WO2017119478A1 - Method for manufacturing laminated structure and laminated structure - Google Patents

Abstract

A method for manufacturing a laminated structure in which a reinforcing material is interposed between a first resin sheet and a second resin sheet comprises: a step for bonding a temporary holding material to a front-side surface or a back-side surface of the reinforcing material; a step for squeezing out a first molten resin sheet and a second molten resin sheet between a first split mold and a second split mold that face each other; a step for pressing the first molten resin sheet against a forming surface of the first split mold and pressing the second molten resin sheet against a forming surface of the second split mold; a step for pressing the surface of the reinforcing material, to which the temporary holding material is bonded, against the first molten resin sheet to thereby cause the first molten resin sheet to hold the reinforcing material; and a step for clamping the first split mold and the second split mold.

Description

Manufacturing method of laminated structure, laminated structure

The present invention relates to a method for manufacturing a laminated structure and a laminated structure.

Conventionally, resin laminated structures have been used for various purposes such as automobiles, building materials, sports and leisure. The laminated structure is obtained by laminating two resin sheets. In order to ensure the strength and rigidity of the laminated structure, one resin sheet may protrude from the other resin sheet to form a rib.

In order to further improve the rigidity and strength of the laminated structure, it is known to interpose a reinforcing material between two resin sheets. For example, in a resin panel as a laminated structure described in Japanese Patent Application Laid-Open No. 2013-176905, a reinforcing material unit is disposed between a front wall and a back wall which are two resin sheets.
Also, as shown in JP-A No. 2002-166464, a fiber mat as a core material is filled between two thermoplastic resin sheets for the purpose of reducing the weight and improving the strength (particularly impact resistance). A laminated structure (resin panel) is known.

In JP 2013-176905 A, when a resin panel is molded, as shown in FIG. 7 of JP 2013-176905 A, a resin sheet adsorbed in a cavity of a mold is held in a manipulator. It is described that the stiffening material unit is pressed by moving it horizontally.
However, the reinforcing material unit disclosed in Japanese Patent Application Laid-Open No. 2013-176905 is made of a metal such as aluminum or a hard plastic. Even when the reinforcing material unit of such a material is pressed against the molten resin, the reinforcing material unit is not provided between the reinforcing material unit and the molten resin. In some cases, the reinforcing material unit fell off before the mold was clamped.
It is conceivable that a hole for inserting a reinforcing material is provided at the time of molding the resin, and the reinforcing material is inserted from the hole after the molding of the resin. In this case, the hole is closed with a decorative material sheet or the like after the reinforcing material is inserted. This is not desirable from an aesthetic point of view.
Therefore, in one aspect of the present disclosure, when manufacturing a laminated structure in which a reinforcing material is interposed between two resin sheets, the reinforcing material can be stably interposed between the resin sheets. The purpose is to do.

By the way, after molding of the two resin sheets, a reinforcing material may be inserted between the two resin sheets. In that case, it is preferable to place the rib and the reinforcing material as close as possible in view of avoiding a decrease in local strength and rigidity. However, in the conventional laminated structure, due to the steep surface shape change of the protrusion of the mold surface corresponding to the rib at the time of molding, surplus molten resin occurs around the protrusion, An unintended thin protrusion may be formed around the rib. Due to the presence of these protrusions, the reinforcing material could not be properly inserted later.
Therefore, in another aspect of the present disclosure, in a laminated structure including a structure in which two resin sheets are laminated, an object is to allow a reinforcing material to be inserted properly without reducing strength and rigidity. And

Further, when manufacturing the resin panel described in Japanese Patent Laid-Open No. 2002-166464, the front side thermoplastic resin sheet and the fiber mat serving as the core material are such that the thermoplastic resin sheet has a predetermined thickness. It is melted and fused so as to impregnate the fiber mat (see paragraphs [0027] to [0031] and FIGS. 10 to 14 of JP-A No. 2002-166464). That is, in the resin panel described in Japanese Patent Application Laid-Open No. 2002-166464, since the two resin sheets are not directly fused or welded, it may not be possible to secure the necessary rigidity as the entire resin panel.
Therefore, in still another aspect of the present disclosure, in a laminated structure having a structure in which two resin sheets are laminated, sufficient rigidity of the laminated structure is ensured while improving the impact resistance of the laminated structure. The purpose is to be able to.

One aspect of the present disclosure is a method for manufacturing a laminated structure in which a reinforcing material is interposed between a first resin sheet and a second resin sheet. This manufacturing method is
A step of attaching a temporary holding material to the front surface or the back surface of the reinforcing material;
A step of extruding a first molten resin sheet and a second molten resin sheet between a first divided mold and a second divided mold opposed to each other;
Pressing the first molten resin sheet against the formation surface of the first split mold, and pressing the second molten resin sheet against the formation surface of the second split mold;
Pressing the surface of the reinforcing material to which the temporary holding material is attached to the first molten resin sheet, thereby holding the reinforcing material on the first molten resin sheet;
A step of clamping the first split mold and the second split mold;
including.
“Temporary holding” of “temporary holding material” means that the reinforcing material is held on the first molten resin sheet at least until the first divided mold and the second divided mold are clamped. Means you can.

Another aspect of the present disclosure includes a first resin sheet formed on the front side, a second resin sheet formed on the back side and facing the first resin sheet across a hollow portion, and the hollow And a long reinforcing member extending in the first direction within the section. In this laminated structure, the second resin sheet protrudes from the front sheet surface of the second resin sheet toward the first resin sheet, and when the laminated structure is viewed in plan view, A first projecting portion extending in a strip shape in the first direction along the side wall surface of the reinforcing material, and projecting from the front sheet surface of the second resin sheet to the back sheet surface of the first resin sheet, and the lamination The structure has a second protrusion that extends in a band shape when viewed in plan and is connected to the first protrusion at an end of the reinforcing member.

Still another aspect of the present disclosure is that the first resin sheet provided on the front side and having a flat portion and the first resin sheet are provided on the back side with a hollow portion therebetween. And a reinforcing material sheet interposed between the first resin sheet and the second resin sheet and having an opening, wherein the second resin sheet is formed of the first resin sheet. A plurality of projecting portions projecting toward the flat portion are formed, and the top surfaces of the plurality of projecting portions are welded to the back surface of the first resin sheet through the opening of the reinforcing material sheet. .

According to one aspect of the present disclosure, when manufacturing a laminated structure in which a reinforcing material is interposed between two resin sheets, the reinforcing material can be stably interposed between the resin sheets.
According to another aspect of the present disclosure, in a laminated structure including a structure in which two resin sheets are laminated, strength and rigidity can be reduced and a reinforcing material can be appropriately inserted. .
According to still another aspect of the present disclosure, in a laminated structure having a structure in which two resin sheets are laminated, sufficient rigidity of the laminated structure is ensured while improving the impact resistance of the laminated structure. can do.

The perspective view of the laminated structure of 1st Embodiment. The top view of the laminated structure of 1st Embodiment. FIG. 3 is a cross-sectional view taken along a line AA in FIG. 2. FIG. 3 is a sectional view taken along line BB in FIG. 2. FIG. 3 is a cross-sectional view taken along a line CC in FIG. 2. The perspective view of the reinforcing material arrange | positioned inside the laminated structure of 1st Embodiment. The figure which shows the manufacturing method of the laminated structure of 1st Embodiment. The figure which shows the manufacturing method of the laminated structure of 1st Embodiment. The figure which shows the manufacturing method of the laminated structure of 1st Embodiment. The figure which shows the manufacturing method of the laminated structure of 1st Embodiment. The figure which shows the manufacturing method of the laminated structure of 1st Embodiment. The figure which shows the manufacturing method of the laminated structure of 1st Embodiment. Sectional drawing which expands and shows the vicinity of the reinforcing material of the laminated structure of 1st Embodiment. Sectional drawing of the laminated structure which concerns on the modification of 1st Embodiment. The top view of the laminated structure of 2nd Embodiment. The front view of the laminated structure of 2nd Embodiment. FIG. 14 is a cross-sectional view taken along line AA in FIG. 13. FIG. 14 is a cross-sectional view taken along line BB in FIG. 13. FIG. 14 is a cross-sectional view taken along the line CC of FIG. FIG. 14 is a sectional view taken along line DD of FIG. 13. FIG. 14 is a cross-sectional view taken along line EE in FIG. 13. The figure for demonstrating the molding method of the resin laminated body of 2nd Embodiment. The figure for demonstrating the molding method of the resin laminated body of 2nd Embodiment. The figure for demonstrating the molding method of the resin laminated body of 2nd Embodiment. The figure for demonstrating the molding method of the resin laminated body of 2nd Embodiment. The fragmentary top view which shows the surplus protrusion formed in the rib of the laminated structure of 2nd Embodiment. The partial top view which shows the surplus protrusion formed in the rib of the laminated structure which concerns on a reference example. The figure seen from the arrow G of FIG. 22A. The partial top view which shows the surplus protrusion formed in the rib of the laminated structure which concerns on a reference example. The figure seen from the arrow H of FIG. 23A. The partial top view which shows the surplus protrusion formed in the rib of the laminated structure which concerns on a reference example. The fragmentary top view which shows the surplus protrusion formed in the rib of the laminated structure which concerns on the modification of 2nd Embodiment. Sectional drawing equivalent to FIG. 14 of the other modification of the laminated structure of 2nd Embodiment. The perspective view when the laminated structure of 3rd Embodiment is seen from the direction which the front side can visually recognize. The perspective view when the laminated structure of 3rd Embodiment is seen from the direction which the back side can visually recognize. The top view which expands and shows a part of reinforcement material contained in the laminated structure of 3rd Embodiment. The expanded sectional view which expands and shows a cross section when it cut | disconnects by the surface parallel to the side surface of the laminated structure of 3rd Embodiment. The figure for demonstrating the manufacturing method of the laminated structure of 3rd Embodiment. The figure for demonstrating the manufacturing method of the laminated structure of 3rd Embodiment. The figure for demonstrating the manufacturing method of the laminated structure of 3rd Embodiment. The figure for demonstrating the manufacturing method of the laminated structure of 3rd Embodiment. The figure for demonstrating the manufacturing method of the laminated structure of 3rd Embodiment. The figure for demonstrating the manufacturing method of the laminated structure of 3rd Embodiment. Sectional drawing of the laminated structure of 4th Embodiment.

