WO2021075375A1 - Molded body and molded-body producing method - Google Patents

Molded body and molded-body producing method Download PDF

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Publication number
WO2021075375A1
WO2021075375A1 PCT/JP2020/038299 JP2020038299W WO2021075375A1 WO 2021075375 A1 WO2021075375 A1 WO 2021075375A1 JP 2020038299 W JP2020038299 W JP 2020038299W WO 2021075375 A1 WO2021075375 A1 WO 2021075375A1
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WO
WIPO (PCT)
Prior art keywords
reinforcing member
core material
molded product
product according
molded body
Prior art date
Application number
PCT/JP2020/038299
Other languages
French (fr)
Japanese (ja)
Inventor
吉田　攻一郎
Original Assignee
キョーラク株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2019188990A external-priority patent/JP7239832B2/en
Priority claimed from JP2019188988A external-priority patent/JP7239831B2/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 WO2021075375A1 publication Critical patent/WO2021075375A1/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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance

Definitions

  • the present invention relates to a molded product and a method for manufacturing the molded product.
  • molded bodies used for interior materials in vehicle interiors have been manufactured.
  • a sandwich panel in which a skin member, which is a resin sheet, is arranged on both sides of a core material is often used.
  • Patent Document 1 discloses an example of a sandwich panel.
  • such a molded body (sandwich panel) has a problem that its strength becomes weaker when it is enlarged.
  • a plurality of core materials may be used and a metal reinforcing member may be inserted between adjacent core materials like a splint (for example, as shown in FIG. 7), but in such a case.
  • a metal reinforcing member may be inserted between adjacent core materials like a splint (for example, as shown in FIG. 7), but in such a case.
  • the present invention has been made in view of such circumstances, and an object of the present invention is to provide a molded body that is lightweight while ensuring strength, and a method for manufacturing the molded body.
  • Another object of the present invention is to provide a molded product that suppresses the elongation of the epidermis member that may occur with the passage of time and has less risk of bending, and a method for producing the molded product.
  • the present invention is a panel-shaped molded body, which includes a core material, a reinforcing member, and a skin member, and the reinforcing member is formed in a sheet or tape shape, and the surface of the core material is formed.
  • the skin member is a resin sheet, which is configured to be attached to at least a part of the back surface, and is provided on both sides of the core material.
  • the panel-shaped molded body includes a core material, a skin member, and a reinforcing member
  • the skin member is a resin sheet, which is a core material.
  • FIG. 3 is a cross-sectional view of the molded body 1 according to the first embodiment.
  • FIG. 3 is a plan view of an insert member 15 in which a reinforcing member 13 is attached to a core material 12.
  • a mode of a molding machine 3 for manufacturing a molded body 1. A mode in which the dies 71 and 72 are opened in the production of the molded body 1.
  • the plan view of the molded body 1 (insert member 15) which concerns on a modification.
  • FIG. 3 is a cross-sectional view of a molded body 9 according to a comparative example. It is sectional drawing which shows the structure of the molded body 101 which concerns on 2nd Embodiment.
  • FIG. 3 is a cross-sectional view of a molded body 9 according to a comparative example. It is sectional drawing which shows the structure of the molded body 101 which concerns on 2nd Embodiment.
  • FIG. 8 is an exploded cross-sectional view of FIG. It is a top view of the insert member 115 formed by temporarily fastening a reinforcing member 113 to a core material 112.
  • the aspect of the molding machine 3 for manufacturing a molded body 101 is shown. In the production of the molded body 101, the molds 71 and 72 are opened. In the production of the molded body 101, the molds 71 and 72 are closed.
  • FIG. 1 is a cross-sectional view showing the structure of the molded body 1.
  • FIG. 2 is a plan view of the insert member 15 in which the reinforcing member 13 is attached to the core material 12.
  • the panel-shaped molded body 1 includes skin members 11a and 11b, a core member 12, and a reinforcing member 13.
  • skin members 11a and 11b As shown in FIG. 1, the panel-shaped molded body 1 includes skin members 11a and 11b, a core member 12, and a reinforcing member 13.
  • each configuration will be described in detail.
  • the skin members 11a and 11b are resin sheets and are arranged on both sides of the core material 12 described later.
  • a knitted fabric, a woven fabric, a non-woven fabric, or a polyvinyl chloride (PVC) obtained by processing natural fibers, regenerated fibers, semi-synthetic fibers, synthetic fibers, and fibers obtained by mixing these.
  • thermoplastic elastomer such as thermoplastic polyurethane elastomer (TPU) or thermoplastic polyolefin elastomer (TPO), resin sheet made of thermoplastic resin such as polyethylene polyolefin resin, and laminated sheets thereof, plastic cardboard, It can be appropriately selected from a hard board or the like.
  • the core material 12 is made of, for example, a foam of a thermoplastic resin, and it is desirable that polyethylene, polypropylene, polystyrene or the like is appropriately adopted as the thermoplastic resin. Further, a filler such as glass fiber, carbon fiber, calcium carbonate, talc, or mica can be appropriately added to the foam.
  • the core material 12 is a foam produced by so-called bead foam molding.
  • bead foam molding The features of bead foam molding are that the shape can be freely designed and that a high-magnification foam molded product can be obtained.
  • the bead foam molding process is divided into pre-foaming, aging, molding and curing.
  • the beads used for bead foam molding are small-diameter resin particles impregnated with a physical foaming agent such as a hydrocarbon.
  • polystyrene particles containing a foaming agent can be obtained by allowing a hydrocarbon (pentane or the like) as a foaming agent to be present in the polymerization system during suspension polymerization.
  • a hydrocarbon penentane or the like
  • the mini pellets prepared in advance are impregnated with hydrocarbons in water.
  • Examples of the foaming agent that can be used for forming the core material 12 include known physical foaming agents, chemical foaming agents, and mixtures thereof.
  • the physical foaming agent an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, and an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, and dichloroethane can be applied.
  • the chemical foaming agent include azodicarboxylic amide (ADCA), N, N'-dinitrosopentamethylenetetramine, 4,4'-oxybis (benzenesulfonylhydrazide), and diphenylsulfone-3,3'-disulfonyl.
