WO2014058059A1 - Panneau pris en sandwich dans de la résine et son procédé de fabrication - Google Patents

Panneau pris en sandwich dans de la résine et son procédé de fabrication Download PDF

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Publication number
WO2014058059A1
WO2014058059A1 PCT/JP2013/077798 JP2013077798W WO2014058059A1 WO 2014058059 A1 WO2014058059 A1 WO 2014058059A1 JP 2013077798 W JP2013077798 W JP 2013077798W WO 2014058059 A1 WO2014058059 A1 WO 2014058059A1
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WO
WIPO (PCT)
Prior art keywords
resin
sandwich panel
sheet
insert
core material
Prior art date
Application number
PCT/JP2013/077798
Other languages
English (en)
Japanese (ja)
Inventor
吉田　攻一郎
Original Assignee
キョーラク株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2012227551A external-priority patent/JP6003009B2/ja
Priority claimed from JP2012227550A external-priority patent/JP6015921B2/ja
Priority claimed from JP2012227549A external-priority patent/JP5971073B2/ja
Application filed by キョーラク株式会社 filed Critical キョーラク株式会社
Publication of WO2014058059A1 publication Critical patent/WO2014058059A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B29C2049/2008—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B29C2049/2017—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements outside the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B29C2049/2021—Inserts characterised by the material or type
    • B29C2049/2034—Attachments, e.g. hooks to hold or hang the blown article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/48—Moulds
    • B29C49/4802—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity
    • B29C2049/4807—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity by movable mould parts in the mould halves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/025—General arrangement or layout of plant
    • B29C48/0255—General arrangement or layout of plant for extruding parallel streams of material, e.g. several separate parallel streams of extruded material forming separate articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B29C48/31—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets being adjustable, i.e. having adjustable exit sections
    • B29C48/313—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets being adjustable, i.e. having adjustable exit sections by positioning the die lips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
    • B29C48/388—Plasticisers, homogenisers or feeders comprising two or more stages using a screw extruder and a ram or piston
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • B29C49/041—Extrusion blow-moulding using an accumulator head
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • B29C49/04104—Extrusion blow-moulding extruding the material discontinuously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/4242—Means for deforming the parison prior to the blowing operation
    • B29C49/4247—Means for deforming the parison prior to the blowing operation using spreading or extending means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B29C51/303—Moulds with sealing means or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous

Definitions

  • the present invention relates to a resin sandwich panel and a method for manufacturing a resin sandwich panel, and more specifically, a resin sandwich panel and a resin sandwich panel that can maintain light weight and high rigidity while firmly fixing an insert. It relates to a manufacturing method.
  • sandwich panels have been used for various purposes such as transportation equipment for automobiles, aircrafts, etc., building materials, floors for beds, housings for electrical equipment, sports and leisure.
  • the sandwich panel has two skin material sheets and a core material interposed between both skin material sheets, and the laminated structure of the skin material sheet, the core material and the skin material sheet is a basic form.
  • the functions required for sandwich panels change accordingly. For example, in the case of an interior panel used in a bathroom, aesthetic appearance is important, but if not so strong, a cosmetic material is further applied to the front side skin sheet that exhibits the appearance.
  • emphasis is placed on the surface properties or the overall molded shape of the decorative material, and in the case of use as a structural material, strength is required from the appearance of appearance.
  • a resin sandwich panel when used as a cargo floor lid of an automobile, it is used not only for aesthetic appearance but also for placing heavy loads on the cargo floor lid. While rigidity (especially bending rigidity) that can withstand the weight of the load is necessary, weight reduction is required from the viewpoint of improving fuel efficiency, and it is necessary to overcome the technical challenges that are difficult to achieve at the same time, such as high rigidity and weight reduction. It is. Therefore, as a resin-made sandwich panel for such applications, a hard resin material with a high Young's modulus is adopted as the skin material sheet, while a core (thickness of the core material) is used as a core material.
  • Patent Document 1 and Patent Document 2 are common as sandwich structures for interior material panels such as automobile deck boards or floor panels, and Patent Document 1 discloses a two-piece melted parison between divided molds. Is positioned, and a foamed core material such as polypropylene, which is preformed between two melted parisons, is placed and pressed against a split mold by vacuum or compressed air to be molded.
  • a foamed core material such as polypropylene
  • Patent Document 2 in the upper and lower divided molds, a pre-formed back side sheet material softened by reheating is placed on the lower mold, and then the back side sheet material is vacuum sucked through the lower mold. And then placing a foamed resin such as polyethylene on the back side sheet material, and re-heating the softened front side sheet material on the foamed resin. It discloses that the sandwich structure is formed by placing and then clamping with vacuum suction through the upper and lower molds.
  • Patent Document 2 further uses, as an alternative to the foamed resin core material, a lattice-shaped structure formed body, a honeycomb structure formed body, or an embossed structure formed body formed in advance by press punching or injection molding, The point which shape
  • Patent Document 3 discloses a technique for firmly fixing a screw to a panel. That is, in a resin-made sandwich panel, a metal plate is interposed between one thermoplastic resin sheet and the foam core so as to cover a part of the outer surface of the foam core, so that no metal plate is interposed. This eliminates the problem that the screw comes off the foam core.
  • a metal plate due to the interposition of such a metal plate, the following technical problems exist.
  • the metal plate is provided inside the panel, when the screw is passed through the mounting member on the outside of the panel and screwed into the metal plate from the outer surface of the thermoplastic resin sheet, the metal plate is not visible from the outside. It is difficult to determine the position where the screw is screwed in. To avoid this difficulty, if the area of the metal plate is increased, the weight increases, and the effect of achieving weight reduction by the foam core material is offset. End up.
  • the attachment member is inserted only halfway into the penetration, and only the one skin material sheet is welded and fixed, and the attachment member is particularly sensitive to the load in the thickness direction of the sandwich panel. On the other hand, it moved easily, and it was difficult to sufficiently fix the sandwich panel. For example, if a large load is applied to the sandwich panel through the mounting member, the sandwich panel itself may be damaged. Furthermore, when providing a plurality of attachment members, providing the through-holes in the foam core more than necessary causes a reduction in rigidity as a sandwich panel.
