WO2014103580A1 - 発泡構造材、樹脂製パネル、樹脂製パネルの製造方法 - Google Patents

発泡構造材、樹脂製パネル、樹脂製パネルの製造方法 Download PDF

Info

Publication number
WO2014103580A1
WO2014103580A1 PCT/JP2013/081431 JP2013081431W WO2014103580A1 WO 2014103580 A1 WO2014103580 A1 WO 2014103580A1 JP 2013081431 W JP2013081431 W JP 2013081431W WO 2014103580 A1 WO2014103580 A1 WO 2014103580A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
foam
core
reinforcing
resin panel
Prior art date
Application number
PCT/JP2013/081431
Other languages
English (en)
French (fr)
Inventor
福田　達也
丹治　忠敏
芳裕 山崎
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
Application filed by キョーラク株式会社 filed Critical キョーラク株式会社
Priority to CN201380063558.8A priority Critical patent/CN104837606B/zh
Priority to EP13868050.9A priority patent/EP2942184B1/en
Priority to US14/651,169 priority patent/US9987821B2/en
Priority to CN201711043232.5A priority patent/CN107839241B/zh
Publication of WO2014103580A1 publication Critical patent/WO2014103580A1/ja
Priority to US15/970,681 priority patent/US10688751B2/en

Links

Images

Classifications

    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • B29C65/028—Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B29C65/564—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined hidden in the joint, e.g. dowels or Z-pins
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool reciprocating along one axis
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • B32B37/185—Laminating sheets, panels or inserts between two discrete plastic layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
    • B29C65/5071—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and being composed by one single element
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
    • B29C65/5085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and comprising grooves, e.g. being E-shaped, H-shaped
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81415—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/462—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • 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
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B29K2025/04—Polymers of styrene
    • B29K2025/06—PS, i.e. polystyrene
    • 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
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • 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
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
    • B29K2033/08—Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
    • 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
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
    • B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
    • 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
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/776—Walls, e.g. building panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/19—Sheets or webs edge spliced or joined
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y10T428/233—Foamed or expanded material encased
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24496—Foamed or cellular component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/2457—Parallel ribs and/or grooves