Hereinafter, a laminated structure which is an embodiment of the laminated structure of the present invention and a manufacturing method thereof will be described.

(1) First Embodiment (1-1) Configuration of Laminated Structure The configuration of the laminated structure 1 of the present embodiment will be described with reference to FIGS.
FIG. 1 is a perspective view of the laminated structure 1 of the present embodiment. FIG. 2 is a plan view of the laminated structure 1 of the present embodiment. 3A to 3C are cross-sectional views taken along lines AA, BB, and CC of FIG. 2, respectively. FIG. 4 is a perspective view of the reinforcing member 3 disposed inside the laminated structure 1 of the present embodiment.
The appearance shape, the internal shape, and the shape, arrangement, and the like of the laminated structure 1 shown in FIGS. 1 to 4 are exemplary for explaining the method for manufacturing the laminated structure according to the present invention. Not too much.

As shown in FIGS. 1 and 2, the multilayer structure 1 has a front surface FS and a back surface BF, and has a substantially rectangular parallelepiped shape. As shown in an enlarged cutaway view in FIG. 1, the laminated structure 1 includes a resin laminate 2 in which a first resin sheet 21 and a second resin sheet 22 are laminated, and a front surface of the first resin sheet 21. And a decorative material sheet 23 provided on the surface side. The front surface of the decorative material sheet 23 constitutes the front surface FS of the laminated structure 1. A hollow portion H is formed between the first resin sheet 21 and the second resin sheet 22. At the boundary between the first resin sheet 21 and the second resin sheet 22, a parting line PL at the time of molding the resin is formed.
It is not essential to provide the decorative material sheet 23.

The first resin sheet 21 and the second resin sheet 22 are thermoplastic resins. The resin material is not limited and may be a foamed resin or a non-foamed resin, but is preferably formed from a non-foamed resin in order to ensure the rigidity of the laminated structure 1. It is preferable to use a resin material having a high melt tension from the viewpoint of preventing variations in thickness due to drawdown, neck-in, etc. during molding, while improving transferability to the mold and followability. Therefore, it is preferable to use a resin material with high fluidity. Examples of the resin material of the first resin sheet 21 and the second resin sheet 22 include 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. Can be mentioned.

The first resin sheet 21 and the second resin sheet 22 may be molded using a resin material mixed with a glass filler for the purpose of increasing rigidity and strength.
Examples of the 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. Examples of 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.
Not only glass fillers, but also talc, calcium carbonate, wollastonite, inorganic fillers such as magnesium-based materials, carbon fibers, and the like for increasing rigidity may be mixed.

The decorative material sheet 23 is configured for the purpose of improving the appearance or decoration of the laminated structure 1 or protecting an object in contact with the laminated structure 1. As the material of the decorative material sheet 23, a fiber skin material sheet-like skin material, a film-like skin material, or the like is applied. As the material of such a fiber skin material, 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.

As shown in FIGS. 2 and 3, the laminated structure 1 is formed with rib groups R110 to R160 and R210 to R260. As shown in FIGS. 3A and 3B, each rib has a front surface of the second resin sheet 22 protruding toward the first resin sheet 21, and a surface on the back surface side of the first resin sheet 21. It is formed so as to be welded to (the surface opposite to the surface on which the decorative material sheet 23 is disposed).

As shown in FIGS. 2 and 3C, the elongated reinforcing material 3 is disposed in the hollow portion H between the rib groups R110 to R160 and the rib groups R210 to R260. The material of the reinforcing material 3 is not particularly limited, but is preferably made of a metal such as aluminum or a hard plastic in order to ensure the strength and rigidity of the laminated structure 1. The reinforcing material 3 is formed by, for example, extrusion molding.
As shown in FIG. 4, the reinforcing member 3 includes a first plate-like portion 31 and a second plate-like portion 32 that are parallel to each other, and a connecting plate-like shape that connects the first plate-like portion 31 and the second plate-like portion 32. The section 33 has an H-shaped cross section. A surface of the first plate portion 31 that faces the first resin sheet 21 is the first surface 311, and a surface of the second plate portion 32 that faces the second resin sheet 22 is the second surface 321.

In the present embodiment, the reinforcing material 3 is temporarily held on the molten resin sheet by pressing the first surface 311 of the reinforcing material 3 against the molten resin sheet at the time of molding the resin described later. In order to ensure the holding force at that time, the nonwoven fabric 5 is affixed on the 1st surface 311 of the reinforcing material 3, as shown in FIG. Examples of the nonwoven fabric 5 include polyethylene, polypropylene, polystyrene, polyester, polyurethane, a mixture of these, and hair (felt, etc.). The nonwoven fabric 5 is an example of a temporary holding material in the present invention.

(1-2) Manufacturing Method of Laminated Structure Next, a manufacturing method of the laminated structure 1 of the present embodiment will be described with reference to FIGS. 5 to 10 are views for sequentially explaining the method for manufacturing the laminated structure of the present embodiment. Each of FIGS. 6 to 10 shows a view when the mold clamping device 140 and the molten resin sheet are cut at a position corresponding to the CC cross section of FIG. In each of FIGS. 6 to 10, the decorative material sheet 23 is not shown.

(1-2-1) Configuration of Molding Device As shown in FIG. 5, the molding apparatus 100 for a resin molded product includes an extrusion device 120 and a mold clamping device 140 disposed below the extrusion device 120.

As shown in FIG. 5, the extrusion device 120 is composed of two systems of molten resin extrusion mechanisms. That is, the extrusion device 120 includes cylinders 18A and 18B each provided with hoppers 16A and 16B, hydraulic motors 23A and 23B connected to the cylinders 18A and 18B, and accumulators 24A in which the cylinders 18A and 18B communicate with each other. , 24B and plungers 26A, 26B. The plungers 26A and 26B are inserted into the accumulators 24A and 24B, respectively, and by driving the plungers 26A and 26B, the plungers 26A and 26B are advanced and retracted in the accumulators 24A and 24B, thereby the contents of the accumulators 24A and 24B. The product is variable. The extrusion device 120 is provided with a hydraulic cylinder (not shown) for driving the plungers 26A and 26B.

In the extrusion device 120, the thermoplastic resin introduced from the hoppers 16A and 16B is melted and kneaded by rotation of the screws by the hydraulic motors 23A and 23B in the cylinders 18A and 18B, and is in a molten state (hereinafter referred to as “molten resin”). Is also transferred to accumulators 24A and 24B and stored in a certain amount. The molten resin stored in the accumulators 24A and 24B is supplied to the T die 28 through the valve 27 by driving the plungers 26A and 26B. That is, the plungers 26A and 26B are driven to reduce the internal volumes of the accumulators 24A and 24B, and the molten resin stored in the accumulators 24A and 24B is pressurized and fed into the T dies 28A and 28B. The extrusion pressure is generated.

T dies 28A and 28B push the supplied molten resin downward as continuous sheet-like molten resin sheets P and P from the extrusion slit. The extruded molten resin sheets P and P are sent downward while being sandwiched between a pair of rollers 40AA and 40AB and a pair of rollers 40BA and 40BB that are arranged at intervals, and are sent to the split molds 42A and 42B. Drooped in between. The extrusion direction of the molten resin sheets P and P corresponds to the longitudinal direction of FIG.

The mold clamping device 140 includes divided molds 42A and 42B. The split molds 42A and 42B are provided with sliding portions 43A and 43B, respectively. The sliding portions 43A and 43B face each other. The sliding portion 43A is slidable in a direction orthogonal to the molten resin sheet P (that is, in the horizontal direction), thereby being movable relative to the forming surface 116A (see FIG. 6) of the split mold 42A. It is configured. Similarly, the sliding portion 43B is slidable in a direction orthogonal to the molten resin sheet P (that is, in the horizontal direction), thereby being relative to the formation surface 116B (see FIG. 6) of the split mold 42B. It is configured to be movable.