  • the mounting member when the mounting member is inserted into the through hole of the core material, the mounting member interferes with the core material, so that one skin sheet is torn. May cause molding defects. In this sense, when attaching the mounting member to the resin sandwich panel, while maintaining the light weight and high rigidity as the sandwich panel while firmly fixing the mounting member to the resin sandwich panel, Technically difficult.
  • an object of the present invention is to provide a resin sandwich panel and a resin sandwich panel manufacturing method capable of maintaining light weight and high rigidity while firmly fixing an insert.
  • the resin sandwich panel of the present invention is made of resin that is surface-bonded to each of the two skin material sheets in a form sandwiched between the two resin skin material sheets and the two skin material sheets.
  • a concave portion extending toward the other resin skin material sheet is provided on at least one outer surface of the two resin skin material sheets, and constitutes the concave portion.
  • An insert inserted from the outside with respect to the outer surface of one resin skin sheet is provided in close contact with a portion of the outer surface of the resin skin sheet, and the correspondence of the insert of the resin core material
  • a space having a size that does not allow the insert to contact is provided in the thickness direction of the resin core material so that one of the resin surfaces constituting the bottom of the recessed portion is formed.
  • a portion of the inner surface of the material sheet is joined to a contact portion with which the portion abuts, and the insert is fixed to the sandwich panel by joining the recessed portion to the contact portion. It is said.
  • the resin sandwich panel having the above configuration, two resin skin sheets and a resin core material that is surface-bonded to each of the skin sheets in a form sandwiched between both skin sheets.
  • at least one outer surface of the two resin skin sheets is provided with a recess extending toward the other resin skin sheet, and one of the resin skin sheets constituting the recess is provided.
  • An insert that is inserted from the outside with respect to the outer surface of one of the resin skin sheets is provided in a form that is in close contact with a portion of the outer surface, and the insert is located at a corresponding position of the insert of the resin core material.
  • the portion on the inner surface of one of the resin skin sheets constituting the bottom of the recessed portion corresponds to that portion.
  • Contact The insert can be fixed to the sandwich panel by bonding the recessed portion to the abutting portion, and is lightweight and highly rigid while firmly fixing the insert. It can be maintained.
  • the space need only be large enough not to make contact with the insert, and is at least larger than the outer dimension of the insert inserted into the recessed portion of the insert, and the insert insert and the resin core interfere with each other during molding. It can be set to a predetermined size so that it does not occur. Also, if the space is too large, the strength of the sandwich panel will be reduced because the resin core material and the resin skin sheet will not be welded at the recessed portion, so that the strength of the sandwich panel and other requirements may be compromised. Its size can be determined.
  • a method for producing a resin sandwich panel of the present invention is a method for forming a sandwich panel having a resin core material interposed between two resin skin sheets, the sandwich panel A pair of split molds, which are provided with recesses for inserting the inserts, which are open toward the other mold, and are sufficient for inserting the inserts.
  • a step of preparing a resin core material having a space extending in the thickness direction, and two strips that protrude around the annular pinch-off portion formed at the peripheral edge of each cavity of the pair of split molds Positioning a molten thermoplastic resin sheet between a pair of split molds, and a thermoplastic resin sheet corresponding to the at least one mold By forming a sealed space between them and reducing the pressure of the air from the sealed space, the thermoplastic resin sheet is sucked into the cavity and shaped along the cavity.
  • a step of welding the protruding outer surface of the insert to the recess while forming a recess that is recessed toward the other split mold a step of welding the protruding outer surface of the insert to the recess while forming a recess that is recessed toward the other split mold,
  • the space of the preformed resin core material disposed between the thermoplastic resin sheets in a molten state is positioned with respect to the recessed portion, and the recessed portion is inserted through the space.
  • thermoplastic resin sheets By moving the pair of split molds to the clamping position and welding the inner surfaces of the two thermoplastic resin sheets along the pinch-off portions of the pair of molds, two thermoplastic resin sheets
  • the peripheral parts of the recesses are integrated with each other, and the inner surface of the thermoplastic resin sheet and the corresponding surface of the resin core material are welded, and the bottom part of the recessed part is brought into contact with the contact part.
  • FIG. 10 It is a fragmentary sectional view around insert 40 of resin sandwich panel 10 concerning a 1st embodiment of the present invention. It is a perspective view of insert 40 inserted in resin sandwich panel 10 concerning a 1st embodiment of the present invention. It is a top view explaining the relationship between the foaming core material 13 and the insert 40 of the resin sandwich panel 10 according to the first embodiment of the present invention. It is a top view explaining the relationship between the foaming core material 13 and the insert 40 of the resin-made sandwich panels 10 which concern on the modification of this invention. It is a top view explaining the relationship between the foaming core material 13 and the insert 40 of the resin-made sandwich panel 10 which concerns on the further modification of this invention. It is a figure similar to FIG.
  • FIG. 1 of the resin sandwich panel 10 which concerns on the modification 1 of this invention It is a perspective view which shows the insert 40 vicinity of the resin-made sandwich panels 10 which concern on the modification 2 of this invention. It is the same figure as FIG. 1 of the resin sandwich panel 10 which concerns on the said modification 2.
  • FIG. It is a perspective view of insert 40 inserted in resin sandwich panel 10 concerning the modification 2.
  • molding apparatus of the resin sandwich panel 10 which concerns on embodiment of this invention is shown, and in the shaping
  • FIG. 5 is a schematic side view showing a state in which a mold of a split mold 73 is brought into contact with a side surface of a thermoplastic resin sheet P1 in the molding process of the resin sandwich panel 10 according to the embodiment of the present invention. It is a schematic fragmentary sectional view which shows the condition which is shaping the thermoplastic resin sheet P1 in the formation process of the resin sandwich panel 10 which concerns on embodiment of this invention. It is a figure which shows the state which clamped the division mold 73 in the formation process of the resin sandwich panel 10 which concerns on embodiment of this invention. It is a figure which shows the state which open
  • FIG. 16 is a view similar to FIG. 15 of a resin sandwich panel 10 according to a modification of the embodiment. It is a figure which shows the state which clamped the division mold 73 in the formation process of the resin sandwich panel 10 which concerns on the said embodiment. It is a fragmentary sectional view around insert 40 of conventional resin sandwich panel 10.