  • Organic foaming agents such as hydrazide, p-toluenesulfonyl semicarbazide, trihydrazinotriazine or azobisisobutyronitrile, citric acid, oxalic acid, fumaric acid, phthalic acid, malic acid, tartaric acid, cyclohexane-1,2-dicarboxylic acid ,
  • a mixture of polycarboxylic acids such as gyonoic acid, ethylenediamine tetraacetic acid, triethylenetetramine hexaacetic acid and nitriloic acid and inorganic carbonate compounds such as sodium hydrogen carbonate, sodium hydrogen carbonate aluminum, potassium hydrogen carbonate, ammonium hydrogen carbonate and ammonium carbonate , Salts of polycarboxylic acids such as sodium dihydrogen citrate and potassium oxalate can be mentioned as inorganic foaming agents.
  • the insert member 15 is formed by attaching the reinforcing member 13 described later to the core material 12 via the adhesive layer 14. It is preferable that the core material 12 has a recess 12A for attaching the reinforcing member 13, and the reinforcing member 13 is housed in the recess 12A provided in the core material 12. The insert member 15 will be described again in the method for manufacturing the molded body 1 in Section 2.
  • the reinforcing member 13 contains glass fiber reinforced plastic or carbon fiber reinforced plastic, or it is preferable to use these. Since the fiber reinforced plastic is used, it contributes to weight reduction as compared with the case where the metal reinforcing member 93 shown in FIG. 7 is used.
  • the reinforcing member 13 is configured to be attached to at least a part of the front surface or the back surface of the core material 12, and may be formed in the form of a sheet or tape.
  • FIGS. 1 and 2 an example is shown in which the reinforcing member 13 is configured to be attached to both the front surface and the back surface of the core material 12, and the reinforcing member 13 is formed in an elongated tape shape.
  • recesses 121 are provided on the front surface and the back surface of the core material 12, and a tape-shaped reinforcing member 13 is attached thereto. Since it is formed in a tape shape in this way, weight reduction is expected as compared with the case where the metal reinforcing member 93 shown in FIG. 7 is adopted.
  • the molded body 9 (comparative example) shown in FIG. 7 includes skin members 91a and 91b, a core member 92, and an H-shaped reinforcing member 93 (so-called reinforce). Since the reinforcing member 93 of the molded body 9 has a metal reinforcing member 93 inserted between two adjacent core members 92 like a splint, the weight increases.
  • the reinforcing member 13 is attached along the center line X on the surface of the core material 12.
  • An adhesive or the like is used for such affixing.
  • the core material 12 and the reinforcing member 13 are adhered to each other via the adhesive layer 14.
  • the rigidity of the reinforcing member 13 directly affects the core material 12, and the strength of the core material 12 which is relatively soft as compared with the reinforcing member 13 can be strengthened.
  • the strength of the molded product 1 can be increased while maintaining the light weight.
  • the reinforcing member 13 is a UD (Uni-Direction) sheet or a UD tape.
  • UD Uni-Direction
  • UD tape are sheets or tapes in which fibers are aligned in one direction and impregnated with a thermoplastic resin.
  • the UD sheet or UD tape is a fiber reinforced plastic using long fibers and has high tensile strength in the direction in which the fibers are oriented. As a result, the strength of the molded product 1 can be remarkably increased.
  • the tensile elastic modulus of the reinforcing member 13 is preferably 12 GPa or more and 400 GPa or less. Specifically, for example, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34,35,36,37,38,39,40,50,60,70,80,90,100,110,120,130,140,150,160,170,180,190,200,210,220, It is 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400 GPa, and is between any two of the numerical values exemplified here. It may be within the range.
  • the thickness of the core material 12 is t1 and the thickness of the reinforcing member 13 is t2, it is preferable that 0.01 ⁇ t2 / t1 ⁇ 0.3 is satisfied (see FIG. 1).
  • the reinforcing member 13 is in the form of a sheet or a tape, and when preparing the insert member 15, it is preferable that the reinforcing member 13 is thin enough to be easily attached by an operator.
  • the value of t2 / t1 is 0.01,0.015,0.02,0.025,0.03,0.035,0.04,0.045,0.05,0.
  • the width of the core material 12 is w1 and the width of the reinforcing member 13 is w2, it is preferable that 0.05 ⁇ w2 / w1 ⁇ 0.95 is satisfied (see FIG. 2).
  • the value of w2 / w1 is 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.
  • FIG. 3 shows an aspect of a molding machine 3 for manufacturing a molded body 1.
  • FIG. 4 shows a mode in which the molds 71 and 72 are opened in the production of the molded product 1.
  • FIG. 5 shows a mode in which the molds 71 and 72 are closed in the production of the molded product 1.
  • the molding machine 3 includes a resin supply device 4, a T-die 5, and a pair of molds 71 and 72.
  • the resin supply device 4 includes a hopper 41, an extruder 42, and an accumulator 45.
  • the extruder 42 and the accumulator 45 are connected via a connecting pipe 61.
  • the accumulator 45 and the T-die 5 are connected via a connecting pipe 62.
  • the hopper 41 is used to put the raw material resin M1 into the cylinder 43 of the extruder 42.
  • the form of the raw material resin M1 is not particularly limited, but is usually in the form of pellets.
  • the raw material resin M1 is charged into the cylinder 43 from the hopper 41 and then melted by being heated in the cylinder 43 to become a molten resin. Further, it is conveyed toward the tip of the cylinder 43 by the rotation of the screw arranged in the cylinder 43.
  • the screw is arranged in the cylinder 43, and the molten resin is kneaded and conveyed by its rotation.
  • a gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device.
  • the number of screws arranged in the cylinder 43 may be one or two or more.
  • the melt-kneaded resin M2 is extruded from the resin extrusion port of the cylinder 43 and injected into the accumulator 45 through the connecting pipe 61.
  • the accumulator 45 includes a cylinder 46 and a piston 47 slidable inside the cylinder 46, so that the molten resin M2 can be stored in the cylinder 46. Then, by moving the piston 47 after a predetermined amount of the resin M2 is stored in the cylinder 46, the resin M2 is pushed out from the slit provided in the T die 5 through the connecting pipe 62 and hung down to form a pair of resin sheets 21. , 22 is formed.
  • the pair of resin sheets 21 and 22 are guided between the pair of molds 71 and 72.
  • the pair of dies 71 and 72 are each provided with a large number of decompression suction holes (not shown), and the resin sheets 21 and 22 are decompressed and suctioned to form a shape along the pair of dies 71 and 72. It is possible to do.
  • the molds 71 and 72 have a shape having recesses 71c and 72c, and pinch-off portions 71p and 72p are provided so as to surround the recesses 71c and 72c. In the mold clamping step described later, the resin sheets 21 and 22 are cut off by the pinch-off portions 71p and 72p.