Definitions

  • the present invention relates to a foam structure material, a resin panel that covers the foam structure material with a skin material sheet, and a manufacturing technique thereof.
  • Resin panels have been used for various purposes such as automobiles, airplanes and other transport machines, building materials, electrical equipment housings, sports and leisure. Resin panels are those in which the core material is covered with the skin material sheet, but there are those in which only one surface of the core material is covered with the skin material sheet and those in which both surfaces of the core material are covered with the skin material sheet. . Resin panels that cover only one surface of the core material with a skin material sheet are used for applications that do not require the other surface of the core material to be covered with a skin material sheet, for example, for building materials, etc. . A resin panel covering both sides of the core material with a skin sheet is also called a sandwich panel. The resin panel has two skin material sheets and a core material interposed between both skin material sheets. That is, the resin panel has a basic structure of a laminated structure of a skin material sheet, a core material, and a skin material sheet.
  • a metal foam inserted into a resin foam as a core material is known.
  • a reinforcing material is fitted into a hollow core of a hollow double wall structure and a core material made of a thermoplastic resin preformed in substantially the same shape as the space in the hollow portion.
  • a resin panel that can accurately position the interior material by decorating the interior material, which is made of an integral material and reinforcing material, and prevents deformation due to rattling and molding shrinkage. ing.
  • a conventional resin panel interior material in which a core material and a reinforcing material are integrated is a material in which a reinforcing material is fitted between two foams that serve as a core material.
  • the body is basically molded using the same molding device. However, even in that case, it may be molded in different lots or in different situations (operating conditions of the equipment and environmental conditions in and around the equipment), and the volume of each foam after removal from the molding equipment. Changes may vary. If the volume changes of the individual foams are different, when two foams are subsequently fitted to the reinforcing material, only one of them becomes a resin panel because the gap with the reinforcing material becomes relatively large, etc. When it looks bad. An example of a case where the appearance is deteriorated is a case where the surface of the resin panel is not flat in the entire region but is partially raised.
  • the present invention has been made in view of the above-described points, and its purpose is to fit a core material to a reinforcing material in manufacturing a foamed structural material in which the core material and the reinforcing material are integrated, and a resin panel. It is to provide a foamed structural material and a resin panel that are improved in accuracy when compared with conventional ones, and improved in accuracy.
  • a first aspect of the present invention is a foamed structural material.
  • the foamed structural material includes a first core material, a second core material, a first core material, and a first core material obtained by cleaving a foam in which a linear groove portion for fitting a reinforcing material is provided in the groove portion.
  • the second core member includes a reinforcing member fitted from one and the other of the reinforcing members.
  • a second aspect of the present invention is a resin panel in which the foamed structural material is covered with a skin material sheet.
  • the 3rd viewpoint of this invention is a manufacturing method of the resin-made panels which cover a foam structure material with a skin material sheet.
  • a foam provided with a linear groove for fitting a reinforcing material is cleaved at the groove and divided into a first core material and a second core material.
  • a step of welding the resin sheet to the foamed structural material is a manufacturing method of the resin-made panels which cover a foam structure material with a skin material sheet.
  • molding the foam shown in FIG. The figure for demonstrating the process of shape
  • the outer shape of the resin panel 1 includes a front surface 1a and a back surface 1b, and a front surface 1a and a back surface. It consists of the side wall surface 1c interposed between 1b.
  • the front surface 1a, the back surface 1b, and the side wall surface 1c are made of resin sheets SA and SB made of thermoplastic resin, and an interior material 10 is provided therein. That is, the resin panel 1 has a sandwich structure in which the interior material 10 is sandwiched between the resin sheets SA and SB of thermoplastic resin.
  • the interior material 10 is an example of a foam structure material.
  • the resin sheets SA and SB serving as the skin material sheets are not limited to the resin material, but are preferably formed from a non-foamed resin in order to ensure the rigidity of the resin panel 1.
  • the resin sheets SA and SB may be made by mixing polystyrene (PS) and styrene ethylene butylene styrene block copolymer resin (SEBS) into polypropylene (PP) as a main material.
  • the interior material 10 includes core materials 21 and 22, which are resin foams, fitted to one side and the other side of the reinforcing material 30, respectively.
  • 30 is an integrated composite structure.
  • the reinforcing member 30 is a long member having the same length as the ends of the core members 21 and 22.
  • the reinforcing member 30 of the present embodiment is a member having a H-shaped cross section (so-called H-shaped extrusion reinforcement), but the shape of the reinforcing member 30 is not limited to this.
  • the cross-sectional shape of the reinforcing member 30 may be, for example, a C shape, a U shape, a square pipe shape, a circular pipe shape, or the like, and may be any appropriate shape as long as it can be fitted and integrated with the core materials 21 and 22. .
  • the reinforcing member 30 is preferably made of a metal such as aluminum or a hard plastic.
  • the thicknesses of the core materials 21 and 22 are appropriately determined according to the target thickness of the resin panel 1 and further the thickness of the resin sheet for ensuring the target rigidity of the resin panel 1, and are particularly limited. Is not to be done.
  • the core materials 21 and 22 are formed using, for example, a thermoplastic resin.
  • the resin material is not limited, but includes any one of polyolefins such as polypropylene and polyethylene, acrylic derivatives such as polyamide, polystyrene, and polyvinyl chloride, or a mixture of two or more.
  • the core materials 21 and 22 have a large proportion of the volume of the resin panel 1 and are preferably foamed resins that are foamed using a foaming agent for weight reduction, but the foaming ratio is not particularly limited.
  • examples of the foaming agent that can be used for the core materials 21 and 22 include known physical foaming agents, chemical foaming agents, and mixtures thereof.
  • the physical foaming agent inorganic physical foaming agents such as air, carbon dioxide gas and nitrogen gas, and organic physical foaming agents such as butane, pentane, hexane, dichloromethane and dichloroethane can be applied.
  • the chemical foaming agent include azodicarbonamide (ADCA), N, N′-dinitrosopentamethylenetetramine, 4,4′-oxybis (benzenesulfonylhydrazide), diphenylsulfone-3,3′-disulfonyl.
  • Organic blowing agents such as hydrazide, p-toluenesulfonyl semicarbazide, trihydrazinotriazine or azobisisobutyronitrile, citric acid, oxalic acid, fumaric acid, phthalic acid, malic acid, tartaric acid, cyclohexane-1,2-dicarboxylic acid , A mixture of polycarboxylic acids such as camphoric acid, ethylenediaminetetraacetic acid, triethylenetetraminehexaacetic acid, nitrilolic acid and inorganic carbonic acid compounds such as sodium bicarbonate, sodium aluminum bicarbonate, potassium bicarbonate, ammonium bicarbonate, ammonium carbonate Citric dihydrogen sodium hydrogen salts of polycarboxylic acids, such as potassium oxalate and the like as the inorganic foaming agent.
  • the resin sheets SA and SB and the core materials 21 and 22 may be molded using a resin material mixed with a glass filler for the purpose of increasing rigidity and strength.
  • a glass filler include glass fiber, glass fiber cloth such as glass cloth and glass nonwoven fabric, glass beads, glass flakes, glass powder, and milled glass.
  • the glass include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, quartz, low dielectric constant glass, and high dielectric constant glass.
  • inorganic fillers such as talc, calcium carbonate, wollastonite, magnesium-based material, and the like for increasing rigidity may be mixed.
  • FIG. 3 is a perspective view of the foam 20 that becomes the core materials 21 and 22 of the interior material 10 of the embodiment.
  • 4A and 4B are diagrams for sequentially explaining the process of molding the foam 20 shown in FIG.
  • FIG. 5 is a plan view of the foam 20 that becomes the core materials 21 and 22 of the interior material 10 of the embodiment.
  • FIG. 6 shows cross sections AA, BB, CC, and DD shown in FIG.
  • FIG. 7 is an enlarged perspective view of an E portion shown in FIG. Drawing 8 is a figure showing the process of assembling interior material 10 of an embodiment.
  • FIG. 10 is a cross-sectional view of the interior material 10 of the embodiment at a position corresponding to BB in FIG.
  • the core materials 21 and 22 according to the present embodiment are produced by cleaving the foam 20 formed as an integral body.
  • the outer shape of the foam 20 is composed of a front surface 20a and a back surface 20b, and a side wall surface 20c interposed between the front surface 20a and the back surface 20b.
  • a linear groove 230 is formed on the front surface 20a of the foam 20 from one end to the other end.
  • the groove part 230 is formed in the back surface 20b of the foam 20 similarly to the front surface 20a.
  • the groove part 230 is provided to break the foam 20 and to fit the reinforcing member 30 after the breaking.
  • the groove part 230 will be described in detail later.
  • the foam 20 is molded by a bead-in-mold foam molding method using a molding apparatus 50 shown in FIGS. 4A and 4B.
  • molding apparatus 50 is provided with the type
  • the molds 51 and 52 constitute part of the vacancies 53 and 54, respectively.
  • Cooling tubes 41 and 42 are disposed in the vacant chambers 53 and 54.
  • the foam beads are filled through the feeders 43 and 44.
  • the amount of foam beads to be filled is, for example, 105 to 110% of the volume of the cavity 50a.
  • steam for example, a steam pressure of 3.0 to 3.5 kgf / cm 2
  • the vapor enters the bubbles in the foam beads and voids between the individual pores formed in the mold, and fuses the beads together.
  • cooling water is injected into the cooling pipes 41 and 42 from the cooling water inlets 57 and 58 and sprayed onto the molds 51 and 52 to cool the molds 51 and 52 and the foam 20.
  • the foam 20 is solidified.
  • the mold is opened and the foam 20 is taken out.
  • the foam 20 is then cured, for example, by placing it in a room at 50 to 70 ° C. for 12 to 24 hours to promote hardening and prevent sink marks and deformation.
  • engagement surfaces 211 and 221 are formed with a predetermined step amount with reference to the front surface 20a of the foam 20. As shown in FIG. 5, the engaging surfaces 211 and 221 are formed in the entire region of the groove 230 from one end to the other end of the front surface 20 a of the foam 20.
  • the engaging surfaces 211 and 221 are provided so that the reinforcing material 30 (H-shaped extrusion reinforcement) having a cross-sectional shape of H is engaged with the engaging surfaces 211 and 221 so that the core materials 21 and 22 are integrally fitted to the reinforcing material 30. ing.
  • the level difference between the front surface 20a and the engagement surfaces 211 and 221 is substantially the same between the front surface 20a and the upper surface of the reinforcing material 30 in a state where the core materials 21 and 22 are integrally fitted to the reinforcing material 30. As long as it is on a plane, it may be set appropriately. Moreover, the width
  • protrusions 211a and 221a are formed along the direction in which the engagement surfaces 211 and 221 extend, but the number of protrusions 211a and 221a is merely an example, and the number shown in the figure is Not limited.
  • the protrusions 211a and 221a increase the surface pressure generated between the reinforcing member 30 and the engaging surfaces 211 and 221 when the reinforcing member 30 (H-shaped extrusion reinforcement) having an H-shaped cross section is engaged. It is provided for the purpose of increasing the fitting force of the core materials 21 and 22 to the reinforcing material 30.
  • the core materials 21 and 22 extend from the reinforcing material 30 in a direction orthogonal to the direction in which the engaging surfaces 211 and 221 extend. It can be made difficult to leave.
  • the protrusion 211a and the protrusion 221a may be provided at positions independent of each other on the engaging surface 211 and the engaging surface 221, respectively.
  • the height of the protrusions 211a and 221a, the length along the direction in which the engagement surfaces 211 and 221 extend, and the number of protrusions are determined according to workability when the core materials 21 and 22 and the reinforcing material 30 are assembled (that is, fitting) Force) and the detachment force after the core members 21 and 22 are fitted to the reinforcing member 30 are set appropriately.
  • the protrusions 211a and 221a are formed at the ends of the engaging surfaces 211 and 221 respectively, but the present invention is not limited to this example. Since the surface pressure generated between the reinforcing material 30 and the engaging surfaces 211 and 221 can be increased within a range where the reinforcing material 30 is engaged with the engaging surfaces 211 and 221, the protrusions 211 a and 221 a are engaged. It does not need to be formed at the ends of the mating surfaces 211 and 221.
  • a shallow groove 230 a having a relatively shallow groove is preferably provided between the engagement surfaces 211 and 221 as a groove for cleaving the foam 20.
  • a deep groove 230b having a relatively deep depth is formed.
  • eleven shallow grooves 230a and ten deep grooves 230b are provided.
  • the reason why the shallow groove 230a and the deep groove 230b are provided as grooves for cleaving the foam 20 is as follows. That is, if only the deep groove is provided, the force for cleaving the foam 20 in the subsequent process can be reduced, and workability is improved, but at the position corresponding to the deep groove in the process of forming the foam 20.