  • the resin-made sandwich panel 10 made of resin according to the present invention is used for automobiles, aircrafts, vehicles / ships, building materials, housings for various electric devices, bed floor boards, sports / leisure flexural rigidity or bent seats. It can be suitably used as a structural member that resists bending. In particular, it can improve fuel efficiency from the viewpoint of weight reduction as a structural member for automobiles, specifically, interior panels such as cargo floor boards, deck boards, rear parcel shelves, roof panels, door trims, and other doors. It contributes to weight reduction as a structural member such as inner panel, platform, hardtop, sunroof, bonnet, bumper, floor spacer, devia pad, etc.
  • the shape of the resin sandwich panel 10 should be determined appropriately according to the purpose of the product Can do.
  • such a resin sandwich panel 10 has a foaming property that is interposed between a front surface skin material sheet 12A, a back surface skin material sheet 12B, and both skin material sheets 12A and 12B. It is composed of a foam core 13 and a decorative material sheet 14 bonded to the outer surface of the front surface skin sheet 12A.
  • the resin sandwich panel 10 includes a decorative material sheet 14 and a front surface skin material. This is a laminated structure of the sheet 12A, the foam core 13 and the back side skin material sheet 12B.
  • the insert 40 will be described.
  • the insert 40 is a jig attached to the resin sandwich panel 10 from the outside.
  • the insert 40 is used to fix a separate member to the resin sandwich panel 10. Yes, it is necessary to be firmly fixed to the resin sandwich panel 10.
  • the insert 40 is made of metal and protrudes from the outer surface 41 of the back surface skin sheet 12B to which the insert 40 is attached, and the outer surface 41 of the back surface skin sheet 12B.
  • an insertion portion 46 to be inserted into a recessed portion 44 (described later).
  • the main body 42 is provided with a recess 48 for mounting a separate member to fix the separate member using the insert 40, for example, and the insertion portion 46 is directed to the front surface skin sheet 12A.
  • the taper degree of taper is such that, as will be described later, the molten thermoplastic resin sheet P1 constituting the back surface sheet 12B that covers the outer peripheral surface of the insert 40 is a foam core. What is necessary is just to determine from the viewpoint of preventing the molten thermoplastic resin sheet P1 from being torn and causing poor molding by contacting the space 50 of the material 13 (through hole 501 in the present embodiment).
  • the insertion portion 46 is provided with an overhanging flange portion 52 that extends in the lateral direction with respect to the extending direction of the insertion portion 46.
  • the molten thermoplastic resin sheet P1 constituting the back surface skin sheet 12B wraps around the outer peripheral surface of the overhang flange portion 52, particularly the constricted portion 54 between the overhang flange portion 52 and the main body portion 42.
  • the metal insert 40 that is difficult to weld directly to the thermoplastic resin sheet P1 can be firmly fixed to the thermoplastic resin sheet P1.
  • the insert 40 is not made of metal but is made of resin, in particular, the same material as the sheet P made of thermoplastic resin, the insert 40 is easily welded to the sheet P made of thermoplastic resin.
  • Such an overhanging flange portion 52 may be omitted.
  • the depth of the insertion portion 46 is such that when the resin sandwich panel 10 is molded, the recessed portion 44 of the back side skin material sheet 12B formed thereby can be abutted and welded to the contact portion with which the recessed portion 44 abuts.
  • a welding surface 51 is formed at the tapered tip of the insertion portion 46, and the width of the welding surface 51 is sufficient for the recessed portion 44 of the back side skin material sheet 12B to be in contact with the contact portion.
  • What is necessary is just to determine from a viewpoint that the butt welding is carried out and thereby the insert 40 is firmly fixed to the resin sandwich panel 10.
  • the insert 40 is inserted from the outside with respect to the outer surface 41 of the back-side skin material sheet 12B in a form in close contact with the outer peripheral surface portion of the back-side skin material sheet 12B constituting the recessed portion 44. .
  • a space 50 is provided in the thickness direction of the resin foam core material 13 so that the insert 40 does not come into contact therewith.
  • the insert 40 is in close contact.
  • the part of the inner surface of one resin skin sheet constituting the bottom of the recessed part 44 is joined to the contact part with which the part comes into contact, and the insert 40 has the recessed part 44 at the contact part.
  • the resin sandwich panel 10 is firmly fixed.
  • the space 50 is formed as a through hole 501 provided over the thickness direction of the resin foam core material 13.
  • the contact portion with which the bottom portion of the recessed portion 44 contacts is the inner surface 43 of the front surface skin sheet 12A.
  • the portion of the inner surface 47 of the back side skin material sheet 12B constituting the bottom of the recessed portion 44 is joined to the inner surface 43 of the front side skin material sheet 12A via the through hole 501, and the insert 40 is joined to the front surface skin material sheet 12A in which the recessed portion 44 is the other sheet.
  • the space 50 only needs to have a size such that the insert 40 does not come into contact with it, and is at least larger than the outer dimension of the insertion portion 46 to be inserted into the recessed portion 44 of the insert 40.
  • 46 and the resin foamed core material 13 can be set to a predetermined size so as not to interfere with each other. If the space 50 is too large, the resin foam core material 13 and the resin skin material sheet are not welded at the recessed portion 44, so that the strength of the sandwich panel is lowered. The size can be determined based on the balance.
  • the shape of the through hole 501 is a quadrangular prism shape
  • the axis of the quadrangular column is provided so as to be orthogonal to the back surface skin sheet 12B
  • the shape of the through hole 501 is the shape of the insert 40.
  • the thermoplastic resin sheet P1 of the molten state which comprises the back surface skin material sheet
  • What is necessary is just to determine from the viewpoint of preventing the molten thermoplastic resin sheet P1 from being torn and causing poor molding by contacting the through-hole 501 of the foam core 13.
  • the width of the through hole 501 is larger than the value obtained by adding twice the thickness of the back surface skin sheet 12B covering the periphery of the overhang flange portion 52 to the width of the overhang flange portion 52. It is necessary to.
  • each through hole 501 is preferably as small as possible.
  • the insert 40 can be easily inserted in a non-contact manner and the rigidity of the through hole 501 is not reduced. Decide the size.
  • the position where the space 50 is provided may be determined according to the position where the insert 40 is provided in the resin sandwich panel 10.
  • the space 50 may be formed by a hole 50 provided on the inner side of the side edge of the resin foam core 13, and is provided in the resin foam core 13.
