WO2019107319A1 - Resin panel and method for manufacturing the same - Google Patents

Resin panel and method for manufacturing the same Download PDF

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Publication number
WO2019107319A1
WO2019107319A1 PCT/JP2018/043452 JP2018043452W WO2019107319A1 WO 2019107319 A1 WO2019107319 A1 WO 2019107319A1 JP 2018043452 W JP2018043452 W JP 2018043452W WO 2019107319 A1 WO2019107319 A1 WO 2019107319A1
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WO
WIPO (PCT)
Prior art keywords
resin
reinforcing member
core material
core
air flow
Prior art date
Application number
PCT/JP2018/043452
Other languages
French (fr)
Japanese (ja)
Inventor
洋介 林
丹治　忠敏
素晴 藤井
吉田　攻一郎
Original Assignee
キョーラク株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2017229341A external-priority patent/JP6959522B2/en
Priority claimed from JP2018123964A external-priority patent/JP7078848B2/en
Application filed by キョーラク株式会社 filed Critical キョーラク株式会社
Publication of WO2019107319A1 publication Critical patent/WO2019107319A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B29C51/38—Opening, closing or clamping means

Definitions

  • the present invention relates to a resinous panel which can be used in architectural applications, in-vehicle applications, furniture applications and the like, and a method of manufacturing the same.
  • Patent Document 1 discloses a method of manufacturing a resin panel by clamping a mold after welding a foam structure in which a core material and a reinforcing material are integrated to a resin sheet.
  • This invention is made in view of such a situation, and provides the resin-made panels which can suppress generation
  • the present invention also provides a method of manufacturing a resinous panel capable of suppressing the displacement of the insert position of the core member and the reinforcing member.
  • the resin panel is provided with a resin wall, a core member, and a reinforcing member, the core member and the reinforcing member are surrounded by the resin wall, and the reinforcing member is air. It has a flow path,
  • the reinforcement member has an adjacent part which adjoins the core material, and a projected part which protrudes from the side of the core material, and the air flow path extends from the adjacent part to the projection.
  • the resin flow path is provided, and the air flow path communicates with the outside of the air flow path in both the adjacent portion and the projecting portion.
  • the air between the resin sheet and the core material can be extracted through the first opening, the air flow path, and the second opening, the generation of residual air can be suppressed.
  • the reinforcing member is a resin panel provided with a first opening communicating with the air flow passage at the adjacent portion.
  • the first opening is provided so as not to be in contact with the resin wall.
  • the first opening is a resin panel provided on the side surface of the reinforcing member.
  • the first opening is a resin panel provided at a position facing the core material.
  • a gap between the reinforcing member and the core member is provided at a portion where the first opening is provided.
  • the first opening is a resin panel provided at a plurality of circumferential positions of the reinforcing member.
  • a groove communicating with the air flow channel is provided on the surface of the core material.
  • the grooves are provided in a grid shape.
  • the reinforcing member is a resin panel provided with a second opening communicating with the air flow passage in the protrusion.
  • the second opening is a resin panel provided on an end face of the reinforcing member.
  • a plurality of the reinforcing members are provided at intervals, the plurality of the reinforcing members are connected to each other by a connecting member, and the connecting member is the core member.
  • the second side is disposed along the second side, and the second side is a resin panel facing the first side.
  • the resin wall has no hole.
  • the resin panel is provided with a resin wall, a core and a reinforcing member, and the core and the reinforcing member are surrounded by the resin wall, and the reinforcing
  • the member is inserted into the insertion hole provided in the core, the core has a front surface and a back surface facing each other, and the core is a front surface side locking portion;
  • a back surface side locking portion is provided, the front surface side locking portion locks the reinforcing member from the front surface side, and the back surface side locking portion is configured to contact the reinforcing member from the back surface side
  • a resin panel is provided, in which the front surface side locking portion and the back surface side locking portion are provided alternately along the longitudinal direction of the insertion hole.
  • a method of manufacturing a resinous panel comprising a hanging step, an inserting step, and a clamping step, wherein, in the hanging step, the space between the first and second molds.
  • the first and second resin sheets are suspended, and in the inserting step, a core material and a reinforcing member are disposed between the first and second resin sheets, and in the clamping step, the first and second molds are dies.
  • the reinforcing member has an air flow path
  • the reinforcing member has an adjacent portion adjacent to the core member, and a protrusion projecting from the side surface of the core member
  • the air flow path includes: A method is provided, which extends from the adjacent part to the projecting part, and the air flow path communicates with the outside of the air flow path in both the adjacent part and the protruding part.
  • a method of manufacturing a resin panel comprising: a drooping step, an inserting step, and a clamping step, wherein in the drooping step, the first and second dies are interposed between the first and second molds.
  • a second resin sheet is suspended, and in the inserting step, a reinforcing member is disposed between the first and second resin sheets, and in the inserting step, the reinforcing member is supported by a support device, and the mold is tightened.
  • a method is provided, wherein the first and second molds are clamped while the reinforcing member is supported by the support device.
  • the core material is supported by the reinforcing member and the first and second molds are clamped while the reinforcing member is supported by the supporting device, the core material and the reinforcing member are heavy even when the weight is large. Deviation of the insert position of the reinforcing member can be suppressed.
  • the core material and the reinforcing member are disposed between the first and second resin sheets, and the reinforcing member is a portion adjacent to the core material. And the core material is supported by the reinforcing member.
  • the reinforcing member has a protrusion protruding from the side surface of the core material.
  • at least one of the first and second molds has a slide core at a position facing the end of the reinforcing member, and the slide core is formed by the clamping step.
  • the end covering process disposed after the mold clamping process, the end covering process including moving the slide core to the mold clamping position;
  • at least one of the first and second resin sheets covers the end of the reinforcing member.
  • the reinforcing member has an air flow path
  • the support device has an elongated insertion portion, and the support device inserts the insertion portion into the air flow path.
  • a method of supporting the reinforcing member by inserting is configured to press the inner surface of the reinforcing member in a state of being inserted into the air flow channel.
  • the core material and the reinforcing member are disposed between the first and second resin sheets, and the reinforcing member is a portion adjacent to the core material.
  • the core member is supported by the reinforcing member, the reinforcing member has an opening at the adjacent portion, the opening is in communication with the air flow path, and the insertion portion is
  • the method is configured to not block the air flow path.
  • the reinforcing member is supported by the support device in a horizontally oriented state.
  • FIG. 6 is a cross-sectional view showing a shaping process and an insertion process in the same cross section as FIG. 5.
  • FIG. 6 is a perspective view of a state in which the reinforcing members 5 and 6 and the core material 3 are supported by a support device 8;
  • FIG. 8 is a perspective view of the main part of the support device 8; It is an enlarged view of protrusion part 5b, 6b vicinity of FIG. 11A and B are cross-sectional views of the protruding portions 5b and 6b in the state in which the insertion portions 8a and 8b are inserted, respectively.
  • FIG. 7 is a perspective view of a state in which the reinforcing members 5 and 6 are inserted into the core material 3; It is an enlarged view of reinforcement member 5 vicinity of FIG. FIG.
  • FIG. 14 is a perspective view of FIG. 13 with the reinforcing member 5 removed.
  • 15A-15B are respectively a plan view and a front view of FIG. 14, and
  • FIG. 15C is a cross-sectional view taken along the line BB in FIG. 15A.
  • It is a perspective view of the reinforcement members 5 and 6 and the connection member 7 in FIG. 17A to 17B are enlarged views in the vicinity of the protrusions 5b and 6b of FIG.
  • FIG. 9 is an enlarged cross-sectional view in the vicinity of the opening 5 d of FIG. 8 in a cross section passing through the center of the opening 5 d and parallel to the side surface 3 a.
  • FIG. 14 is a cross-sectional view taken along line AA in FIG. FIG.
  • FIGS. 23A to 23C are views corresponding to FIGS. 15A to 15C, of the resin panel 1 according to the second embodiment of the present invention.
  • the resin panel 1 of the first embodiment of the present invention includes a panel portion 1a and projecting portions 1b and 1c.
  • the panel portion 1a has a plate shape, and the projecting portions 1b and 1c project from the side surface of the panel portion 1a.
  • the resin panel 1 is covered with a resin wall 2. It is preferable that the resin wall 2 has no hole. Further, it is preferable that the resin wall 2 has no hole formed at the completion of molding, rather than the hole formed at the completion of molding being closed by post processing or another member. When the resin wall 2 has a hole, there is a possibility that water or dust may get inside the resin panel 1. Moreover, since what closed the hole by post-processing or another member may open a hole again by impact etc., resin wall 2 is formed by the molding method by which the hole is not formed in resin wall 2 Is preferred.
  • a core 3 and reinforcing members 5 and 6 are disposed inside the resin panel 1.
  • the reinforcing members 5 and 6 are provided so as to protrude from the side surface 3 a of the core material 3.
  • the core material 3 has a function of improving the strength of the resin panel 1 and the like, and is made of a foam or the like.
  • the reinforcing members 5 and 6 are adjacent to the core material 3.
  • the reinforcing members 5 and 6 are formed of a material (example: non-foamed resin or metal) having a rigidity higher than that of the core 3 to further improve the strength of the resin panel 1 or to form a portion protruding from the core 3
  • the reinforcing members 5 and 6 preferably have an elongated shape, and have portions whose cross-sectional shape is constant along the longitudinal direction, and the ratio of length to width is 10 or more.
  • the reinforcing members 5 and 6 are preferably in the form of a pipe having a round cross section, but may be in the shape of a square cross section, an H section or a C section.
  • the reinforcing members 5 and 6 have adjacent portions 5 a and 6 a adjacent to the core 3 and protrusions 5 b and 6 b protruding from the side surface of the core 3. As shown in FIGS. 11 and 16 to 17, the shapes of the adjacent parts 5a and 6a are the same, but the cross-sectional shapes of the protrusions 5b and 6b are different. For this reason, the cross-sectional shapes of the protrusions 1b and 1c of the resin panel 1 are also different. Although the protrusions 1b and 1c can be used to attach the resin panel 1 to another member, the protrusions 1b and 1c also have different cross sectional shapes to prevent the resin panel 1 from being attached in the reverse direction. be able to. In the present embodiment, the protrusion 5 b has an oval cross section, and the protrusion 6 b has a circular cross section.
  • the portion in which the core 3 and the adjacent portions 5a and 6a are covered with the resin wall 2 is the panel portion 1a, and the portion in which the protruding portions 5b and 6b are covered with the resin wall 2 is the protruding portions 1b and 1c.
  • the diameters of the adjacent portions 5a and 6a are larger than the diameters of the protruding portions 5b and 6b. Thereby, the reinforcing members 5 and 6 are stably held.
  • “diameter” means the diameter of the circumscribed circle.
  • the adjacent portions 5 a and 6 a are inserted into the insertion holes 3 d and 3 e provided in the core member 3.
  • the reinforcing members 5 and 6 are preferably fixed to the core 3, and by welding the core 3 to the resin wall 2, the reinforcing members 5 and 6 and the core 3 are fixed.
  • the core material 3 has a front surface 3i and a back surface 3j facing each other.
  • a front surface side locking portion 3k and a back surface side locking portion 3l are provided on the front surface 3i and the back surface 3j.
  • the front surface side locking portion 3k locks the reinforcing member 5 inserted in the insertion hole 3d from the front surface 3i side
  • the back surface side locking portion 3l is a reinforcing member inserted in the insertion hole 3d 5 is locked from the back surface 3j side.
  • the front surface side locking portion 3k and the back surface side locking portion 3l are alternately arranged along the longitudinal direction of the insertion hole 3d.
  • the reinforcing member 5 is stably held in the insertion hole 3d.
  • the front surface side locking portion 3k and the back surface side locking portion 3l do not overlap in a plan view, and the front surface side locking portion 3k and the back surface side locking portion 3l A through hole 3m is provided between the two.
  • the insertion hole 3d is sandwiched between the front surface side locking portion 3k and the back surface side locking portion 3l.
  • the inner surfaces of the front surface side locking portion 3k and the back surface side locking portion 3l are arc-shaped, and are shaped along the outer surface of the adjacent portion 5a.
  • one or both of the front surface side locking portion 3k and the back surface side locking portion 3l may be configured to press the reinforcing member 5. That is, the front surface side locking portion 3k may press the reinforcing member 5 toward the back surface 3j, and the back surface side locking portion 3l may press the reinforcing member 5 toward the front surface 3i. You may do so. In this case, the reinforcing member 5 is held more stably in the insertion hole 3d. Such a configuration can be achieved by inserting the reinforcing member 5 into the insertion hole 3d while the reinforcing member 5 is pressed by one or both of the front surface side locking portion 3k and the back surface side locking portion 3l. .
  • the front surface side locking portion 3k and the back surface side locking portion 3l are provided so as to project from the front surface 3i and the back surface 3j, respectively.
  • the thickness of the front surface side locking portion 3k and the thickness of the back surface side locking portion 3l increase, and the reinforcing member 5 is held more stably.
  • the front surface side locking portion 3k and the back surface side locking portion 3l are melted and compressed in the case of the resin panel 1, and the front surface 3i and the back surface side locking portion 3l are formed. It becomes almost flush with the back surface 3j. At the time of compression, the rigidity of the front surface side locking portion 3k and the back surface side locking portion 3l is enhanced, so that the reinforcing member 5 is held more stably.
  • the reinforcing member 6 is also held in the insertion hole 3e by the same configuration.
  • the reinforcing members 5 and 6 have air flow paths 5 c and 6 c.
  • the air flow paths 5c, 6c are provided from the adjacent portions 5a, 6a to the protruding portions 5b, 6b. Openings 5d, 6d, 5e, 6e are provided in the adjacent portions 5a, 6a and the protruding portions 5b, 6b, respectively, so that the air can be easily removed at the time of manufacture.
  • the adjacent portions 5a and 6a have a plurality of (in the present embodiment, four at 90.degree. Intervals) openings 5d and 6d (in the present embodiment, 90) in the circumferential direction. 4) are provided at intervals.
  • the insertion hole 3 d includes a narrow portion 3 g and a wide portion 3 h.