  • the shallow groove 230a and the deep groove 230b are provided. As shown in FIG. 5, it is preferable to provide a plurality of shallow grooves 230a and deep grooves 230b alternately. This is because the position of the plurality of shallow grooves is dispersed along the direction in which the engagement surfaces 211 and 221 extend while achieving both formability and workability, so that the accuracy of the cleaving position of the foam 20 is improved. It is.
  • stoppers 212 and 222 for preventing the reinforcing member 30 from falling off after the interior material 10 is assembled are preferably formed at the E portion of FIG. .
  • the stoppers 212 and 222 constitute the same plane as the front surface 20a, but the present invention is not limited to this.
  • the stoppers 212 and 222 need only be able to prevent the reinforcing member 30 from moving and dropping along the longitudinal direction thereof, and therefore do not necessarily have to be flush with the front surface 20a. What is necessary is just to protrude to the surface 20a side rather than the engaging surfaces 211 and 221.
  • the surface pressure against the reinforcing material 30 of the core materials 21 and 22 is high, and the core materials 21 and 22 are respectively in the right side of the figure.
  • the protrusion 30 a of the reinforcing member 30 abuts against the protrusions 211 a and 221 a of the core members 21 and 22 even when moving in the left or right direction, and the core members 21 and 22 do not leave the reinforcing member 30.
  • the foam 20 that is the base material of the core materials 21 and 22 is integrally molded using the same molding apparatus, so that the operation state of the molding apparatus, the environmental conditions in and around the molding apparatus, etc. Even if the volume change of the foam 20 at the time of molding occurs due to this, the difference in the shape of the portion that fits the reinforcing material 30 in the core materials 21 and 22 obtained by cleaving based on the foam 20 is It is equal to no. Therefore, when the core materials 21 and 22 are fitted to the reinforcing material 30, a problem caused by a mismatch in the shape of the core material, such as a relatively large gap between the reinforcing material 30 and only one of the core materials. Is unlikely to occur. Therefore, when the resin panel 1 is produced by the resin panel molding process described later, the appearance of the resin panel 1 is deteriorated, for example, the surface of the resin panel is not flat but partially raised. hard.
  • the molding device 90 includes an extrusion device 60 and a mold clamping device 70 disposed below the extrusion device 60.
  • the molten resin sheet P extruded from the extrusion device 60 is sent to the mold clamping device 70, and the molten resin sheet P is molded in the mold clamping device 70.
  • FIG. 11 only the mold clamping device 70 and the molten resin sheet P are shown in a sectional view.
  • the extrusion device 60 includes T dies 61A and 61B, accumulators 81A and 81B, plungers 82A and 82B, extruders 83A and 83B, and resin supply hoppers 84A and 84B.
  • the resin raw material is plasticized and melted using an extruder, and this molten resin is pushed out of the die by T dies 61A and 61B.
  • the extrusion capabilities of the extruders 83A and 83B can be appropriately selected depending on the size of the resin panel 1, but from the viewpoint of shortening the molding cycle of the resin panel 1, it is 50 kg / hour or more. It is preferable.
  • the extrusion speed of the resin sheet is set by the T dies 61A and 61B and the accumulators 81A and 81B. Further, from the viewpoint of preventing drawdown, the extrusion of the resin sheet in the T dies 61A and 61B is preferably completed within 40 seconds, and more preferably within 30 seconds. For this reason, the molten resin material stored in the accumulators 81A and 81B is extruded from the T dies 61A and 61B at 50 kg / hour or more, preferably 60 kg / hour or more per 1 cm 2 .
  • the effect of the drawdown can be further suppressed by changing the slits at the die tips of the T dies 61A and 61B according to the extrusion speed of the resin sheet. That is, by gradually widening the interval between the slits of the T dies 61A and 61B from the start of extrusion and maximizing it at the end of extrusion, the thickness change due to the weight of the resin sheet is suppressed, and the resin sheet is spread over a wide range in the vertical direction. A uniform thickness can be obtained. Thereby, the thickness of the resin sheet can be made uniform when a pair of split molds described later are moved from the open position to the closed position.
  • the mold clamping device 70 includes a pair of split molds 71 ⁇ / b> A that are moved between an open position and a closed position in a direction substantially orthogonal to the supply direction of the molten resin sheet P. 71B.
  • the pair of split molds 71A and 71B are arranged in a state where the formation surfaces 72A and 72B corresponding to each of them are opposed to each other. Irregularities may be provided on the surfaces of the formation surfaces 72A and 72B in accordance with the approximate outer shape of the resin panel 1.
  • pinch-off portions 74A and 74B are formed in the vicinity of the upper and lower ends of the corresponding formation surfaces 72A and 72B.
  • the pinch-off portions 74A and 74B are formed annularly around the formation surfaces 72A and 72B, respectively, and project toward the opposing split molds 71B and 71A.
  • the pair of split molds 71A and 71B are provided with sliding portions 75A and 75B that can protrude from the formation surfaces 72A and 72B around the formation surfaces 72A and 72B.
  • the sliding portions 75A and 75B protrude from the formation surfaces 72A and 72B, and the end surfaces thereof are in contact with the resin sheet P, whereby the formation surfaces 72A and 72B of the resin sheet P and the pair of split molds 71A and 71B are contacted.
  • the vacuum chambers 73A and 73B are built in the pair of split molds 71A and 71B.
  • the vacuum chambers 73A and 73B are connected to a vacuum pump and a vacuum tank (both not shown). Between the vacuum chambers 73A and 73B and the formation surfaces 72A and 72B, a communication path (not shown) that communicates for vacuum suction of the cavity is provided.
  • the pair of split molds 71A and 71B are driven by a mold driving device (not shown) so as to be movable between an open position and a closed position.
  • a mold driving device not shown
  • two continuous resin sheets P in a molten state can be arranged with a space between each other between the pair of split molds 71A and 71B.
  • the two resin sheets P become the resin sheets SA and SB in the resin panel 1 after molding.
  • the pinch-off portions 74A and 74B of the pair of split molds 71A and 71B come into contact with each other, so that each of the pair of molds 71A and 71B is melted when two sheets are moved from the open position to the closed position. Cavities are formed in the resin split molds 71A and 71B in the state.
  • Each of the pair of molds 71A and 71B is driven so as to move toward the position of the center line of the pair of divided sheets P.
  • the molten resin sheet P is extruded vertically downward from each die slit from the extrusion device 60.
  • the extruded resin sheet P is supplied between the pair of split molds 71A and 71B through rollers 65A and 65B, respectively. At this point, the pair of split molds 71A and 71B are in the open position.
  • a decorative sheet for example, a decorative sheet made of cloth
  • the hanging resin sheet P and the decorative sheet can be pressed against each other by the rollers 65A and 65B.
  • the decorative sheet has a cloth-like inner surface in order to strengthen welding with the resin sheet P.
  • the rollers 65A and 65B are preferably coated with a fluorine thin film on the surface and heated to about 70 to 100 ° C. in order to prevent resin adhesion and improve the welding strength.
  • a decorative sheet may be installed on the formation surface of the split mold in advance, and the resin sheet P may be welded to the decorative sheet simultaneously with the molding of the resin sheet P.
  • a nonwoven fabric is preferable. In particular, it is preferable to use a needle punched nonwoven fabric obtained by piercing a needle with a barb and mechanically binding fibers to improve the welding strength.
  • the sliding portions 75A and 75B around the formation surfaces 72A and 72B are protruded, and the end surfaces thereof are brought into contact with the resin sheet P.
  • a cavity is formed between the resin sheet P and the formation surfaces 72A and 72B of the pair of split molds 71A and 71B.
  • the air in a cavity is attracted
  • the two resin sheets P are pressed against the formation surfaces 72A and 72B of the pair of split molds 71A and 71B, respectively, and as shown in FIG.
  • the shapes along the formation surfaces 72A and 72B It is formed in a substantially outer shape of the resin panel 1.
  • the resin sheet P is brought into contact with the sliding portions 75A and 75B by being configured so that the air on the resin sheet P side can be sucked from the tips of the sliding portions 75A and 75B around the forming surfaces 72A and 72B. In a state, it can hold
  • the interior material 10 is positioned between the pair of split molds 71A and 71B using a manipulator (not shown), and as shown in FIG. 14, one split mold (in FIG. Inserted so as to press against the split mold 71B). Thereby, the interior material 10 is welded to the resin sheet P. Although depending on the resin material, the resin sheet P shrinks around 1% by cooling after molding.
  • the shapes of the formation surfaces 72A and 72B of the split molds 71A and 71B are set in consideration of the contraction. That is, the formation surfaces 72A and 72B are set to be slightly larger than the target dimension after molding of the resin sheet. Therefore, the interior material 10 in the normal temperature state can be inserted into the split mold with a margin.
  • the pair of split molds 71A and 71B are moved from the open position to the closed position and clamped.
  • the interior material 10 welded to one resin sheet P (right side of the drawing) is also welded to the other resin sheet P (left side of the drawing).
  • the pinch-off portions 74A and 74B of the pair of split molds 71A and 71B the peripheral edges of the pair of resin sheets P are welded to form the parting line PL.
  • the interior material 10 itself is pre-positioned so as not to be deformed by mold clamping in order to weld the preformed room temperature interior material 10 to the molten resin sheet P during mold clamping. Yes.
  • the pair of split molds 71A and 71B are moved again to the open position, the molded resin panel 1 is separated from the formation surfaces 72A and 72B, and the burrs formed around the parting line PL are removed with a cutter or the like. Cut and remove. In addition, you may comprise so that a burr
  • a glass filler, an inorganic filler, or a carbon filler may be mixed in the resin sheet P for the purpose of increasing rigidity and strength.
  • the molding cost can be reduced according to the method in which the extruded resin sheet in the molten state is sandwiched between the split molds and is welded to the interior material before it is solidified. This is because, for example, compared with a method in which the solidified resin sheet is heated again and melted and welded to the interior material, a reheating step is not required, and the molding cost can be reduced. Moreover, the occupation area of a manufacturing apparatus can be reduced by setting it as the structure which extrudes the molten resin sheet vertically downward.
  • the cavity is formed between the resin sheet P and the forming surfaces 72A and 72B of the pair of split molds 71A and 71B before the pair of split molds 71A and 71B is moved to the closed position.
  • the present invention is not limited to this. You may make it form a cavity by moving a pair of division
  • the step of pressing the outer layer of the molten resin sheet against the formation surface of the split mold used a method by suction from the cavity or a method by blow molding. Not limited to. A method of pressing the molten resin sheet against the cavity of the split mold using the interior material 10 without forming the cavity may be applied. This method will be described with reference to FIGS.
  • FIG. 16 is a diagram illustrating a state before the interior material 10 is pressed against the molten resin sheet.
  • FIG. 17 is a diagram illustrating a state after the interior material 10 is pressed against the molten resin sheet until it reaches the formation surface of the split mold.
  • the interior material held by the manipulator 120 in a state where the molten resin sheet P is extruded vertically downward (the same state as FIG. 11). 10 is positioned at a position facing the split mold 71B with the resin sheet P interposed therebetween.
  • the manipulator 120 that holds the interior material 10 is moved toward the formation surface 72B of the split mold 71B.
  • the interior material 10 comes into contact with the molten resin sheet P, and the interior material 10 and the resin sheet P are welded.
  • the molten resin sheet P is kept at a relatively high temperature because it is not in contact with the split mold 71B having high thermal conductivity.
  • the interior material 10 and the resin sheet P are welded satisfactorily.
  • the manipulator 120 is further moved and the outer layer of the resin sheet P reaches the formation surface 72B of the split mold 71B, the state shown in FIG. 17 is obtained.
  • the outer layer of the resin sheet P is pressed against the formation surface 72 ⁇ / b> B through the interior material 10 by the manipulator 120. Thereafter, the manipulator 120 is removed from the interior material 10.
  • the pair of split molds 71A and 71B are moved from the open position to the closed position and clamped. Thereby, the interior material 10 welded to one resin sheet P (right side of the drawing) is also welded to the other resin sheet P (left side of the drawing). Then, the pair of resin sheets are pressed against the formation surfaces 72A and 72B of the split molds 71A and 71B, and as shown in FIG. 13, the shape along the formation surfaces 72A and 72B, that is, the approximate outline of the resin panel 1 Formed.
  • the peripheral edges of the pair of resin sheets P are welded to form the parting line PL.
  • the pair of split molds 71A and 71B are moved again to the open position, the molded resin panel 1 is separated from the formation surfaces 72A and 72B, and the burrs formed around the parting line PL are removed with a cutter or the like. Cut and remove.
  • the resin panel 1 in which the resin sheet SA, the interior material 10, and the resin sheet SB are laminated is completed.
  • the foamed structure material and its manufacturing method of this invention and the resin-made panels and its manufacturing method are not limited to the said embodiment, The range which does not deviate from the main point of this invention
  • the foamed structural material of the present invention is not limited to the case where it is used as an interior material for a resin panel.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