(1-2-2) Method for Manufacturing Laminated Structure Hereinafter, a method for manufacturing the laminated structure 1 using the molding apparatus 100 described above will be described.
First, as shown in FIG. 4, the reinforcing material 3 in which the nonwoven fabric 5 is bonded to the first surface 311 is prepared. The adhesive used when the nonwoven fabric 5 is stuck to the reinforcing material 3 may be any adhesive as long as the reinforcing material 3 has its own weight and does not fall off the nonwoven fabric 5.
Next, the decorative material sheet 23 is temporarily fixed by a temporary fixing pin (not shown) provided on the divided mold 42A so as to cover the formation surface of the divided mold 42A. That is, the decorative material sheet 23 is disposed between the split mold 42A and the molten resin sheet P.
Next, as shown in FIG. 5, the molten resin sheets P and P extruded from the T dies 28A and 28B (an example of the first molten resin sheet and the second molten resin sheet, respectively) are divided into molds 42A, 42B (which is an example of the first split mold and the second split mold, respectively).
Then, as shown in FIG. 6, the sliding parts 43A and 43B are moved (slid) in directions close to each other, thereby bringing the tips of the sliding parts 43A and 43B into contact with the molten resin sheets P and P. Thereby, a sealed space SP1 is formed between the forming surface 116A of the split mold 42A and the molten resin sheet P, and a sealed space SP2 is formed between the forming surface 116B of the split mold 42B and the molten resin sheet P.

Although not shown, each of the split molds 42A and 42B includes a vacuum chamber, and a communication path for vacuum suction is provided between the vacuum chamber and the formation surfaces 116A and 116B. And the air in sealed space SP1, SP2 is attracted | sucked from a communicating path by a vacuum chamber. By this suction, as shown in FIG. 7, the pair of molten resin sheets P and P are pressed against the formation surfaces 116A and 116B, respectively, and formed (shaped) into shapes along the formation surfaces 116A and 116B.
At this time, the molten resin sheet P on the left side is shaped and the decorative material sheet 23 is pressed against the forming surface 116B of the split mold 42B together with the molten resin sheet P. Thereby, the decorative material sheet 23 is welded to the molten resin sheet P.

Next, the reinforcing material 3 to which the nonwoven fabric 5 is pasted is placed between the split molds 42A and 42B while being held by the manipulator 90. And the surface (1st surface 311 of FIG. 4) which affixed the nonwoven fabric 5 of the reinforcing material 3 is pressed on the molten resin sheet P adsorbed by the formation surface 116B of the split mold 42B. Then, the molten resin enters the fine irregularities on the material surface of the nonwoven fabric 5 to increase the adhesive force of the reinforcing material 3 to the molten resin sheet P (anchor effect), and the reinforcing material 3 is interposed by the molten resin sheet P through the nonwoven fabric 5. It will be held. In this state, even if the holding of the reinforcing material 3 by the manipulator 90 is released, the reinforcing material 3 is detached from the molten resin sheet P and dropped at least within a short period until the molds 42A and 42B are clamped. Never do.

Next, as shown in FIG. 9, the molds 42 </ b> A and 42 </ b> B are clamped to sandwich the molten resin sheets P and P. A pinch-off portion 118 is provided on the outer periphery of the divided molds 42A and 42B so as to surround the formation surfaces 116A and 116B of the divided molds 42A and 42B, and a pair of molten resin sheets P, The periphery of P is welded, and a parting line is formed.
Next, as shown in FIG. 10, the split molds 42 </ b> A and 42 </ b> B are opened to take out a resin molded product having a hollow portion. The burr formed around the parting line is removed by cutting with a cutter or the like. Thus, the laminated structure 1 is completed.

As described above, according to the method for manufacturing the laminated structure 1 of the present embodiment, the nonwoven fabric 5 is pasted on the surface of the reinforcing material 3 that contacts the molten resin sheet, and the reinforcing material 3 is bonded to the molten resin via the nonwoven fabric 5. The sheet was pressed. Therefore, it is possible to prevent the reinforcing material 3 from being detached from the molten resin sheet until at least the subsequent mold clamping (that is, sandwiching the reinforcing material 3 between the two molten resin sheets). Therefore, the laminated structure 1 having the reinforcing material 3 in the hollow portion H between the two resin sheets can be stably manufactured.

In the above-described embodiment, the case where the decorative material sheet 23 is stacked on the front surface of the first resin sheet 21 has been described, but the provision of the decorative material sheet 23 is not essential. That is, the decorative material sheet 23 may not be disposed between the split molds 42A and 42B, and the decorative material sheet 23 may not be pressed against the formation surface 116A of the split mold 42A together with the molten resin sheet P. However, by providing the decorative material sheet 23, it is assumed that a pressing mark is generated on the front surface of the first resin sheet 21 due to the reinforcing material 3 being pressed by the first resin sheet 21. However, it is difficult to see the pressing marks by the decorative material sheet 23. Therefore, it is preferable to provide the decorative material sheet 23 from the aesthetic point of view of the laminated structure 1.

In the above-described embodiment, when the surface of the reinforcing material 3 to which the nonwoven fabric 5 is attached is pressed against the molten resin sheet P adsorbed on the forming surface 116B of the split mold 42B, the first corresponding to the molten resin sheet P. It can also be carried out so strongly that the raised portion is formed on the resin sheet 21. Thereby, as shown in FIG. 11, a raised portion 211 p can be formed on the periphery of the first surface 311 of the first plate-like portion 31 of the reinforcing member 3. FIG. 11 is a partially enlarged view of the vicinity of the reinforcing member 3 in the BB cross section of FIG. That is, when the reinforcing material 3 is pressed against the molten resin sheet P, the reinforcing material 3 is pressed so strongly that the raised portion 211p of the molten resin sheet P is formed on the periphery of the first surface 311 of the first plate-like portion 31 of the reinforcing material 3. You can also By forming the raised portion 211p at the periphery of the reinforcing material 3, the movement of the reinforcing material 3 in the direction along the surface of the first resin sheet 21 is restricted. That is, the raised portion 211p functions as positioning of the reinforcing material 3 after molding.
In addition, since the raised portions 211p are formed at both ends in the longitudinal direction of the reinforcing material 3, the reinforcing material 3 is prevented from shifting in the longitudinal direction. When the protruding portion 211p is not formed, the first resin sheet 21 and / or the second resin sheet 22 corresponding to the side wall portion of the resin laminate 2 are damaged by the movement of the reinforcing member 3 in the longitudinal direction, or Although there is a risk of breakage, such a situation is prevented by the raised portion 211p.

In the modification of the present embodiment, the formation surface 116A of the split mold 42A protrudes toward the formation surface of the split mold 42B in a region facing the surface of the reinforcing material 3 to which the nonwoven fabric 5 is attached. A part may be formed. By providing such a protruding portion, the BB cross section (cross section corresponding to FIG. 3B) of the molded laminated structure becomes as shown in FIG. That is, the protrusion 221j is formed on the second resin sheet 22 corresponding to the protruding portion of the forming surface 116A of the split mold 42A. In this case, since the protrusion 221j comes into contact with the back surface of the reinforcing material 3A in FIG. 12, the plate-like portion of the reinforcing material 3A is formed on the back surface of the laminated structure (that is, the back surface of the second resin sheet 22). The appearance of the entire trace is prevented.

As mentioned above, although embodiment of this invention was described in detail, the manufacturing method of the laminated structure of this invention is not limited to the said embodiment, In the range which does not deviate from the main point of this invention, various improvement and change are carried out. Of course, it is good.
For example, the shape of the reinforcing member 3 of the above-described embodiment is an H-shaped cross section as shown in FIG. 4, but is not limited to such a form, and can be configured in an arbitrary shape. For example, the reinforcing material may have a polygonal, circular, C-shaped, or U-shaped cross section. The reinforcing material may be solid or hollow.

In embodiment mentioned above, although the nonwoven fabric was mentioned as an example of the temporary holding material of this invention, it is not the limitation. The temporary holding material may be made of any material as long as it is a member that exhibits an anchor effect on the molten resin and generates an adhesive force to the molten resin. From the viewpoint of handleability, the temporary holding material is preferably a sheet-like member. Specifically, as the temporary holding material, woven fabric, knitted fabric, fabric with brushed them, paper, sheet-like cork, wood, or the like can be applied. Among these, it is preferable to use, as a temporary holding material, a cloth (nonwoven fabric, woven fabric, knitted fabric, fabric having raised them, etc.) that can exhibit a high anchoring effect on the molten resin. When the temporary holding material is a sheet-like member, its thickness and hardness are not limited.
As the temporary holding material, a relatively thin foam sheet made of resin may be used. Examples of the resin material include, for example, polyolefins such as polypropylene and polyethylene, acrylic derivatives such as polyamide, polystyrene, and polyvinyl chloride, and materials obtained by foaming polyurethane or a mixture of two or more kinds.

In the above-described embodiment, the resin molding method may be performed by blow molding instead of vacuum molding. When blow molding is performed, the split mold is provided with a hole for blow molding and is shaped by pressing the foam parison against the cavity surface of the split mold in a state where the split mold is clamped. Specifically, a compressed gas such as air is blown into the inside of the foam parison from a blow molding hole provided in the split mold, and blow molding is performed with a predetermined blow pressure.
Moreover, you may shape | mold by the method of combining blow molding and vacuum forming.

In the embodiment described above, the case where the nonwoven fabric 5 is pasted on the first surface 311 on the front side of the reinforcing member 3 as shown in FIG. 4 and the first surface 311 is pressed against the molten resin sheet P in FIG. However, this is not the case. The nonwoven fabric 5 may be pasted on the second surface 321 on the back side of the reinforcing material 3 and the second surface 321 in FIG. 8 may be pressed against the molten resin sheet P on the right side (that is, pressed by the split mold 42A).