  • the manufacturing method of the molded product 1 includes a preparation step, a hanging step, an arrangement step, and a molding step.
  • a preparation step a preparation step
  • a hanging step a hanging step
  • an arrangement step a molding step.
  • the reinforcing member 13 is attached to at least a part of the surface of the core material 12. Specifically, as shown in FIG. 2, a reinforcing member 13 containing a fiber reinforced plastic is adhered (adhered) to at least one of the front surface and the back surface of the panel-shaped core material 12 which is a foam. By sticking (via the layer 14), the insert member 15 is configured.
  • the two molten resin sheets are hung between the pair of molds 71 and 72.
  • the reinforcing member 13 is attached to the core material 12 by the adhesive layer 14, and the insert member 15 prepared in the preparatory step is arranged between the pair of molds 71 and 72.
  • two resin sheets 21 and 22 are hung on both sides of the insert member 15.
  • a pair of resin sheets 21 and 22 formed by extruding the molten resin M2 from the slit of the T die 5 and hanging the resin sheets 21 and 22 are hung.
  • direct vacuum forming is performed using the pair of resin sheets 21 and 22 extruded from the T die 5 as they are, so that the pair of resin sheets 21 and 22 are cooled to room temperature and solidified before molding.
  • the solidified pair of resin sheets 21 and 22 are not heated before molding.
  • the insert member 15 is shown between the pair of resin sheets 21 and 22 during the hanging step, but in the hanging step, the insert member 15 may be kept on standby at another place. Good.
  • the pair of dies 71 and 72 are molded and then opened, so that the two resin sheets become the skin members 11a and 11b to manufacture the molded body 1.
  • the pair of molds 71 and 72 are molded. That is, the insert member 15 is arranged at a position sandwiched between the two resin sheets 21 and 22. As a result, the resin sheets 21 and 22 become the skin members 11a and 11b in the molded body 1 shown in FIG.
  • the molded product 1 shown in FIG. 5 is obtained.
  • Modification Example Section 3 describes a modification of the molded body 1. That is, the molded body 1 or the molded body 1 may be carried out according to the following aspects.
  • the molded body 1 has a panel shape, it does not necessarily have to be a rectangular parallelepiped shape.
  • the molded body 1 core material 12 forming the insert member 15
  • the molded body 1 may be configured to further include the eggplant 12s.
  • the reinforcing member 13 is attached to the core material 12 so as to avoid the shavings 12s.
  • the number, arrangement, shape, etc. of the reinforcing member 13 are not limited. Various examples are shown below. Of course, it is not limited to these. (1) Two may be attached at a position away from the center line X of the core material 12. (2) It may be attached along the two diagonal lines of the core material 12. (3) Although the tape-shaped reinforcing member 13 is attached in the longitudinal direction in FIG. 2, the reinforcing member 13 may be attached in place of or together with the reinforcing member 13 in the lateral direction. (4) In FIG. 2, the reinforcing member 13 is shorter than the length of the core material 12 in the longitudinal direction, but the lengths of the core material 12 and the reinforcing member 13 may be the same.
  • the core material 12 may be a honeycomb structure instead of the foam formed by bead foam molding.
  • the reinforcing member is formed in an elongated tape shape and is attached along the center line on the surface of the core material.
  • the thickness of the core material is t1 and the thickness of the reinforcing member is t2, 0.01 ⁇ t2 / t1 ⁇ 0.3 is satisfied.
  • the width of the core material is w1 and the width of the reinforcing member is w2, 0.05 ⁇ w2 / w1 ⁇ 0.95 is satisfied.
  • the reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic.
  • the tensile elastic modulus of the reinforcing member is 12 GPa or more and 400 GPa or less.
  • the reinforcing member is configured to be attached to both the front surface and the back surface of the core material.
  • the core material has a recess for attaching the reinforcing member, and the reinforcing member is housed in the recess.
  • one further provided with a shaving in the molded product.
  • the method for manufacturing a molded product includes a preparation step, a hanging step, an arrangement step, and a molding step. In the preparation step, the reinforcing member is attached to at least a part of the surface of the core material.
  • the hanging step two molten resin sheets are hung between a pair of molds, and in the placement step, the core material and the reinforcing member are placed between the two resin sheets, and the molding step is performed. Then, a method of manufacturing the molded body in which the two resin sheets serve as the skin member by molding the pair of molds and then opening the molds. Of course, this is not the case.
  • FIG. 8 is a cross-sectional view showing the structure of the molded body 1.
  • FIG. 9 is an exploded cross-sectional view of FIG.
  • FIG. 10 is a plan view of the insert member 115 formed by temporarily fixing the reinforcing member 113 to the core material 112.
  • the panel-shaped molded body 101 includes a skin member 111, a core member 112, and a reinforcing member 113.
  • a skin member 111 As shown in FIGS. 8 and 9, the panel-shaped molded body 101 includes a skin member 111, a core member 112, and a reinforcing member 113.
  • a core member 112 As shown in FIGS. 8 and 9, the panel-shaped molded body 101 includes a skin member 111, a core member 112, and a reinforcing member 113.
  • the skin member 111 is a resin sheet, and is arranged on both sides of the core material 112, which will be described later, to form the appearance of the molded body 101.
  • the outer surface 211 of the skin member 111 is visually recognized.
  • the reinforcing member 113 is integrally welded to the inner surface 212 of the skin member 111.
  • the material of the skin member 111 the same material as that of the skin member 11 of the first embodiment can be used.
  • Core material 112 As the core material 112, the same core material 12 as that of the first embodiment can be used.
  • the insert member 115 is formed by temporarily fixing the reinforcing member 113, which will be described later, to the core material 112 with the double-sided tape 114. It should be noted that this is only temporary fastening at the time of manufacturing, and as described above, the reinforcing member 113 is integrally welded to the inner surface 212 of the skin member 111. The insert member 115 will be described again in the method for manufacturing the molded body 101 in Section 2.
  • the reinforcing member 113 contains glass fiber reinforced plastic or carbon fiber reinforced plastic, or it is preferable to use these. Since the fiber reinforced plastic is used, a lightweight molded body 1 can be realized.
  • the reinforcing member 113 is formed in the form of a sheet or tape. It should be noted that the reinforcing member 113 has thermoplasticity, and the surface 231 of the reinforcing member 113 is integrally welded to at least a part of the inner surface 212 of the skin member 111. On the other hand, the reinforcing member 113 is configured such that its back surface 232 is temporarily fastened on both the front surface and the back surface of the core material 112. Note that FIG. 10 shows an example in which the reinforcing member 113 is formed in the shape of an elongated tape. Since it is formed in a tape shape in this way, a lightweight molded body 101 can be manufactured.