  • You may comprise by the notch 56, or the space 50 may be comprised in the resin-made foaming core material 13 divided
  • a metallic reinforcement (not shown) may be provided in the gap 58 between the divided resin foam cores 13, thereby ensuring the rigidity of the resin sandwich panel 10. Is possible.
  • the foam core 13 is formed of a resin to which a foaming agent is added.
  • the resin that forms the foamed core material 13 include polyolefins (for example, polypropylene and high-density polyethylene) that are homopolymers or copolymers of olefins such as ethylene, propylene, butene, isoprenepentene, and methylpentene, polyamide, and polystyrene.
  • Acrylic derivatives such as polyvinyl chloride, polyacrylonitrile, ethylene-ethyl acrylate copolymers, polycarbonate, vinyl acetate copolymers such as ethylene-vinyl acetate copolymers, terpolymers such as ionomers, ethylene-propylene-dienes, Examples include acrylonitrile-styrene copolymer, ABS resin, polyphenylene oxide, polyacetal, phenol resin, polymethacrylimide, and polyetherimide. In addition, these may be used individually by 1 type, or may mix and use 2 or more types. In particular, by making the foam core material 13 and the skin material sheet 12 the same material, they can be bonded by heat welding without using a solvent or the like.
  • the foam core material 13 may contain an additive.
  • the additive include silica, mica, talc, calcium carbonate, glass fiber, carbon fiber, and other inorganic fillers, plasticizers, stabilizers, colorants, An antistatic agent, a flame retardant, a foaming agent, etc. are mentioned.
  • any of a physical foaming agent, a chemical foaming agent and a mixture thereof may be used.
  • physical foaming agents inorganic physical foaming agents such as air, carbon dioxide, nitrogen gas, and water, and organic physical foaming agents such as butane, pentane, hexane, dichloromethane, dichloroethane, and their supercritical fluids are used. be able to.
  • supercritical fluid carbon dioxide, nitrogen or the like is preferably used. If nitrogen is used, the critical temperature is 149.1 ° C. and the critical pressure is 3.4 MPa or more. If carbon dioxide is used, the critical temperature is 31 ° C. and the critical pressure is 7 It is obtained by setting it to 4 MPa or more.
  • the outer surface 41 of the back side skin material sheet 12B is provided with a recessed portion 44 extending toward the front side skin material sheet 12A.
  • the resin sandwich panel 10 is molded, by inserting the insert 40 into the cavity recess 77 provided in one cavity 74A of the split mold 73, the back side skin material The melted thermoplastic resin sheet P1 forming the sheet 12B is vacuum-sucked toward the one cavity 74A, and the concave portion 44 having a shape along the outer peripheral surface of the insertion portion 46 of the insert 40 is formed. .
  • the molten thermoplastic resin sheet P1 wraps around the constricted portion 54 between the main body portion 42 and the projecting flange portion 52.
  • the insert 40 is more closely attached to the back surface skin sheet 12B and is firmly fixed.
  • the skin material sheet 12 is a sheet formed of polypropylene, engineering plastics, olefin resin, or the like.
  • the skin material sheet 12 constitutes the upper surface wall and the lower surface wall of the resin sandwich panel 10, and preferably the outer ends of the skin material sheet 12 A and the end of the skin material sheet 12 B are welded and integrated by a pinch-off portion. Construct side walls.
  • a gap (not shown) is formed between the outer peripheral side wall of the resin sandwich panel 10 and the outer periphery of the foam core 13, and thereby the difference in thermal shrinkage between the skin sheet 12 and the foam core 13 after molding. Therefore, deformation of the resin sandwich panel 10 can be prevented.
  • the skin material sheet 12 is preferably made of a resin material having a high melt tension from the viewpoint of preventing a variation in thickness due to drawdown, neck-in, or the like.
  • a resin material with high fluidity is preferable to use.
  • it is a polyolefin (for example, polypropylene, high density polyethylene) which is a homopolymer or copolymer of olefins such as ethylene, propylene, butene, isoprene pentene, methyl pentene, etc., and has an MFR (JIS K) at 230 ° C. Measured at a test temperature of 230 ° C.
  • melt tension (using a melt tension tester manufactured by Toyo Seiki Co., Ltd., preheating temperature 230 ° C, extrusion speed 5.7 mm / min, diameter 2.095 mm, long A strand is extruded from an orifice having a length of 8 mm, and a tension when the strand is wound around a roller having a diameter of 50 mm at a winding speed of 100 rpm is 50 mN or more, preferably 120 mN or more.
  • a hydrogenated styrene thermoplastic elastomer is added in a range of less than 30 wt%, preferably less than 15 wt%.
  • styrene-ethylene / butylene-styrene block copolymers, styrene-ethylene / propylene-styrene block copolymers, hydrogenated styrene-butadiene rubbers and mixtures thereof are suitable as hydrogenated styrene-based thermoplastic elastomers.
  • the styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to JIS K-7210) is 1.0 to 10 g / 10 Minute, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more.
  • the skin material sheet 12 may contain an additive in the same manner as the foamed core material 13, and examples of the additive include silica, mica, talc, calcium carbonate, glass fiber, carbon fiber and other inorganic fillers, Examples include plasticizers, stabilizers, colorants, antistatic agents, flame retardants, and foaming agents. Specifically, silica, mica, glass fiber or the like is added in an amount of 50 wt% or less, preferably 30 to 40 wt% with respect to the molding resin.
  • the decorative material sheet 14 is an object that improves appearance, decoration, and contacts with the molded product (for example, in the case of a cargo floor board, placed on the upper surface of the board). Configured for the purpose of protecting the baggage, etc.).
  • a fiber skin material sheet-like skin material, a film-like skin material, or the like is applied as the material of the decorative material sheet 14.
  • synthetic fibers such as polyester, polypropylene, polyamide, polyurethane, acrylic and vinylon, semi-synthetic fibers such as acetate and rayon, regenerated fibers such as viscose rayon and copper ammonia rayon, cotton, hemp, Examples thereof include natural fibers such as wool and silk, or blended fibers thereof.
  • an outer surface 49 at a corresponding position of the recessed portion 44 of the front surface side skin material sheet 12 ⁇ / b> A is directed toward the back surface side skin material sheet 12 ⁇ / b> B.