  • the width of the insertion hole 3d in the wide width portion 3h is wider than the width of the insertion hole 3d in the narrow width portion 3g. That is, the wide portion 3h is recessed by one step than the narrow portion 3g.
  • the gap 3 f is provided in the wide portion 3 h.
  • the insertion hole 3e also has the same configuration.
  • the narrow portion 3g is provided at a portion where the front locking portion 3k and the back locking portion 3l are provided.
  • the wide portion 3h is provided in the through hole 3m between the front locking portion 3k and the back locking portion 3l.
  • the air between the core 3 and the resin sheet is discharged through the openings 5d and 6d, the air flow paths 5c and 6c, and the openings 5e and 6e. After the air is discharged, the openings 5e and 6e may be closed.
  • Grooves 3b communicating with the openings 5d, 6d are provided on the surface of the core member 3 so as to further facilitate air removal during manufacture. Further, the grooves 3b are formed in a lattice, which further facilitates air removal at the time of manufacture.
  • the air flow path 4 is provided between the outer surface of the reinforcing member 5 and the inner surface of the insertion hole 3d.
  • the air between the core material 3 and the resin sheet includes the groove 3b, the air flow path 4, the openings 5d and 6d, the air flow paths 5c and 6c, and the openings 5e and 6e. Exhausted through.
  • a plurality of (two in the present embodiment) reinforcing members 5 and 6 are provided at intervals.
  • the two reinforcing members 5 and 6 are connected to each other by the connecting member 7.
  • the connection member 7 is disposed along the side surface 3 c of the core 3.
  • the side surfaces 3a and 3c face each other.
  • the vertically penetrated openings 5 d and 6 d can be used to position the reinforcing members 5 and 6 when connecting the reinforcing members 5 and 6 to the connecting member 7.
  • the reinforcing members 5 and 6 can be positioned by inserting pins into the openings 5 d and 6 d.
  • the resin wall 2 which comprises the panel part 1a is provided with the front wall 2a, the back wall 2b, and the surrounding wall 2c which connects these.
  • the core 3 and the adjacent portions 5a and 6a are sandwiched by the front wall 2a and the back wall 2b and surrounded by the peripheral wall 2c.
  • the resin wall 2 constituting the projecting portions 1b and 1c includes a peripheral wall 2d and an end wall 2e.
  • the circumferential surfaces of the protrusions 5b and 6b are surrounded by the peripheral wall 2d, and the end faces of the protrusions 5b and 6b are covered by the end wall 2e.
  • the walls 2 a to 2 e are connected to each other, and the core 3 and the reinforcing members 5 and 6 are entirely surrounded by the resin wall 2.
  • the core material 3 and the reinforcing members 5 and 6 are preferably completely surrounded by the resin wall 2, but a portion may be exposed.
  • Examples of applications of the resin panel 1 include automobile headrests, chair backrests, partitions, side rails, and the like.
  • the molding machine 10 includes a pair of resin sheet forming devices 20 and a pair of molds 21 and 31.
  • Each resin sheet forming apparatus 20 includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18.
  • the extruder 13 and the accumulator 17 are connected via a connecting pipe 25.
  • the accumulator 17 and the T-die 18 are connected via a connecting pipe 27.
  • the hopper 12 is used to introduce the raw material resin 11 into the cylinder 13 a of the extruder 13.
  • the form of the raw material resin 11 is not particularly limited, but is usually in the form of pellets.
  • the raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer and mixtures thereof.
  • the raw material resin 11 is introduced into the cylinder 13a from the hopper 12 and then melted by being heated in the cylinder 13a to become a molten resin.
  • the screw is disposed in the cylinder 13a and is conveyed while kneading the molten resin by its rotation.
  • a gear device is provided at the proximal end of the screw, and the screw device is rotationally driven by the gear device.
  • the number of screws disposed in the cylinder 13a may be one or two or more.
  • the molten resin is extruded from the resin extrusion port of the cylinder 13 a and injected into the accumulator 17 through the connecting pipe 25.
  • the accumulator 17 includes a cylinder 17a and a piston 17b slidable therein, and the molten resin 11a can be stored in the cylinder 17a. Then, after the molten resin 11a is stored in the cylinder 17a by a predetermined amount, the piston 17b is moved to extrude the molten resin 11a from the slit provided in the T die 18 through the connecting pipe 27 and hang down to be in a molten state.
  • the resin sheets 23 and 33 are formed.
  • the resin sheets 23 and 33 are suspended between the molds 21 and 31.
  • the molds 21 and 31 have cavities 21a and 31a, and pinch off portions 21b and 31b are provided so as to surround the cavities 21a and 31a.
  • vacuum suction holes (not shown) are provided, and the resin sheets 23 and 33 are vacuum suctioned through the vacuum suction holes and along the inner surfaces of the cavities 21a and 31a of the molds 21 and 31. It is possible to shape in the shape of The decompression suction hole is a very small hole, and one end thereof is communicated with the inner surface of the cavity 21a, 31a through the inside of the mold 21, 31, and the other end is connected to the decompression device.
  • the method of the present embodiment comprises a drooping step, a shaping step, an inserting step, and a clamping step. The details will be described below.
  • the shaping step as shown in FIGS. 5 to 6, while the resin sheets 23 and 33 are in contact with the pinch-off portions 21b and 31b, respectively, vacuum suction is performed by the molds 21 and 31.
  • the resin sheets 23, 33 are shaped into a shape along the inner surfaces of the cavities 21a, 31a.
  • the shaping process may be performed after the inserting process. Also, it may be performed before the mold clamping process or may be performed simultaneously with the mold clamping process.
  • the shaping process may be omitted.
  • the core material 3 and the reinforcing members 5 and 6 are disposed between the resin sheets 23 and 33.
  • the core member 3 is supported by the reinforcing members 5 and 6, and the reinforcing members 5 and 6 are supported by the supporting device 8, thereby accurately arranging the core member 3 and the reinforcing members 5 and 6.
  • the support device 8 has elongated insertion portions 8a and 8b. As shown in FIGS. 10 to 11, the support device 8 supports the reinforcing members 5 and 6 by inserting the insertion portions 8a and 8b into the air flow paths 5c and 6c, respectively.
  • the support device 8 includes enlarged diameter portions 8a2 and 8b2 at the root side of the insertion portions 8a and 8b.
  • the reinforcement members 5 and 6 can be positioned in the longitudinal direction of the reinforcement members 5 and 6 by bringing the reinforcement members 5 and 6 into contact with the enlarged diameter portions 8 a 2 and 8 b 2.
  • the longitudinal length Lb of the insertion portion 8b is longer than the longitudinal length La of the insertion portion 8a.
  • the tip of the insertion portion 8b is disposed so as to protrude further than the tip of the insertion portion 8a. Therefore, after the insertion portion 8b is inserted into the air flow path 6c, the insertion portion 8a can be inserted into the air flow path 5c, which is excellent in workability.
  • the insertion portion 8a includes a pair of insertion pieces 8a1. As shown in FIG. 11A, the insertion portion 8a is configured to press the inner surface of the reinforcing member 5 by widening the distance between the pair of insertion pieces 8a1 with the insertion portion 8a inserted into the air flow path 5c. .
  • the pair of insertion pieces 8a1 is attached to the pair of linear sliders 8a3, and the distance between the pair of insertion pieces 8a1 changes with the sliding movement of the pair of linear sliders 8a3.
  • the reinforcing member 5 is supported with the reinforcing member 5 facing in the horizontal direction as in the present embodiment, there is a risk that the reinforcing member 5 may be detached from the supporting device 8. Is securely fixed to the support device 8.
  • the insertion part 8b is comprised by one rod in this embodiment, you may make it the structure similar to the insertion part 8a.
  • the resin panel 1 is inevitably A mold having a size corresponding to the long side of the mold is required, and the mold is enlarged.
  • the metal sheet 23, 33 is made of gold so that the hanging direction You can design a mold. Therefore, the mold size can be reduced.
  • FIG. 11A there is a gap between the pair of insertion pieces 8a1.
  • FIG. 11B there is also a gap between the insertion portion 8b and the inner surface of the protrusion 6b. Therefore, even if the insertion portions 8a and 8b are inserted into the air flow paths 5c and 6c, the air flow paths 5c and 6c are not blocked, so that the air can be smoothly removed through the air flow paths 5c and 6c.
  • the molds 21 and 31 have the end portions of the reinforcing member 5 Slide cores 21c, 21d, 31c, 31d (hereinafter, “slide cores 21c and the like") are provided at opposing positions.
  • the slide cores 21c and 31c are provided with pinch-off portions corresponding to the end portions of the protruding portions 5b.
  • the slide cores 21d, 31d are provided with pinch-off portions corresponding to the end portions of the protruding portions 6b.
  • the slide cores 21c and 31c are clamped, and the end face of the protrusion 5b is covered with the resin wall 2, and the slide cores 21d and 31d are clamped, and the end face of the protrusion 6b is covered with the resin wall 2.
  • the slide cores 21c and the like may be directly provided to the molds 21 and 31, but in the present embodiment, the slide cores 21c and the like are provided to the separation blocks 21c1, 21d1, 31c1, and 31d1 provided separably to the molds 21 and 31. Is provided. According to such a configuration, it is possible to easily cope with the shape change of the protrusions 5 b and 6 b.
  • the slide cores 21c and the like are arranged at the retracted position as shown in FIG. 22 when the molds 21 and 31 are clamped, so that the slide cores 21c and the like do not interfere with the insertion portions 8a and 8b. It has become.
  • the resin sheets 23 and 33 are formed on the portions other than the end portions of the protruding portions 5b and 6b (that is, the portions other than the portion where the slide core 21c and the like are provided). It pinches and welds with pinch off parts 21b and 31b.
  • the slide core 21c and the like are clamped.
  • the resin sheets 23 and 33 are sandwiched and pinched by the pinch-off portions of the slide core 21 c and the like also at the end portions of the protruding portions 5 b and 6 b. Since the slide core 21 c and the like are disposed at the retracted position when the molds 21 and 31 are clamped, the resin sheets 23 and 33 are stretched by that amount.
  • the resin sheets 23 and 33 are gradually slackened, and the slide core 21c and the like are clamped in a slackened state (in this case, The slide core 21c and the like are disposed at the clamping position shown in FIG. While the resin sheets 23 and 33 are stretched to cover the end faces of the projecting portions 5b and 6b when clamping the slide core 21c and the like, the slide cores 21c and the like are clamped while the resin sheets 23 and 33 are slackened. Therefore, the resin sheets 23 and 33 are not stretched locally excessively, and the resin wall 2 is prevented from being extremely thin in the vicinity of the end faces of the protruding portions 5 b and 6 b.
  • Air may be entrapped between the resin sheets 23 and 33 and the core 3 when the molds 21 and 31 are clamped. This air may be formed by the grooves 3b, the openings 5d and 6d, and the air flow path 5c. , 6c and the openings 5e, 6e, the air is prevented from remaining between the resin sheets 23, 33 and the core member 3 because the air is discharged to the outside.
  • the openings 5 e and 6 e are opened to the outside because the slide core 21 c and the like are not clamped. For this reason, air removal is performed smoothly.
  • the position of the end 3k1 of the front surface side locking portion 3k and the position of the end portion 3l1 of the back surface side locking portion 3l coincide in plan view. Even in such a mode, the same function and effect as those of the first embodiment can be obtained.
  • the air flow paths 5c and 6c communicate with the outside through the openings 5d and 6d provided on the side surfaces of the reinforcing members 5 and 6, but the reinforcing members
  • the air flow paths 5c, 6c may communicate with the outside through the gaps between the reinforcing members 5, 6 and the core 3.
  • the openings 5d and 6d may be provided on the end face of the reinforcing members 5 and 6 on the side of the adjacent parts 5a and 6a.
  • the openings 5d and 6d may be any shape that allows air to flow, and may be slits or the like instead of small holes.
  • the openings 5e and 6e are provided on the end faces of the protrusions 5b and 6b, but may be provided at other positions of the protrusions 5b and 6b.
  • the openings 5e and 6e can be provided at portions overlapping the slide core 21c and the like. This portion is not covered by the resin sheet when the molds 21 and 31 are clamped, so even if the openings 5e and 6e are provided at this position, the openings 5e and 6e may be blocked by the resin sheet. Absent.
  • the insertion portion 8a is configured to press the inner surface of the reinforcing member 5 by widening the distance between the pair of insertion pieces 8a1, but the diameter of the circumscribed circle of the insertion portion 8a may be changed by another configuration. You may enlarge it.
  • the projecting piece may be protruded from the side surface of the insertion portion 8a to press the inner surface of the reinforcing member 5.
  • the core material 3 can be omitted if unnecessary.
  • the reinforcing members 5 and 6 may be fixed by bonding or welding the reinforcing members 5 and 6 to the resin wall 2.
  • -Adjacent part 5a, 6a may be made to adjoin along the side of core material 3 instead of making insertion holes 3d and 3e provided in core material 3 insert.
  • core material 3 is constituted by two or more pieces and reinforcement members 5 and 6 are section H-shaped, it may constitute so that core materials of two sheets may be connected using a reinforcement member.
  • the reinforcing members 5 and 6 are connected by the connecting member 7, the reinforcing members 5 and 6 may not be connected.
  • the number of reinforcing members may be one or three or more.
  • four openings 5 d are provided vertically and horizontally, but the openings 5 d may be provided obliquely.
  • the openings provided in the oblique direction have an advantage that it is difficult to contact any of the resin sheets 23 and 33 and the core material 3.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

[Problem] To provide a resin panel capable of suppressing the generation of residual air. [Solution] The present invention provides a resin panel comprising a resin wall, a core, and a reinforcing member, wherein the core and the reinforcing member are surrounded by the resin wall, the reinforcing member has an air flow passage, the reinforcing member also has an adjacent portion adjacent to the core, and a protruding portion protruding from a side surface of the core, and the air flow passage is provided across a section from the adjacent portion to the protruding portion, and the air flow passage communicates with the outside of the air flow passage in both the adjacent portion and the protruding portion.