　芯材と補強材が一体となった発泡構造材、及び樹脂製パネルを製造するに当たって、芯材を補強材に嵌合させるときの精度を従来よりも向上させること、及び精度を向上させた発泡構造材、及び樹脂製パネルが提供される。本発明の発泡構造材は、補強材を嵌合するための直線状の溝部が設けられる発泡体を、前記溝部において割断した、第１の芯材及び第２の芯材と、第１の芯材及び第２の芯材がそれぞれ前記補強材の一方及び他方から嵌合された補強材と、を含む。

Description

発泡構造材、樹脂製パネル、樹脂製パネルの製造方法
　本発明は、発泡構造材、及び、当該発泡構造材を表皮材シートで覆う樹脂製パネル、並びにその製造技術に関する。
　従来から、樹脂製パネルが、自動車、航空機等の輸送機械用、建材用、電気機器のハウジング用、スポーツ・レジャー用等多用途に用いられてきた。樹脂製パネルは、芯材を表皮材シートで覆うものであるが、芯材の一方の面のみを表皮材シートで覆うものと、芯材の両方の面を表皮材シートで覆うものが存在する。芯材の一方の面のみを表皮材シートで覆う樹脂製パネルは、例えば建材用等、使用者に視認されないために芯材の他方の面を表皮材シートで覆う必要がない用途などに用いられる。芯材の両方の面を表皮材シートで覆う樹脂製パネルは、サンドイッチパネルとも呼称される。樹脂製パネルは、２枚の表皮材シート、両表皮材シートとの間に介在する芯材とを有する。すなわち、樹脂製パネルは、表皮材シート、芯材および表皮材シートの積層構造が基本的形態である。
　従来、芯材となる樹脂発泡体に金属製の補強材をインサートしたものが知られている。例えば特開２０１０－１７４５７７号公報には、中空二重壁構造の中空部に、中空部内の空間と略同一形状に予め成形された熱可塑性樹脂からなる芯材に補強材を嵌合して芯材と補強材が一体となった内装材を内装することにより、内装する内装材の位置決めが的確にできて、ガタツキ防止や成形収縮による変形を起こすことがないようにした樹脂製パネルが開示されている。
　芯材と補強材が一体となった従来の樹脂製パネル用内装材（発泡構造材）は、芯材となる２つの発泡体の間に補強材を嵌合させるものであり、その２つの発泡体は基本的には同一の成形装置を用いて成形される。しかしその場合であっても、異なるロット、あるいは異なる状況（装置の動作状態や、装置内及び周囲の環境条件）で成形される場合が生じ、成形装置から取り出した後の個々の発泡体の体積変化が異なることがある。個々の発泡体の体積変化が異なると、その後に２つの発泡体を補強材に嵌合させたときに、一方にのみ補強材との間隙が相対的に大きくなる等によって、樹脂製パネルにしたときの見栄えが悪くなる。見栄えが悪くなる場合の一例は、樹脂製パネルの面が全域で平坦ではなく、部分的にも隆起している等の場合である。
　本発明を上述した点に鑑みてなされたものであり、その目的は、芯材と補強材が一体となった発泡構造材、及び樹脂製パネルを製造するに当たって、芯材を補強材に嵌合させるときの精度を従来よりも向上させること、及び精度を向上させた発泡構造材、及び樹脂製パネルを提供することである。
　本発明の第１の観点は、発泡構造材である。
　この発泡構造材は、補強材を嵌合するための直線状の溝部が設けられる発泡体を、前記溝部において割断した、第１の芯材及び第２の芯材と、第１の芯材及び第２の芯材がそれぞれ前記補強材の一方及び他方から嵌合された補強材と、を含む。
　本発明の第２の観点は、上記発泡構造材を表皮材シートで覆った樹脂製パネルである。
　本発明の第３の観点は、発泡構造材を表皮材シートで覆う樹脂製パネルの製造方法である。
　この樹脂製パネル用の製造方法は、補強材を嵌合するための直線状の溝部が設けられる発泡体を、前記溝部において割断して、第１の芯材及び第２の芯材に分割する工程と、第１の芯材及び第２の芯材をそれぞれ前記補強材の一方及び他方から嵌合して、芯材と補強材が一体となった発泡構造材を組み立てる工程と、表皮材シートとなる樹脂シートを前記発泡構造材に溶着させる工程とを含む。
実施形態の樹脂製パネルの斜視図及びその一部の拡大破断図。 実施形態の樹脂製パネル用内装材の斜視図。 実施形態の樹脂製パネル用内装材の芯材となる発泡体の斜視図。 図３に示す発泡体を成形する工程を説明するための図。 図３に示す発泡体を成形する工程を説明するための図。 実施形態の樹脂製パネル用内装材の芯材となる発泡体の平面図。 図５に示すＡ－Ａ，Ｂ－Ｂ，Ｃ－Ｃ，Ｄ－Ｄの断面図。 図５に示すＥ部の拡大斜視図。 実施形態の樹脂製パネル用内装材を組み立てる工程を示す図。 図８において別の補強材を使用した場合の工程を示す図。 実施形態の樹脂製パネル用内装材の断面図。 実施形態の樹脂製パネルの成形装置の全体構成を示す図。 実施形態の樹脂製パネルの成形方法において、樹脂シートと分割金型の形成面との間でキャビティが形成された状態を示す図。 実施形態の樹脂製パネルの成形方法において、樹脂シートが分割金型の形成面に沿った形状に形成された状態を示す図。 実施形態の樹脂製パネルの成形方法において、芯材を分割金型内に挿入した状態を示す図。 実施形態の樹脂製パネルの成形方法において、分割金型を閉位置まで移動させた状態を示す図。 実施形態の変形例において、溶融状態の樹脂シートに対して芯材を押し付ける前の状態を示す図。 実施形態の変形例において、溶融状態の樹脂シートに対して芯材を分割金型の形成面に達するまで押し付けた後の状態を示す図。
　以下、本発明の樹脂製パネル、樹脂製パネル用内装材、及びこれらの製造方法の一実施形態について説明する。
　（１）樹脂製パネル、及び樹脂製パネル用内装材
　図１に示すように、実施形態に係る樹脂製パネル１の外形は、おもて面１ａと裏面１ｂ、及びおもて面１ａと裏面１ｂの間に介在する側壁面１ｃからなる。おもて面１ａ、裏面１ｂ、及び側壁面１ｃは熱可塑性樹脂の樹脂シートＳＡ，ＳＢによって構成されており、その内部には内装材１０が内装されている。つまり、樹脂製パネル１は、熱可塑性樹脂の樹脂シートＳＡ，ＳＢによって、内装材１０を挟み込むようにしたサンドイッチ構造となっている。内装材１０は、発泡構造材の一例である。
　実施形態の樹脂製パネル１において、表皮材シートとなる樹脂シートＳＡ，ＳＢは、その樹脂材料を限定しないが、樹脂製パネル１の剛性を確保するために非発泡樹脂から形成されることが好ましい。例えば、成形性を考慮して、樹脂シートＳＡ，ＳＢは、主材料であるポリプロピレン（ＰＰ）にポリスチレン（ＰＳ）とスチレンエチレンブチレンスチレンブロック共重合体樹脂（ＳＥＢＳ）を混合させてもよい。
　図２に示すように、内装材１０は、樹脂発泡体である芯材２１，２２がそれぞれ補強材３０の一方の側、及び他方の側に嵌合して、芯材２１，２２と補強材３０が一体となった複合構造体である。補強材３０は芯材２１，２２の端と同程度の長さの長尺状の部材である。本実施形態の補強材３０はその断面形状がＨ形の部材（いわゆるＨ形押出リンフォース）であるが、補強材３０の形状はこれに限られない。補強材３０の断面形状は、例えばＣ形、コ字形、角形パイプ状あるいは円形パイプ状等であってもよく、芯材２１，２２に嵌合一体化可能な形状であれば適宜のものでよい。補強材３０は、好ましくはアルミニウムなどの金属製あるいは硬質のプラスチック製である。
　芯材２１，２２の厚さは、樹脂製パネル１としての目標厚さ、さらには、樹脂製パネル１の目標の剛性を確保するための樹脂シートの厚さに応じて適宜決定され、特に限定されるものではない。
　実施形態の樹脂製パネル１において、芯材２１，２２は例えば熱可塑性樹脂を用いて成形される。その樹脂材料は限定しないが、例えば、ポリプロピレン、ポリエチレン等のポリオレフィンや、ポリアミド、ポリスチレン、ポリ塩化ビニル等のアクリル誘導体のいずれか、又は２種類以上の混合物を含む。芯材２１，２２は樹脂製パネル１の体積に占める割合が大きく、軽量化のために発泡剤を用いて発泡させた発泡樹脂であることが好ましいが、発泡倍率は特に限定するものではない。
　実施形態の樹脂製パネル１において、芯材２１，２２に使用されうる発泡剤としては、公知の物理発泡剤、化学発泡剤及びその混合物が挙げられる。例えば、物理発泡剤としては、空気、炭酸ガス、窒素ガス等の無機系物理発泡剤、及びブタン、ペンタン、ヘキサン、ジクロロメタン、ジクロロエタン等の有機系物理発泡剤を適用できる。また、化学発泡剤としては、例えば、アゾジカルボンアミド（ＡＤＣＡ）、Ｎ，Ｎ’－ジニトロソペンタメチレンテトラミン、４，４’－オキシビス（ベンゼンスルホニルヒドラジド）、ジフェニルスルホン－３，３’－ジスルホニルヒドラジド、ｐ－トルエンスルホニルセミカルバジド、トリヒドラジノトリアジン又はアゾビスイソブチロニトリルなどの有機発泡剤、クエン酸、シュウ酸、フマル酸、フタル酸、リンゴ酸、酒石酸、シクロヘキサン－１，２－ジカルボン酸、ショウノウ酸、エチレンジアミン四酢酸、トリエチレンテトラミン六酢酸、ニトリロ酸などのポリカルボン酸と、炭酸水素ナトリウム、炭酸水素ナトリウムアルミニウム、炭酸水素カリウム、炭酸水素アンモニウム、炭酸アンモニウムなどの無機炭酸化合物の混合物や、クエン酸ニ水素ナトリウム、シュウ酸カリウムなどのポリカルボン酸の塩が無機発泡剤として挙げられる。
　樹脂シートＳＡ，ＳＢ及び芯材２１，２２は、剛性及び強度を増加させる目的で、ガラスフィラーを混入した樹脂材料を用いて成形するようにしてもよい。
　ガラスフィラーとしては、ガラス繊維、ガラスクロスやガラス不織布などのガラス繊維布、ガラスビーズ、ガラスフレーク、ガラスパウダー、ミルドガラスなどが挙げられる。ガラスの種類としては、Ｅガラス、Ｃガラス、Ａガラス、Ｓガラス、Ｄガラス、ＮＥガラス、Ｔガラス、クオーツ、低誘電率ガラス、高誘電率ガラスなどが挙げられる。
　なお、ガラスフィラーに限らず、剛性を上げるためのタルク、炭酸カルシウム、珪灰石（Wollastonite）、マグネシウム系材料等の無機フィラー、カーボンファイバー等を混入させてもよい。
　（２）内装材１０及びその製造方法
　次に、図３～図１０を参照して、本実施形態の内装材１０及びその製造方法について説明する。
　図３は、実施形態の内装材１０の芯材２１，２２となる発泡体２０の斜視図である。図４Ａ及び図４Ｂは、図３に示す発泡体２０を成形する工程を順に説明するための図である。図５は、実施形態の内装材１０の芯材２１，２２となる発泡体２０の平面図である。図６には、図５に示すＡ－Ａ，Ｂ－Ｂ，Ｃ－Ｃ，Ｄ－Ｄの断面を示す。図７は、図５に示すＥ部の拡大斜視図である。図８は、実施形態の内装材１０を組み立てる工程を示す図である。図１０は、実施形態の内装材１０の、図５のＢ－Ｂに相当する位置における断面図である。
　（２－１）芯材の元となる発泡体
　本実施形態の芯材２１，２２は、一体物として成形される発泡体２０を割断することによって作製される。図３に示すように、発泡体２０の外形は、おもて面２０ａと裏面２０ｂ、及びおもて面２０ａと裏面２０ｂの間に介在する側壁面２０ｃからなる。
　図３に示すように、発泡体２０のおもて面２０ａには一端から他端に亘って直線状の溝部２３０が形成されている。なお、発泡体２０の裏面２０ｂにもおもて面２０ａと同様に、溝部２３０形成されている。溝部２３０は、発泡体２０を割断し、かつ割断後に補強材３０を嵌合するために設けられている。溝部２３０については後で詳述する。
　（２－２）芯材の元となる発泡体の成形