  • An extending recess 48 may be provided, and the recess 44 and the recess 48 may be butt-joined. This is because the foamed core material 13 is thick, and if the recessed portion 44 that extends over the entire thickness of the foamed core material 13 is provided only on the back side skin sheet 12B, the blow ratio of the molten thermoplastic resin sheet P is high. It is useful to prevent such a situation by providing a recess in both the resin skin sheets 12 when it becomes too thin and a thin wall portion is formed, resulting in a decrease in rigidity and possibly tearing. is there.
  • the insert 40 is plate-shaped.
  • the insert 40 has a thin plate shape, it is difficult to firmly fix the plate surface to the resin sandwich panel 10 when attaching the plate surface in a direction orthogonal to the panel surface of the resin sandwich panel 10.
  • the plate surface is used as the panel surface of the resin sandwich panel 10.
  • the insert 40 can be firmly fixed.
  • the resin sandwich panel 10 of the second embodiment is substantially orthogonal to the outer surface 41 of one resin skin sheet (back side skin sheet) 12B.
  • a plate-like insert 40 inserted from the outside is provided in the direction, and a space 50 extending in the thickness direction of the resin-made core material is provided at a position corresponding to the plate-like insert 40 of the resin-made core material 13.
  • the inner surface portion is joined to the inner surface 43 of the other resin skin sheet (front side skin sheet) 12A, and the plate-like insert 40 has the recessed portion 44 joined to the back side skin sheet 12B.
  • Do And a is fixed to the resin sandwich panel 10.
  • the plate-like insert 40 of the second modification is made of a plate-like metal, and a main body portion 42 protruding from the side surface of the back-side skin material sheet 12B to which the plate-like insert 40 is attached, And an insertion portion 46 inserted into a recessed portion 44 provided on the outer surface 41 of the back surface skin sheet 12B.
  • the plate-like insert 40 is inserted into the outer surface 41 of the back-side skin material sheet 12B in a direction substantially orthogonal to the outer surface 41 of the back-side skin material sheet 12B constituting the recessed portion 44. Is done.
  • the main body portion 42 is provided with a recess 48 for mounting a separate member to fix the separate member using, for example, the plate-like insert 40, and the insertion portion 46 is obliquely connected to the main body portion 42.
  • the insertion portion 46 has an opening 52, and opposing portions of the back side skin material sheet 12B constituting the recessed portion 44 are joined to each other through the opening 52, whereby the plate-like insert 40 is connected to the back side. It is designed to be more firmly fixed to the skin material sheet 12B.
  • the shape or size of the opening 52 may be determined from such a viewpoint in relation to the plate thickness of the plate-like insert 40, that is, the depth of the opening 52.
  • the depth of the insertion portion 46 may be set so that the recessed portion 44 can be abutted and welded to the inner surface 43 of the front surface skin sheet 12A.
  • the width of the welding surface 45, that is, the plate-like insert 40 The plate thickness is such that the recessed portion 44 of the back-side skin material sheet 12B is sufficiently abutted and welded to the inner surface 43 of the front-side skin material sheet 12A, whereby the plate-like insert 40 is attached to the resin sandwich panel 10. And can be determined from the viewpoint of being firmly fixed.
  • the insertion portion 46 is embedded in the recessed portion 44, and the recessed portion 44 is closed by a corresponding portion of the back surface skin sheet 12B constituting the recessed portion 44, and the main body portion 42 is formed of the resin sandwich panel 10. It is provided so as to protrude from the side wall, which is advantageous, for example, for adhering the decorative material sheet 14 not only to the front surface skin material sheet 12A but also to the back surface skin material sheet 12B.
  • the space 50 is formed as a through hole in which the side surface of the resin foam core 13 is cut out, and the shape thereof is a rectangular parallelepiped. As shown in FIG. 8, the width X of the space 50 is set to be larger than the sum of the plate thickness t1 of the plate-like insert 40 and twice the thickness t2 of the back-side skin material sheet 12B. 10, when the plate-like insert 40 is inserted into the space 50, a molten thermoplastic resin sheet constituting the back-side skin material sheet 12 ⁇ / b> B tightly joined to the outer peripheral surface of the plate-like insert 40. P1 is prevented from contacting the inner peripheral surface of the space 50.
  • the outer surface of the corresponding position of the recessed portion 44 of the front surface skin sheet 12A has a concave portion extending toward the back surface skin sheet 12B.
  • the recess 44 and the recess may be butt-joined.
  • the space 50 is a space penetrating in the thickness direction of the resin core material 13, but is a recess formed in the resin core material 13 as in the second embodiment to be described later.
  • the recess 44, the resin core 13 and the recess may be joined.
  • the molding device 60 of the resin sandwich panel 10 includes an extrusion device 62 and a mold clamping device 64 disposed below the extrusion device 62, and is in a molten state extruded from the extrusion device 62.
  • the thermoplastic resin sheet P is sent to the mold clamping device 64, and the mold clamping device 64 molds the molten thermoplastic resin sheet P.
  • the extruding device 62 is a conventionally known type, and detailed description thereof is omitted. However, a cylinder 66 provided with a hopper 65, a screw (not shown) provided in the cylinder 66, and a screw are connected to the screw. A hydraulic motor 68, an accumulator 70 communicating with the inside of the cylinder 66, and a plunger 72 provided in the accumulator 70, and resin pellets introduced from the hopper 65 are screwed by the hydraulic motor 68 in the cylinder 66. The molten resin is melted and kneaded by the rotation of the resin, and the molten resin is transferred to the accumulator chamber and stored in a certain amount.
  • the plunger 72 is driven to feed the molten resin toward the T die 71 and continuously through the die slit (not shown).
  • Sheet-like thermoplastic resin sheet P was extruded and spaced apart While it is pressed between the pair of rollers 79 and fed downward is suspended between the split mold blocks 73. Thereby, the sheet-like thermoplastic resin sheet P is disposed between the split molds 73 in a stretched state without wrinkles or slack.
  • the extrusion capability of the extrusion device 62 is appropriately selected from the viewpoints of the size of the front side skin material sheet 12A and the back side skin material sheet 12B to be molded, and the prevention of the drawdown of the thermoplastic resin sheet P. More specifically, from a practical viewpoint, the extrusion rate of the resin from the die slit is several hundred kg / hour or more, more preferably 700 kg / hour or more. Further, from the viewpoint of preventing the drawdown of the thermoplastic resin sheet P, the extrusion process of the thermoplastic resin sheet P is preferably as short as possible, and generally depends on the type of resin and the MFR value. Should be completed within 40 seconds, more preferably within 30 seconds. For this reason, the extrusion area per unit area and unit time of the thermoplastic resin from the die slit is 50 kg / hour cm 2 or more, more preferably 60 kg / hour cm 2 or more.