Description

樹脂製パネル及びその製造方法Resin panel and method of manufacturing the same
　本発明は、建築用途、車載用途、家具用途などで利用可能な樹脂性パネル及びその製造方法に関する。 The present invention relates to a resinous panel which can be used in architectural applications, in-vehicle applications, furniture applications and the like, and a method of manufacturing the same.
　特許文献１には、芯材と補強材が一体となった発泡構造体を樹脂シートに溶着させた後に、金型を型締めして樹脂製パネルを製造する方法が開示されている。 Patent Document 1 discloses a method of manufacturing a resin panel by clamping a mold after welding a foam structure in which a core material and a reinforcing material are integrated to a resin sheet.
特開２０１４－１２８９３８号公報JP 2014-128938 A
　特許文献１の方法では、発泡構造体と樹脂シートの間にエアが残留してしまい、その結果、樹脂製パネルの表面に残留エアに起因する膨らみができてしまったり、溶着不良によって剛性が低下したりするという問題が生じる場合がある。 In the method of Patent Document 1, air remains between the foam structure and the resin sheet, and as a result, the surface of the resin panel may have a bulge due to the remaining air, or the rigidity may be reduced due to welding failure. Problems may occur.
　また、特許文献１の方法では、発泡構造体の溶着が不十分な場合、発泡構造体の溶着後に、発泡構造体の位置がずれてしまう場合がある。発泡構造体の位置がずれると、発泡構造体が金型と干渉して金型を損傷させたり、樹脂製パネルが期待される性能を発揮しなかったりする場合があるという問題がある。発泡構造体の位置ずれの問題は、補強材の重量が大きい場合に特に顕著である。 Further, in the method of Patent Document 1, when the adhesion of the foam structure is insufficient, the position of the foam structure may be shifted after the adhesion of the foam structure. If the position of the foam structure is shifted, there is a problem that the foam structure may interfere with the mold to damage the mold or the resin panel may not exhibit the expected performance. The problem of misalignment of the foam structure is particularly noticeable when the weight of the reinforcing material is large.
　本発明はこのような事情に鑑みてなされたものであり、残留エアの発生を抑制することが可能な樹脂製パネルを提供するものである。 This invention is made in view of such a situation, and provides the resin-made panels which can suppress generation | occurrence | production of a residual air.
　また、本発明は、芯材及び補強部材のインサート位置のずれを抑制することが可能な樹脂製パネルの製造方法を提供するものである。 The present invention also provides a method of manufacturing a resinous panel capable of suppressing the displacement of the insert position of the core member and the reinforcing member.
　本発明によれば、樹脂製パネルであって、樹脂壁と、芯材と、補強部材を備え、前記芯材及び前記補強部材は、前記樹脂壁によって取り囲まれており、前記補強部材は、エア流路を有し、前記補強部材は、前記芯材に隣接する隣接部と、前記芯材の側面から突出する突出部を有し、前記エア流路は、前記隣接部から前記突出部に渡って設けられ、前記エア流路は、前記隣接部と前記突出部の両方において前記エア流路の外部と連通している、樹脂製パネルが提供される。 According to the present invention, the resin panel is provided with a resin wall, a core member, and a reinforcing member, the core member and the reinforcing member are surrounded by the resin wall, and the reinforcing member is air. It has a flow path, The reinforcement member has an adjacent part which adjoins the core material, and a projected part which protrudes from the side of the core material, and the air flow path extends from the adjacent part to the projection. The resin flow path is provided, and the air flow path communicates with the outside of the air flow path in both the adjacent portion and the projecting portion.
　本発明では、第１開口部、エア流路、及び第２開口部を通じて、樹脂シートと芯材の間のエアを抜くことができるので、残留エアの発生を抑制することができる。 In the present invention, since the air between the resin sheet and the core material can be extracted through the first opening, the air flow path, and the second opening, the generation of residual air can be suppressed.
　以下、本発明の種々の実施形態を例示する。以下に示す実施形態は互いに組み合わせ可能である。
　好ましくは、前記補強部材は、前記隣接部に前記エア流路に連通する第１開口部を備える、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、第１開口部は、前記樹脂壁に接触しないように設けられる、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、第１開口部は、前記補強部材の側面に設けられる、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、第１開口部は、前記芯材に対向する位置に設けられる、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、第１開口部が設けられている部位において前記補強部材と前記芯材の間の隙間が設けられている、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、第１開口部は、前記補強部材の周方向の複数箇所に設けられる、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、前記芯材の表面には、前記エア流路に連通する溝が設けられる、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、前記溝は、格子状に設けられる、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、前記補強部材は、前記突出部に前記エア流路に連通する第２開口部を備える、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、第２開口部は、前記補強部材の端面に設けられる、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、前記補強部材は、間隔を空けて複数設けられ、複数の前記補強部材は、連結部材によって互いに連結されており、前記連結部材は、前記芯材の第２側面に沿って配置され、第２側面は、第１側面に対向する、樹脂製パネルである。
　好ましくは、前記記載の樹脂製パネルであって、前記樹脂壁には穴が空いていない、樹脂製パネルである。
　　本発明の別の観点によれば、樹脂製パネルであって、樹脂壁と、芯材と、補強部材を備え、前記芯材及び前記補強部材は、前記樹脂壁によって取り囲まれており、前記補強部材は、前記芯材に設けられた挿通孔に挿入されており、前記芯材は、互いに対向するおもて面及び裏面を備え、前記芯材は、おもて面側係止部と、裏面側係止部を備え、前記おもて面側係止部は、前記補強部材を前記おもて面側から係止し、前記裏面側係止部は、前記補強部材を前記裏面側から係止し、前記おもて面側係止部と前記裏面側係止部は、前記挿通孔の長手方向に沿って、交互に並んで設けられる、樹脂製パネルが提供される。
　本発明のさらに別の観点によれば、樹脂製パネルの製造方法であって、垂下工程と、インサート工程と、型締め工程を備え、前記垂下工程では、第１及び第２金型の間に第１及び第２樹脂シートを垂下させ、前記インサート工程では、第１及び第２樹脂シートの間に芯材及び補強部材を配置し、前記型締め工程では、第１及び第２金型が型締めされ、前記補強部材は、エア流路を有し、前記補強部材は、前記芯材に隣接する隣接部と、前記芯材の側面から突出する突出部を有し、前記エア流路は、前記隣接部から前記突出部に渡って設けられ、前記エア流路は、前記隣接部と前記突出部の両方において前記エア流路の外部と連通している、方法が提供される。 Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with one another.
Preferably, the reinforcing member is a resin panel provided with a first opening communicating with the air flow passage at the adjacent portion.
Preferably, in the resin panel described above, the first opening is provided so as not to be in contact with the resin wall.
Preferably, in the resin panel described above, the first opening is a resin panel provided on the side surface of the reinforcing member.
Preferably, in the resin panel described above, the first opening is a resin panel provided at a position facing the core material.
Preferably, in the resin panel described above, a gap between the reinforcing member and the core member is provided at a portion where the first opening is provided.
Preferably, in the resin panel described above, the first opening is a resin panel provided at a plurality of circumferential positions of the reinforcing member.
Preferably, in the resin panel described above, a groove communicating with the air flow channel is provided on the surface of the core material.
Preferably, in the resin panel described above, the grooves are provided in a grid shape.
Preferably, in the resin panel described above, the reinforcing member is a resin panel provided with a second opening communicating with the air flow passage in the protrusion.
Preferably, in the resin panel described above, the second opening is a resin panel provided on an end face of the reinforcing member.
Preferably, in the resin panel described above, a plurality of the reinforcing members are provided at intervals, the plurality of the reinforcing members are connected to each other by a connecting member, and the connecting member is the core member. The second side is disposed along the second side, and the second side is a resin panel facing the first side.
Preferably, in the resin panel described above, the resin wall has no hole.
According to another aspect of the present invention, the resin panel is provided with a resin wall, a core and a reinforcing member, and the core and the reinforcing member are surrounded by the resin wall, and the reinforcing The member is inserted into the insertion hole provided in the core, the core has a front surface and a back surface facing each other, and the core is a front surface side locking portion; A back surface side locking portion is provided, the front surface side locking portion locks the reinforcing member from the front surface side, and the back surface side locking portion is configured to contact the reinforcing member from the back surface side A resin panel is provided, in which the front surface side locking portion and the back surface side locking portion are provided alternately along the longitudinal direction of the insertion hole.
According to still another aspect of the present invention, there is provided a method of manufacturing a resinous panel, comprising a hanging step, an inserting step, and a clamping step, wherein, in the hanging step, the space between the first and second molds. The first and second resin sheets are suspended, and in the inserting step, a core material and a reinforcing member are disposed between the first and second resin sheets, and in the clamping step, the first and second molds are dies. Tightened, the reinforcing member has an air flow path, the reinforcing member has an adjacent portion adjacent to the core member, and a protrusion projecting from the side surface of the core member, and the air flow path includes: A method is provided, which extends from the adjacent part to the projecting part, and the air flow path communicates with the outside of the air flow path in both the adjacent part and the protruding part.
　また、本発明によれば、樹脂製パネルの製造方法であって、垂下工程と、インサート工程と、型締め工程を備え、前記垂下工程では、第１及び第２金型の間に第１及び第２樹脂シートを垂下させ、前記インサート工程では、第１及び第２樹脂シートの間に補強部材を配置し、前記インサート工程では、前記補強部材は、支持装置によって支持されており、前記型締め工程では、前記補強部材が前記支持装置によって支持された状態で第１及び第２金型が型締めされる、方法が提供される。 Further, according to the present invention, there is provided a method of manufacturing a resin panel, the method comprising: a drooping step, an inserting step, and a clamping step, wherein in the drooping step, the first and second dies are interposed between the first and second molds. A second resin sheet is suspended, and in the inserting step, a reinforcing member is disposed between the first and second resin sheets, and in the inserting step, the reinforcing member is supported by a support device, and the mold is tightened. In a process, a method is provided, wherein the first and second molds are clamped while the reinforcing member is supported by the support device.
　本発明では、芯材が補強部材によって支持され、補強部材が支持装置によって支持された状態 で第１及び第２金型が型締めされるので、補強部材の重量が大きい場合でも、芯材及び補強部材のインサート位置のずれを抑制することができる。 In the present invention, since the core material is supported by the reinforcing member and the first and second molds are clamped while the reinforcing member is supported by the supporting device, the core material and the reinforcing member are heavy even when the weight is large. Deviation of the insert position of the reinforcing member can be suppressed.
　以下、本発明の種々の実施形態を例示する。以下に示す実施形態は互いに組み合わせ可能である。
　好ましくは、前記記載の方法であって、前記インサート工程では、第１及び第２樹脂シートの間に芯材及び前記補強部材を配置し、前記補強部材は、前記芯材に隣接する隣接部を有し、前記芯材は、前記補強部材によって支持されている、方法である。
　好ましくは、前記記載の方法であって、前記補強部材は、前記芯材の側面から突出する突出部を有する、方法である。
　好ましくは、前記記載の方法であって、第１及び第２金型の少なくとも一方は、前記補強部材の端部に対向する位置にスライドコアを有し、前記スライドコアは、前記型締め工程では、前記支持装置に干渉しないように退避位置に配置され、前記型締めの工程の後に、端部被覆工程を備え、前記端部被覆工程では、前記スライドコアを型締め位置に移動させることによって第１及び第２樹脂シートの少なくとも一方で前記補強部材の端部を被覆する、方法である。
　好ましくは、前記記載の方法であって、前記補強部材は、エア流路を有し、前記支持装置は、細長い挿入部を有し、前記支持装置は、前記挿入部を前記エア流路内に挿入することによって前記補強部材を支持する、方法である。
　好ましくは、前記記載の方法であって、前記挿入部は、前記エア流路内に挿入された状態で前記補強部材の内面を押圧するように構成される、方法である。
　好ましくは、前記記載の方法であって、前記インサート工程では、第１及び第２樹脂シートの間に芯材及び前記補強部材を配置し、前記補強部材は、前記芯材に隣接する隣接部を有し、前記芯材は、前記補強部材によって支持され、前記補強部材は、前記隣接部に開口部を有し、前記開口部は、前記エア流路に連通しており、前記挿入部は、前記エア流路を閉塞させないように構成される、方法である。
　好ましくは、前記記載の方法であって、前記補強部材は、水平方向に向いた状態で前記支持装置によって支持される、方法である。 Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with one another.
Preferably, in the method described above, in the inserting step, the core material and the reinforcing member are disposed between the first and second resin sheets, and the reinforcing member is a portion adjacent to the core material. And the core material is supported by the reinforcing member.
Preferably, in the method described above, the reinforcing member has a protrusion protruding from the side surface of the core material.
Preferably, in the method described above, at least one of the first and second molds has a slide core at a position facing the end of the reinforcing member, and the slide core is formed by the clamping step. An end covering process disposed after the mold clamping process, the end covering process including moving the slide core to the mold clamping position; In the method, at least one of the first and second resin sheets covers the end of the reinforcing member.
Preferably, in the method described above, the reinforcing member has an air flow path, the support device has an elongated insertion portion, and the support device inserts the insertion portion into the air flow path. A method of supporting the reinforcing member by inserting.
Preferably, in the method described above, the insertion portion is configured to press the inner surface of the reinforcing member in a state of being inserted into the air flow channel.
Preferably, in the method described above, in the inserting step, the core material and the reinforcing member are disposed between the first and second resin sheets, and the reinforcing member is a portion adjacent to the core material. The core member is supported by the reinforcing member, the reinforcing member has an opening at the adjacent portion, the opening is in communication with the air flow path, and the insertion portion is The method is configured to not block the air flow path.
Preferably, in the method described above, the reinforcing member is supported by the support device in a horizontally oriented state.