  • the back surface 232 of the reinforcing member 113 is temporarily fastened to the core material 112 along the center line X on the front surface of the core material 112.
  • the reinforcing member 113 is integrally welded to the skin member 111, the rigidity of the reinforcing member 113 directly affects the skin member 111, and the strength of the skin member 111, which is relatively easy to stretch as compared with the reinforcing member 113, is strengthened. can do.
  • the elongation of the skin member 111 in the fiber direction can be suppressed, and the deflection of the molded body 101 that may occur with the passage of time can be reduced, which is an advantageous effect.
  • the reinforcing member 113 is a UD (Uni-Direction) sheet or a UD tape.
  • UD Uni-Direction
  • UD tape are sheets or tapes in which fibers are aligned in one direction and impregnated with a thermoplastic resin.
  • the UD sheet or UD tape is a fiber reinforced plastic using long fibers and has high tensile strength in the direction in which the fibers are oriented. As a result, the elongation of the skin member 111 in the fiber direction can be remarkably suppressed.
  • the tensile elastic modulus of the reinforcing member 113 is the same as that of the reinforcing member 13 of the first embodiment.
  • the thickness of the core material 112 is t1 and the thickness of the reinforcing member 113 is t2, it is preferable that 0.01 ⁇ t2 / t1 ⁇ 0.3 is satisfied (see FIG. 8).
  • the reinforcing member 113 is in the form of a sheet or a tape, and when preparing the insert member 115, it is preferable that the reinforcing member 113 is thin enough to be easily temporarily fastened by an operator.
  • the value of t2 / t1 is 0.01,0.015,0.02,0.025,0.03,0.035,0.04,0.045,0.05,0.
  • the width of the core material 112 is w1 and the width of the reinforcing member 113 is w2, it is preferable that 0.05 ⁇ w2 / w1 ⁇ 0.95 is satisfied (see FIG. 10).
  • This is a trade-off with cost, and if the effect of preventing deflection is desired to be high, the value of w2 / w1 should be relatively high, and if cost reduction is considered, the value of w2 / w1 should be relatively low. You should do it.
  • the value of w2 / w1 is 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.
  • FIG. 11 shows an aspect of the molding machine 3 for manufacturing the molded body 101.
  • FIG. 12 shows a mode in which the molds 71 and 72 are opened in the production of the molded product 101.
  • FIG. 13 shows a mode in which the molds 71 and 72 are closed in the production of the molded product 101.
  • the manufacturing method of the molded product 101 includes a preparation step, a hanging step, an arrangement step, and a molding step.
  • a preparation step a preparation step
  • a hanging step a hanging step
  • an arrangement step a molding step.
  • the reinforcing member 113 is temporarily fastened to at least a part of both sides of the core material 112. Specifically, as shown in FIG. 10, by temporarily fixing the reinforcing member 113 containing the fiber reinforced plastic to at least one of the front surface and the back surface of the panel-shaped core material 112 which is a foam, with double-sided tape 114. , The insert member 115 is configured.
  • the two molten resin sheets 21 and 22 are hung between the pair of molds 71 and 72.
  • the insert member 115 prepared in the preparation step is arranged between the pair of molds 71 and 72, and further, as shown in FIG. 12, both sides of the insert member 115. Two resin sheets 21 and 22 are hung down.
  • FIG. 411 illustrates the insert member 115 between the pair of resin sheets 21 and 22 during the hanging step, but in the hanging step, the insert member 115 may be kept waiting at another place. Good.
  • the pair of dies 71 and 72 are molded and then opened, so that the two resin sheets 21 and 22 become the skin member 111 and the reinforcing member 113 becomes the skin member 111.
  • the molded body 101 is manufactured by being integrally welded to the molded body 101. Specifically, as shown in FIG. 13, the pair of molds 71 and 72 are molded. That is, the insert member 115 is arranged at a position sandwiched between the two resin sheets 21 and 22. As a result, the resin sheets 21 and 22 become the skin member 111 in the molded body 101 shown in FIG.
  • the surface 231 of the thermoplastic reinforcing member 113 is welded to the inner surface 212 of the skin member 111 and integrated. Finally, by taking out the molded product from the pair of molds 71 and 72 and removing the burr 25, the molded product 101 shown in FIG. 13 is obtained.
  • Modification Example Section 3 describes a modification of the molded body 101. That is, the molded body 101 or the molded body 101 may be carried out according to the following aspects.
  • the reinforcing member 113 is integrally welded to the skin member 111
  • the number, arrangement, shape, etc. of the reinforcing member 113 are not limited. Various examples are shown below. Of course, it is not limited to these.
  • the two reinforcing members 113 may be integrally welded to the skin member 111 at a position away from the center line X of the core material 112.
  • Two reinforcing members 113 may be integrally welded to the skin member 111 along the two diagonal lines of the core material 112.
  • the tape-shaped reinforcing member 113 is temporarily fastened and integrally welded in the longitudinal direction, but instead of or together with this, the reinforcing member 113 is temporarily fastened and integrally welded in the lateral direction. May be transformed.
  • the length of the core material 112 and the length of the reinforcing member 113 are substantially the same in the longitudinal direction, but the length of the reinforcing member 113 is larger than the length of the core material 112. The length may be shortened. However, it should be noted that the effect of preventing deflection is lower than that of the same.
  • the core material 112 may be a honeycomb structure instead of the foam formed by bead foam molding.
  • the double-sided tape 114 is only an example for temporarily fixing the reinforcing member 113 to the core material 112, and the adhesive or the curing tape may be attached from above to temporarily fix the reinforcing member 113.
  • the reinforcing member is formed in an elongated tape shape and integrally welded to the skin member along the center line of the core material.
  • the thickness of the core material is t1 and the thickness of the reinforcing member is t2, 0.01 ⁇ t2 / t1 ⁇ 0.3 is satisfied.
  • the width of the core material is w1 and the width of the reinforcing member is w2, 0.05 ⁇ w2 / w1 ⁇ 0.95 is satisfied.
  • the reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic.
  • the tensile elastic modulus of the reinforcing member is 12 GPa or more and 400 GPa or less.
  • the reinforcing member is configured to be temporarily fastened on both the front surface and the back surface of the core material.
  • the method for manufacturing a molded product includes a preparation step, a hanging step, an arrangement step, and a molding step.