  • the die slit 75 is arranged vertically downward, and the thermoplastic resin sheet P extruded from the die slit 75 is sent vertically downward in a form that hangs down from the die slit 75 as it is.
  • the die slit can change the thickness of the continuous sheet-like thermoplastic resin sheet P by making the width variable.
  • the mold clamping device 64 is also a conventionally known type like the extrusion device 62, and detailed description thereof will be omitted.
  • two divided molds 73 and a sheet-like heat in which the mold 73 is melted are used.
  • a mold driving device that moves between an open position and a closed position in a direction substantially orthogonal to the supply direction of the plastic resin sheet P;
  • the two divided molds 73 are arranged with the cavities 74 facing each other, and the cavities 74 are arranged so as to face substantially vertically.
  • the cavities 74 are arranged so as to face substantially vertically.
  • a pinch-off portion 76 is formed around the cavity 74.
  • the pinch-off portion 76 is formed in an annular shape around the cavity 74 and protrudes toward the opposing mold 73. To do. As a result, when the two divided molds 73 are clamped, the tip portions of the respective pinch-off portions 76 come into contact with each other so that a parting line is formed at the periphery of the molten thermoplastic resin sheet P. ing.
  • a cavity 74A of one mold 73A of the split mold 73 for shaping the molten sheet-like thermoplastic resin sheet P1 is formed with a cavity recess 77 for fitting the main body 42 of the insert 40.
  • the cavity recess 77 is formed so that the sheet-like thermoplastic resin sheet P1 is formed from the cavity 74A when the molten sheet-like thermoplastic resin sheet P1 forming the back side skin sheet 12B is suction-molded toward the cavity 74A.
  • the main body portion 42 of the insert 40 is pressed against the outer peripheral surface of the insertion portion 46 of the projecting insert 40 so as to form a concave portion 44 and not flow into the gap between the cavity concave portion 77 and the main body portion 42. Is fitted without gaps.
  • the mold 81 is slidably fitted around the outer periphery of the split mold 73A, and the mold 81 can be moved relative to the mold 73A by a mold moving device (not shown). More specifically, as shown in FIG. 11, the mold 81 protrudes toward the mold 73 ⁇ / b> B with respect to the mold 73 ⁇ / b> A, whereby one of the thermoplastic resin sheets P ⁇ b> 1 disposed between the molds 73. It is possible to abut on the side surface 117.
  • a vacuum suction chamber 85 is provided inside the split mold 73 ⁇ / b> A, and the vacuum suction chamber 85 communicates with the cavity 74 ⁇ / b> A through the suction hole 87 and extends from the vacuum suction chamber 85 to the suction hole 87.
  • the sheet P1 made of thermoplastic resin is adsorbed toward the cavity 74A, and is shaped into a shape along the outer surface of the cavity 74A.
  • the mold driving device is the same as the conventional one, and the description thereof is omitted.
  • the two divided molds 73 are each driven by the mold driving device, and in the open position, the two divided molds are used.
  • two continuous sheet-like thermoplastic resin sheets P1 and P2 in a molten state can be arranged with a space between each other, and in one closed position, pinch-off portions of the two split molds 73 76 abuts and the annular pinch-off portions 76 abut each other so that a sealed space is formed in the two split molds 73.
  • the closed position is the position of the center line of the two continuous sheet-like thermoplastic resin sheets P1 and P2 in the molten state, and each mold 73 is It is driven by the mold driving device so as to move toward the position.
  • the foam core material 13 in which the space 50 (through hole 501 in this embodiment) is formed is prepared in advance, and the insert 40 is fitted into the cavity recess 77 of the cavity 74A, and the insertion portion 64 of the insert 40 is used as the other gold. It arrange
  • thermoplastic resin sheets P1 and P2 in the molten state are extruded vertically downward from the corresponding die slits 75, and the two continuous sheet-like thermoplastic resin sheets P1 and P2 are corresponding.
  • the sheet is supplied between the two divided molds 73 so as to protrude from the pinch-off portion 76.
  • the thermoplastic resin sheet P1 that forms the recessed portion 44 has a higher blow ratio than the planar thermoplastic resin sheet P2 that does not form the recessed portion 44, in consideration thereof, When extruding from the die slit 75, the thickness of the thermoplastic resin sheet P1 may be set larger than the thickness of the thermoplastic resin sheet P2.
  • the mold frame 81 of the split mold 73A is moved toward the thermoplastic resin sheet P1 with respect to the split mold 73A so as to contact the side surface 117 of the thermoplastic resin sheet P1. Make contact. Thereby, a sealed space 84 is formed by the side surface 117 of the thermoplastic resin sheet P1, the inner peripheral surface of the mold 81, and the cavity 73A.
  • thermoplastic resin sheet P1 is adsorbed to the cavity 74A, thereby The thermoplastic resin sheet P1 is shaped into a shape along the surface of the cavity 74A. More specifically, a recess 44 that is recessed toward the other split mold 73B is formed on the thermoplastic resin sheet P1 in accordance with the insert 40 that is fitted in the cavity recess 75 in advance and protrudes from the cavity 74A. However, the protruding outer surface of the insertion portion 46 of the insert 40 is welded to the recessed portion 44. In particular, the thermoplastic resin sheet P1 wraps around the constricted portion 54, whereby the metal insert 40 is firmly fixed to the thermoplastic resin sheet P1.
  • the foam core material 13 is disposed between the two thermoplastic resin sheets P1 and P2 in parallel with both sheets, and the through hole 501 of the foam core material 13 is formed using, for example, a known manipulator.
  • the position is adjusted with respect to the position of the formed recessed portion 44, and the recessed portion 44 is formed in the through hole 501 so that the recessed portion 44, which is a molten thermoplastic resin sheet P 1, does not contact the through hole 501.
  • the surface of the foam core 13 is pressed against the inner surface of the thermoplastic resin sheet P1 to be fixed by welding. In this sense, it is advantageous to dispose the foamed core material 13 at the stage where the recessed portion 44 is formed because the target position of the through hole 501 can be easily set.