本発明の第１実施形態の樹脂製パネル１の斜視図である。It is a perspective view of the resin-made panel 1 of 1st Embodiment of this invention. 図１の樹脂製パネル１の樹脂壁２の一部を除去した状態の斜視図である。It is a perspective view in the state where a part of resin wall 2 of panel 1 made of resin of Drawing 1 was removed. 図２の突出部５ｂ近傍の拡大図である。It is an enlarged view of the protrusion part 5b vicinity of FIG. 本発明の一実施形態の樹脂製パネル１の製造の利用可能な成形機１０の構成図（金型２１，３１及び樹脂シート２３，３３については断面図）である。It is a block diagram (a sectional view about molds 21 and 31 and resin sheets 23 and 33) of usable molding machine 10 of manufacture of resin panel 1 of one embodiment of the present invention. 開口部５ｄの中央を通り且つ側面３ａに平行な断面での垂下工程を示す断面図である。It is sectional drawing which shows the drooping process in the cross section which passes through the center of the opening 5d and is parallel to the side 3a. 図５と同じ断面での賦形工程及びインサート工程を示す断面図である。FIG. 6 is a cross-sectional view showing a shaping process and an insertion process in the same cross section as FIG. 5. 図５と同じ断面での型締め工程を示す断面図である。It is sectional drawing which shows the clamping process in the same cross section as FIG. 補強部材５，６及び芯材３が支持装置８で支持されている状態の斜視図である。FIG. 6 is a perspective view of a state in which the reinforcing members 5 and 6 and the core material 3 are supported by a support device 8; 支持装置８の主要部の斜視図である。FIG. 8 is a perspective view of the main part of the support device 8; 図８の突出部５ｂ，６ｂ近傍の拡大図である。It is an enlarged view of protrusion part 5b, 6b vicinity of FIG. 図１１Ａ～図Ｂは、それぞれ、挿入部８ａ，８ｂが挿入された状態での、突出部５ｂ，６ｂの断面図である。11A and B are cross-sectional views of the protruding portions 5b and 6b in the state in which the insertion portions 8a and 8b are inserted, respectively. 芯材３に補強部材５，６が挿入された状態の斜視図である。FIG. 7 is a perspective view of a state in which the reinforcing members 5 and 6 are inserted into the core material 3; 図１２の補強部材５近傍の拡大図である。It is an enlarged view of reinforcement member 5 vicinity of FIG. 図１３から補強部材５を除いた状態の斜視図である。FIG. 14 is a perspective view of FIG. 13 with the reinforcing member 5 removed. 図１５Ａ～図１５Ｂは、それぞれ、図１４の平面図及び正面図であり、図１５Ｃは、図１５Ａ中のＢ－Ｂ断面図である。15A-15B are respectively a plan view and a front view of FIG. 14, and FIG. 15C is a cross-sectional view taken along the line BB in FIG. 15A. 図１２中の補強部材５，６及び連結部材７の斜視図である。It is a perspective view of the reinforcement members 5 and 6 and the connection member 7 in FIG. 図１７Ａ～図１７Ｂは、図１６の突出部５ｂ，６ｂ近傍の拡大図である。17A to 17B are enlarged views in the vicinity of the protrusions 5b and 6b of FIG. 開口部５ｄの中央を通り且つ側面３ａに平行な断面での、図８の開口部５ｄ近傍の拡大断面図である。FIG. 9 is an enlarged cross-sectional view in the vicinity of the opening 5 d of FIG. 8 in a cross section passing through the center of the opening 5 d and parallel to the side surface 3 a. 図１３中のＡ－Ａ断面図である。FIG. 14 is a cross-sectional view taken along line AA in FIG. 金型２１，３１の斜視図である。FIG. 2 is a perspective view of molds 21 and 31. スライドコア２１ｃが型締め位置にある状態での、分離ブロック２１ｃ１及びスライドコア２１ｃの斜視図である。It is a perspective view of separation block 21c1 and slide core 21c in the state where slide core 21c is in a clamp position. スライドコア２１ｃが退避位置にある状態での、分離ブロック２１ｃ１及びスライドコア２１ｃの斜視図である。It is a perspective view of separation block 21c1 and slide core 21c in the state where slide core 21c is in a retreat position. 図２３Ａ～図２３Ｃは、本発明の第２実施形態の樹脂製パネル１についての、図１５Ａ～図１５Ｃに対応する図である。FIGS. 23A to 23C are views corresponding to FIGS. 15A to 15C, of the resin panel 1 according to the second embodiment of the present invention.
　以下、図面を用いて本発明の実施形態について説明する。以下に示す実施形態中で示した各種特徴事項は、互いに組み合わせ可能である。また、各特徴事項について独立して発明が成立する。 Hereinafter, embodiments of the present invention will be described using the drawings. The various features shown in the embodiments described below can be combined with one another. In addition, the invention is established independently for each feature.
１．第１実施形態の樹脂製パネルの構造
　図１～図３に示すように、本発明の第１実施形態の樹脂製パネル１は、パネル部１ａと、突出部１ｂ，１ｃを備える。パネル部１ａは、板状であり、突出部１ｂ，１ｃは、パネル部１ａの側面から突出する。樹脂製パネル１は、樹脂壁２で被覆されている。樹脂壁２には穴が空いていないことが好ましい。また、樹脂壁２は、成形完了時点で形成されている穴を後加工又は別部材によって塞いだものであるよりは、成形完了時点で穴が形成されていないものであることが好ましい。樹脂壁２に穴が空いていると樹脂製パネル１の内部に水やゴミが入り込む虞がある。また、後加工又は別部材によって穴を塞いだものは、衝撃等によって穴が再び開いてしまう虞があるので、樹脂壁２は、樹脂壁２に穴が形成されない成形方法によって形成されたものであることが好ましい。 1. Structure of Resin Panel of First Embodiment As shown in FIGS. 1 to 3, the resin panel 1 of the first embodiment of the present invention includes a panel portion 1a and projecting portions 1b and 1c. The panel portion 1a has a plate shape, and the projecting portions 1b and 1c project from the side surface of the panel portion 1a. The resin panel 1 is covered with a resin wall 2. It is preferable that the resin wall 2 has no hole. Further, it is preferable that the resin wall 2 has no hole formed at the completion of molding, rather than the hole formed at the completion of molding being closed by post processing or another member. When the resin wall 2 has a hole, there is a possibility that water or dust may get inside the resin panel 1. Moreover, since what closed the hole by post-processing or another member may open a hole again by impact etc., resin wall 2 is formed by the molding method by which the hole is not formed in resin wall 2 Is preferred.
　図２に示すように、樹脂製パネル１の内部には、芯材３と、補強部材５，６が配置されている。補強部材５，６は、芯材３の側面３ａから突出するように設けられている。芯材３は、樹脂製パネル１の強度を向上させる等の機能を有し、発泡体などで構成される。芯材３には、補強部材５，６が隣接されている。補強部材５，６は、芯材３よりも剛性の高い材料（例：非発泡樹脂や金属）で形成され、樹脂製パネル１の強度をさらに向上させたり、芯材３から突出する部位を形成したりする等の目的で設けられる。補強部材５，６は、好ましくは、細長い形状であり、その長手方向に沿って断面形状が一定である部位を有し、幅に対する長さの比が１０以上である。補強部材５，６は、好ましくは断面丸形状のパイプ状であるが、断面四角形状、断面Ｈ形状又は断面Ｃ形状などの形状であってもよい。 As shown in FIG. 2, a core 3 and reinforcing members 5 and 6 are disposed inside the resin panel 1. The reinforcing members 5 and 6 are provided so as to protrude from the side surface 3 a of the core material 3. The core material 3 has a function of improving the strength of the resin panel 1 and the like, and is made of a foam or the like. The reinforcing members 5 and 6 are adjacent to the core material 3. The reinforcing members 5 and 6 are formed of a material (example: non-foamed resin or metal) having a rigidity higher than that of the core 3 to further improve the strength of the resin panel 1 or to form a portion protruding from the core 3 Provided for the purpose of The reinforcing members 5 and 6 preferably have an elongated shape, and have portions whose cross-sectional shape is constant along the longitudinal direction, and the ratio of length to width is 10 or more. The reinforcing members 5 and 6 are preferably in the form of a pipe having a round cross section, but may be in the shape of a square cross section, an H section or a C section.
　補強部材５，６は、芯材３に隣接する隣接部５ａ，６ａと、芯材３の側面から突出する突出部５ｂ，６ｂを有する。図１１、図１６～図１７に示すように、隣接部５ａ，６ａの形状は、同一であるが、突出部５ｂ，６ｂは、断面形状が異なっている。このため、樹脂製パネル１の突出部１ｂ，１ｃも断面形状が異なる。突出部１ｂ，１ｃは、樹脂製パネル１を別の部材に取り付けるために利用可能であるが、突出部１ｂ，１ｃも断面形状を異ならせることによって樹脂製パネル１を逆向きに取り付けることを防ぐことができる。本実施形態では、突出部５ｂは断面が長円形状であり，突出部６ｂは断面が円形状である。 The reinforcing members 5 and 6 have adjacent portions 5 a and 6 a adjacent to the core 3 and protrusions 5 b and 6 b protruding from the side surface of the core 3. As shown in FIGS. 11 and 16 to 17, the shapes of the adjacent parts 5a and 6a are the same, but the cross-sectional shapes of the protrusions 5b and 6b are different. For this reason, the cross-sectional shapes of the protrusions 1b and 1c of the resin panel 1 are also different. Although the protrusions 1b and 1c can be used to attach the resin panel 1 to another member, the protrusions 1b and 1c also have different cross sectional shapes to prevent the resin panel 1 from being attached in the reverse direction. be able to. In the present embodiment, the protrusion 5 b has an oval cross section, and the protrusion 6 b has a circular cross section.
　芯材３及び隣接部５ａ，６ａが樹脂壁２で被覆された部位がパネル部１ａとなり、突出部５ｂ，６ｂが樹脂壁２で被覆された部位が突出部１ｂ，１ｃとなる。隣接部５ａ，６ａの直径が突出部５ｂ，６ｂの直径よりも大きくなっている。これによって、補強部材５，６が安定して保持される。なお、本明細書において、「直径」とは、外接円の直径を意味する。隣接部５ａ，６ａは、芯材３に設けた挿通孔３ｄ，３ｅに挿通されている。補強部材５，６は、好ましくは、芯材３に固定され、芯材３が樹脂壁２に溶着されることによって、補強部材５，６及び芯材３が固定される。 The portion in which the core 3 and the adjacent portions 5a and 6a are covered with the resin wall 2 is the panel portion 1a, and the portion in which the protruding portions 5b and 6b are covered with the resin wall 2 is the protruding portions 1b and 1c. The diameters of the adjacent portions 5a and 6a are larger than the diameters of the protruding portions 5b and 6b. Thereby, the reinforcing members 5 and 6 are stably held. In the present specification, “diameter” means the diameter of the circumscribed circle. The adjacent portions 5 a and 6 a are inserted into the insertion holes 3 d and 3 e provided in the core member 3. The reinforcing members 5 and 6 are preferably fixed to the core 3, and by welding the core 3 to the resin wall 2, the reinforcing members 5 and 6 and the core 3 are fixed.
　図１４～図１５に示すように、芯材３は、互いに対向するおもて面３ｉ及び裏面３ｊを備える。おもて面３ｉ及び裏面３ｊには、おもて面側係止部３ｋと裏面側係止部３ｌが設けられている。おもて面側係止部３ｋは、挿通孔３ｄに挿通された補強部材５をおもて面３ｉ側から係止し、裏面側係止部３ｌは、挿通孔３ｄに挿通された補強部材５を裏面３ｊ側から係止する。おもて面側係止部３ｋと裏面側係止部３ｌは、挿通孔３ｄの長手方向に沿って交互に並んで設けられている。このような構成によって、補強部材５が挿通孔３ｄ内に安定して保持される。図１５Ａに示すように、おもて面側係止部３ｋと裏面側係止部３ｌは、平面視において重なっておらず、おもて面側係止部３ｋと裏面側係止部３ｌの間には、貫通孔３ｍが設けられている。また、図１５Ｂの正面図において、挿通孔３ｄは、おもて面側係止部３ｋと裏面側係止部３ｌで挟まれている。また、図１５Ｂに示すように、おもて面側係止部３ｋと裏面側係止部３ｌの内面は、それぞれ円弧状であり、隣接部５ａの外面に沿った形状になっている。 As shown in FIGS. 14 to 15, the core material 3 has a front surface 3i and a back surface 3j facing each other. A front surface side locking portion 3k and a back surface side locking portion 3l are provided on the front surface 3i and the back surface 3j. The front surface side locking portion 3k locks the reinforcing member 5 inserted in the insertion hole 3d from the front surface 3i side, and the back surface side locking portion 3l is a reinforcing member inserted in the insertion hole 3d 5 is locked from the back surface 3j side. The front surface side locking portion 3k and the back surface side locking portion 3l are alternately arranged along the longitudinal direction of the insertion hole 3d. With such a configuration, the reinforcing member 5 is stably held in the insertion hole 3d. As shown in FIG. 15A, the front surface side locking portion 3k and the back surface side locking portion 3l do not overlap in a plan view, and the front surface side locking portion 3k and the back surface side locking portion 3l A through hole 3m is provided between the two. Further, in the front view of FIG. 15B, the insertion hole 3d is sandwiched between the front surface side locking portion 3k and the back surface side locking portion 3l. Further, as shown in FIG. 15B, the inner surfaces of the front surface side locking portion 3k and the back surface side locking portion 3l are arc-shaped, and are shaped along the outer surface of the adjacent portion 5a.
　なお、おもて面側係止部３ｋと裏面側係止部３ｌの一方又は両方は、補強部材５を押圧するように構成してもよい。つまり、おもて面側係止部３ｋが補強部材５を裏面３ｊに向かって押圧するようにしてもよく、裏面側係止部３ｌが補強部材５をおもて面３ｉに向かって押圧するようにしてもよい。この場合、補強部材５が挿通孔３ｄ内に、さらに安定して保持される。おもて面側係止部３ｋと裏面側係止部３ｌの一方又は両方によって補強部材５が押圧されながら補強部材５を挿通孔３ｄ内に挿入することによってこのような構成とすることができる。 Note that one or both of the front surface side locking portion 3k and the back surface side locking portion 3l may be configured to press the reinforcing member 5. That is, the front surface side locking portion 3k may press the reinforcing member 5 toward the back surface 3j, and the back surface side locking portion 3l may press the reinforcing member 5 toward the front surface 3i. You may do so. In this case, the reinforcing member 5 is held more stably in the insertion hole 3d. Such a configuration can be achieved by inserting the reinforcing member 5 into the insertion hole 3d while the reinforcing member 5 is pressed by one or both of the front surface side locking portion 3k and the back surface side locking portion 3l. .