(2) Second embodiment

Hereinafter, the laminated structure according to the second embodiment of the present invention will be described.

(2-1) Configuration of Laminated Structure of Second Embodiment Hereinafter, the configuration of the laminated structure 1A of the second embodiment will be described with reference to FIGS.
FIG. 13A is a plan view of the laminated structure 1A according to the embodiment, and FIG. 13B is a front view of the laminated structure 1A. 14 is a cross-sectional view taken along the line AA of FIG. 13A. FIG. 15 is a cross-sectional view taken along the line BB of FIG. 13A. 16A is a cross-sectional view taken along line CC in FIG. 13A, FIG. 16B is a cross-sectional view taken along line DD in FIG. 13A, and FIG. 16C is a cross-sectional view taken along line EE in FIG.

As shown in FIG. 13, the laminated structure 1 </ b> A of the embodiment has a substantially rectangular parallelepiped shape. The laminated structure 1A includes a resin laminate 2A having a structure in which a first resin sheet 21A and a second resin sheet 22A are laminated with a parting line PL interposed therebetween, and a reinforcing material 3A. The first resin sheet 21A is formed on the front side of the laminated structure 1A, and the second resin sheet 22A is formed on the back side of the laminated structure 1A. As shown in FIGS. 14 to 16, the second resin sheet 22A is opposed to the first resin sheet 21A with the hollow portion H therebetween.
As shown in FIG. 13A, the reinforcing member 3A is a long member, and extends in the hollow portion H in the extending direction 3Y (an example of the first direction). As shown in FIG. 13B, an insertion port 2a for inserting the reinforcing material 3A from the outside is provided on any side wall of the resin laminate 2A. In FIG. 13B, the parting line PL is formed at the time of molding of a resin laminate 2A described later.

The resin material of the first resin sheet 21A and the second resin sheet 22A is not limited, and is, for example, a thermoplastic resin such as polyolefin. Examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, and high-density polyethylene. , Polypropylene, ethylene-propylene copolymer, and mixtures thereof.
The first resin sheet 21A and the second resin sheet 22A may be molded using a resin material mixed with a glass filler for the purpose of increasing strength and rigidity.

The material of the reinforcing material 3A is not particularly limited, but is preferably made of a metal such as aluminum or a hard plastic in order to ensure the strength of the laminated structure 1A. The reinforcing material 3A is formed by, for example, extrusion molding.

As shown in FIG. 14, the first resin sheet 21 </ b> A has a front side sheet surface 211 and a back side sheet surface 212. The front sheet surface 211 of the first resin sheet 21A constitutes the front surface of the laminated structure 1A and is a flat surface. The second resin sheet 22 </ b> A has a front side sheet surface 221 and a back side sheet surface 222. The front sheet surface 221 of the second resin sheet 22A partially protrudes toward the first resin sheet 21A, and a plurality of ribs are formed.
As shown in FIG. 13, the plurality of ribs formed by the second resin sheet 22A include ribs r11, r12, r21, r22 (one example of first protrusions) and ribs R11 to R13, R21, respectively. To R23, R31 to R33, and R41 to R43 (each example of the second protrusion).

As shown in FIG. 13, the ribs r11, r12, r21, and r22 are band-shaped in the extending direction 3Y of the reinforcing material 3A along the side wall surface 3w of the reinforcing material 3A when the laminated structure 1A is viewed in plan view. It extends. That is, the ribs r11, r12, r21, r22 are arranged side by side on the side wall surface 3w of the reinforcing material 3A.
It is preferable that the top surfaces of the ribs r11, r12, r21, r22 do not reach (be connected to) the back side sheet surface 212 of the first resin sheet 21A. For example, as shown in FIG. 16A, the top surface r11t of the rib r11 and the top surface r21t of the rib r21 do not reach (be connected to) the back side sheet surface 212 of the first resin sheet 21A. By doing in this way, it is avoided that molten resin is drawn near to the 1st resin sheet 21A side at the time of shaping | molding, Therefore The thin part of the top part and / or side wall of rib r11, r12, r21, r22 is suppressed. be able to.

On the other hand, the top surfaces of the ribs R11 to R13, R21 to R23, R31 to R33, R41 to R43 protrude to the back side sheet surface 212 of the first resin sheet 21A. For example, as shown in FIG. 16B, the top surface R12t of the rib R12, the top surface R22t of the rib R22, the top surface R32t of the rib R32, and the top surface R42t of the rib R42 are the back sheet surface of the first resin sheet 21A. It protrudes to 212. Since the ribs R11 to R13, R21 to R23, R31 to R33, and R41 to R43 are arranged at positions away from the reinforcing material 3A in plan view, the required strength and rigidity can be secured only by the resin laminate 2A. These ribs are connected to the first resin sheet 21A by welding to the back side sheet surface 212 of the first resin sheet 21A. It is not essential that all of the ribs R11 to R13, R21 to R23, R31 to R33, and R41 to R43 protrude to the first resin sheet 21A, and there is a rib that does not protrude to the first resin sheet 21A. It doesn't matter.

As shown in FIG. 13, the ribs R11 to R13, R21 to R23, R31 to R33, and R41 to R43 extend in a band shape when the laminated structure 1A is viewed in a plan view. The extending direction of the ribs R11 to R13, R21 to R23, R31 to R33, R41 to R43 is orthogonal to the extending direction of the ribs r11, r12, r21, r22 (that is, the extending direction 3Y). This is due to the following reason. That is, if the ribs R11 to R13, R21 to R23, R31 to R33, R41 to R43 are arranged in parallel with the extending direction 3Y, the structure is relatively weak against bending around the axis in the extending direction 3Y. turn into. On the other hand, in this embodiment, the ribs R11 to R13, R21 to R23, R31 to R33, R41 to R43 are strong against bending around the extending direction 3Y, and the ribs r11, r12, r21, and r22 are flat with the extending direction 3Y. The structure is strong against bending around an axis in a direction orthogonal to the eye.

The ribs R12 and R22 are connected to the rib r11 at the end on the reinforcing material 3A side. The ribs R13 and R23 are connected to the rib r12 at the end on the reinforcing material 3A side. The ribs R32 and R42 are connected to the rib r21 at the end on the reinforcing material 3A side. The ribs R33 and R43 are connected to the rib r22 at the end on the reinforcing material 3A side.
For example, in FIG. 14, focusing on the relationship between the rib R12 and the rib r11, the end surface R12s of the rib R12 on the reinforcing material 3A side is connected to the top surface r11t of the rib r11 on the way from the top surface R12t to the back side. R12 is connected to the side wall surface r11s of the rib r11. Focusing on the relationship between the rib R13 and the rib r12 in FIG. 14, the end surface R13s of the rib R13 on the reinforcing material 3A side is connected to the top surface r12t of the rib r12 on the way from the top surface R13t to the rib R13. The rib r12 is connected to the side wall surface r12s.

In the following description, the ribs r11, r12, r21, r22 formed in parallel with the reinforcing material 3A in FIG. 13 are also referred to individually or collectively as “parallel rib r”. The ribs R12, R13, R22, R23, R32, R33, R42, and R43 connected to the juxtaposed rib r are also referred to individually or collectively as “connecting ribs R”.

In the present embodiment, the connection rib R is connected to the side wall surface of the juxtaposed rib r at the end for the following reason.
The first reason is to increase the strength and rigidity of the laminated structure 1A at a portion close to the side wall surface 3w of the reinforcing material 3A. In FIG. 13, the strength and rigidity of the region where the reinforcing material 3A is arranged are high, but if there are no juxtaposed ribs r, the region adjacent to the region where the reinforcing material 3A is arranged is relatively strong and strong. Stiffness will decrease. Therefore, the side-by-side ribs r are formed side by side with the reinforcing material 3A. Further, by connecting the side wall surface of the juxtaposed rib r and the connecting rib R, the local strength and rigidity of the laminated structure 1A are prevented from being lowered. That is, if the end portions of the ribs R12, R13, R22, R23, R32, R33, R42, and R43 are provided slightly apart from the side-by-side rib r, the laminated structure is locally formed at the separated portions. The strength and rigidity of 1A will decrease. By connecting the connecting rib R to the side wall surface of the juxtaposed rib r at the end portion, this local reduction in strength and rigidity can be prevented.

The second reason is that the reinforcing material 3A can be reliably inserted into the resin laminate 2A from the insertion port 2a. In FIG. 13, the reinforcing material 3A is arranged even when the end portions of the ribs R12, R13, R22, R23 are extended to the vicinity of the side wall surface 3w of the reinforcing material 3A without providing the parallel ribs r. It is possible to suppress a decrease in strength and rigidity of a region adjacent to the region. However, in that case, when the ribs R12, R13, R22, and R23 are formed, extra protrusions (described later) that are unintended protrusions are formed at the longitudinal ends of the ribs. When the surplus protrusion enters the region where the reinforcing material 3A is disposed, it becomes difficult to insert the reinforcing material 3A after the molding of the resin laminate 2A.
This second reason will be described again later.