  • thermoplastic resin sheet P1 is sucked and held in a state where the mold 81 that is in contact with the outer surface 117 of the thermoplastic resin sheet P1 is held as it is.
  • the molds 73A and 73B are moved toward each other until the pinch-off portions 76A and 76B come into contact with each other, and the molds are clamped. More specifically, the pair of split molds 73 are moved to the mold clamping position, and the inner surfaces of the two thermoplastic resin sheets P1 and P2 are welded along the pinch-off portions of the pair of molds 73.
  • the peripheral portions of the two thermoplastic resin sheets P1 and P2 are integrated with each other, and the foamed resin is fixedly welded to the inner surface of the thermoplastic resin sheet P2 and the thermoplastic resin sheet P1. While welding the corresponding surface of the core material 13 and the decorative material sheet 14 being welded to the sheet P2 made of thermoplastic resin, the welding surface 45 at the bottom of the recessed portion 44 is passed through the through hole 501 that is the space 50.
  • thermoplastic resin sheet P1 is welded and fixed to the thermoplastic resin sheet P2, it is firmly fixed to the resin sandwich panel 10.
  • the extruded thermoplastic resin sheet P may be formed into a sheet by crushing the molten cylindrical parison, or at least two locations during extrusion by extruding the molten cylindrical parison.
  • the cylindrical parison may be cut along the extrusion direction to form two sheets.
  • the two split molds 73 are opened, the completed resin sandwich panel 10 is separated from the cavity 74, and the burrs B formed around the parting line are removed.
  • the molding of the resin sandwich panel 10 is completed.
  • it can manufacture similarly about the said modification 2 and 3.
  • thermoplastic resin sheets P1 and P2 in a molten state, and shape the extruded thermoplastic resin sheets P1 and P2 into a predetermined shape using a mold 73.
  • the resin skin panels 12A and 12B are surface-bonded to the skin sheets 12A and 12B in a form sandwiched between the skin sheets 12A and 12B.
  • a recessed portion extending toward the front-side skin material sheet 12A. 44, and an insert 40 that is inserted from the outside with respect to the outer surface of the back side skin sheet 12B is provided in a form in close contact with the outer surface part of the back side skin sheet 12B that constitutes the recessed portion 44, At a position corresponding to the insert 40 of the resin foam core material 13, there is a space large enough to insert the insert 40.
  • the insert 40 can be fixed to the resin sandwich panel 10, and the insert 40 can be firmly fixed while being lightweight. High rigidity can be maintained.
  • the second embodiment will be described.
  • the other resin skin material sheet is planar.
  • a decorative material can be bonded.
  • FIG. 15 is a cross-sectional view of the resin sandwich panel 10 of the present embodiment
  • FIG. 16 is a view showing the insert 40 of the present embodiment.
  • the insertion portion 46 is composed of an overhang flange portion 52 and a constricted portion 54, and the bottom surface of the overhang flange portion 52 is flat.
  • description is abbreviate
  • the space 50 is formed as a recess 502 that is a recess in which the insert 40 is located.
  • the abutting portion with which the bottom 45 of the recessed portion 44 abuts is a recess 502, and more specifically, the bottom of the recess constituting the recess 502.
  • the shape of the recess 502 is a quadrangular prism shape, and the axis of the quadrangular prism is provided so as to be orthogonal to the back surface skin sheet 12B.
  • the shape of the recess 502 may be determined in accordance with the shape of the insert 40 as in the first embodiment.
  • the position where the recess 502 is provided may be determined in accordance with the position where the insert 40 is provided on the resin sandwich panel 10.
  • the recess 502 is formed on the resin core 13. It may be provided inside the edge, or may be provided as a notch 56 so as to be pulled out from the edge of the resin core material 13, or in the divided resin core material 13 and adjacent to the core material 12. You may provide as the notch 58 so that the surface of this may be straddled.
  • FIG. 20 is a modification of the insert 40 and constitutes an insert nut.
  • a screw portion provided on a member is screwed into the nut to fix the member to the sandwich.
  • the upper surface of the insert 40 is flush with the outer surface 41 of the back-side skin sheet 12 ⁇ / b> B, there is no main body portion protruding from the outer surface 41, and the insert portion 46 is embedded in the recess 502. ing.
  • the molding apparatus and method for the resin sandwich panel 10 of the present embodiment are substantially the same as those of the first embodiment.
  • the space 50 formed in the resin foam core 13 is a recess 502.
  • the recess 44 is inserted into the recess 502, and the welding surface 45 at the bottom of the recess 44 is foamed with resin. It welds to the recessed part 502 of the core material 13.
  • the insert 40 tightly fixed to the thermoplastic resin sheet P1 is firmly fixed to the resin sandwich panel 10 through the resin foam core 13 being welded to both the thermoplastic resin sheets P1 and P2. Is done.
  • the resin sandwich panel 10 having the above configuration, particularly when a large load is applied to the resin sandwich panel 10 through the insert 40 fixed to the resin sandwich panel 10,
  • the resin sandwich panel 10 is prevented from being lowered in rigidity.
  • the recess 44 formed in one resin skin sheet 12B can be extended to the other resin skin sheet 12A. 13 is extended to a thickness of 13 so that the blow ratio of one resin skin sheet 12B is excessively increased, and the recess 44 is thinned, so that the insert 40 is fixed to the one resin skin sheet 12B. Without being insufficient, it is possible to maintain light weight and high rigidity while firmly fixing the insert 40.
  • the resin core material 13 is not provided with a through hole extending in the thickness direction, and the blow ratio of the one resin skin material sheet 12B is not excessively increased.
  • the other resin skin sheet 12A is effective in the case where it is held flat and, for example, the decorative material sheet 14 is bonded.
  • the molten thermoplastic resin sheets P1 and P2 extruded from the extrusion slit are directly molded, but the present invention is not limited thereto, and one and / or the other thermoplastic resin sheet P1 is formed. , P2 may be preformed in advance and reheated into a molten state.
  • the present invention is not limited to this.
  • the plurality of inserts 40 are arranged in a straight line at intervals in the longitudinal direction of the sandwich.
  • the size of the space 50 provided in the foam core 13 is preferably as small as possible from the viewpoint of preventing the rigidity from being lowered as long as interference during insertion of the insert 40 can be avoided. .