  • the preparation step the reinforcing member is temporarily fastened to at least a part of both sides of the core material.
  • the hanging step two molten resin sheets are hung between a pair of molds, and in the arrangement step, the core material and the reinforcement temporarily fastened to the core material are placed between the two resin sheets.

Abstract

[Problem] To provide a molded body that is lightweight while strength is ensured and a molded-body producing method. Provided are: a molded body in which stretching of a skin member that can occur over time is suppressed and in which the risk of deflection is less; and a molded-body producing method. [Solution] According to one aspect, the present invention provides a panel-like molded body including a core material, a reinforcing member, and skin members, the reinforcing member being formed into a sheet or tape and being configured so as to be stuck on at least a section of a front surface or a back surface of the core material, and the skin members being resin sheets and being disposed on both surfaces of the core material. According to another aspect, the present invention provides a panel-like molded body including a core material, skin members, and a reinforcing member, the skin members being resin sheets and being disposed on both surfaces of the core material to make up the appearance of the molded body, and the reinforcing member being formed into a sheet or tape, having thermoplasticity, and being integrally welded on at least a section of inner surfaces of the skin members.

Description

成形体、及び成形体の製造方法Molded product and method for manufacturing the molded product
　本発明は、成形体、及び成形体の製造方法に関する。 The present invention relates to a molded product and a method for manufacturing the molded product.
　従来から、車両室内の内装材等に利用される成形体が製造されている。このような成形体の中でも、芯材の両面に、樹脂シートである表皮部材が配置されてなるサンドイッチパネルといわれるものが多く用いられている。 Conventionally, molded bodies used for interior materials in vehicle interiors have been manufactured. Among such molded bodies, a sandwich panel in which a skin member, which is a resin sheet, is arranged on both sides of a core material is often used.
　特許文献１には、サンドイッチパネルの一例が開示されている。 Patent Document 1 discloses an example of a sandwich panel.
特開２０１６－４３６８０号公報Japanese Unexamined Patent Publication No. 2016-43680
　ところで、このような成形体（サンドイッチパネル）は、大型化させると強度が弱くなるという問題点がある。また、強度を担保するために、芯材を複数として隣接する芯材の間に金属製の補強部材を添え木のように入れることがあるが（例えば図７に示されるもの）、このような場合は、成形体そのものの重量が大きくなるという問題点がある。 By the way, such a molded body (sandwich panel) has a problem that its strength becomes weaker when it is enlarged. Further, in order to ensure the strength, a plurality of core materials may be used and a metal reinforcing member may be inserted between adjacent core materials like a splint (for example, as shown in FIG. 7), but in such a case. Has a problem that the weight of the molded body itself becomes large.
　また、このような成形体（サンドイッチパネル）は、時間経過とともに表皮部材が繊維方向に伸びてたわんでしまうおそれがある。 In addition, in such a molded body (sandwich panel), there is a risk that the skin member may stretch and bend in the fiber direction with the passage of time.
　本発明は、かかる事情を鑑みてなされたものであり、強度を担保しつつも軽量な成形体、及び成形体の製造方法を提供することを目的とする。 The present invention has been made in view of such circumstances, and an object of the present invention is to provide a molded body that is lightweight while ensuring strength, and a method for manufacturing the molded body.
　また、本発明は、時間経過とともに発生しうる表皮部材の伸びを抑制し、たわみのおそれが少ない成形体、及び成形体の製造方法を提供することを目的とする。 Another object of the present invention is to provide a molded product that suppresses the elongation of the epidermis member that may occur with the passage of time and has less risk of bending, and a method for producing the molded product.
　本発明の一態様によれば、パネル状の成形体であって、芯材と、補強部材と、表皮部材とを備え、前記補強部材は、シート又はテープ状に形成され、前記芯材の表面又は裏面の少なくとも一部に貼付されるように構成され、前記表皮部材は、樹脂のシートであり、前記芯材の両面に配置されるものが提供される。 According to one aspect of the present invention, it is a panel-shaped molded body, which includes a core material, a reinforcing member, and a skin member, and the reinforcing member is formed in a sheet or tape shape, and the surface of the core material is formed. Alternatively, the skin member is a resin sheet, which is configured to be attached to at least a part of the back surface, and is provided on both sides of the core material.
　このような成形体によれば、強度を担保しつつも軽量な成形体を実現することができる、という有利な効果を奏する。 According to such a molded product, it is possible to realize a lightweight molded product while ensuring strength, which is an advantageous effect.
　また、本発明の他の態様によれば、パネル状の成形体であって、芯材と、表皮部材と、補強部材とを備え、前記表皮部材は、樹脂のシートであり、前記芯材の両面に配置されることで、本成形体の外観を構成し、前記補強部材は、シート又はテープ状に形成され、熱可塑性を有し、前記表皮部材の内面の少なくとも一部に一体溶着化されてなるものが提供される。 Further, according to another aspect of the present invention, the panel-shaped molded body includes a core material, a skin member, and a reinforcing member, and the skin member is a resin sheet, which is a core material. By arranging on both sides, the appearance of the molded body is formed, and the reinforcing member is formed in a sheet or tape shape, has thermoplasticity, and is integrally welded to at least a part of the inner surface of the skin member. Is provided.
　このような成形体によれば、時間経過とともに発生しうる表皮部材の伸びを抑制し、たわみのおそれが少ない成形体を実現することができる、という有利な効果を奏する。 According to such a molded product, it is possible to suppress the elongation of the epidermis member that may occur with the passage of time, and to realize a molded product with less risk of bending, which is an advantageous effect.
第1の実施形態に係る成形体１の断面図。FIG. 3 is a cross-sectional view of the molded body 1 according to the first embodiment. 芯材１２に補強部材１３を貼付してなるインサート部材１５の平面図。FIG. 3 is a plan view of an insert member 15 in which a reinforcing member 13 is attached to a core material 12. 成形体１を製造するための成形機３の態様。A mode of a molding machine 3 for manufacturing a molded body 1. 成形体１の製造において、金型７１，７２が開放された態様。A mode in which the dies 71 and 72 are opened in the production of the molded body 1. 成形体１の製造において、金型７１，７２が閉じられた態様。A mode in which the molds 71 and 72 are closed in the production of the molded body 1. 変形例に係る成形体１（インサート部材１５）の平面図。The plan view of the molded body 1 (insert member 15) which concerns on a modification. 比較例に係る成形体９の断面図。FIG. 3 is a cross-sectional view of a molded body 9 according to a comparative example. 第２の実施形態に係る成形体１０１の構成を示す断面図である。It is sectional drawing which shows the structure of the molded body 101 which concerns on 2nd Embodiment. 図８の分解断面図である。FIG. 8 is an exploded cross-sectional view of FIG. 芯材１１２に補強部材１１３を仮留めしてなるインサート部材１１５の平面図である。It is a top view of the insert member 115 formed by temporarily fastening a reinforcing member 113 to a core material 112. 成形体１０１を製造するための成形機３の態様を示している。The aspect of the molding machine 3 for manufacturing a molded body 101 is shown. 成形体１０１の製造において、金型７１，７２が開放された態様を示している。In the production of the molded body 101, the molds 71 and 72 are opened. 成形体１０１の製造において、金型７１，７２が閉じられた態様を示している。In the production of the molded body 101, the molds 71 and 72 are closed.