Referring to FIG. 13 again, the rib R11 and the rib R12 are separated from each other, and the rib r11 and the rib r21 are separated from each other. If the ribs R11 and R12 are integrated ribs and the ribs r11 and r21 are integrated ribs, the length of the ribs in the longitudinal direction becomes too long. This is because the rib may be broken halfway when an excessive load is applied. From the same viewpoint, the rib R21 and the rib R22 are separated, the rib R31 and the rib R32 are separated, the rib R41 and the rib R42 are separated, and the rib r12 and the rib r22 are separated.

The juxtaposed rib r is formed with a protrusion for supporting the side wall surface 3w of the reinforcing material 3A. For example, as shown in FIG. 15, a projection r11j is formed on the side wall surface r11s of the rib r11 which is a side-by-side rib r, and the projection r11j abuts on the side wall surface 3w of the reinforcement material 3A to attach the reinforcement material 3A. Support from the side. On the side wall surface of the rib r12 on the opposite side of the rib r11 across the reinforcing material 3A, projections that support the side wall surface 3w of the reinforcing material 3A are similarly formed. Accordingly, the reinforcing material 3A is supported from both side wall surfaces by the ribs r11 and r12. Although not shown, the ribs r21 and r22 have the same configuration.
In the example of the present embodiment, the protrusion that partially contacts the side wall surface 3w of the reinforcing member 3A with respect to each parallel rib r is shown, but the present invention is not limited to this example. You may provide the protrusion extended in the whole area of the longitudinal direction of each juxtaposed rib r.

As shown in FIGS. 15 and 16C, ribs 225 for supporting the reinforcing material 3A from the back side are formed on the second resin sheet 22A in the region where the reinforcing material 3A is disposed. One end 3f of the reinforcing member 3A is preferably recessed, so that when the reinforcing member 3A is inserted into the resin laminate 2A from the insertion port 2a in the extending direction 3Y, the end 3f of the reinforcing member 3A is ribbed 225. Therefore, the insertion workability is improved.
Although FIG. 16C illustrates the case where the number of ribs 225 is three, the number is not limited to this.

(2-2) Manufacturing Method of Laminated Structure of Second Embodiment Next, a manufacturing method of the laminated structure 1A of the present embodiment will be described. As described above, the laminated structure 1A is manufactured by inserting the reinforcing material 3A into the resin laminate 2A. Hereinafter, a method for molding the resin laminate 2A will be described with reference to FIGS.
FIGS. 17 to 20 are diagrams for explaining the molding method of the resin laminate 2A of the present embodiment, respectively, which are orthogonal to the surface of the molten resin sheet described later and extend in the vertical direction (extrusion direction of the molten resin sheet). A cross-section taken along a plane (a plane corresponding to DD in FIG. 13A) is shown.

As shown in FIG. 17, in order to mold the resin laminate 2A of the present embodiment, first, a pair of split molds 51 and 52 corresponding to the shape of the resin laminate 2A are prepared. Then, the molten resin sheets (parisons) P and P are extruded from an extrusion device (not shown) and are suspended between the divided molds 51 and 52. The split molds 51 and 52 are provided with sliding portions 511 and 521, respectively. The sliding part 511 and the sliding part 521 face each other. The sliding part 511 is configured to be slidable in a direction orthogonal to the molten resin sheet P, and is configured to be relatively movable with respect to the formation surface 51 a of the split mold 51. Similarly, the sliding part 521 is slidable in a direction orthogonal to the molten resin sheet P, and is thereby configured to be movable relative to the formation surface 52 a of the split mold 52.

After the molten resin sheets P and P are suspended between the divided molds 51 and 52, as shown in FIG. 18, the sliding portions 511 and 521 are moved (slid) in directions close to each other, thereby sliding. The tips of the portions 511 and 521 are connected to the molten resin sheet P. Thereby, a sealed space SP1 is formed between the forming surface 51a of the split mold 51 and the molten resin sheet P, and a sealed space SP2 is formed between the forming surface 52a of the split mold 52 and the molten resin sheet P.
Although not shown, each of the split molds 51 and 52 has a built-in vacuum chamber, and a communication path for vacuum suction is provided between the vacuum chamber and the forming surfaces 51a and 52a. And the air in sealed space SP1, SP2 is attracted | sucked from a communicating path by a vacuum chamber. By this suction, as shown in FIG. 19, the pair of molten resin sheets P and P are pressed against the formation surfaces 51a and 52a, respectively, and formed (shaped) into shapes along the formation surfaces 51a and 52a.

Next, as shown in FIG. 20, the molds 51 and 52 are clamped to sandwich the molten resin sheets P and P. By this clamping, the portion of the molten resin sheet P that becomes the top surfaces of the ribs R11 to R13, R21 to R23, R31 to R33, and R41 to R43 of the second resin sheet 22A and the first resin sheet 21A are melted. The resin sheet P is pressed and welded together.
Pinch-off portions (not shown) are provided on the outer circumferences of the divided molds 51, 52 so as to surround the formation surfaces 51a, 52a of the divided molds 51, 52, and the molten resin sheets P, P are formed by clamping. In the pinch-off portion, the peripheral edges of the pair of molten resin sheets P and P are welded to form the parting line PL.
Next, the split molds 51 and 52 are opened to take out the molded product. Finally, the burr formed along the parting line PL is cut with a cutter to obtain the resin laminate 2A of the present embodiment.

(2-3) Excess protrusion of the resin laminate of the second embodiment When a rib is formed as described above using a split mold having a forming surface provided with a protrusion, the molten resin protrudes. A thin projection around the protrusion (that is, the rib) due to an excess of molten resin around the protrusion due to a sharp change in the surface shape of the protrusion when pressed against the protrusion (Hereinafter referred to as “remaining protrusion”) may be formed. The surplus protrusion is not intentionally formed, and whether or not the surplus protrusion is formed, and the position at the outer edge of the rib when the surplus protrusion is formed and the extending direction of the surplus protrusion are Is determined by factors such as the shape and arrangement of the protrusions on the forming surface corresponding to the above, and / or the relationship between the direction in which the protrusions extend and the extrusion direction of the molten resin.

The resin laminate 2A according to the present embodiment is provided with ribs so that the strength and rigidity are not lowered, and the insertion workability of the reinforcing material 3A is not caused by the excess protrusion when the reinforcing material 3A is inserted after molding. It is characterized in that the position of the excess protrusion and the extending direction thereof are controlled by devising the arrangement of. This point will be described below with reference to FIGS.
FIG. 21 is a partial plan view showing surplus protrusions formed on the ribs of the laminated structure according to this embodiment. 22 to 24 are partial plan views showing surplus protrusions formed on the ribs of the laminated structure according to the reference example for comparison with FIG. FIG. 25 is a partial plan view showing surplus protrusions formed on the ribs of the laminated structure according to the modification of the present embodiment. Each figure has shown the state which removed the 1st resin sheet of the resin laminated body.

As shown in FIG. 21, in the resin laminate 2A of the present embodiment, the ends of the ribs R12 and R22 are connected to the side wall surface on the side opposite to the reinforcing material 3A among the side wall surfaces of the rib r11, and the rib R13. , R23 are connected to the side wall surface on the opposite side of the reinforcing material 3A from the side wall surface of the rib r12. In such a rib arrangement, extra protrusions EX are formed at the longitudinal ends of the ribs r11 and r12 at both ends in the longitudinal direction of the ribs r11 and r12. The surplus protrusion EX extends in the longitudinal direction of the ribs r11 and r12 and does not overlap with the reinforcing material arrangement region 3P of the reinforcing material 3A in plan view. Therefore, the reinforcing material 3A and the excess protrusion EX do not interfere when the reinforcing material 3A is inserted, and the insertion workability is not affected.

Unlike the present embodiment, the reference example shown in FIG. 22 does not include the ribs r11 and r12, and the ends of the ribs R12, R13, R22, and R23 are extended to the vicinity of the side wall surface of the reinforcing material 3A. It is an example. In this example, since there are no ribs r11 and r12, as shown in FIG. 22B, the side wall surface of the reinforcing material 3A is supported by a part of the end surface on the reinforcing material 3A side of the ribs R12, R13, R22, and R23. . The inclination of the end surfaces of the ribs R12, R13, R22, R23 (the end surface R22s in the case of the rib R22) is the same as that of this embodiment.
In this example, since the end portions of the ribs R12, R13, R22, and R23 are formed close to the side wall surface of the reinforcing material 3A, the strength and rigidity of the region adjacent to the region where the reinforcing material 3A is disposed are reduced. Can be suppressed. However, when the ribs R12, R13, R22, and R23 are formed, the surplus protrusion EX is formed at the longitudinal end of each rib, and the surplus protrusion EX enters the reinforcing material arrangement region 3P in plan view. Therefore, the reinforcing material 3A interferes with the extra protrusion EX when the reinforcing material 3A is inserted, and the reinforcing material 3A cannot be inserted, or the insertion workability is lowered.

Unlike the present embodiment, the reference example shown in FIG. 23 differs from the present embodiment in that the ribs R12A, R13A, R22A, and R23A are extended to near the side wall surface of the reinforcing member 3A without providing the ribs r11 and r12. This is an example in the case of being installed. The difference from the reference example of FIG. 22 is that, as shown in FIG. 23B, the inclination of the end surface (for example, end surfaces R12As, R22As) of the ribs R12A, R13A, R22A, R23A on the reinforcing material 3A side is the case of the reference example of FIG. It is a point that is more gradual. Thus, when the inclination of the edge part of a rib is made moderate, since the surplus protrusion is not formed, it does not affect insertion workability | operativity of 3 A of reinforcing materials. However, since the inclination of the end face of each rib on the reinforcing material 3A side is gentle, the strength and rigidity of the laminated structure 1A in the vicinity of the end of each rib on the reinforcing material 3A side is higher than in the case of the present embodiment in FIG. Will also decline.