　図１４では、おもて面側係止部３ｋと裏面側係止部３ｌは、それぞれ、おもて面３ｉ及び裏面３ｊから突出するように設けられている。これによって、おもて面側係止部３ｋと裏面側係止部３ｌの肉厚が大きくなって、補強部材５がより安定して保持されるようになっている。また、おもて面側係止部３ｋと裏面側係止部３ｌは、図６～図７に示すように、樹脂製パネル１の際に溶融されて圧縮されて、おもて面３ｉ及び裏面３ｊと略面一になる。圧縮の際に、おもて面側係止部３ｋと裏面側係止部３ｌの剛性が高められるので、補強部材５がより安定して保持される。 In FIG. 14, the front surface side locking portion 3k and the back surface side locking portion 3l are provided so as to project from the front surface 3i and the back surface 3j, respectively. As a result, the thickness of the front surface side locking portion 3k and the thickness of the back surface side locking portion 3l increase, and the reinforcing member 5 is held more stably. Further, as shown in FIGS. 6 to 7, the front surface side locking portion 3k and the back surface side locking portion 3l are melted and compressed in the case of the resin panel 1, and the front surface 3i and the back surface side locking portion 3l are formed. It becomes almost flush with the back surface 3j. At the time of compression, the rigidity of the front surface side locking portion 3k and the back surface side locking portion 3l is enhanced, so that the reinforcing member 5 is held more stably.
　補強部材６も、同様の構成によって、挿通孔３ｅ内に保持される。 The reinforcing member 6 is also held in the insertion hole 3e by the same configuration.
　図１１及び図１７に示すように、補強部材５，６は、エア流路５ｃ，６ｃを有している。エア流路５ｃ，６ｃは、隣接部５ａ，６ａから突出部５ｂ，６ｂに渡って設けられている。隣接部５ａ，６ａ及び突出部５ｂ，６ｂには、それぞれ開口部５ｄ，６ｄ，５ｅ，６ｅが設けられており、これによって製造時のエア抜きが容易になっている。なお、図１７～図１８に示すように、隣接部５ａ，６ａには、周方向に複数（本実施形態では、９０度間隔で４つ）の開口部５ｄ，６ｄ（本実施形態では、９０度間隔で４つ）が設けられている。そのうちの少なくとも１つは樹脂壁２に接触しないようになっている。これによって樹脂壁２によって開口部５ｄ，６ｄが閉塞されることが抑制される。また、開口部５ｄ，６ｄが設けられている部位において補強部材５，６と芯材３の間の隙間３ｆが設けられている。これによって、芯材３に対向する開口部５ｄ，６ｄが閉塞されることが抑制される。また、挿通孔３ｄは、図１３～図１４及び図１８～図１９に示すように、狭幅部３ｇと、広幅部３ｈを備える。広幅部３ｈでの挿通孔３ｄの幅は、狭幅部３ｇでの挿通孔３ｄの幅よりも広くなっている。つまり、広幅部３ｈは、狭幅部３ｇよりも一段凹んでいる。隙間３ｆは、広幅部３ｈに設けられている。挿通孔３ｅも同様の構成を有する。 As shown in FIGS. 11 and 17, the reinforcing members 5 and 6 have air flow paths 5 c and 6 c. The air flow paths 5c, 6c are provided from the adjacent portions 5a, 6a to the protruding portions 5b, 6b. Openings 5d, 6d, 5e, 6e are provided in the adjacent portions 5a, 6a and the protruding portions 5b, 6b, respectively, so that the air can be easily removed at the time of manufacture. As shown in FIGS. 17 to 18, the adjacent portions 5a and 6a have a plurality of (in the present embodiment, four at 90.degree. Intervals) openings 5d and 6d (in the present embodiment, 90) in the circumferential direction. 4) are provided at intervals. At least one of them is not in contact with the resin wall 2. As a result, blocking of the openings 5 d and 6 d by the resin wall 2 is suppressed. In addition, a gap 3f between the reinforcing members 5 and 6 and the core member 3 is provided at a portion where the openings 5d and 6d are provided. As a result, the closing of the openings 5 d and 6 d facing the core material 3 is suppressed. Further, as shown in FIGS. 13 to 14 and FIGS. 18 to 19, the insertion hole 3 d includes a narrow portion 3 g and a wide portion 3 h. The width of the insertion hole 3d in the wide width portion 3h is wider than the width of the insertion hole 3d in the narrow width portion 3g. That is, the wide portion 3h is recessed by one step than the narrow portion 3g. The gap 3 f is provided in the wide portion 3 h. The insertion hole 3e also has the same configuration.
　狭幅部３ｇは、おもて面側係止部３ｋ及び裏面側係止部３ｌが設けられる部位に設けられている。広幅部３ｈは、おもて面側係止部３ｋと裏面側係止部３ｌの間の貫通孔３ｍに設けられている。 The narrow portion 3g is provided at a portion where the front locking portion 3k and the back locking portion 3l are provided. The wide portion 3h is provided in the through hole 3m between the front locking portion 3k and the back locking portion 3l.
　製造時には、芯材３と樹脂シートの間のエアが開口部５ｄ，６ｄ、エア流路５ｃ，６ｃ、開口部５ｅ，６ｅを通って排出される。エアの排出後には開口部５ｅ，６ｅは閉塞されてもよい。 At the time of manufacture, the air between the core 3 and the resin sheet is discharged through the openings 5d and 6d, the air flow paths 5c and 6c, and the openings 5e and 6e. After the air is discharged, the openings 5e and 6e may be closed.
　芯材３の表面には、開口部５ｄ，６ｄに連通する溝３ｂが設けられており、製造時のエア抜きがさらに容易になっている。さらに、溝３ｂが格子状に形成されることによって、製造時のエア抜きがさらに容易になっている。狭幅部３ｇでは、図１９に示すように、補強部材５の外面と挿通孔３ｄの内面の間にエア流路４が設けられている。狭幅部３ｇの近傍では、製造時には、芯材３と樹脂シートの間のエアは、溝３ｂ、エア流路４、開口部５ｄ，６ｄ、エア流路５ｃ，６ｃ、開口部５ｅ，６ｅを通って排出される。 Grooves 3b communicating with the openings 5d, 6d are provided on the surface of the core member 3 so as to further facilitate air removal during manufacture. Further, the grooves 3b are formed in a lattice, which further facilitates air removal at the time of manufacture. In the narrow portion 3g, as shown in FIG. 19, the air flow path 4 is provided between the outer surface of the reinforcing member 5 and the inner surface of the insertion hole 3d. In the vicinity of the narrow width portion 3g, at the time of manufacture, the air between the core material 3 and the resin sheet includes the groove 3b, the air flow path 4, the openings 5d and 6d, the air flow paths 5c and 6c, and the openings 5e and 6e. Exhausted through.
　図２及び図１６に示すように、補強部材５，６は、間隔を空けて複数（本実施形態では２つ）設けられている。２つの補強部材５，６は、連結部材７によって互いに連結されている。連結部材７は、芯材３の側面３ｃに沿って配置されている。側面３ａ，３ｃは対向している。上下方向に貫通された開口部５ｄ，６ｄは、補強部材５，６を連結部材７に連結させる際に、補強部材５，６の位置決めをするために利用可能である。例えば、開口部５ｄ，６ｄにピンを挿入することによって、補強部材５，６を位置決めすることができる。 As shown in FIGS. 2 and 16, a plurality of (two in the present embodiment) reinforcing members 5 and 6 are provided at intervals. The two reinforcing members 5 and 6 are connected to each other by the connecting member 7. The connection member 7 is disposed along the side surface 3 c of the core 3. The side surfaces 3a and 3c face each other. The vertically penetrated openings 5 d and 6 d can be used to position the reinforcing members 5 and 6 when connecting the reinforcing members 5 and 6 to the connecting member 7. For example, the reinforcing members 5 and 6 can be positioned by inserting pins into the openings 5 d and 6 d.
　パネル部１ａを構成する樹脂壁２は、表壁２ａと、裏壁２ｂと、これらを繋ぐ周囲壁２ｃを備える。芯材３及び隣接部５ａ，６ａは、表壁２ａと裏壁２ｂによって挟まれ、周囲壁２ｃによって取り囲まれる。突出部１ｂ，１ｃを構成する樹脂壁２は、周囲壁２ｄと、端壁２ｅを備える。突出部５ｂ，６ｂの周面は、周囲壁２ｄによって取り囲まれ、突出部５ｂ，６ｂの端面は、端壁２ｅによって被覆される。壁２ａ～２ｅは、互いに連結されており、芯材３及び補強部材５，６の全体が樹脂壁２によって取り囲まれる。芯材３及び補強部材５，６は、樹脂壁２によって完全に取り囲まれていることが好ましいが、一部が露出していてもよい。 The resin wall 2 which comprises the panel part 1a is provided with the front wall 2a, the back wall 2b, and the surrounding wall 2c which connects these. The core 3 and the adjacent portions 5a and 6a are sandwiched by the front wall 2a and the back wall 2b and surrounded by the peripheral wall 2c. The resin wall 2 constituting the projecting portions 1b and 1c includes a peripheral wall 2d and an end wall 2e. The circumferential surfaces of the protrusions 5b and 6b are surrounded by the peripheral wall 2d, and the end faces of the protrusions 5b and 6b are covered by the end wall 2e. The walls 2 a to 2 e are connected to each other, and the core 3 and the reinforcing members 5 and 6 are entirely surrounded by the resin wall 2. The core material 3 and the reinforcing members 5 and 6 are preferably completely surrounded by the resin wall 2, but a portion may be exposed.
　樹脂製パネル１の用途としては、自動車のヘッドレスト、椅子の背もたれ、パーテーション、サイドレールなどが挙げられる。 Examples of applications of the resin panel 1 include automobile headrests, chair backrests, partitions, side rails, and the like.
２．成形機１０
　次に、図４を用いて、本発明の一実施形態の樹脂製パネルの製造方法の実施に利用可能な成形機１０について説明する。成形機１０は、一対の樹脂シート形成装置２０と、一対の金型２１，３１を備える。各樹脂シート形成装置２０は、ホッパー１２と、押出機１３と、アキュームレータ１７と、Ｔダイ１８を備える。押出機１３とアキュームレータ１７は、連結管２５を介して連結される。アキュームレータ１７とＴダイ１８は、連結管２７を介して連結される。
　以下、各構成について詳細に説明する。 2. Molding machine 10
Next, with reference to FIG. 4, a molding machine 10 that can be used to carry out the method of manufacturing a resin panel according to an embodiment of the present invention will be described. The molding machine 10 includes a pair of resin sheet forming devices 20 and a pair of molds 21 and 31. Each resin sheet forming apparatus 20 includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27.
Each component will be described in detail below.
＜ホッパー１２，押出機１３＞
　ホッパー１２は、原料樹脂１１を押出機１３のシリンダ１３ａ内に投入するために用いられる。原料樹脂１１の形態は、特に限定されないが、通常は、ペレット状である。原料樹脂は、例えばポリオレフィンなどの熱可塑性樹脂であり、ポリオレフィンとしては、低密度ポリエチレン、直鎖状低密度ポリエチレン、高密度ポリエチレン、ポリプロピレン、エチレン－プロピレン共重合体及びその混合物などが挙げられる。原料樹脂１１は、ホッパー１２からシリンダ１３ａ内に投入された後、シリンダ１３ａ内で加熱されることによって溶融されて溶融樹脂になる。また、シリンダ１３ａ内に配置されたスクリューの回転によってシリンダ１３ａの先端に向けて搬送される。スクリューは、シリンダ１３ａ内に配置され、その回転によって溶融樹脂を混練しながら搬送する。スクリューの基端にはギア装置が設けられており、ギア装置によってスクリューが回転駆動される。シリンダ１３ａ内に配置されるスクリューの数は、１本でもよく、２本以上であってもよい。 Hopper 12, extruder 13
The hopper 12 is used to introduce the raw material resin 11 into the cylinder 13 a of the extruder 13. The form of the raw material resin 11 is not particularly limited, but is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer and mixtures thereof. The raw material resin 11 is introduced into the cylinder 13a from the hopper 12 and then melted by being heated in the cylinder 13a to become a molten resin. Further, it is conveyed toward the tip of the cylinder 13a by the rotation of a screw disposed in the cylinder 13a. The screw is disposed in the cylinder 13a and is conveyed while kneading the molten resin by its rotation. A gear device is provided at the proximal end of the screw, and the screw device is rotationally driven by the gear device. The number of screws disposed in the cylinder 13a may be one or two or more.
＜アキュームレータ１７、Ｔダイ１８＞
　溶融樹脂は、シリンダ１３ａの樹脂押出口から押し出され、連結管２５を通じてアキュームレータ１７内に注入される。アキュームレータ１７は、シリンダ１７ａとその内部で摺動可能なピストン１７ｂを備えており、シリンダ１７ａ内に溶融樹脂１１ａが貯留可能になっている。そして、シリンダ１７ａ内に溶融樹脂１１ａが所定量貯留された後にピストン１７ｂを移動させることによって、連結管２７を通じて溶融樹脂１１ａをＴダイ１８内に設けられたスリットから押し出して垂下させて溶融状態の樹脂シート２３，３３を形成する。 <Accumulator 17, T die 18>
The molten resin is extruded from the resin extrusion port of the cylinder 13 a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b slidable therein, and the molten resin 11a can be stored in the cylinder 17a. Then, after the molten resin 11a is stored in the cylinder 17a by a predetermined amount, the piston 17b is moved to extrude the molten resin 11a from the slit provided in the T die 18 through the connecting pipe 27 and hang down to be in a molten state. The resin sheets 23 and 33 are formed.