　発泡体２０は、図４Ａ及び図４Ｂに示す成形装置５０を使用してビーズ法型内発泡成形法によって成形される。図４ＡのＳ１に示すように、成形装置５０には対向して配置される型５１，５２が設けられる。型５１，５２はそれぞれ、空室５３，５４の一部を構成している。空室５３，５４には、冷却管４１，４２が配設されている。
　図４ＡのＳ１に示す状態から型５１，５２を閉じると、図４ＡのＳ２に示すように型５１，５２による密閉空間であるキャビティ５０ａが形成される。型５１，５２が閉じられた状態で、フィーダ４３，４４を通して発泡ビーズを充填する。充填される発泡ビーズの量は、例えばキャビティ５０ａの容積の１０５～１１０％である。次に、図４ＢのＳ３に示すように、蒸気注入口５５，５６より、空室５３，５４に蒸気（例えば蒸気圧３．０～３．５kgｆ／cm2 ）を、例えば１０～３０秒間注入する。蒸気は型に形成された細孔から発泡ビーズ内の気泡、個々間の空隙に入り込み、ビーズ相互を融着させる。その後、図４ＢのＳ４に示すように、冷却水注入口５７，５８から冷却水を冷却管４１，４２に注入し、型５１，５２に噴霧して型５１，５２および発泡体２０を冷して発泡体２０を固化させる。次いで、図４ＢのＳ５に示すように型を開けて発泡体２０を取り出す。発泡体２０はその後、例えば５０～７０°Ｃの部屋に１２～２４時間置いて養生させることで硬化を促進させ、ヒケ、変形を防止する。
　（２－３）芯材の元となる発泡体の詳細形状の一例
　次に、発泡体２０の溝部２３０の詳細形状について、図５～７を参照して説明する。以下では、おもて面２０ａ側の溝部２３０についてのみ説明するが、裏面２０ｂ側の溝部２３０も同様の形状である。なお、本実施形態では、溝部２３０の中央にあるおもて面２０ａに直交する面を想定したときに、その面を挟んで溝部２３０は対称構な構造になっている。
　溝部２３０では、発泡体２０のおもて面２０ａを基準に所定の段差量をもって係合面２１１，２２１が形成されている。図５に示すように、係合面２１１，２２１は、発泡体２０のおもて面２０ａの一端から他端に亘って溝部２３０の全域で形成されている。係合面２１１，２２１は、断面形状がＨ形の補強材３０（Ｈ形押出リンフォース）が係合し、それによって、芯材２１，２２が補強材３０に一体嵌合するために設けられている。おもて面２０ａと係合面２１１，２２１の間の段差量は、芯材２１，２２が補強材３０に一体嵌合した状態においておもて面２０ａと補強材３０の上面とが概ね同一平面上となる限り、適宜設定されてよい。また、係合面２１１，２２１の幅は、少なくとも補強材３０が係合可能な長さが確保されていればよい。
　図５に示すように、係合面２１１，２２１が延びる方向に沿って突起２１１ａ，２２１ａがそれぞれ６箇所形成されているが、突起２１１ａ，２２１ａの個数は一例に過ぎず、図示された個数に限られない。突起２１１ａ，２２１ａは、断面形状がＨ形の補強材３０（Ｈ形押出リンフォース）が係合したときに、補強材３０と係合面２１１，２２１の間に生ずる面圧を高め、それによって芯材２１，２２の補強材３０に対する嵌合力を大きくすることを目的として設けられている。つまり、突起２１１ａ，２２１ａを設けることで、芯材２１，２２を補強材３０に嵌合した後に、係合面２１１，２２１が延びる方向と直交する方向に芯材２１，２２が補強材３０から離脱しにくくすることができる。
　なお、図５及び図６では、突起２１１ａ，２２１ａがすべての箇所で対向する位置に設けている場合が示されているが、この場合に限られない。突起２１１ａ及び突起２２１ａはそれぞれ係合面２１１及び係合面２２１上で互いに独立した位置に設けてもよい。
　突起２１１ａ，２２１ａの高さ、係合面２１１，２２１が延びる方向に沿った長さ、及び各突起の個数は、芯材２１，２２と補強材３０を組み立てるときの作業性（つまり、嵌合するときの力）と、芯材２１，２２を補強材３０に嵌合した後の離脱力とを勘案して、適宜に設定される。
　図５及び図６に示した例では、突起２１１ａ，２２１ａはそれぞれ、係合面２１１，２２１の端に形成されているが、この例に限られない。補強材３０が係合面２１１，２２１に係合している範囲であれば、補強材３０と係合面２１１，２２１の間に生ずる面圧を高めることができるため、突起２１１ａ，２２１ａは係合面２１１，２２１の端に形成されていなくても構わない。
　図６で明瞭に見られるように、好ましくは、係合面２１１，２２１の間には、発泡体２０を割断するための溝として、溝の深さが比較的浅い浅溝２３０ａと、溝の深さが比較的深い深溝２３０ｂとが形成される。図５及び図６に示した例では、１１箇所の浅溝２３０ａと１０箇所の深溝２３０ｂが設けられている。発泡体２０を割断するための溝として浅溝２３０ａと深溝２３０ｂを設ける理由は、以下のとおりである。すなわち、仮に深溝のみを設けた場合には、後の工程において発泡体２０を割断する力が少なくて済み、作業性が向上するが、発泡体２０を成形する工程において深溝に相当する位置での型のキャビティの通路が狭いために発泡ビーズをフィーダからキャビティの全域に充填し難くなる。一方、仮に浅溝のみを設けた場合には、発泡体２０を成形する工程において発泡ビーズをフィーダから充填しやすくなるが、後の工程において発泡体２０を割断する力が大きくなってしまい、作業性が悪化する。そこで、成形性と作業性を両立する観点から、浅溝２３０ａと深溝２３０ｂを設けている。
　なお、図５に示したように、浅溝２３０ａと深溝２３０ｂはそれぞれ複数個を交互に設けることが好ましい。これは、成形性と作業性を両立しつつ、係合面２１１，２２１が延びる方向に沿って複数の浅溝の位置が分散されるため、発泡体２０の割断位置の精度が良好となるためである。
　図７に示すように、図５のＥ部、つまり溝部２３０の一端には、内装材１０を組み立てた後に補強材３０の脱落を防止するためのストッパ２１２，２２２が形成されていることが好ましい。
　なお、図７に示す例では、ストッパ２１２，２２２はおもて面２０ａと同一の平面を構成しているが、これに限られない。ストッパ２１２，２２２は、補強材３０がその長手方向に沿って移動して脱落することを防止できればよいので、必ずしもおもて面２０ａと同一平面である必要はなく、補強材３０が係合する係合面２１１，２２１よりもおもて面２０ａ側に突出していればよい。
　（２－４）発泡体の割断、及び内装材の組み立て
　次に、発泡体２０が成形された後の工程について説明する。
　発泡体２０が成形されると、発泡体２０を溝部２３０の浅溝２３０ａ及び深溝２３０ｂにおいて割断して、第１の芯材及び第２の芯材としての芯材２１，２２に分割する。次いで、図８に示すように、芯材２１，２２をそれぞれ補強材３０の一方及び他方から嵌合して、芯材２１，２２と補強材３０が一体となった内装材１０を組み立てる。図９に示すように、内装材１０において突起２１１ａ，２２１ａが形成された箇所では芯材２１，２２の補強材３０に対する面圧が高くなり、かつ仮に芯材２１，２２がそれぞれ図中の右方向又は左方向に移動した場合でも補強材３０の突起３０ａが芯材２１，２２の突起２１１ａ，２２１ａと当接して芯材２１，２２が補強材３０から離脱しない。なお、図１０に示すように、突起３０ａがない補強材３０を使用してもよい。この場合でも、芯材２１，２２の突起２１１ａ，２２１ａが設けられた位置で補強材３０との間の面圧が高くなるため、芯材２１，２２がそれぞれ図中の右方向又は左方向に離脱し難くなる。
　本実施形態では、芯材２１，２２の元となる発泡体２０は同一の成形装置を用いて一体的に成形されるため、成形装置の動作状態や、成形装置内及び周囲の環境条件等に起因して成形時の発泡体２０の体積変化が生じたとしても、その発泡体２０を元に割断して得られる芯材２１，２２について、補強材３０と嵌合する部位の形状の差は無いに等しい。そのため、芯材２１，２２を補強材３０に嵌合させたときに、一方の芯材にのみ補強材３０との間隙が相対的に大きくなる等といった、芯材の形状の不一致に起因する問題が生じ難い。そのため、後述する樹脂製パネルの成形工程によって樹脂製パネル１を作製したときに、例えば、樹脂製パネルの面が全域で平坦ではなく部分的にも隆起している等といった、見栄えの悪化が生じ難い。
　（３）樹脂製パネルの成形方法
　次に、図１１～１７を参照して、実施形態の樹脂製パネル１を、金型を用いて成形する装置および方法について説明する。
　先ず、実施形態の樹脂製パネル１の成形装置について説明する。
　図１１に示すように、実施形態の成形装置９０は、押出装置６０と、押出装置６０の下方に配置された型締装置７０とを有する。押出装置６０から押出された溶融状態の樹脂シートＰは、型締装置７０に送られ、型締装置７０において溶融状態の樹脂シートＰが成形される。なお、図１１では、型締装置７０及び溶融状態の樹脂シートＰのみを断面図で示してある。
　押出装置６０は、Ｔダイ６１Ａ，６１Ｂ、アキュムレータ８１Ａ，８１Ｂ、プランジャー８２Ａ，８２Ｂ、押出機８３Ａ，８３Ｂ、及び樹脂供給ホッパー８４Ａ，８４Ｂを備える。押出装置６０では、樹脂原料が押出機を用いて可塑化溶融させられ、この溶融樹脂がＴダイ６１Ａ，６１Ｂでダイ外へ押し出される。押出装置６０において、押出機８３Ａ，８３Ｂの押出能力は、樹脂製パネル１の大きさにより適宜選択することができるが、樹脂製パネル１の成形サイクルを短縮させる観点から、５０kg/時以上であることが好ましい。
　押出装置６０では、樹脂シートの押出速度は、Ｔダイ６１Ａ，６１Ｂ及びアキュムレータ８１Ａ，８１Ｂにより設定される。また、ドローダウンを防止する観点から、Ｔダイ６１Ａ，６１Ｂにおける樹脂シートの押し出しは、４０秒以内に完了することが好ましく、３０秒以内に完了するのがさらに好ましい。このため、アキュムレータ８１Ａ，８１Ｂに貯留された溶融樹脂材料は、Ｔダイ６１Ａ，６１Ｂから１cm2当たり５０kg/時以上、好ましくは６０kg/時以上で押し出されることになる。このとき、Ｔダイ６１Ａ，６１Ｂのダイ先端のスリットを樹脂シートの押出速度に応じて変化させることでドローダウンの影響をさらに抑制することができる。すなわち、Ｔダイ６１Ａ，６１Ｂのスリットの間隔を押出開始から徐々に広げ、押出終了時に最大とすることで、樹脂シートの自重による肉厚変化を抑制し、上下方向の広い範囲に亘り樹脂シートを均一な厚さとすることができる。これにより、後述する一対の分割金型を開位置から閉位置へ移動させる時点において、樹脂シートの厚みを均一にすることができる。
　図１１を再度参照すると、型締装置７０は、溶融状態の樹脂シートＰの供給方向に対して略直交する方向に、開位置と閉位置との間で移動させられる一対の分割金型７１Ａ，７１Ｂを有する。一対の分割金型７１Ａ，７１Ｂは、各々に対応する形成面７２Ａ，７２Ｂを対向させた状態で配置される。形成面７２Ａ，７２Ｂの表面には、樹脂製パネル１の略外形に応じて凹凸部が設けられてもよい。
　一対の分割金型７１Ａ，７１Ｂの各々において、各々に対応する形成面７２Ａ，７２Ｂの上下端近傍には、ピンチオフ部７４Ａ，７４Ｂが形成されている。このピンチオフ部７４Ａ，７４Ｂはそれぞれ、形成面７２Ａ，７２Ｂのまわりに環状に形成され、対向する分割金型７１Ｂ，７１Ａに向かって突出する。これにより、一対の分割金型７１Ａ，７１Ｂを型締する際、それぞれのピンチオフ部７４Ａ，７４Ｂの先端部が当接し、溶融状態の樹脂シートＰの周縁にパーティングラインＰＬが形成されるようになっている。