　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 with reference to the drawings. The features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each feature.
（第1の実施形態）
１．全体構成
　第１節では、本実施形態に係るパネル状の成形体１について説明する。図１は、成形体１の構成を示す断面図である。図２は、芯材１２に補強部材１３を貼付してなるインサート部材１５の平面図である。 (First Embodiment)
1. 1. Overall Configuration Section 1 describes the panel-shaped molded body 1 according to the present embodiment. FIG. 1 is a cross-sectional view showing the structure of the molded body 1. FIG. 2 is a plan view of the insert member 15 in which the reinforcing member 13 is attached to the core material 12.
　図１に示されるように、パネル状の成形体１は、表皮部材１１ａ，１１ｂと、芯材１２と、補強部材１３とを備える。以下、各構成について詳細に説明する。 As shown in FIG. 1, the panel-shaped molded body 1 includes skin members 11a and 11b, a core member 12, and a reinforcing member 13. Hereinafter, each configuration will be described in detail.
＜表皮部材１１ａ，１１ｂ＞
　図１に示されるように、表皮部材１１ａ，１１ｂは、樹脂のシートであり、後述の芯材１２の両面に配置される。具体的には、表皮部材１１ａ，１１ｂとしては、天然繊維、再生繊維、半合成繊維、合成繊維、及びこれらを混合した繊維を加工して得られる編物、織物、不織布、またはポリ塩化ビニル（ＰＶＣ）、熱可塑性ポリウレタンエラストマー（ＴＰＵ）または熱可塑性ポリオレフィンエラストマー（ＴＰＯ）等の熱可塑性エラストマー（ＴＰＥ）、ポリエチレンポリオレフィン系樹脂等の熱可塑性樹脂からなる樹脂シート、及びこれらの積層シート、プラスチック製段ボール、ハードボード等から適宜選択可能である。 < Skin members 11a, 11b>
As shown in FIG. 1, the skin members 11a and 11b are resin sheets and are arranged on both sides of the core material 12 described later. Specifically, as the skin members 11a and 11b, a knitted fabric, a woven fabric, a non-woven fabric, or a polyvinyl chloride (PVC) obtained by processing natural fibers, regenerated fibers, semi-synthetic fibers, synthetic fibers, and fibers obtained by mixing these. ), Thermoplastic elastomer (TPE) such as thermoplastic polyurethane elastomer (TPU) or thermoplastic polyolefin elastomer (TPO), resin sheet made of thermoplastic resin such as polyethylene polyolefin resin, and laminated sheets thereof, plastic cardboard, It can be appropriately selected from a hard board or the like.
＜芯材１２＞
　芯材１２は、例えば、熱可塑性樹脂の発泡体からなるものであり、熱可塑性樹脂としては、ポリエチレン、ポリプロピレン、ポリスチレン等が適宜採用されることが望ましい。また、かかる発泡体には、適宜、ガラス繊維、カーボンファイバー、炭酸カルシウム、タルク、マイカ等の充填材を添加することもできる。 <Core material 12>
The core material 12 is made of, for example, a foam of a thermoplastic resin, and it is desirable that polyethylene, polypropylene, polystyrene or the like is appropriately adopted as the thermoplastic resin. Further, a filler such as glass fiber, carbon fiber, calcium carbonate, talc, or mica can be appropriately added to the foam.
　より具体的には、芯材１２は、いわゆるビーズ発泡成形により製造された発泡体である。ビーズ発泡成形の特長は、形状を自由に設計できることと、高倍率の発泡成形品が得られることにある。ビーズ発泡成形の工程は、予備発泡、熟成、成形、養生に分けられる。ビーズ発泡成形に用いられるビーズは炭化水素等の物理発泡剤を含浸した小径の樹脂粒子である。発泡剤を含浸させる方法として、ポリスチレンの場合には懸濁重合の際に重合系に発泡剤である炭化水素（ペンタン等）を存在させることで、発泡剤を含んだポリスチレン粒子が得られる。ＰＰやＰＥの場合には、あらかじめ用意したミニペレットに水中で炭化水素を含浸させる。 More specifically, the core material 12 is a foam produced by so-called bead foam molding. The features of bead foam molding are that the shape can be freely designed and that a high-magnification foam molded product can be obtained. The bead foam molding process is divided into pre-foaming, aging, molding and curing. The beads used for bead foam molding are small-diameter resin particles impregnated with a physical foaming agent such as a hydrocarbon. As a method of impregnating with a foaming agent, in the case of polystyrene, polystyrene particles containing a foaming agent can be obtained by allowing a hydrocarbon (pentane or the like) as a foaming agent to be present in the polymerization system during suspension polymerization. In the case of PP or PE, the mini pellets prepared in advance are impregnated with hydrocarbons in water.