＜金型２１，３１＞
　樹脂シート２３，３３は、金型２１，３１の間に垂下される。金型２１，３１は、キャビティ２１ａ，３１ａを有し、キャビティ２１ａ，３１ａを取り囲むようにピンチオフ部２１ｂ，３１ｂが設けられている。キャビティ２１ａ，３１ａ内には、減圧吸引孔（図示せず）が設けられており、減圧吸引孔を通じて樹脂シート２３，３３を減圧吸引して金型２１，３１のキャビティ２１ａ，３１ａの内面に沿った形状に賦形することが可能になっている。減圧吸引孔は、極小の孔であり、一端が金型２１，３１内部を通ってキャビティ２１ａ，３１ａの内面にまで連通されてり、他端が減圧装置に接続されている。 < Mold 21, 31>
The resin sheets 23 and 33 are suspended between the molds 21 and 31. The molds 21 and 31 have cavities 21a and 31a, and pinch off portions 21b and 31b are provided so as to surround the cavities 21a and 31a. In the cavities 21a and 31a, vacuum suction holes (not shown) are provided, and the resin sheets 23 and 33 are vacuum suctioned through the vacuum suction holes and along the inner surfaces of the cavities 21a and 31a of the molds 21 and 31. It is possible to shape in the shape of The decompression suction hole is a very small hole, and one end thereof is communicated with the inner surface of the cavity 21a, 31a through the inside of the mold 21, 31, and the other end is connected to the decompression device.
３．樹脂製パネルの製造方法
　ここで、図４～図２２を用いて、本発明の一実施形態の樹脂製パネルの製造方法について説明する。本実施形態の方法は、垂下工程と、賦形工程と、インサート工程と、型締め工程を備える。以下、詳細に説明する。 3. Method of Manufacturing Resin Panel Here, a method of manufacturing a resin panel according to an embodiment of the present invention will be described with reference to FIGS. 4 to 22. The method of the present embodiment comprises a drooping step, a shaping step, an inserting step, and a clamping step. The details will be described below.
３－１．垂下工程
　垂下工程では、図４～図５に示すように、金型２１，３１の間に樹脂シート２３，３３を垂下させる。 3-1. In the drooping step, as shown in FIGS. 4 to 5, the resin sheets 23 and 33 are suspended between the molds 21 and 31.
３－２．賦形工程
　賦形工程では、図５～図６に示すように、樹脂シート２３，３３を、それぞれ、ピンチオフ部２１ｂ，３１ｂに当接させた状態で金型２１，３１によって減圧吸引を行って樹脂シート２３、３３をキャビティ２１ａ，３１ａの内面に沿った形状に賦形する。賦形工程は、インサート工程の後に行ってもよい。また、型締め工程の前に行ってもよく、型締め工程と同時に行ってもよい。賦形工程を省略してもよい。 3-2. In the shaping step, as shown in FIGS. 5 to 6, while the resin sheets 23 and 33 are in contact with the pinch-off portions 21b and 31b, respectively, vacuum suction is performed by the molds 21 and 31. The resin sheets 23, 33 are shaped into a shape along the inner surfaces of the cavities 21a, 31a. The shaping process may be performed after the inserting process. Also, it may be performed before the mold clamping process or may be performed simultaneously with the mold clamping process. The shaping process may be omitted.
３－３．インサート工程
　インサート工程では、図６に示すように、樹脂シート２３，３３の間に芯材３及び補強部材５，６を配置する。図８に示すように、補強部材５，６で芯材３を支持し、支持装置８で補強部材５，６を支持することによって、芯材３及び補強部材５，６を精度良く配置する。 3-3. Insert Process In the insert process, as shown in FIG. 6, the core material 3 and the reinforcing members 5 and 6 are disposed between the resin sheets 23 and 33. As shown in FIG. 8, the core member 3 is supported by the reinforcing members 5 and 6, and the reinforcing members 5 and 6 are supported by the supporting device 8, thereby accurately arranging the core member 3 and the reinforcing members 5 and 6.
　図９に示すように、支持装置８は、細長い挿入部８ａ，８ｂを有する。図１０～図１１に示すように、支持装置８は、挿入部８ａ，８ｂをそれぞれエア流路５ｃ，６ｃに挿入することによって補強部材５，６を支持する。支持装置８は、挿入部８ａ，８ｂよりも根本側に拡径部８ａ２，８ｂ２を備える。補強部材５，６を拡径部８ａ２，８ｂ２に当接させることによって、補強部材５，６の長手方向について補強部材５，６を位置決めすることができる。挿入部８ｂの長手方向の長さＬｂは、挿入部８ａの長手方向の長さＬａよりも長くなっている。このため、挿入部８ｂの先端は、挿入部８ａの先端よりも突出して配置されている。このため、挿入部８ｂをエア流路６ｃに挿入した後に、挿入部８ａをエア流路５ｃに挿入することが可能であり、作業性に優れている。 As shown in FIG. 9, the support device 8 has elongated insertion portions 8a and 8b. As shown in FIGS. 10 to 11, the support device 8 supports the reinforcing members 5 and 6 by inserting the insertion portions 8a and 8b into the air flow paths 5c and 6c, respectively. The support device 8 includes enlarged diameter portions 8a2 and 8b2 at the root side of the insertion portions 8a and 8b. The reinforcement members 5 and 6 can be positioned in the longitudinal direction of the reinforcement members 5 and 6 by bringing the reinforcement members 5 and 6 into contact with the enlarged diameter portions 8 a 2 and 8 b 2. The longitudinal length Lb of the insertion portion 8b is longer than the longitudinal length La of the insertion portion 8a. For this reason, the tip of the insertion portion 8b is disposed so as to protrude further than the tip of the insertion portion 8a. Therefore, after the insertion portion 8b is inserted into the air flow path 6c, the insertion portion 8a can be inserted into the air flow path 5c, which is excellent in workability.
　挿入部８ａは、一対の挿入片８ａ１を備える。図１１Ａに示すように、挿入部８ａをエア流路５ｃ内に挿入した状態で一対の挿入片８ａ１の間隔を広げることによって挿入部８ａが補強部材５の内面を押圧するように構成されている。一対の挿入片８ａ１は、一対のリニアスライダ８ａ３に取り付けられており、一対のリニアスライダ８ａ３のスライド移動に伴って一対の挿入片８ａ１の間隔が変化する。本実施形態のように補強部材５が水平方向を向いた状態で補強部材５を支持する場合、補強部材５が支持装置８から外れてしまう虞があるが、上記構成によれば、補強部材５が支持装置８に確実に固定される。挿入部８ｂは、本実施形態では１本の棒で構成されているが、挿入部８ａと同様の構成にしてもよい。突出部１ｂ，１ｃを樹脂製パネル１の長辺に相当する側面から突出させる場合、補強部材５が鉛直方向を向いた状態で補強部材５を支持しようとすると、必然的に、樹脂製パネル１の長辺に相当するサイズの金型が必要になり、金型が大型化する。一方、本実施形態では、補強部材５が水平方向を向いた状態で補強部材５を支持しているので、樹脂シート２３，３３の垂下方向が樹脂製パネル１の長辺方向になるように金型を設計することができる。このため、金型サイズを小さくすることができる。 The insertion portion 8a includes a pair of insertion pieces 8a1. As shown in FIG. 11A, the insertion portion 8a is configured to press the inner surface of the reinforcing member 5 by widening the distance between the pair of insertion pieces 8a1 with the insertion portion 8a inserted into the air flow path 5c. . The pair of insertion pieces 8a1 is attached to the pair of linear sliders 8a3, and the distance between the pair of insertion pieces 8a1 changes with the sliding movement of the pair of linear sliders 8a3. When the reinforcing member 5 is supported with the reinforcing member 5 facing in the horizontal direction as in the present embodiment, there is a risk that the reinforcing member 5 may be detached from the supporting device 8. Is securely fixed to the support device 8. Although the insertion part 8b is comprised by one rod in this embodiment, you may make it the structure similar to the insertion part 8a. When projecting the projecting portions 1b and 1c from the side surface corresponding to the long side of the resin panel 1, if the reinforcing member 5 is to be supported in a state where the reinforcing member 5 is directed in the vertical direction, the resin panel 1 is inevitably A mold having a size corresponding to the long side of the mold is required, and the mold is enlarged. On the other hand, in the present embodiment, since the reinforcing member 5 is supported in a state in which the reinforcing member 5 faces in the horizontal direction, the metal sheet 23, 33 is made of gold so that the hanging direction You can design a mold. Therefore, the mold size can be reduced.
　図１１Ａに示すように、一対の挿入片８ａ１の間には隙間がある。図１１Ｂに示すように、挿入部８ｂと突出部６ｂの内面の間にも隙間がある。このため、エア流路５ｃ，６ｃに挿入部８ａ，８ｂを挿入してもエア流路５ｃ，６ｃを閉塞させることがないので、エア流路５ｃ，６ｃを通じたエア抜きがスムーズに行われる。 As shown in FIG. 11A, there is a gap between the pair of insertion pieces 8a1. As shown in FIG. 11B, there is also a gap between the insertion portion 8b and the inner surface of the protrusion 6b. Therefore, even if the insertion portions 8a and 8b are inserted into the air flow paths 5c and 6c, the air flow paths 5c and 6c are not blocked, so that the air can be smoothly removed through the air flow paths 5c and 6c.
３－４．型締め工程
　型締め工程では、図７に示すように、金型２１，３１の型締めを行う。型締めは、補強部材５が支持装置８によって支持された状態で行う。このため、補強部材５及び芯材３の位置付けを抑制することができる。金型２１，３１の型締めによって樹脂シート２３，３３がピンチオフ部２１ｂ，３１ｂに沿って溶着されると共に、樹脂シート２３，３３が芯材３に溶着される。 3-4. Clamping Process In the clamping process, as shown in FIG. 7, the molds 21 and 31 are clamped. The clamping is performed with the reinforcing member 5 supported by the supporting device 8. For this reason, positioning of the reinforcement member 5 and the core material 3 can be suppressed. The resin sheets 23 and 33 are welded along the pinch-off portions 21 b and 31 b by clamping of the molds 21 and 31, and the resin sheets 23 and 33 are welded to the core 3.
　ところで、補強部材５が支持装置８によって支持された状態で金型２１，３１の型締めを行うためには、金型２１，３１が挿入部８ａ，８ｂと干渉しないようにする必要がある。挿入部８ａ，８ｂが入る凹部を金型２１，３１に設けることによって干渉を防ぐことができるが、その場合、突出部５ｂ，６ｂの端面が樹脂壁２で被覆されない。 By the way, in order to clamp the molds 21 and 31 in a state where the reinforcing member 5 is supported by the support device 8, it is necessary to prevent the molds 21 and 31 from interfering with the insertion portions 8 a and 8 b. Interference can be prevented by providing the molds 21 and 31 with recesses into which the insertion portions 8a and 8b are inserted. In that case, the end faces of the protruding portions 5b and 6b are not covered with the resin wall 2.
　そこで、金型２１，３１と挿入部８ａ，８ｂの干渉を防ぎつつ、突出部５ｂ，６ｂの端面を樹脂壁２で被覆すべく、金型２１，３１には、補強部材５の端部に対向する位置にスライドコア２１ｃ，２１ｄ，３１ｃ，３１ｄ（以下、「スライドコア２１ｃ等」）を設けている。スライドコア２１ｃ，３１ｃには、突出部５ｂの端部に対応するピンチオフ部が設けられている。スライドコア２１ｄ，３１ｄには、突出部６ｂの端部に対応するピンチオフ部が設けられている。スライドコア２１ｃと３１ｃが型締めされて突出部５ｂの端面が樹脂壁２で被覆され、スライドコア２１ｄと３１ｄが型締めされて突出部６ｂの端面が樹脂壁２で被覆される。 Therefore, in order to cover the end faces of the protruding portions 5b and 6b with the resin wall 2 while preventing interference between the molds 21 and 31 and the insertion portions 8a and 8b, the molds 21 and 31 have the end portions of the reinforcing member 5 Slide cores 21c, 21d, 31c, 31d (hereinafter, "slide cores 21c and the like") are provided at opposing positions. The slide cores 21c and 31c are provided with pinch-off portions corresponding to the end portions of the protruding portions 5b. The slide cores 21d, 31d are provided with pinch-off portions corresponding to the end portions of the protruding portions 6b. The slide cores 21c and 31c are clamped, and the end face of the protrusion 5b is covered with the resin wall 2, and the slide cores 21d and 31d are clamped, and the end face of the protrusion 6b is covered with the resin wall 2.
　スライドコア２１ｃ等は、金型２１，３１に直接設けてもよいが、本実施形態では、金型２１，３１に分離可能に設けられた分離ブロック２１ｃ１，２１ｄ１，３１ｃ１，３１ｄ１にスライドコア２１ｃ等を設けている。このような構成によれば、突出部５ｂ，６ｂの形状変更に容易に対応可能である。 The slide cores 21c and the like may be directly provided to the molds 21 and 31, but in the present embodiment, the slide cores 21c and the like are provided to the separation blocks 21c1, 21d1, 31c1, and 31d1 provided separably to the molds 21 and 31. Is provided. According to such a configuration, it is possible to easily cope with the shape change of the protrusions 5 b and 6 b.
　スライドコア２１ｃ等は、金型２１，３１の型締めの際には、図２２に示すように、退避位置に配置されることにより、スライドコア２１ｃ等が挿入部８ａ，８ｂと干渉しないようになっている。この状態で金型２１，３１の型締めを行うと、突出部５ｂ，６ｂの端部以外の部位（つまり、スライドコア２１ｃ等が設けられている部位以外の部位）において樹脂シート２３，３３がピンチオフ部２１ｂ，３１ｂによって挟持されて溶着される。 The slide cores 21c and the like are arranged at the retracted position as shown in FIG. 22 when the molds 21 and 31 are clamped, so that the slide cores 21c and the like do not interfere with the insertion portions 8a and 8b. It has become. When the molds 21 and 31 are clamped in this state, the resin sheets 23 and 33 are formed on the portions other than the end portions of the protruding portions 5b and 6b (that is, the portions other than the portion where the slide core 21c and the like are provided). It pinches and welds with pinch off parts 21b and 31b.