　一対の分割金型７１Ａ，７１Ｂには、形成面７２Ａ，７２Ｂの周囲において、形成面７２Ａ，７２Ｂから突出可能に摺動部７５Ａ，７５Ｂが設けられている。摺動部７５Ａ，７５Ｂは、形成面７２Ａ，７２Ｂから突出した状態において、その端面が樹脂シートＰに接触し、それにより、樹脂シートＰと一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂとの間に密閉空間（キャビティ）が形成されるようにして、設けられている。
　一対の分割金型７１Ａ，７１Ｂには、真空チャンバ７３Ａ，７３Ｂが内蔵されている。真空チャンバ７３Ａ，７３Ｂは、真空ポンプおよび真空タンク（いずれも図示せず）と接続されている。真空チャンバ７３Ａ，７３Ｂと形成面７２Ａ，７２Ｂの間には、キャビティの真空吸引のために連通する連通路（図示せず）が設けられている。
　一対の分割金型７１Ａ，７１Ｂは、金型駆動装置（図示せず）によって、開位置と閉位置の間を移動可能となるように駆動される。開位置では、一対の分割金型７１Ａ，７１Ｂの間に、２枚の溶融状態の連続した樹脂シートＰが、互いに間隔を隔てて配置可能となっている。２枚の樹脂シートＰは、成形後に、樹脂製パネル１における樹脂シートＳＡ，ＳＢとなる。閉位置では、一対の分割金型７１Ａ，７１Ｂのピンチオフ部７４Ａ，７４Ｂが当接することにより、一対の金型７１Ａ，７１Ｂの各々は、開位置から閉位置への移動の際、２枚の溶融状態の樹脂分割金型７１Ａ，７１Ｂ内にキャビティが形成されるようにしている。なお、一対の金型７１Ａ，７１Ｂの各々は、一対の分割シートＰの中心線の位置に向かって移動するように駆動される。
　次に、樹脂製パネル１の成形方法について説明する。
　先ず、図１１に示したように、押出装置６０から溶融状態の樹脂シートＰが各ダイスリットから鉛直下方に押し出される。この押し出された樹脂シートＰはそれぞれ、ローラ６５Ａ，６５Ｂを通して、一対の分割金型７１Ａ，７１Ｂの間に供給される。この時点で、一対の分割金型７１Ａ，７１Ｂは開位置にある。
　なお、樹脂製パネル１の表面に装飾シート（例えば布製の装飾シート）を付加する場合には、垂下する樹脂シートＰと装飾シートを、ローラ６５Ａ，６５Ｂにより互いに圧着させることができる。このとき、装飾シートは、その内面が布状であることが、樹脂シートＰとの溶着を強くするうえで好適である。ローラ６５Ａ，６５Ｂは、表面にフッ素の薄膜でコーティングを施し、また７０～１００℃程度に加熱することが樹脂の付着防止および溶着強度の向上のうえで好ましい。
　また、あらかじめ、装飾シートを分割金型の形成面に設置しておき、樹脂シートＰの成形と同時に、樹脂シートＰを装飾シートに溶着させてもよい。
　尚、布製の装飾シートとしては、不織布が好ましい。特に、かえしのある針を突き刺して機械的に繊維を結合させてなるニードルパンチ不織布を用いることが、溶着強度向上のうえで好ましい。
　次に、図１２に示すように、形成面７２Ａ，７２Ｂの周囲にある摺動部７５Ａ，７５Ｂを突出させて、その端面を樹脂シートＰに接触させる。これにより、樹脂シートＰと一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂとの間にキャビティが形成される。そして、真空チャンバ７３Ａ，７３Ｂと形成面７２Ａ，７２Ｂの間に設けられた連通路（図示せず）によって、キャビティ内の空気を吸引する。この吸引により、２枚の樹脂シートＰがそれぞれ、一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂに押圧させられ、図１３に示すように、形成面７２Ａ，７２Ｂに沿った形状、すなわち、樹脂製パネル１の略外形に形成される。
　尚、形成面７２Ａ，７２Ｂの周囲にある摺動部７５Ａ，７５Ｂの先端から樹脂シートＰ側の空気を吸引できるように構成することで、樹脂シートＰを摺動部７５Ａ，７５Ｂに接触させた状態で、確実に保持することができる。また、キャビティを吸引して樹脂シートＰを形成面７２Ａ，７２Ｂに沿った形状にするときに、皺が発生することを抑制できる。
　次に、マニピュレータ（図示せず）を用いて一対の分割金型７１Ａ，７１Ｂの間で内装材１０を位置決めし、図１４に示すように、側方より一方の分割金型（図１４では、分割金型７１Ｂ）に押し付けるようにして挿入する。これにより、内装材１０が樹脂シートＰに溶着する。なお、樹脂材料にもよるが、樹脂シートＰは成形後の冷却により１％前後収縮する。分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂは、その収縮を見込んで形状が設定されている。すなわち、形成面７２Ａ，７２Ｂは、樹脂シートの成形後の目標寸法よりも僅かに大きく設定されている。そのため、常温状態の内装材１０を余裕を持って分割金型内に挿入することができる。
　次に、図１５に示すように、一対の分割金型７１Ａ，７１Ｂを開位置から閉位置まで移動させて、型締する。これにより、一方の樹脂シートＰ（図面右側）に対して溶着されていた内装材１０は、他方の樹脂シートＰ（図面左側）に対しても溶着される。さらに、一対の分割金型７１Ａ，７１Ｂのピンチオフ部７４Ａ，７４Ｂにおいて、一対の樹脂シートＰの周縁が溶着させられ、パーティングラインＰＬが形成される。なお、型締の際、予め成形された常温状態の内装材１０を溶融状態の樹脂シートＰに対して溶着させるため、内装材１０自体は、型締により変形を受けないように予め位置決めされている。
　最後に、一対の分割金型７１Ａ，７１Ｂを再び開位置に移動させ、成形した樹脂製パネル１を形成面７２Ａ，７２Ｂから離間させ、パーティングラインＰＬまわりに形成されたバリを、カッター等で切断して除去する。尚、型締めと同時に、ピンチオフ部７４Ａ，７４Ｂでバリが切断されるように構成してもよい。以上で、樹脂シートＳＡ、内装材１０、樹脂シートＳＢが積層された樹脂製パネル１が完成する。
　なお、前述したように、剛性及び強度を増加させる目的で、樹脂シートＰにはガラスフィラー、無機フィラーやカーボンフィラーを混入するようにしてもよい。
　上述したように、押し出された溶融状態の樹脂シートが固化する前に、分割金型で挟み込んで、内装材に溶着させる方法によれば、成形コストを低減できる。なぜなら、例えば、固化した樹脂シートを再度加熱して溶融させ、内装材に溶着させる方法に比べて、再加熱工程が不要になり、成形コストを低減できるからである。
　また、鉛直下方に溶融状態の樹脂シートを押し出す構成とすることで製造装置の占有面積を減らすことができる。なぜなら、例えば、水平方向に押し出して成形する場合は、水平方向に樹脂シートを移動させるための搬送装置が別途必要になるとともに、当該搬送装置や金型を押出装置と水平方向に並べて設置することが必要になるからである。
　なお、上述した実施形態の樹脂製パネルの成形方法は、適宜変形するようにしてもよい。以下、実施形態の樹脂製パネルの成形方法の変形例について説明する。
　（変形例１）
　上述した樹脂製パネルの成形方法では、一対のＴダイが溶融状態の樹脂シートを押し出す場合について説明したが、円筒状のパリソンを切断しつつ押し出すことで樹脂シートを得るようにしてもよい。
　（変形例２）
　上述した樹脂製パネルの成形方法では、一対の分割金型７１Ａ，７１Ｂを閉位置に移動させる前に、樹脂シートＰと一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂとの間にキャビティを形成する場合について説明したが、これに限られない。一対の分割金型７１Ａ，７１Ｂを閉位置に移動させることでキャビティを形成するようにしてもよい。
　（変形例３）
　上述した樹脂製パネルの成形方法では、樹脂シートＰを一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂに押圧させるために、キャビティ内部の空気を吸引するようにした場合について説明したが、これに限られない。樹脂シートＰに空気等の流体を吹き付けることによって樹脂シートＰを一対の分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂに押圧させるようにしてもよい（ブロー成形）。
　（変形例４）
　上述した樹脂製パネルの成形方法では、溶融状態の樹脂シートの外層を分割金型の形成面に押圧させる工程は、キャビティからの吸引による方法、又はブロー成形による方法を用いたが、これらの方法に限られない。キャビティを形成することなく、内装材１０を用いて溶融状態の樹脂シートを分割金型のキャビティに押し付ける方法を適用してもよい。この方法について、図１６及び図１７を参照して説明する。
　図１６は、溶融状態の樹脂シートに対して内装材１０を押し付ける前の状態を示す図である。図１７は、溶融状態の樹脂シートに対して内装材１０を分割金型の形成面に達するまで押し付けた後の状態を示す図である。
　本変形例の方法では先ず、図１６に示すように、押出装置６０から溶融状態の樹脂シートＰが鉛直下方に押し出された状態（図１１と同じ状態）で、マニピュレータ１２０によって保持された内装材１０が、樹脂シートＰを挟んで分割金型７１Ｂと対向する位置に位置決めされる。内装材１０が位置決めされると、内装材１０を保持するマニピュレータ１２０は、分割金型７１Ｂの形成面７２Ｂに向けて移動させられる。すると、内装材１０が溶融状態の樹脂シートＰに接触し、内装材１０と樹脂シートＰが溶着する。内装材１０との接触時において、溶融状態の樹脂シートＰは、熱伝導率の高い分割金型７１Ｂと接触していないため比較的高温に保たれている。よって、内装材１０と樹脂シートＰは良好に溶着する。
　マニピュレータ１２０がさらに移動させられ、樹脂シートＰの外層が分割金型７１Ｂの形成面７２Ｂに達すると、図１７に示す状態となる。このとき、マニピュレータ１２０によって樹脂シートＰの外層が内装材１０を介して形成面７２Ｂに押し付けられる。その後、内装材１０からマニピュレータ１２０が取り外される。
　以降の工程は、前述したとおりである。
　すなわち、図１５に示したように、一対の分割金型７１Ａ，７１Ｂを開位置から閉位置まで移動させて、型締する。これにより、一方の樹脂シートＰ（図面右側）に対して溶着されていた内装材１０が他方の樹脂シートＰ（図面左側）に対しても溶着される。そして、一対の樹脂シートが分割金型７１Ａ，７１Ｂの形成面７２Ａ，７２Ｂに押圧させられ、図１３に示すように、形成面７２Ａ，７２Ｂに沿った形状、すなわち、樹脂製パネル１の略外形に形成される。さらに、一対の分割金型７１Ａ，７１Ｂのピンチオフ部７４Ａ，７４Ｂにおいて、一対の樹脂シートＰの周縁が溶着させられ、パーティングラインＰＬが形成される。最後に、一対の分割金型７１Ａ，７１Ｂを再び開位置に移動させ、成形した樹脂製パネル１を形成面７２Ａ，７２Ｂから離間させ、パーティングラインＰＬまわりに形成されたバリを、カッター等で切断して除去する。以上で、樹脂シートＳＡ、内装材１０、樹脂シートＳＢが積層された樹脂製パネル１が完成する。
　以上、本発明の実施形態について詳細に説明したが、本発明の発泡構造材とその製造方法、及び樹脂製パネルとその製造方法は上記実施形態に限定されず、本発明の主旨を逸脱しない範囲において、種々の改良や変更をしてもよいのは勿論である。
　例えば、本発明の発泡構造材は、樹脂製パネルの内装材として用いる場合に限定されず、発泡構造材を樹脂シートで覆わずに、そのままの状態で、補強部材、緩衝部材、断熱部材などとして用いることができる。具体的には、木材などで形成された板材に固定したり、当該板材でサンドイッチして使用してもよい。
 