The reference example shown in FIG. 24 is different from FIG. 21 which is the resin laminate 2A of this embodiment in that the ribs R12B and R22B are not connected to the rib r11 and the ribs R13B and R23B are not connected to the rib r12. . When the ribs are arranged in this way, when the ribs R12B, R13B, R22B, and R23B are formed, extra protrusions EX are formed at the longitudinal ends of the ribs, and the ribs r11 and r12 have ribs at both ends in the longitudinal direction. A surplus protrusion EX is formed at the longitudinal ends of r11 and r12. Since any surplus protrusion EX does not enter the reinforcing material arrangement region 3P, the insertion workability of the reinforcing material 3A is not affected. However, there are no ribs in the region between the end of the ribs R12B and R22B on the reinforcing material 3A side and the rib r11 and the region between the end of the ribs R13B and R23B on the reinforcing material 3A side and the rib r12. In the region, the strength and rigidity of the laminated structure 1A are locally reduced.

In the modification of the embodiment shown in FIG. 25, the ribs R12C and R22C are connected to the side wall surface of the rib r11 opposite to the position of the reinforcing material 3A, and the ribs R13C and R23C are connected to the rib r12. It is the same as the case of FIG. 21 in that the side wall surface is connected to the side wall surface on the side opposite to the position of the reinforcing material 3A. The difference from FIG. 21 is that the connecting positions of the ribs R12C, R22C and the rib r11 are both ends in the longitudinal direction of the rib r11, and the connecting positions of the ribs R13C, R23C and the rib r12 are both ends in the longitudinal direction of the rib r12. is there.
As shown in FIG. 25, in such a rib arrangement, the surplus protrusion EX is formed in an oblique direction starting from the connecting position of the rib. Compared to the case of FIG. 21, the surplus protrusion EX tends to be closer to the reinforcing material arrangement region 3P, but there is no problem in inserting the reinforcing material 3A. However, in order to provide a margin in the distance between the surplus protrusion EX and the reinforcing material arrangement region 3P, as shown in FIG. 21, the connecting ribs R are arranged side by side on the center side of the end portions in the longitudinal direction of the arranged ribs r. It is preferable to connect with the rib r.

As described above, according to the laminated structure of the present embodiment, the second resin sheet 22A includes the parallel ribs r extending in a strip shape in the extending direction 3Y along the side wall surface 3w of the reinforcing material 3A, and the reinforcing material 3A. And a connecting rib R that is connected to the side wall surface of the side-by-side rib r on the opposite side of the position. Therefore, the strength and rigidity of the laminated structure 1A can be reduced, and the reinforcing material 3A can be appropriately inserted after the resin laminated body 2A is molded.

As mentioned above, although embodiment of this invention was described in detail, in the range which does not deviate from the main point of this invention, the laminated structure of this invention is not limited to embodiment, What may be variously improved and changed. Of course.

For example, the aspect in which the connecting rib R is connected to the juxtaposed rib r on the side wall surface on the side of the reinforcing member 3A is such that the end surface on the reinforcing member 3A side of the connecting rib R is from the top surface to the back side. It is not restricted to the case where it connects with the top face of juxtaposed rib r on the way. FIG. 26 is a cross-sectional view corresponding to FIG. 14 showing a modification of the laminated structure according to the embodiment. In the modification shown in FIG. 26, the end surface of the connecting rib R on the side of the reinforcing material 3A is connected to the side wall surface of the juxtaposed rib r on the way from the top surface to the back side. When attention is paid to the relationship between the rib R12 and the rib r11 in FIG. 26, the end surface R12s on the reinforcing material 3A side of the rib R12 is connected to the side wall surface r11s of the rib r11 on the way from the top surface R12t to the rib R12. It is connected to the rib r11. When attention is paid to the relationship between the rib R13 and the rib r12 in FIG. 26, the end surface R13s on the reinforcing material 3A side of the rib R13 is connected to the side wall surface r12s of the rib r12 on the way from the top surface R13t to the rib R13. It is connected to the rib r12.

In the above-described embodiment, the case where the molten resin is extruded from the top to the bottom along the longitudinal direction of the juxtaposed rib r in FIG. 13 when the resin laminate 2A is molded has been described. Absent. The extrusion direction of the molten resin may be performed downward from above along the longitudinal direction of the connecting rib R. In the case where a fiber filler such as glass fiber is mixed with the molten resin, it is preferable to extrude the molten resin along the longitudinal direction of the connecting rib R in that pinholes are less likely to occur.

(3) Third Embodiment Hereinafter, a laminated structure according to a third embodiment of the present invention will be described.

(3-1) Configuration of Laminated Structure of Third Embodiment Hereinafter, the configuration of the laminated structure 1B of the third embodiment will be described with reference to FIGS.
FIG. 27 is a perspective view of the laminated structure 1B according to the third embodiment when viewed from a direction in which the front side can be visually recognized. FIG. 28 is a perspective view of the laminated structure 1 </ b> B according to the third embodiment when viewed from a direction in which the back side is visible. FIG. 27 and FIG. 28 show a state when cut along a plane parallel to the side surface of the multilayer structure 1B so that the internal structure of the multilayer structure 1B can be seen.
FIG. 29 is an enlarged plan view showing a part of the reinforcing material sheet 30 included in the laminated structure 1B of the third embodiment. FIG. 30 is an enlarged cross-sectional view showing an enlarged cross section when cut by a plane parallel to the side surface of the laminated structure 1B.

As shown in FIG. 27, the laminated structure 1B of the third embodiment has a substantially rectangular parallelepiped shape, and has a structure in which the first resin sheet 10 and the second resin sheet 20 are laminated. The first resin sheet 10 is provided on the front side and has a flat portion. The 2nd resin sheet 20 is provided in the back side through the hollow part H from the 1st resin sheet 10. In the example of the laminated structure 1B shown in FIG. 27, all of the first resin sheets 10 are flat portions.
Although the resin material of the 1st resin sheet 10 and the 2nd resin sheet 20 is not limited, For example, they are thermoplastic resins, such as polyolefin, As a polyolefin, a low density polyethylene, a linear low density polyethylene, a high density polyethylene is mentioned. , Polypropylene, ethylene-propylene copolymer and mixtures thereof

The second resin sheet 20 is formed with ribs R as a plurality of protrusions protruding toward the first resin sheet 10. A hollow portion H is formed between adjacent ribs R of the second resin sheet 20. The plurality of ribs R are provided to increase the rigidity of the laminated structure 1 </ b> B while providing a hollow portion H to reduce the weight.

As shown in FIG. 28, a reinforcing material sheet 30 is interposed between the first resin sheet 10 and the second resin sheet 20.
The reinforcing material sheet 30 is preferably a woven fabric made of a material having high strength, particularly a material excellent in impact resistance. When the reinforcing material sheet 30 is made of woven fabric, for example, glass fiber, synthetic fiber, carbon fiber, or a composite material (carbon fiber) in combination of these is used as the material of the yarn (yarn) used in the woven fabric. Reinforced plastic). In a preferred example, the reinforcing material sheet 30 is a woven fabric (glass sheet) made of yarn (glass yarn) made of glass fiber because it is inexpensive and easily available.
The thread diameter, the weave density, and the thickness of the reinforcing material sheet 30 are not particularly limited, but can be appropriately determined from the viewpoint of required impact resistance and manufacturing.

FIG. 29 shows a case where the reinforcing material sheet 30 is a woven fabric obtained by plain weaving yarn made of glass fiber as a preferred example. The reinforcing material sheet 30 shown in FIG. 29 is woven so that the warp group 310 and the weft group 320 intersect each other, and a plurality of openings 330 are provided at positions where the warp group 310 and the weft group 320 intersect. . That is, the opening 330 is formed in a region surrounded by a pair of adjacent warp groups 310, 310 and a pair of adjacent weft groups 320, 320. The opening 330 is provided for directly welding the first resin sheet 10 and the second resin sheet 20 during manufacturing.
The weaving method is not particularly limited when the reinforcing material sheet 30 is a woven fabric, but an entangled weave may be used in addition to the plain weave shown in FIG. Further, the reinforcing material sheet 30 may be subjected to a surface treatment such as a sealing treatment with an adhesive to prevent misalignment.

The woven fabric is preferable as the reinforcing material sheet 30 for the following reason.
That is, when the reinforcing material sheet 30 is a woven fabric, the linear warp or weft is configured to extend in a direction orthogonal to the direction in which the rib R extends, so that the warp or weft is adjacent to the adjacent rib R. It is fixed with. Therefore, the first resin sheet 10 is effectively applied to the impact input in which the warp or weft fixed by the adjacent ribs R is applied to the first resin sheet 10 in the region between the adjacent ribs R. It can be supported and the impact resistance of the laminated structure 1B can be improved.