　芯材１２の形成に使用されうる発泡剤としては、公知の物理発泡剤、化学発泡剤及びその混合物が挙げられる。例えば、物理発泡剤としては、空気、炭酸ガス、窒素ガス等の無機系物理発泡剤、及びブタン、ペンタン、ヘキサン、ジクロロメタン、ジクロロエタン等の有機系物理発泡剤を適用できる。また、化学発泡剤としては、例えば、アゾジカルボンアミド（ＡＤＣＡ）、Ｎ，Ｎ’－ジニトロソペンタメチレンテトラミン、４，４’－オキシビス（ベンゼンスルホニルヒドラジド）、ジフェニルスルホン－３，３’－ジスルホニルヒドラジド、ｐ－トルエンスルホニルセミカルバジド、トリヒドラジノトリアジン又はアゾビスイソブチロニトリルなどの有機発泡剤、クエン酸、シュウ酸、フマル酸、フタル酸、リンゴ酸、酒石酸、シクロヘキサン－１，２－ジカルボン酸、ショウノウ酸、エチレンジアミン四酢酸、トリエチレンテトラミン六酢酸、ニトリロ酸などのポリカルボン酸と、炭酸水素ナトリウム、炭酸水素ナトリウムアルミニウム、炭酸水素カリウム、炭酸水素アンモニウム、炭酸アンモニウム等の無機炭酸化合物の混合物や、クエン酸二水素ナトリウム、シュウ酸カリウム等のポリカルボン酸の塩が無機発泡剤として挙げられる。 Examples of the foaming agent that can be used for forming the core material 12 include known physical foaming agents, chemical foaming agents, and mixtures thereof. For example, as the physical foaming agent, an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, and an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, and dichloroethane can be applied. Examples of the chemical foaming agent include azodicarboxylic amide (ADCA), N, N'-dinitrosopentamethylenetetramine, 4,4'-oxybis (benzenesulfonylhydrazide), and diphenylsulfone-3,3'-disulfonyl. Organic foaming agents such as hydrazide, p-toluenesulfonyl semicarbazide, trihydrazinotriazine or azobisisobutyronitrile, citric acid, oxalic acid, fumaric acid, phthalic acid, malic acid, tartaric acid, cyclohexane-1,2-dicarboxylic acid , A mixture of polycarboxylic acids such as gyonoic acid, ethylenediamine tetraacetic acid, triethylenetetramine hexaacetic acid and nitriloic acid and inorganic carbonate compounds such as sodium hydrogen carbonate, sodium hydrogen carbonate aluminum, potassium hydrogen carbonate, ammonium hydrogen carbonate and ammonium carbonate , Salts of polycarboxylic acids such as sodium dihydrogen citrate and potassium oxalate can be mentioned as inorganic foaming agents.
　なお、芯材１２に後述の補強部材１３が接着層１４を介して貼付されることで、インサート部材１５が構成される。芯材１２は、補強部材１３を貼付するための凹部１２Ａを有し、補強部材１３が芯材１２に設けられた凹部１２Ａに収容されるように実施することが好ましい。インサート部材１５については、第２節における成形体１の製造方法において、改めて説明する。 The insert member 15 is formed by attaching the reinforcing member 13 described later to the core material 12 via the adhesive layer 14. It is preferable that the core material 12 has a recess 12A for attaching the reinforcing member 13, and the reinforcing member 13 is housed in the recess 12A provided in the core material 12. The insert member 15 will be described again in the method for manufacturing the molded body 1 in Section 2.
＜補強部材１３＞
　成形体１においては、補強部材１３は、ガラス繊維強化プラスチック、又は炭素繊維強化プラスチックを含む、又はこれらを採用することが好ましい。繊維強化プラスチックを採用していることから、図７に示される金属製の補強部材９３を採用する場合に比して軽量化に寄与している。 <Reinforcing member 13>
In the molded body 1, the reinforcing member 13 contains glass fiber reinforced plastic or carbon fiber reinforced plastic, or it is preferable to use these. Since the fiber reinforced plastic is used, it contributes to weight reduction as compared with the case where the metal reinforcing member 93 shown in FIG. 7 is used.
　補強部材１３は、芯材１２の表面又は裏面の少なくとも一部に貼付されるように構成され、シート又はテープ状に形成されるとよい。特に図１及び図２においては、補強部材１３は、芯材１２の表面及び裏面の両側に貼付されるように構成され、且つ補強部材１３が細長のテープ状に形成される例が示されている。特に、芯材１２の表面及び裏面には、凹部１２１が設けられており、ここにテープ状の補強部材１３が貼付されている。このようにテープ状に形成されていることから、図７に示される金属製の補強部材９３を採用する場合に比して軽量化が見込まれる。参考までに、図７に示される成形体９（比較例）は、表皮部材９１ａ，９１ｂと、芯材９２と、Ｈ字形状の補強部材９３（いわゆるリインフォース）とを備える。このような成形体９の補強部材９３は、隣接する２つの芯材９２の間に金属製の補強部材９３を添え木のように入れているため、重量が大きくなる。 The reinforcing member 13 is configured to be attached to at least a part of the front surface or the back surface of the core material 12, and may be formed in the form of a sheet or tape. In particular, in FIGS. 1 and 2, an example is shown in which the reinforcing member 13 is configured to be attached to both the front surface and the back surface of the core material 12, and the reinforcing member 13 is formed in an elongated tape shape. There is. In particular, recesses 121 are provided on the front surface and the back surface of the core material 12, and a tape-shaped reinforcing member 13 is attached thereto. Since it is formed in a tape shape in this way, weight reduction is expected as compared with the case where the metal reinforcing member 93 shown in FIG. 7 is adopted. For reference, the molded body 9 (comparative example) shown in FIG. 7 includes skin members 91a and 91b, a core member 92, and an H-shaped reinforcing member 93 (so-called reinforce). Since the reinforcing member 93 of the molded body 9 has a metal reinforcing member 93 inserted between two adjacent core members 92 like a splint, the weight increases.
　また、図２に示されるように、補強部材１３は、芯材１２の表面における中央線Ｘに沿って貼付されることが好ましい。このような貼付に際しては、接着剤等が採用される。換言すると、図１に示されるように、芯材１２と補強部材１３とが接着層１４を介して接着されることとなる。これにより、補強部材１３の剛性が芯材１２にダイレクトに影響し、補強部材１３に比して相対的に柔らかい芯材１２の強度を強化することができる。ひいては軽量性を維持しつつ、成形体１の強度を高めることができる。 Further, as shown in FIG. 2, it is preferable that the reinforcing member 13 is attached along the center line X on the surface of the core material 12. An adhesive or the like is used for such affixing. In other words, as shown in FIG. 1, the core material 12 and the reinforcing member 13 are adhered to each other via the adhesive layer 14. As a result, the rigidity of the reinforcing member 13 directly affects the core material 12, and the strength of the core material 12 which is relatively soft as compared with the reinforcing member 13 can be strengthened. As a result, the strength of the molded product 1 can be increased while maintaining the light weight.