Claims (6)

  1. 　補強材を嵌合するための直線状の溝部が設けられる発泡体を、前記溝部において割断した、第１の芯材及び第２の芯材と、
    　第１の芯材及び第２の芯材がそれぞれ前記補強材の一方及び他方から嵌合された補強材と、
    　を含む、発泡構造材。
  2. 　前記補強材は、断面形状がＨ形であって、
    　前記発泡体の溝部は補強材と係合する係合面を含み、係合面には１又は複数の突起が形成されていることを特徴とする、
    　請求項１に記載された、発泡構造材。
  3. 　前記発泡体の溝部の両端には、前記補強材の脱落を防止するためのストッパが形成されていることを特徴とする、
    　請求項１又は２に記載された、発泡構造材。
  4. 　前記発泡体の溝部には、前記発泡体を割断するための溝として複数の浅溝と深溝がそれぞれ交互に形成されていることを含むことを特徴とする、
    　請求項１～３のいずれかに記載された、発泡構造材。
  5. 　請求項１～４に記載の発泡構造材を表皮材シートで覆った樹脂製パネル。
  6. 　発泡構造材を表皮材シートで覆う樹脂製パネルの製造方法であって、
    　補強材を嵌合するための直線状の溝部が設けられる発泡体を、前記溝部において割断して、第１の芯材及び第２の芯材に分割する工程と、
    　第１の芯材及び第２の芯材をそれぞれ前記補強材の一方及び他方から嵌合して、芯材と補強材が一体となった発泡構造材を組み立てる工程と、
    　表皮材シートとなる樹脂シートを前記発泡構造材に溶着させる工程と
    　を含む、樹脂製パネルの製造方法。
PCT/JP2013/081431 2012-12-28 2013-11-21 発泡構造材、樹脂製パネル、樹脂製パネルの製造方法 WO2014103580A1 (ja)