　その後、挿入部８ａ，８ｂをエア流路５ｃ，６ｃから抜いた後に、スライドコア２１ｃ等の型締めを行う。これによって、突出部５ｂ，６ｂの端部においても、樹脂シート２３，３３がスライドコア２１ｃ等のピンチオフ部によって挟持されて溶着される。金型２１，３１の型締めの際にスライドコア２１ｃ等が退避位置に配置されているので、その分だけ、樹脂シート２３，３３が引き伸ばされている。この状態でスライドコア２１ｃ等を型締めするために前進させると、樹脂シート２３，３３が徐々に弛み、樹脂シート２３，３３が弛んだ状態でスライドコア２１ｃ等が型締めされる（この際、スライドコア２１ｃ等は、図２１に示す型締め位置に配置される）。スライドコア２１ｃ等の型締めの際に突出部５ｂ，６ｂの端面を被覆するために樹脂シート２３，３３が引き伸ばされるが、樹脂シート２３，３３が弛んだ状態でスライドコア２１ｃ等が型締めされるので、樹脂シート２３，３３が過度に局所的に引き伸ばされることがなく、突出部５ｂ，６ｂの端面近傍において樹脂壁２が極端に薄肉になることが抑制される。 Thereafter, after the insertion portions 8a and 8b are removed from the air flow paths 5c and 6c, the slide core 21c and the like are clamped. As a result, the resin sheets 23 and 33 are sandwiched and pinched by the pinch-off portions of the slide core 21 c and the like also at the end portions of the protruding portions 5 b and 6 b. Since the slide core 21 c and the like are disposed at the retracted position when the molds 21 and 31 are clamped, the resin sheets 23 and 33 are stretched by that amount. When the slide core 21c and the like are advanced in order to clamp the slide core 21c and the like in this state, the resin sheets 23 and 33 are gradually slackened, and the slide core 21c and the like are clamped in a slackened state (in this case, The slide core 21c and the like are disposed at the clamping position shown in FIG. While the resin sheets 23 and 33 are stretched to cover the end faces of the projecting portions 5b and 6b when clamping the slide core 21c and the like, the slide cores 21c and the like are clamped while the resin sheets 23 and 33 are slackened. Therefore, the resin sheets 23 and 33 are not stretched locally excessively, and the resin wall 2 is prevented from being extremely thin in the vicinity of the end faces of the protruding portions 5 b and 6 b.
　金型２１，３１の型締めの際に、樹脂シート２３，３３と芯材３の間にエアが巻き込まれることがあるが、このエアは、溝３ｂ、開口部５ｄ，６ｄ、エア流路５ｃ，６ｃ、及び開口部５ｅ，６ｅを通じて、外部に排出されるので、樹脂シート２３，３３と芯材３の間にエアが残留することが抑制される。金型２１，３１の型締めの際には、スライドコア２１ｃ等が型締めされていないために、開口部５ｅ，６ｅは外部に開放されている。このため、エア抜きがスムーズに行われる。 Air may be entrapped between the resin sheets 23 and 33 and the core 3 when the molds 21 and 31 are clamped. This air may be formed by the grooves 3b, the openings 5d and 6d, and the air flow path 5c. , 6c and the openings 5e, 6e, the air is prevented from remaining between the resin sheets 23, 33 and the core member 3 because the air is discharged to the outside. When the molds 21 and 31 are clamped, the openings 5 e and 6 e are opened to the outside because the slide core 21 c and the like are not clamped. For this reason, air removal is performed smoothly.
　本実施形態の方法では、上記経路でエアが排出可能であるので、エア抜き用の穴を別途設ける必要がない。このため、穴がない樹脂壁２で覆われた樹脂製パネル１を製造可能である。 In the method of the present embodiment, since the air can be discharged through the above path, it is not necessary to separately provide the air vent hole. For this reason, the resin panel 1 covered with the resin wall 2 which does not have a hole can be manufactured.
　以上の工程によって、金型２１，３１及びスライドコア２１ｃ等によって形成されるキャビティの内面に沿った形状の樹脂製パネル１が得られる。ピンチオフ部の外側がバリ４１となる。この後は、金型２１，３１を開いて樹脂製パネル１を取り出し、バリ４１を除去にすることによって、図１に示す樹脂製パネル１が得られる。
４．第２実施形態
　図２３を用いて、本発明の第２実施形態について説明する。本実施形態は、第１実施形態に類似しており、芯材３の構造の違いが主な相違点である。以下、相違点を中心に説明する。 By the above process, the resin panel 1 having a shape along the inner surface of the cavity formed by the molds 21, 31 and the slide core 21c and the like can be obtained. The outside of the pinch off portion is a burr 41. Thereafter, the molds 21 and 31 are opened, the resin panel 1 is taken out, and the burrs 41 are removed to obtain the resin panel 1 shown in FIG.
4. Second Embodiment A second embodiment of the present invention will be described with reference to FIG. The present embodiment is similar to the first embodiment, and the difference in the structure of the core 3 is the main difference. The differences will be mainly described below.
　本実施形態では、図２３Ａに示すように、おもて面側係止部３ｋの端部３ｋ１の位置と裏面側係止部３ｌの端部３ｌ１の位置が平面視で一致している。このような形態であっても、第１実施形態と同様の作用効果が奏される。 In the present embodiment, as shown in FIG. 23A, the position of the end 3k1 of the front surface side locking portion 3k and the position of the end portion 3l1 of the back surface side locking portion 3l coincide in plan view. Even in such a mode, the same function and effect as those of the first embodiment can be obtained.
５．その他実施形態
・上記実施形態では、隣接部５ａ，６ａにおいて、補強部材５，６の側面に設けられた開口部５ｄ，６ｄを通じてエア流路５ｃ，６ｃが外部に連通しているが、補強部材５，６が断面Ｈ形状や断面Ｃ形状である場合には、補強部材５，６と芯材３の間の隙間からエア流路５ｃ，６ｃが外部に連通するようにしてもよい。また、開口部５ｄ，６ｄは、補強部材５，６の隣接部５ａ，６ａ側の端面に設けてもよい。
・開口部５ｄ，６ｄは、エアを流通可能な形状であればよく、小孔ではなく、スリットなどであってもよい。
・上記実施形態では、開口部５ｅ，６ｅは、突出部５ｂ，６ｂの端面に設けられているが、突出部５ｂ，６ｂの別の位置に設けてもよい。例えば、開口部５ｅ，６ｅは、スライドコア２１ｃ等に重なる部位に設けることができる。この部位は、金型２１，３１を型締めした時点では樹脂シートによって被覆されていないので、この位置に開口部５ｅ，６ｅを設けても樹脂シートによって開口部５ｅ，６ｅが閉塞されることがない。
・上記実施形態では、一対の挿入片８ａ１の間隔を広げることによって挿入部８ａが補強部材５の内面を押圧するように構成しているが、別の構成によって挿入部８ａの外接円の直径を大きくしてもよい。例えば、挿入部８ａがエア流路５ｃ内に挿入された状態で挿入部８ａの側面から突出片が突出して補強部材５の内面を押圧するように構成してもよい。
・芯材３は不要な場合には省略可能である。この場合、補強部材５，６を樹脂壁２に接着又は溶着させることによって補強部材５，６を固定してもよい。
・隣接部５ａ，６ａは、芯材３に設けた挿通孔３ｄ，３ｅに挿通させる代わりに、芯材３の側面に沿って隣接させてよい。芯材３が複数枚で構成されていて、補強部材５，６が断面Ｈ形状である場合、補強部材を用いて２枚の芯材を連結するように構成してもよい。
・上記実施形態では、連結部材７で補強部材５，６を連結しているが、補強部材５，６は連結していなくてもよい。また、補強部材は、１本又は３本以上であってもよい。
・上記実施形態では、図１８に示すように、開口部５ｄは、上下左右に４つ設けられているが、開口部５ｄは、斜め方向に設けてもよい。斜め方向に設けた開口部は、樹脂シート２３，３３と芯材３の何れにも接触しにくいという利点がある。 5. Other Embodiments In the above embodiment, in the adjacent portions 5a and 6a, the air flow paths 5c and 6c communicate with the outside through the openings 5d and 6d provided on the side surfaces of the reinforcing members 5 and 6, but the reinforcing members When the cross sections 5, 6 have an H-shaped cross section or a C-shaped cross section, the air flow paths 5c, 6c may communicate with the outside through the gaps between the reinforcing members 5, 6 and the core 3. The openings 5d and 6d may be provided on the end face of the reinforcing members 5 and 6 on the side of the adjacent parts 5a and 6a.
The openings 5d and 6d may be any shape that allows air to flow, and may be slits or the like instead of small holes.
In the above embodiment, the openings 5e and 6e are provided on the end faces of the protrusions 5b and 6b, but may be provided at other positions of the protrusions 5b and 6b. For example, the openings 5e and 6e can be provided at portions overlapping the slide core 21c and the like. This portion is not covered by the resin sheet when the molds 21 and 31 are clamped, so even if the openings 5e and 6e are provided at this position, the openings 5e and 6e may be blocked by the resin sheet. Absent.
In the above embodiment, the insertion portion 8a is configured to press the inner surface of the reinforcing member 5 by widening the distance between the pair of insertion pieces 8a1, but the diameter of the circumscribed circle of the insertion portion 8a may be changed by another configuration. You may enlarge it. For example, in a state in which the insertion portion 8a is inserted into the air flow path 5c, the projecting piece may be protruded from the side surface of the insertion portion 8a to press the inner surface of the reinforcing member 5.
The core material 3 can be omitted if unnecessary. In this case, the reinforcing members 5 and 6 may be fixed by bonding or welding the reinforcing members 5 and 6 to the resin wall 2.
- Adjacent part 5a, 6a may be made to adjoin along the side of core material 3 instead of making insertion holes 3d and 3e provided in core material 3 insert. When core material 3 is constituted by two or more pieces and reinforcement members 5 and 6 are section H-shaped, it may constitute so that core materials of two sheets may be connected using a reinforcement member.
In the above embodiment, although the reinforcing members 5 and 6 are connected by the connecting member 7, the reinforcing members 5 and 6 may not be connected. In addition, the number of reinforcing members may be one or three or more.
In the above embodiment, as shown in FIG. 18, four openings 5 d are provided vertically and horizontally, but the openings 5 d may be provided obliquely. The openings provided in the oblique direction have an advantage that it is difficult to contact any of the resin sheets 23 and 33 and the core material 3.
１　　　　：樹脂製パネル
　１ａ　　　：パネル部
　１ｂ　　　：突出部
　１ｃ　　　：突出部
２　　　　：樹脂壁
　２ａ　　　：表壁
　２ｂ　　　：裏壁
　２ｃ　　　：周囲壁
　２ｄ　　　：周囲壁
　２ｅ　　　：端壁
３　　　　：芯材
　３ａ　　　：側面
　３ｂ　　　：溝
　３ｃ　　　：側面
　３ｄ　　　：挿通孔
　３ｅ　　　：挿通孔
　３ｆ　　　：隙間
　３ｇ　　　：狭幅部
　３ｈ　　　：広幅部
　３ｉ　　　：おもて面
　３ｊ　　　：裏面
　３ｋ　　　：おもて面側係止部
　３ｌ　　　：裏面側係止部
　３ｍ　　　：貫通孔
５　　　　：補強部材
　５ａ　　　：隣接部
　５ｂ　　　：突出部
　５ｃ　　　：エア流路
　５ｄ　　　：開口部
　５ｅ　　　：開口部
６　　　　：補強部材
　６ａ　　　：隣接部
　６ｂ　　　：突出部
　６ｃ　　　：エア流路
　６ｄ　　　：開口部
　６ｅ　　　：開口部
７　　　　：連結部材
８　　　　：支持装置
　８ａ　　　：挿入部
　　８ａ１　　：挿入片
　８ａ２　　：拡径部
　８ａ３　　：リニアスライダ
　８ｂ　　　：挿入部
　８ｂ２　　：拡径部
１０　　　：成形機
１１　　　：原料樹脂
　１１ａ　：溶融樹脂
１２　　　：ホッパー
１３　　　：押出機
　１３ａ　　：シリンダ
１７　　　：アキュームレータ
　１７ａ　　：シリンダ
　１７ｂ　　：ピストン
１８　　　：Ｔダイ
２０　　　：樹脂シート形成装置
２１　　　：金型
　２１ａ　　：キャビティ
　２１ｂ　　：ピンチオフ部
　２１ｃ　　：スライドコア
　２１ｃ１　：分離ブロック
　２１ｄ　　：スライドコア
　２１ｄ１　：分離ブロック
２３　　　：樹脂シート
２５　　　：連結管
２７　　　：連結管
３１　　　：金型
　３１ａ　　：キャビティ
　３１ｂ　　：ピンチオフ部
　３１ｃ　　：スライドコア
　３１ｃ１　：分離ブロック
　３１ｄ　　：スライドコア
　３１ｄ１　：分離ブロック
３３　　　：樹脂シート
４１　　　：バリ DESCRIPTION OF SYMBOLS 1: Resin panel 1a: Panel part 1b: Protrusion part 1c: Projection part 2: Resin wall 2a: Front wall 2b: Back wall 2c: Surrounding wall 2d: Surrounding wall 2e: End wall 3: Core 3a: Side 3b: Side 3b: Groove 3c: Side 3d: Insertion hole 3e: Insertion hole 3f: Clearance 3g: Narrow part 3h: Wide part 3i: Front side 3j: Back side 3k: Front side locking part 3l: Back side locking part 3m: through hole 5: reinforcing member 5a: adjacent portion 5b: projecting portion 5c: air flow path 5d: opening 5e: opening 6: reinforcing portion 6a: adjacent portion 6b: protruding portion 6c: air flow path 6d: opening 6e: Opening 7: Connection member 8: Support device 8a: Insertion portion 8a1: Insertion piece 8a2: Expansion diameter portion 8a3: Linear slider 8b: Insertion portion 8b2: Expansion diameter portion 1 : Molding machine 11: Raw material resin 11a: Melt resin 12: Hopper 13: Extruder 13a: Cylinder 17: Accumulator 17a: Cylinder 17b: Piston 18: T die 20: Resin sheet forming device 21: Mold 21a: Cavity 21b: Pinch off Part 21c: Slide core 21c1: Separate block 21d: Slide core 21d1: Separate block 23: Resin sheet 25: Connection tube 27: Connection tube 31: Mold 31a: Cavity 31b: Pinch off part 31c: Slide core 31c1: Separate block 31d: Slide core 31d1: Separation block 33: Resin sheet 41: Burr

Claims (23)

  1. 　樹脂製パネルであって、
    　樹脂壁と、芯材と、補強部材を備え、
    　前記芯材及び前記補強部材は、前記樹脂壁によって取り囲まれており、
    　前記補強部材は、エア流路を有し、
    　前記補強部材は、前記芯材に隣接する隣接部と、前記芯材の側面から突出する突出部を有し、
    　前記エア流路は、前記隣接部から前記突出部に渡って設けられ、
    　前記エア流路は、前記隣接部と前記突出部の両方において前記エア流路の外部と連通している、樹脂製パネル。     It is a resin panel and
    It has a resin wall, a core material, and a reinforcing member,
    The core material and the reinforcing member are surrounded by the resin wall,
    The reinforcing member has an air passage,
    The reinforcing member has an adjacent portion adjacent to the core material, and a protrusion protruding from a side surface of the core material,
    The air flow path is provided from the adjacent portion to the projecting portion,
    The air flow path communicates with the outside of the air flow path in both the adjacent portion and the projecting portion.
