcing member has an upper arm, a lower arm, and a connecting portion,
The upper arm and the lower arm are connected by the connecting portion at positions displaced from the center in the respective width directions,
The spacer member has an upper surface, a lower surface facing the upper surface, and a connecting surface connecting the upper and lower surfaces,
And the reinforcing member is disposed such that the upper arm and the lower arm are positioned on the upper surface side and the lower surface side, respectively. The front wall side skin material, the front wall, the back wall, and the back wall side skin material are provided in this order,
The front wall and the rear wall face each other at a distance,
A peripheral wall connecting the periphery of the front wall and the back wall;
The said back wall side skin material is integrally molded with the back wall so that a part of this back wall may be covered. The method of claim 12,
The said wall side skin material is a resin panel formed along the at least 1 side edge of the said resin panel. The method of claim 13,
When the area | region in which the said back wall side skin material was formed in the said back wall was made into the covering area | region, and the area | region where the back wall side skin material was not formed in the back wall as an exposed area | region,
The said resin panel is a resin panel whose thickness in the said covering area | region is larger than the thickness in the said exposure area | region. The method of claim 14,
The thickness of the said coating area | region is comprised so that it may become close to the thickness in the said exposure area | region as it moves away from the said side edge. The method according to claim 14 or 15,
A reinforcing member is provided between the front wall and the back wall,
The said reinforcing member is a resin panel arrange | positioned so that the one end may overlap in the said covering area, when it sees in planar view. The method of claim 16,
The back wall skin material includes first and second back wall skin materials,
The resin panel has opposing first and second side edges,
The first and second two side skins are formed along the first and second side edges, respectively,
The said reinforcing member is a resin panel arrange | positioned so that the one end and the other end may overlap in the 1st and 2nd back wall side skin materials, respectively, when viewed in plan. The method according to claim 16 or 17,
A resin panel comprising a spacer member between the front wall and the back wall, wherein the reinforcing member is supported by the spacer member. The method according to any one of claims 13 to 18,
The back wall skin member is formed to extend from the back wall to the peripheral wall. The method of claim 19,
The said wall side skin material is a resin panel formed in contact with the said skin wall side skin material. The method according to any one of claims 12 to 20,
The said front wall side skin material is integrally molded with the said front wall so that the whole area | region of the said front wall may be covered. With a drooping step and a mold fastening step,
In the drooping step, the first and second resin sheets are dropped between the first and second molds,
The front wall side skin sheet is disposed between the first mold and the first resin sheet,
A two wall side skin sheet is disposed between the second mold and the second resin sheet,
The two wall side skin sheets are arranged to overlap in a region of a part of the cavity of the second mold when viewed in plan,
In the mold clamping step, a resin panel manufacturing method of mold clamping the first and the second mold. The method of claim 22,
The said two wall side skin sheet is a manufacturing method of the resin panel formed along at least one side edge of the cavity of a 2nd metal mold | die. The method of claim 23,
The 2nd metal mold | die is equipped with the arrangement area | region in which the said back wall side skin sheet was arrange | positioned, and the non-arrangement area | region where the said back wall side skin sheet is not arrange | positioned,
The cavity of a 2nd metal mold | die is a manufacturing method of the resin panel whose depth in the said arrangement area | region is deeper than the depth in the said non-arrangement area | region. The method of claim 24,
The depth in the said arrangement area | region becomes a manufacturing method of the resin panel comprised so that it may become close to the depth in the said non-location area | region as it moves away from the said side edge. The method according to any one of claims 23 to 25,
An insert step between the drooping step and the mold clamping step;
In the insert step, the insert member is welded to the first or second resin sheet,
The insert member is composed of a reinforcing member supported by a spacer member,
The said reinforcement member is a manufacturing method of the resin panel which is arrange | positioned so that the one end may overlap in a two-wall side skin sheet when it sees from a plane. It is provided with a front wall, a spacer member, a back wall, and a plate-shaped member,
The plate member is disposed between at least one of the front wall and the spacer member and between the back wall and the spacer member.
The plate member is formed so as to cover a part of the surface wall side facing surface or the side wall side facing surface of the spacer member.
The surface wall and the spacer member are fixed to each other in the surface wall side exposed area not covered by the plate member,
The back wall and the spacer member are fixed to each other in an exposed area on the back wall side not covered by the plate member. The method of claim 27,
The plate member includes a front wall side plate member and a back wall side plate member,
The front wall, the front wall side plate member, the spacer member, the back wall side plate member, and the back wall are provided in this order.
The surface wall side plate-like member is formed to cover a part of the surface wall side opposing surface of the spacer member,
The surface wall and the spacer member are fixed to each other in the surface wall side exposed area not covered by the surface wall side plate member,
The back wall side plate-like member is formed to cover a part of the back wall side facing surface of the spacer member,
The back wall and the spacer member are fixed to each other in a back wall exposed area not covered by the back wall plate member. The method of claim 27 or 28,
The structure of the area | region defined by the outer periphery of the said plate member is 1/3 or more of the area of the front wall side facing surface or the back wall facing surface of the said spacer member. The method according to any one of claims 27 to 29,
The structure of the said plate-shaped member is 1/10 or less of the thickness of the said spacer member. The method according to any one of claims 28 to 30,
The spacer member has convex portions at the front wall side exposed area and the back wall exposed area,
The front wall and the spacer member are fixed in the convex portion,
The back wall and the spacer member are fixed to the convex portion. The method of claim 31, wherein
The plate member has an opening portion, and the convex portion is formed at a position corresponding to the opening portion. The method of claim 31, wherein
The plate member has a plurality of openings, and the convex portion is formed at a position corresponding to each of the plurality of openings. 34. The method of claim 32 or 33,
And the opening portion of the front wall side plate member and the opening portion of the back wall side plate member are formed at positions facing each other. The method according to any one of claims 32 to 34, wherein
And the opening and the convex portion have substantially the same planar shape. The method according to any one of claims 27 to 34,
The heat resistant temperature of the said plate member is higher than the heat resistant temperature of the said spacer member. The method according to any one of claims 27 to 36,
The spacer member is a foam. The method according to any one of claims 27 to 37,
The plate member is a metal plate structure. Including a drooping step, an insert step, and a mold clamping step,
In the drooping step, the first and second resin sheets are dropped between the first and second molds,
In the insert step, the insert member is fixed to the first or second resin sheet,
In the mold fastening process, the first and second molds are fastened to each other.
The said insert member is a manufacturing method of the structure comprised with the spacer member by the front wall side plate member and the back wall side plate member.

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