  • the divided mold is clamped after being pressed against one thermoplastic resin sheet P1 formed by suction molding the foam core 13 and then fixed thereto.
  • the foamed core material 13 is positioned between the two thermoplastic resin sheets P1 and P2, and the foamed core material 13 is fixed to the two thermoplastic resin sheets P1 and P2 by clamping the divided molds.
  • the present invention is not limited thereto, and the decorative material may also be provided on the thermoplastic resin sheet P1,
  • the insert 40 may be provided so as to protrude obliquely outward from the side surface of the resin sandwich panel 10.
  • the insert 40 is placed in the mold cavity and between the two foamed thermoplastic resin sheets P of the foam core 13.
  • the former is described as before the two molten thermoplastic resin sheets P are arranged in the split mold, and the latter is after the suction molding of the thermoplastic resin sheets P.
  • the insert 40 may be installed until the molten thermoplastic resin sheet P on the side where the insert 40 is provided is formed by suction molding. It may be arranged before the mold 73 is clamped, and may be before the suction molding of the thermoplastic resin sheet P.
  • Thermoplastic resin sheet 10 Resin sandwich panel 12A Front side skin material sheet 12B Back side skin material sheet 13 Foam core material 14 Cosmetic material 40 Insert 41 Outer surface 42 Body portion 43 Inner surface 44 Recessed portion 45 Weld surface 46 Insertion part 48 Concave part 49 Outer surface 50 of front surface side skin sheet 50 Space 501 Through hole 502 Concave part 51 Welding surface 52 Overhang flange part 54 Constriction part 56 Notch 58 Cavity part 77 Cavity concave part 60 Molding of resin sandwich panel Device 62 Extruding device 64 Mold clamping device 65 Hopper 66 Cylinder 68 Hydraulic motor 70 Accumulator 72 Plunger 73 Mold 74 Cavity 75 Die slit 76 Pinch-off part 80 Projection body 81 Mold frame 85 Vacuum suction chamber 87 Suction hole

Abstract

L'invention concerne un panneau pris en sandwich dans de la résine permettant de fixer fermement une pièce rapportée et de conserver des propriétés de légèreté et une rigidité élevée, et son procédé de fabrication. Un évidement (44) s'étendant vers une feuille pelliculaire côté surface avant est ménagé sur une feuille pelliculaire côté surface arrière d'une feuille pelliculaire de résine à deux couches ; une pièce rapportée (40) à introduire, depuis l'extérieur, dans la surface extérieure de la feuille pelliculaire côté surface arrière à un état tel qu'elle adhère à une partie de la surface extérieure de la feuille pelliculaire côté surface arrière formant l'évidement (44) ; un espace (50) d'une dimension telle que la pièce rapportée (40) ne vient pas en contact avec ce dernier, est ménagé dans le sens de l'épaisseur d'un noyau en mousse (13) à une position du noyau de mousse correspondant à la pièce rapportée (40). En conséquence, la partie de la surface interne de la feuille pelliculaire côté surface arrière formant la partie de base de l'évidemment (44) est assemblée avec une partie de contact avec laquelle ladite partie est en contact, et la fixation de la pièce rapportée (40) est le résultat (44) de l'assemblage de l'évidement avec la partie de contact.
PCT/JP2013/077798 2012-10-14 2013-10-11 Panneau pris en sandwich dans de la résine et son procédé de fabrication WO2014058059A1 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
JP2012-227550 2012-10-14
JP2012227551A JP6003009B2 (ja) 2012-10-14 2012-10-14 樹脂製サンドイッチパネルおよび樹脂製サンドイッチパネルの製造方法
JP2012227550A JP6015921B2 (ja) 2012-10-14 2012-10-14 樹脂製サンドイッチパネルおよび樹脂製サンドイッチパネルの製造方法
JP2012-227549 2012-10-14
JP2012227549A JP5971073B2 (ja) 2012-10-14 2012-10-14 樹脂製サンドイッチパネルおよび樹脂製サンドイッチパネルの製造方法
JP2012-227551 2012-10-14

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015172973A1 (fr) * 2014-05-16 2015-11-19 Kautex Textron Gmbh & Co. Kg Récipient en polymère thermoplastique et procédé permettant de produire un récipient de ce type
WO2019167817A1 (fr) * 2018-02-28 2019-09-06 キョーラク株式会社 Panneau de résine et procédé pour le fabriquer

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61148019A (ja) * 1984-12-21 1986-07-05 Kyoraku Co Ltd ブロー成形製プラスチック中空体への別部材取付構造
JPH0425422A (ja) * 1990-05-18 1992-01-29 Nippo Sangyo Kk 合成樹脂成形体へのインサート埋設方法及びインサートを埋設した合成樹脂成形体
JPH11188782A (ja) * 1997-12-26 1999-07-13 Kyoraku Co Ltd プラスチック製中空二重壁構造体
JPH11348157A (ja) * 1998-06-02 1999-12-21 Fuji Heavy Ind Ltd ハニカムサンドイッチパネルへのインサート取付方法

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61148019A (ja) * 1984-12-21 1986-07-05 Kyoraku Co Ltd ブロー成形製プラスチック中空体への別部材取付構造
JPH0425422A (ja) * 1990-05-18 1992-01-29 Nippo Sangyo Kk 合成樹脂成形体へのインサート埋設方法及びインサートを埋設した合成樹脂成形体
JPH11188782A (ja) * 1997-12-26 1999-07-13 Kyoraku Co Ltd プラスチック製中空二重壁構造体
JPH11348157A (ja) * 1998-06-02 1999-12-21 Fuji Heavy Ind Ltd ハニカムサンドイッチパネルへのインサート取付方法

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015172973A1 (fr) * 2014-05-16 2015-11-19 Kautex Textron Gmbh & Co. Kg Récipient en polymère thermoplastique et procédé permettant de produire un récipient de ce type
WO2019167817A1 (fr) * 2018-02-28 2019-09-06 キョーラク株式会社 Panneau de résine et procédé pour le fabriquer
JP2019150967A (ja) * 2018-02-28 2019-09-12 キョーラク株式会社 樹脂製パネル及び製造方法
JP6997374B2 (ja) 2018-02-28 2022-01-17 キョーラク株式会社 樹脂製パネル

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