The direction in which the warp or weft extends and the direction in which the rib R extends (RD in FIG. 28; the direction in which the rib R is formed) are not necessarily perpendicular to each other. By fixing between the ribs R to be performed, the impact resistance of the laminated structure 1B can be improved. By configuring so that the direction in which the warp or weft extends and the direction in which the rib R extends (RD in FIG. 28) are orthogonal to each other, the length of the yarn connecting adjacent ribs R can be relatively shortened. In addition, since the supporting force against the impact input increases, the impact resistance of the laminated structure 1B can be further improved.

As shown in FIG. 30, the first resin sheet 10 includes a front surface 11 that is a surface on the front side of the laminated structure 1 </ b> B and a back surface 12 that is a surface on the second resin sheet 20 side. Become. The 2nd resin sheet 20 consists of the front surface 210 which is the surface by the side of the 1st resin sheet 10, and the back surface 220 which is the surface by the side of the laminated structure 1B.
In each rib R of the second resin sheet 20, the side of the front surface 210 of the second resin sheet 20 is such that the rib R tapers from the back surface of the laminated structure 1B toward the front surface. Wall surfaces 211w and 212w are formed. The top surface 213 of each rib R is welded to the back surface 12 of the first resin sheet 10 through the opening 330 of the reinforcing material sheet 30, thereby the first resin sheet 10 and the second resin sheet 20. Are welded at the welded portion C. In other words, the first resin sheet 10 and the second resin sheet 20 are welded only by the top surface 213 of each rib R, and the reinforcing material sheet 30 is located between the top surfaces 213 of the adjacent ribs R. The first resin sheet 10 is not welded and is not restrained (free) with respect to the first resin sheet 10.

As described above, in the laminated structure 1B of the present embodiment, the reinforcing material sheet 30 is not welded to the first resin sheet 10 in the region between the top surfaces 213 of the adjacent ribs R. In the manufacturing process to be performed, the difference in thermal shrinkage due to the difference in material between the first resin sheet 10 and the reinforcing material sheet 30 is the front surface of the laminated structure 1B (that is, the main surface of the first resin sheet 10). It is possible to suppress adverse effects such as poor appearance on the surface 11).
In addition, since the first resin sheet 10 and the second resin sheet 20 are welded to each other in the rib R, the laminated structure 1B of the present embodiment has a necessary rigidity (particularly bending rigidity) for the laminated structure 1B. The structure is easy to secure.

In the laminated structure 1B of the present embodiment, the reinforcing material sheet 30 is not welded to the first resin sheet 10 in the region between the top surfaces 213 of the adjacent ribs R, but the laminated structure is formed by the reinforcing material sheet 30. The impact resistance against the front surface of the body 1B is improved. For example, when an impact input is applied from the front surface of the laminated structure 1B to the region of the first resin sheet 10 between the top surfaces 213 of the adjacent ribs R, the region is laminated by the impact input. And is supported by the reinforcing material sheet 30 that is fixed on both sides by the adjacent ribs R. Therefore, compared with the case where an impact input is received only by the first resin sheet 10, the impact resistance of the laminated structure 1B is improved.

On the other hand, in the conventional resin panel described in the above cited reference 1, a fiber mat is provided between a pair of resin sheets, and the flat resin sheet is melted to the fiber mat by a predetermined thickness over the entire area. It has become a state. For this reason, due to the difference in thermal shrinkage due to the difference between the resin sheet and the fiber mat material, the appearance of the resin panel tends to be poor after the molding process. Further, since the pair of resin sheets are not directly welded or melted, it is difficult to ensure the rigidity necessary for the resin panel. On the other hand, the laminated structure 1B of the present embodiment has solved the conventional problems such as the appearance failure of the front surface and the structure in which it is difficult to ensure the rigidity. That is, according to the laminated structure 1B of the present embodiment, sufficient rigidity can be ensured while improving the impact resistance.

In the laminated structure 1B of the present embodiment, the opening ratio of the openings in the sheet surface of the reinforcing material sheet 30 (that is, the ratio of the opening area in the unit area in plan view) is preferably in the range of 10 to 90%. More preferably, it is in the range of 20 to 40%. When the opening ratio is smaller than 10%, the amount of the reinforcing material sheet 30 fixed to the rib R in plan view is increased, and the difference in the heat shrinkage rate between the first resin sheet 10 and the reinforcing material sheet 30 is a laminated structure. The front surface of 1B is likely to be adversely affected such as poor appearance. When the opening ratio is larger than 90%, the supporting force for the first resin sheet 10 between the adjacent ribs R cannot be sufficiently ensured, so that the cost for improving the impact resistance is reduced.

Although the case where the reinforcing material sheet 30 is a woven fabric has been described with reference to FIG. 29, the present invention is not limited thereto. The reinforcing material sheet 30 may be a non-woven fabric. When the reinforcing material sheet 30 is a non-woven fabric, the entangled yarn gap is an opening, and the first resin sheet 10 and the second resin sheet 20 are welded through the opening.

As the reinforcing material sheet, a sheet material having no opening (for example, leather) can be used. When such a sheet material is used, the sheet material is used after opening processing is performed with a cutter or the like at a position corresponding to the rib.

(3-2) Manufacturing Method of Laminated Structure of Third Embodiment Next, a manufacturing method of the laminated structure 1B of the present embodiment will be described with reference to FIGS. FIGS. 31 to 36 are diagrams for explaining the method of manufacturing the laminated structure of the present embodiment, and are planes orthogonal to the surface of the molten resin sheet described later and extending in the vertical direction (extrusion direction of the molten resin sheet). It is shown in a cross section when cut by.

As shown in FIG. 31, in order to manufacture the laminated structure 1B of the present embodiment, first, a pair of split molds 61 and 62 corresponding to the shape of the laminated structure 1B is prepared. Then, the molten resin sheets (parisons) P and P are extruded from an extruder (not shown) and are suspended between the divided molds 61 and 62. The split molds 61 and 62 are provided with sliding portions 61s and 62s, respectively. The sliding part 61s and the sliding part 62s face each other. The sliding portion 61s is slidable in a direction orthogonal to the molten resin sheet P, and is thereby configured to be relatively movable with respect to the forming surface 61a of the split mold 61. Similarly, the sliding portion 62 s is slidable in a direction orthogonal to the molten resin sheet P, thereby being configured to be relatively movable with respect to the forming surface 62 a of the split mold 62.

After the molten resin sheets P and P are suspended between the divided dies 61 and 62, as shown in FIG. 32, the sliding portions 61s and 62s are moved (slid) in directions close to each other to slide. The tips of the portions 61 s and 62 s are brought into contact with the molten resin sheet P. Thereby, a sealed space SP1 is formed between the forming surface 61a of the split mold 61 and the molten resin sheet P, and a sealed space SP2 is formed between the forming surface 62a of the split mold 62 and the molten resin sheet P.
Although not shown, each of the split molds 61 and 62 has a built-in vacuum chamber, and a communication path for vacuum suction is provided between the vacuum chamber and the forming surfaces 61a and 62a. And the air in sealed space SP1, SP2 is attracted | sucked from a communicating path by a vacuum chamber. With this suction, as shown in FIG. 33, the pair of molten resin sheets P and P are pressed against the formation surfaces 61a and 62a, respectively, and formed (shaped) into shapes along the formation surfaces 61a and 62a.

Next, as shown in FIG. 34, the sliding portions 61s and 62s are returned to the initial positions (the same positions as in FIG. 31), and the molten resin sheets are formed on the formation surfaces 61a and 62a of the divided molds 61 and 62. A reinforcing material sheet 30 is disposed between P and P. Preferably, the holding member 70 holds the reinforcing material sheet 30 so that the reinforcing material sheet 30 is accurately positioned in the vertical direction.
Next, as shown in FIG. 35, the reinforcing member sheet 30 is pressed against the molten resin sheet P on the forming surface 61 a by moving the holding member 70 toward the forming surface 61 a of the split mold 61. When the material of the reinforcing material sheet 30 is glass fiber, the adhesive force of the reinforcing material sheet 30 to the molten resin sheet P is relatively low, but at least for a short time until the molds 61 and 62 are clamped. The reinforcing material sheet 30 and the molten resin sheet P are maintained in a bonded state.

Next, as shown in FIG. 36, the molds 61 and 62 are clamped to sandwich the molten resin sheets P and P therebetween. By this clamping, the portion of the molten resin sheet P that becomes the top surface 213 of the rib R of the second resin sheet 20 and the molten resin sheet P that becomes the first resin sheet 10 are pressed against each other, and the reinforcing material sheet Weld through 30 openings 330. That is, in the plurality of ribs R, welded portions C where the first resin sheet 10 and the second resin sheet 20 are welded are formed.
Pinch-off portions (not shown) are provided on the outer peripheries of the split molds 61 and 62 so as to surround the formation surfaces 61a and 62a of the split molds 61 and 62, and the molten resin sheets P and P are formed by clamping. In the pinch-off portion, the peripheral edges of the pair of molten resin sheets P and P are welded to form the parting line PL.
Next, the split molds 61 and 62 are opened to take out the molded product. Finally, the burrs formed along the parting line PL are cut with a cutter to obtain the laminated structure 1B of the present embodiment.

(4) Fourth Embodiment Hereinafter, a laminated structure 1C according to a fourth embodiment will be described with reference to FIG. FIG. 37 is a cross-sectional view showing a cross section taken along a plane parallel to the side surface of the laminated structure 1C, as in FIG. FIG. 37 also shows an enlarged view of part B in the cross section.