  2. 　請求項１に記載の樹脂製パネルであって、
    　前記補強部材は、前記隣接部に前記エア流路に連通する第１開口部を備える、樹脂製パネル。     The resin panel according to claim 1, wherein
    The said reinforcement member is a resin-made panel provided with the 1st opening part connected to the said air flow path in the said adjacent part.
  3. 　請求項２に記載の樹脂製パネルであって、
    　第１開口部は、前記樹脂壁に接触しないように設けられる、樹脂製パネル。     The resin panel according to claim 2, wherein
    The resin panel, wherein the first opening is provided so as not to contact the resin wall.
  4. 　請求項２又は請求項３に記載の樹脂製パネルであって、
    　第１開口部は、前記補強部材の側面に設けられる、樹脂製パネル。     It is a resin-made panel of Claim 2 or Claim 3, Comprising:
    A resin panel provided with a first opening on a side surface of the reinforcing member.
  5. 　請求項４に記載の樹脂製パネルであって、
    　第１開口部は、前記芯材に対向する位置に設けられる、樹脂製パネル。     The resin panel according to claim 4, wherein
    A resin panel, wherein the first opening is provided at a position facing the core material.
  6. 　請求項４又は請求項５に記載の樹脂製パネルであって、
    　第１開口部が設けられている部位において前記補強部材と前記芯材の間の隙間が設けられている、樹脂製パネル。     It is a resin-made panel of Claim 4 or Claim 5, Comprising:
    The resin-made panel in which the clearance gap between the said reinforcement member and the said core material is provided in the site | part in which the 1st opening part is provided.
  7. 　請求項４～請求項６の何れか１つに記載の樹脂製パネルであって、
    　第１開口部は、前記補強部材の周方向の複数箇所に設けられる、樹脂製パネル。     The resin panel according to any one of claims 4 to 6, wherein
    The resin panel provided with the 1st opening part in the circumferential direction several places of the said reinforcement member.
  8. 　請求項１～請求項７の何れか１つに記載の樹脂製パネルであって、
    　前記芯材の表面には、前記エア流路に連通する溝が設けられる、樹脂製パネル。     The resin panel according to any one of claims 1 to 7, wherein
    The resin-made panel in which the groove | channel connected to the said air flow path is provided in the surface of the said core material.
  9. 　請求項８に記載の樹脂製パネルであって、
    　前記溝は、格子状に設けられる、樹脂製パネル。     The resin panel according to claim 8, wherein
    The grooves are provided in a grid shape, and are made of resin.
  10. 　請求項１～請求項９の何れか１つに記載の樹脂製パネルであって、
    　前記補強部材は、前記突出部に前記エア流路に連通する第２開口部を備える、樹脂製パネル。     The resin panel according to any one of claims 1 to 9, wherein
    The said reinforcement member is a resin-made panel provided with the 2nd opening part connected to the said air flow path in the said protrusion part.
  11. 　請求項１０に記載の樹脂製パネルであって、
    　第２開口部は、前記補強部材の端面に設けられる、樹脂製パネル。     The resin panel according to claim 10, wherein
    The second opening is provided on the end face of the reinforcing member.
  12. 　請求項１～請求項１１の何れか１つに記載の樹脂製パネルであって、
    　前記補強部材は、間隔を空けて複数設けられ、
    　複数の前記補強部材は、連結部材によって互いに連結されており、
    　前記連結部材は、前記芯材の第２側面に沿って配置され、
    　第２側面は、第１側面に対向する、樹脂製パネル。     The resin panel according to any one of claims 1 to 11, wherein
    A plurality of the reinforcing members are provided at intervals.
    The plurality of reinforcing members are connected to one another by a connecting member,
    The connection member is disposed along the second side surface of the core material,
    The second side faces the first side, and is a resin panel.
  13. 　請求項１～請求項１２の何れか１つに記載の樹脂製パネルであって、
    　前記樹脂壁には穴が空いていない、樹脂製パネル。     The resin panel according to any one of claims 1 to 12, wherein
    Resin panel with no holes in the resin wall.
  14. 　樹脂製パネルであって、
    　樹脂壁と、芯材と、補強部材を備え、
    　前記芯材及び前記補強部材は、前記樹脂壁によって取り囲まれており、
    　前記補強部材は、前記芯材に設けられた挿通孔に挿入されており、
    　前記芯材は、互いに対向するおもて面及び裏面を備え、
    　前記芯材は、おもて面側係止部と、裏面側係止部を備え、
    　前記おもて面側係止部は、前記補強部材を前記おもて面側から係止し、
    　前記裏面側係止部は、前記補強部材を前記裏面側から係止し、
    　前記おもて面側係止部と前記裏面側係止部は、前記挿通孔の長手方向に沿って、交互に並んで設けられる、樹脂製パネル。     It is a resin panel and
    It has a resin wall, a core material, and a reinforcing member,
    The core material and the reinforcing member are surrounded by the resin wall,
    The reinforcing member is inserted into an insertion hole provided in the core material,
    The core material has a front surface and a back surface facing each other,
    The core material includes a front surface side locking portion and a back surface side locking portion,
    The front surface side locking portion locks the reinforcing member from the front surface side,
    The back side locking portion locks the reinforcing member from the back side,
    The resin panel, wherein the front surface side locking portion and the back surface side locking portion are alternately provided along the longitudinal direction of the insertion hole.
  15. 　樹脂製パネルの製造方法であって、
    　垂下工程と、インサート工程と、型締め工程を備え、
    　前記垂下工程では、第１及び第２金型の間に第１及び第２樹脂シートを垂下させ、
    　前記インサート工程では、第１及び第２樹脂シートの間に芯材及び補強部材を配置し、
    　前記型締め工程では、第１及び第２金型が型締めされ、
    　前記補強部材は、エア流路を有し、
    　前記補強部材は、前記芯材に隣接する隣接部と、前記芯材の側面から突出する突出部を有し、
    　前記エア流路は、前記隣接部から前記突出部に渡って設けられ、
    　前記エア流路は、前記隣接部と前記突出部の両方において前記エア流路の外部と連通している、方法。     It is a manufacturing method of resin-made panels,
    Drooping process, insert process and clamping process
    In the hanging step, the first and second resin sheets are hung between the first and second molds,
    In the inserting step, a core member and a reinforcing member are disposed between the first and second resin sheets,
    In the mold clamping step, the first and second molds are clamped,
    The reinforcing member has an air passage,
    The reinforcing member has an adjacent portion adjacent to the core material, and a protrusion protruding from a side surface of the core material,
    The air flow path is provided from the adjacent portion to the projecting portion,
    The method wherein the air channel is in communication with the outside of the air channel at both the abutment and the projection.
  16. 　樹脂製パネルの製造方法であって、
    　垂下工程と、インサート工程と、型締め工程を備え、
    　前記垂下工程では、第１及び第２金型の間に第１及び第２樹脂シートを垂下させ、
    　前記インサート工程では、第１及び第２樹脂シートの間に補強部材を配置し、
    　前記インサート工程では、前記補強部材は、支持装置によって支持されており、
    　前記型締め工程では、前記補強部材が前記支持装置によって支持された状態で第１及び第２金型が型締めされる、方法。     It is a manufacturing method of resin-made panels,
    Drooping process, insert process and clamping process
    In the hanging step, the first and second resin sheets are hung between the first and second molds,
    In the inserting step, a reinforcing member is disposed between the first and second resin sheets,
    In the inserting step, the reinforcing member is supported by a support device,
    In the clamping step, the first and second molds are clamped with the reinforcing member supported by the support device.
  17. 　請求項１６に記載の方法であって、
    　前記インサート工程では、第１及び第２樹脂シートの間に芯材及び前記補強部材を配置し、
    　前記補強部材は、前記芯材に隣接する隣接部を有し、
    　前記芯材は、前記補強部材によって支持されている、方法。     17. The method of claim 16 wherein
    In the inserting step, a core member and the reinforcing member are disposed between the first and second resin sheets,
    The reinforcing member has an adjacent portion adjacent to the core material,
    The method wherein the core material is supported by the reinforcing member.
  18. 　請求項１７に記載の方法であって、
    　前記補強部材は、前記芯材の側面から突出する突出部を有する、方法。     The method according to claim 17, wherein
    The method, wherein the reinforcing member has a protrusion that protrudes from the side surface of the core material.
  19. 　請求項１８に記載の方法であって、
    　第１及び第２金型の少なくとも一方は、前記補強部材の端部に対向する位置にスライドコアを有し、
    　前記スライドコアは、前記型締め工程では、前記支持装置に干渉しないように退避位置に配置され、
    　前記型締めの工程の後に、端部被覆工程を備え、
    　前記端部被覆工程では、前記スライドコアを型締め位置に移動させることによって第１及び第２樹脂シートの少なくとも一方で前記補強部材の端部を被覆する、方法。     Method according to claim 18, wherein
    At least one of the first and second molds has a slide core at a position facing the end of the reinforcing member,
    The slide core is disposed at a retracted position so as not to interfere with the support device in the clamping process.
    After the clamping step, an end coating step is provided,
    In the end covering step, the end of the reinforcing member is covered with at least one of the first and second resin sheets by moving the slide core to a clamping position.
  20. 　請求項１６～請求項１９の何れか１つに記載の方法であって、
    　前記補強部材は、エア流路を有し、
    　前記支持装置は、細長い挿入部を有し、
    　前記支持装置は、前記挿入部を前記エア流路内に挿入することによって前記補強部材を支持する、方法。     A method according to any one of claims 16-19, wherein
    The reinforcing member has an air passage,
    The support device has an elongated insertion portion,
    The support device supports the reinforcing member by inserting the insertion portion into the air flow path.
  21. 　請求項２０に記載の方法であって、
    　前記挿入部は、前記エア流路内に挿入された状態で前記補強部材の内面を押圧するように構成される、方法。     21. The method of claim 20, wherein
    The method, wherein the insertion portion is configured to press the inner surface of the reinforcing member in a state of being inserted into the air flow path.
  22. 　請求項２０又は請求項２１に記載の方法であって、
    　前記インサート工程では、第１及び第２樹脂シートの間に芯材及び前記補強部材を配置し、
    　前記補強部材は、前記芯材に隣接する隣接部を有し、
    　前記芯材は、前記補強部材によって支持され、
    　前記補強部材は、前記隣接部に開口部を有し、
    　前記開口部は、前記エア流路に連通しており、
    　前記挿入部は、前記エア流路を閉塞させないように構成される、方法。     22. A method according to claim 20 or 21, wherein
    In the inserting step, a core member and the reinforcing member are disposed between the first and second resin sheets,
    The reinforcing member has an adjacent portion adjacent to the core material,
    The core material is supported by the reinforcing member,
    The reinforcing member has an opening at the adjacent portion,
    The opening communicates with the air flow path,
    The method, wherein the insert is configured to not close the air flow path.
  23. 　請求項１６～請求項２２に記載の方法であって、
    　前記補強部材は、水平方向に向いた状態で前記支持装置によって支持される、方法。
     

          The method according to claims 16-22, wherein
    The method, wherein the reinforcing member is supported by the support device in a horizontally oriented state.


PCT/JP2018/043452 2017-11-29 2018-11-26 Resin panel and method for manufacturing the same WO2019107319A1 (en)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61104809A (en) * 1984-10-26 1986-05-23 Nissan Shatai Co Ltd Resin molding equipment
JPS649718A (en) * 1987-07-02 1989-01-13 Nishikawa Kasei Kk Vacuum molding method
JPH10100236A (en) * 1996-09-27 1998-04-21 Nippon Steel Chem Co Ltd Foaming resin filled blow molding method and blow molded product
JPH11216768A (en) * 1998-01-30 1999-08-10 Kyoraku Co Ltd Hollow double wall structure and its manufacture
JP2001205692A (en) * 2000-01-31 2001-07-31 Kyoraku Co Ltd Hollow dual wall structure and manufacturing method therefor
JP2014128938A (en) * 2012-12-28 2014-07-10 Kyoraku Co Ltd Formed structure material, resin panel, method for producing resin panel

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61104809A (en) * 1984-10-26 1986-05-23 Nissan Shatai Co Ltd Resin molding equipment
JPS649718A (en) * 1987-07-02 1989-01-13 Nishikawa Kasei Kk Vacuum molding method
JPH10100236A (en) * 1996-09-27 1998-04-21 Nippon Steel Chem Co Ltd Foaming resin filled blow molding method and blow molded product
JPH11216768A (en) * 1998-01-30 1999-08-10 Kyoraku Co Ltd Hollow double wall structure and its manufacture
JP2001205692A (en) * 2000-01-31 2001-07-31 Kyoraku Co Ltd Hollow dual wall structure and manufacturing method therefor
JP2014128938A (en) * 2012-12-28 2014-07-10 Kyoraku Co Ltd Formed structure material, resin panel, method for producing resin panel

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