Priority Applications (5)

Application Number Priority Date Filing Date Title
CN201380063558.8A CN104837606B (zh) 2012-12-28 2013-11-21 发泡结构件、树脂制面板、树脂制面板的制造方法
EP13868050.9A EP2942184B1 (en) 2012-12-28 2013-11-21 Foam structure, resin panel, and resin panel manufacturing method
US14/651,169 US9987821B2 (en) 2012-12-28 2013-11-21 Foam structural material, resin panel, and method for manufacturing a resin panel
CN201711043232.5A CN107839241B (zh) 2012-12-28 2013-11-21 发泡结构件、树脂制面板
US15/970,681 US10688751B2 (en) 2012-12-28 2018-05-03 Foam structural material, resin panel, and method for manufacturing a resin panel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2012288328A JP6032007B2 (ja) 2012-12-28 2012-12-28 発泡構造材、樹脂製パネルの製造方法
JP2012-288328 2012-12-28

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US14/651,169 A-371-Of-International US9987821B2 (en) 2012-12-28 2013-11-21 Foam structural material, resin panel, and method for manufacturing a resin panel
US15/970,681 Division US10688751B2 (en) 2012-12-28 2018-05-03 Foam structural material, resin panel, and method for manufacturing a resin panel

Publications (1)

Publication Number Publication Date
WO2014103580A1 true WO2014103580A1 (ja) 2014-07-03

Family

ID=51020674

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2013/081431 WO2014103580A1 (ja) 2012-12-28 2013-11-21 発泡構造材、樹脂製パネル、樹脂製パネルの製造方法

Country Status (5)

Country Link
US (2) US9987821B2 (ja)
EP (1) EP2942184B1 (ja)
JP (1) JP6032007B2 (ja)
CN (2) CN104837606B (ja)
WO (1) WO2014103580A1 (ja)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015129830A1 (ja) * 2014-02-28 2015-09-03 キョーラク株式会社 サンドイッチパネルおよびサンドイッチパネルの製造方法
CN109641380A (zh) * 2016-08-31 2019-04-16 京洛株式会社 发泡结构体、树脂制面板、树脂制面板的制造方法、树脂层叠体的制造方法以及发泡体

Families Citing this family (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6368985B2 (ja) * 2014-08-29 2018-08-08 キョーラク株式会社 成形方法
JP6485052B2 (ja) * 2015-01-14 2019-03-20 キョーラク株式会社 樹脂製パネル
JP6519272B2 (ja) * 2015-03-30 2019-05-29 キョーラク株式会社 樹脂製パネル及び樹脂製パネルの製造方法
JP6764746B2 (ja) * 2016-09-29 2020-10-07 キョーラク株式会社 発泡構造体、樹脂製パネル
KR102134192B1 (ko) * 2016-02-15 2020-07-15 교라꾸 가부시끼가이샤 발포 구조체, 수지제 패널
JP6708362B2 (ja) * 2016-02-25 2020-06-10 キョーラク株式会社 樹脂製パネル
JP6809757B2 (ja) * 2016-08-31 2021-01-06 キョーラク株式会社 発泡体、樹脂製パネル
JP6764744B2 (ja) * 2016-09-28 2020-10-07 キョーラク株式会社 発泡構造体、樹脂製パネル
JP6721834B2 (ja) 2016-09-29 2020-07-15 キョーラク株式会社 金型及びその製造方法、並びに成形体の製造方法
JP6855270B2 (ja) * 2017-02-17 2021-04-07 積水樹脂株式会社 建材
CN109808126B (zh) * 2017-11-21 2024-05-28 广东美的生活电器制造有限公司 芯件、搅拌器、泡奶机以及搅拌器的制作方法
JP6959522B2 (ja) * 2017-11-29 2021-11-02 キョーラク株式会社 樹脂製パネルの製造方法
WO2019107319A1 (ja) * 2017-11-29 2019-06-06 キョーラク株式会社 樹脂製パネル及びその製造方法
ES2878172T3 (es) * 2018-02-20 2021-11-18 Maucher Formenbau Gmbh & Co Kg Núcleo y procedimiento para la fabricación y el procesamiento posterior de uno tal
WO2019208631A1 (ja) * 2018-04-27 2019-10-31 キョーラク株式会社 構造体の製造方法及びパネル
JP7132489B2 (ja) * 2018-04-27 2022-09-07 キョーラク株式会社 構造体の製造方法及びパネル
JP7064133B2 (ja) * 2018-04-27 2022-05-10 キョーラク株式会社 構造体の製造方法及びパネル
US20220139364A1 (en) * 2020-11-02 2022-05-05 Pratt & Whitney Canada Corp. Sandwich-structured panels and method of manufacture

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0880538A (ja) * 1994-09-13 1996-03-26 Kanegafuchi Chem Ind Co Ltd 発泡合成樹脂製板状部材の製造方法および発泡合成樹脂製組立容器
JPH11320803A (ja) * 1998-05-14 1999-11-24 Daido Steel Sheet Corp 断熱パネルの製造方法及びその切断装置
JP2010174577A (ja) 2009-01-31 2010-08-12 Kyoraku Co Ltd 樹脂製パネルおよびその製造方法

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5129628A (en) * 1988-04-06 1992-07-14 Vesper Dale E Fence panel and wall construction
JP4061744B2 (ja) * 1997-11-26 2008-03-19 東レ株式会社 Ｆｒｐ構造体およびその製造方法
JP3970690B2 (ja) 2002-05-31 2007-09-05 ニチハ株式会社 木質セメント板およびその製造方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0880538A (ja) * 1994-09-13 1996-03-26 Kanegafuchi Chem Ind Co Ltd 発泡合成樹脂製板状部材の製造方法および発泡合成樹脂製組立容器
JPH11320803A (ja) * 1998-05-14 1999-11-24 Daido Steel Sheet Corp 断熱パネルの製造方法及びその切断装置
JP2010174577A (ja) 2009-01-31 2010-08-12 Kyoraku Co Ltd 樹脂製パネルおよびその製造方法

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015129830A1 (ja) * 2014-02-28 2015-09-03 キョーラク株式会社 サンドイッチパネルおよびサンドイッチパネルの製造方法
JP2015164763A (ja) * 2014-02-28 2015-09-17 キョーラク株式会社 サンドイッチパネルおよびサンドイッチパネルの製造方法
US10350797B2 (en) 2014-02-28 2019-07-16 Kyoraku Co., Ltd. Method for manufacturing a sandwich panel
CN109641380A (zh) * 2016-08-31 2019-04-16 京洛株式会社 发泡结构体、树脂制面板、树脂制面板的制造方法、树脂层叠体的制造方法以及发泡体
CN109641380B (zh) * 2016-08-31 2021-04-13 京洛株式会社 发泡结构体以及树脂制面板

Also Published As

Publication number Publication date
CN104837606B (zh) 2017-12-01
EP2942184A1 (en) 2015-11-11
EP2942184B1 (en) 2020-04-15
CN107839241A (zh) 2018-03-27
US20180250911A1 (en) 2018-09-06
EP2942184A4 (en) 2016-09-14
CN107839241B (zh) 2023-06-13
US9987821B2 (en) 2018-06-05
CN104837606A (zh) 2015-08-12
US20150306844A1 (en) 2015-10-29
US10688751B2 (en) 2020-06-23
JP2014128938A (ja) 2014-07-10
JP6032007B2 (ja) 2016-11-24

Similar Documents

Publication Publication Date Title
JP6032007B2 (ja) 発泡構造材、樹脂製パネルの製造方法
JP5613442B2 (ja) 表皮付きパネルの成形方法、表皮付きパネル
JP5966429B2 (ja) 樹脂パネルの製造方法、サンドイッチパネルの製造方法
WO2018043390A1 (ja) 発泡構造体、樹脂製パネル、樹脂製パネルの製造方法、樹脂積層体の製造方法及び発泡体
JP6485052B2 (ja) 樹脂製パネル
JP2018047586A (ja) 発泡構造体、樹脂製パネル
JP2008183834A (ja) 射出発泡成形方法
JP2001334549A (ja) 複合成形品の製造方法および複合成形品
KR20190066010A (ko) 발포성형체의 제조방법
JP6681569B2 (ja) 発泡構造体、樹脂製パネル
JP3128664B2 (ja) 電気装置用ハウジングパネルの製造方法
JP5155053B2 (ja) 樹脂発泡成形品及びその製造方法
JP6764744B2 (ja) 発泡構造体、樹脂製パネル
JP6764746B2 (ja) 発泡構造体、樹脂製パネル
JP7492108B2 (ja) 構造体の製造方法及び金型
JP5202173B2 (ja) 樹脂発泡成形体の製造装置及び製造方法
JP6764748B2 (ja) 樹脂積層体の製造方法
JP2020131628A (ja) 樹脂製サンドイッチパネル用金型及び樹脂製サンドイッチパネルの製造方法
JP2021187039A (ja) 発泡樹脂シートの成形方法
JP2020001322A (ja) 成形体及びその製造方法
JP2001150461A (ja) 自動車内装品の製造方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 13868050

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 14651169

Country of ref document: US

NENP Non-entry into the national phase

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 2013868050

Country of ref document: EP