As shown in FIG. 37, the laminated structure 1C of the fourth embodiment is different from the laminated structure 1B of the third embodiment (see FIG. 27) in that a step is formed on the front surface. Different.
The laminated structure 1C of the present embodiment has a structure in which a first resin sheet 10A and a second resin sheet 20A are laminated. 10 A of 1st resin sheets are provided in the front side, and have flat part 10Aa, 10Ab and inclination part 10Ac. When the back surface 220A (see the enlarged view of the B part) of the laminated structure 1C is used as a reference, the flat part 10Ab is configured by a flat surface located higher than the flat part 10Aa. An inclined portion 10Ac is formed between the flat portion 10Aa and the flat portion 10Ab.

The second resin sheet 20A is provided on the back side of the first resin sheet 10A with a hollow portion H therebetween. On the second resin sheet 20A, ribs R1 and R2 are formed as a plurality of protruding portions that protrude toward the first resin sheet 10A. Each rib R1, R2 of the second resin sheet 20A is formed so as to taper from the back surface of the laminated structure 1C toward the front surface. Since the height of the flat portion 10Aa and the flat portion 10Ab of the first resin sheet 10A with respect to the back surface 220A of the laminated structure 1C is different, the rib R1 corresponding to the flat portion 10Aa and the flat portion 10Ab are correspondingly provided The height of the rib R2 is different. Specifically, the rib R2 is higher than the rib R1.
A hollow portion H is formed between adjacent ribs R1 and R2 of the second resin sheet 20A.

A reinforcing material sheet 30A is interposed between the first resin sheet 10A and the second resin sheet 20A. The material of the reinforcing material sheet 30A is preferably a material having a high strength like the reinforcing material sheet 30, for example, a woven fabric made of yarn made of glass fiber (for example, the same form as shown in FIG. 29). Woven fabric).

Referring to the enlarged view of part B in FIG. 37, the flat portion 10Aa of the first resin sheet 10A is a front surface 11Aa which is the surface on the front side of the laminated structure 1C, and the second resin sheet 20A side. And the rear surface 12Aa. The flat portion 10Ab of the first resin sheet 10A includes a front surface 11Ab that is a surface on the front side of the laminated structure 1C and a back surface 12Ab that is a surface on the second resin sheet 20A side. The inclined portion 10Ac of the first resin sheet 10A includes a front surface 11Ac that is a surface on the front side of the laminated structure 1C and a back surface 12Ac that is a surface on the second resin sheet 20A side.

The top surface 213A of the rib R2 is welded to the back surface 12Ab of the flat portion 10Ab of the first resin sheet 10A through the opening of the reinforcing material sheet 30A (not shown, but similar to the opening 330 shown in FIG. 29). Thereby, the first resin sheet 10A and the second resin sheet 20A are welded at the rib R2.
In the example shown in FIG. 37, the inclined surface 212A extending from the end of the top surface 213A of the rib R2 and the back surface 12Ac of the inclined portion 10Ac of the first resin sheet 10A are in surface contact with each other. The preferable example welded through opening is shown. Since the inclined portion 10Ac is more excellent in impact resistance against impact input from the front side of the laminated structure 1C than the flat portions 10Aa and 10Ab, welding at the inclined portion 10Ac is not essential.

Also in the laminated structure 1C of the fourth embodiment, the flat portions 10Aa, 10Ab of the first resin sheet 10A and the second resin sheet 20A are welded only by the top surfaces of the ribs R1, R2, respectively. The reinforcing material sheet 30A is not welded to the first resin sheet 10A between the top surfaces of adjacent ribs in each flat portion. Therefore, it can suppress that the difference in the heat shrinkage rate resulting from the difference in the material of the 1st resin sheet 10A and the reinforcing material sheet 30A exerts a bad influence such as a poor appearance on the front surface of the laminated structure 1C. .
It will be appreciated by those skilled in the art that the manufacturing method of the laminated structure 1C of the fourth embodiment may be the same as that of the laminated structure 1B of the third embodiment.

As mentioned above, although each embodiment of this invention was described in detail, the laminated structure of this invention is not limited to each embodiment, You may make various improvement and change in the range which does not deviate from the main point of this invention. Of course. For example, the technical matters described in the third embodiment can be applied to the fourth embodiment.

34 and 35, the reinforcing material sheet 30 is held by the holding member 70, and the holding member 70 is moved toward the forming surface 61a of the split mold 61, whereby the reinforcing material sheet 30 and the molten resin sheet P are bonded. Although the example to make was demonstrated, it is not restricted to this example. A method may be employed in which the reinforcing material sheet 30 is suspended between the molten resin sheets P and P pressed against the formation surfaces 61a and 62a, and the molds 61 and 62 are clamped as shown in FIG. . This method is suitable when the adhesive force between the reinforcing material sheet 30 and the molten resin sheet P is weak because there is no need to temporarily bond the reinforcing material sheet 30 and the molten resin sheet P as shown in FIG.

In each of the above-described embodiments, the case where the openings of the reinforcing material sheet are formed in a region surrounded by a pair of adjacent warp groups and a pair of adjacent weft groups is described, but this is not a limitation. As the reinforcing material sheet, for example, a glass sheet having an opening at a desired position after the sealing treatment may be used.

Claims (16)

1. A method for producing a laminated structure in which a reinforcing material is interposed between a first resin sheet and a second resin sheet,
   A step of attaching a temporary holding material to the front surface or the back surface of the reinforcing material;
   A step of extruding a first molten resin sheet and a second molten resin sheet between a first divided mold and a second divided mold opposed to each other;
   Pressing the first molten resin sheet against the formation surface of the first split mold, and pressing the second molten resin sheet against the formation surface of the second split mold;
   Pressing the surface of the reinforcing material to which the temporary holding material is attached to the first molten resin sheet, thereby holding the reinforcing material on the first molten resin sheet;
   A step of clamping the first split mold and the second split mold;
   The manufacturing method of a laminated structure containing this.
2. In the pressing step, a decorative material sheet is disposed between the first split mold and the first molten resin sheet, and the decorative material sheet is formed together with the first molten resin sheet on the first split mold forming surface. It is made to press to,
   The method for manufacturing a laminated structure according to claim 1.
3. On the formation surface of the second split mold, there is a protruding portion that protrudes toward the formation surface of the first split mold in a region facing the surface of the reinforcing material to which the temporary holding material is attached. Characterized by being formed,
   The method for producing a laminated structure according to claim 1 or 2.
4. The step of holding the reinforcing material on the first molten resin sheet is characterized in that a raised portion is formed by the first molten resin sheet on the periphery of the surface of the reinforcing material to which the temporary holding material is attached. ,
   The method for producing a laminated structure according to any one of claims 1 to 3.
5. The cloth is used as a temporary holding material,
   The method for producing a laminated structure according to any one of claims 1 to 4.
6. A first resin sheet formed on the front side;
   A second resin sheet formed on the back side and facing the first resin sheet across the hollow portion;
   An elongated reinforcing material extending in the first direction in the hollow portion;
   A laminated structure comprising:
   The second resin sheet is
   When projecting from the front side sheet surface of the second resin sheet toward the first resin sheet and viewing the laminated structure in plan view, in the first direction along the side wall surface of the reinforcing material A first protrusion extending in a band shape;
   The second resin sheet protrudes from the front sheet surface of the first resin sheet to the back sheet surface of the first resin sheet, and extends in a band shape when the laminated structure is viewed in a plan view. A second protrusion connected to the first protrusion in the portion,
   Laminated structure.
7. When the laminated structure is viewed in plan view, a direction in which the second protrusion extends is orthogonal to the first direction,
   The laminated structure according to claim 6.
8. The top surface of the first projecting portion does not reach the back sheet surface of the first resin sheet,
   The laminated structure according to claim 6 or 7.
9. At least a part of the side wall surface of the first protruding portion protrudes toward the side wall surface of the reinforcing material,
   The laminated structure according to any one of claims 6 to 8.
10. A first resin sheet provided on the front side and having a flat portion;
    A first resin sheet, a second resin sheet provided on the back side across a hollow portion;
    A reinforcing material sheet interposed between the first resin sheet and the second resin sheet and having an opening;
    A laminated structure comprising:
    The second resin sheet is formed with a plurality of protruding portions that protrude toward the flat portion of the first resin sheet,
    The top surfaces of the plurality of protrusions are welded to the back surface of the first resin sheet through the openings of the reinforcing material sheet,
    Laminated structure.
11. The reinforcing material sheet is a woven fabric woven so that warp and weft intersect,
    The laminated structure according to claim 10.
12. The opening is formed in a region surrounded by a pair of adjacent warps and a pair of adjacent wefts,
    The laminated structure according to claim 11.
13. The direction in which the warp or weft of the woven fabric extends and the direction in which the plurality of protrusions are formed are orthogonal to each other,
    The laminated structure according to claim 11 or 12.
14. The woven fabric is composed of yarn made of glass fiber,
    The laminated structure according to any one of claims 11 to 13.
15. The opening ratio of the opening in the sheet surface of the reinforcing material sheet is in the range of 10 to 90%,
    The laminated structure according to any one of claims 10 to 14.
16. Between the two adjacent protrusions of the plurality of protrusions, the first resin sheet and the reinforcing material sheet are not welded,
    The laminated structure according to any one of claims 10 to 15.

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