　さらに具体的には、補強部材１３がＵＤ（Ｕｎｉ－Ｄｉｒｅｃｔｉｏｎ）シート又はＵＤテープであることが好ましい。これらは、繊維を一方向に引きそろえて熱可塑性樹脂を含浸させたシート又はテープである。ＵＤシート又はＵＤテープは、長い繊維を使用した繊維強化プラスチックで、繊維が配向する方向の引張強度が高いことに留意されたい。これにより成形体１の強度を顕著に高めることができる。 More specifically, it is preferable that the reinforcing member 13 is a UD (Uni-Direction) sheet or a UD tape. These are sheets or tapes in which fibers are aligned in one direction and impregnated with a thermoplastic resin. It should be noted that the UD sheet or UD tape is a fiber reinforced plastic using long fibers and has high tensile strength in the direction in which the fibers are oriented. As a result, the strength of the molded product 1 can be remarkably increased.
　成形体１においては、補強部材１３の引張弾性率が１２ＧＰａ以上４００ＧＰａ以下であることが好ましい。具体的には例えば、１２，１３，１４，１５，１６，１７，１８，１９，２０，２１，２２，２３，２４，２５，２６，２７，２８，２９，３０，３１，３２，３３，３４，３５，３６，３７，３８，３９，４０，５０，６０，７０，８０，９０，１００，１１０，１２０，１３０，１４０，１５０，１６０，１７０，１８０，１９０，２００，２１０，２２０，２３０，２４０，２５０，２６０，２７０，２８０，２９０，３００，３１０，３２０，３３０，３４０，３５０，３６０，３７０，３８０，３９０，４００ＧＰａであり、ここで例示した数値の何れか２つの間の範囲内であってもよい。 In the molded body 1, the tensile elastic modulus of the reinforcing member 13 is preferably 12 GPa or more and 400 GPa or less. Specifically, for example, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34,35,36,37,38,39,40,50,60,70,80,90,100,110,120,130,140,150,160,170,180,190,200,210,220, It is 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400 GPa, and is between any two of the numerical values exemplified here. It may be within the range.
　また、成形体１においては、芯材１２の厚さをｔ１、補強部材１３の厚さをｔ２とすると、０．０１≦ｔ２／ｔ１≦０．３を満たすことが好ましい（図１参照）。補強部材１３はシート状またはテープ状であり、インサート部材１５を準備する上で、作業者が簡単に貼付できる程度に、補強部材１３を薄いものにすることが好ましいからである。具体的には例えば、ｔ２／ｔ１の値が０．０１，０．０１５，０．０２，０．０２５，０．０３，０．０３５，０．０４，０．０４５，０．０５，０．０５５，０．０６，０．０６５，０．０７，０．０７５，０．０８，０．０８５，０．０９，０．０９５，０．１，０．１０５，０．１１，０．１１５，０．１２，０．１２５，０．１３，０．１３５，０．１４，０．１４５，０．１５，０．１５５，０．１６，０．１６５，０．１７，０．１７５，０．１８，０．１８５，０．１９，０．１９５，０．２，０．２０５，０．２１，０．２１５，０．２２，０．２２５，０．２３，０．２３５，０．２４，０．２４５，０．２５，０．２５５，０．２６，０．２６５，０．２７，０．２７５，０．２８，０．２８５，０．２９，０．２９５，０．３であり、ここで例示した数値の何れか２つの間の範囲内であってもよい。 Further, in the molded body 1, if the thickness of the core material 12 is t1 and the thickness of the reinforcing member 13 is t2, it is preferable that 0.01 ≦ t2 / t1 ≦ 0.3 is satisfied (see FIG. 1). This is because the reinforcing member 13 is in the form of a sheet or a tape, and when preparing the insert member 15, it is preferable that the reinforcing member 13 is thin enough to be easily attached by an operator. Specifically, for example, the value of t2 / t1 is 0.01,0.015,0.02,0.025,0.03,0.035,0.04,0.045,0.05,0. 055, 0.06, 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, 0.095, 0.1, 0.105, 0.11, 0.115, 0.12, 0.125, 0.13, 0.135, 0.14, 0.145, 0.15, 0.155, 0.16, 0.165, 0.17, 0.175, 0. 18, 0.185, 0.19, 0.195, 0.2, 0.205, 0.21, 0.215, 0.22, 0.225, 0.23, 0.235, 0.24 It is 0.245, 0.25, 0.25, 0.26, 0.265, 0.27, 0.275, 0.28, 0.285, 0.29, 0.295, 0.3. It may be within the range between any two of the numerical values exemplified here.
　さらに、成形体１においては、芯材１２の幅をｗ１、補強部材１３の幅をｗ２とすると、０．０５≦ｗ２／ｗ１≦０．９５を満たすことが好ましい（図２参照）。これはコストとの兼ね合いであり、高い強度を望む場合は、ｗ２／ｗ１の値を相対的に高くするとよく、コスト削減を考えるのであれば、ｗ２／ｗ１の値を相対的に低くするとよい。具体的には例えば、ｗ２／ｗ１の値が０．０５，０．０６，０．０７，０．０８，０．０９，０．１，０．１１，０．１２，０．１３，０．１４，０．１５，０．１６，０．１７，０．１８，０．１９，０．２，０．２１，０．２２，０．２３，０．２４，０．２５，０．２６，０．２７，０．２８，０．２９，０．３，０．３１，０．３２，０．３３，０．３４，０．３５，０．３６，０．３７，０．３８，０．３９，０．４，０．４１，０．４２，０．４３，０．４４，０．４５，０．４６，０．４７，０．４８，０．４９，０．５，０．５１，０．５２，０．５３，０．５４，０．５５，０．５６，０．５７，０．５８，０．５９，０．６，０．６１，０．６２，０．６３，０．６４，０．６５，０．６６，０．６７，０．６８，０．６９，０．７，０．７１，０．７２，０．７３，０．７４，０．７５，０．７６，０．７７，０．７８，０．７９，０．８，０．８１，０．８２，０．８３，０．８４，０．８５，０．８６，０．８７，０．８８，０．８９，０．９，０．９１，０．９２，０．９３，０．９４，０．９５であり、ここで例示した数値の何れか２つの間の範囲内であってもよい。 Further, in the molded body 1, if the width of the core material 12 is w1 and the width of the reinforcing member 13 is w2, it is preferable that 0.05 ≦ w2 / w1 ≦ 0.95 is satisfied (see FIG. 2). This is a balance with cost, and if high strength is desired, the value of w2 / w1 may be relatively high, and if cost reduction is considered, the value of w2 / w1 may be relatively low. Specifically, for example, the value of w2 / w1 is 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0. 14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0. 39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58, 0.59, 0.6, 0.61, 0.62, 0.63, 0. 64,0.65,0.66,0.67,0.68,0.69,0.7,0.71,0.72,0.73,0.74,0.75,0.76 0.77, 0.78, 0.79, 0.8, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0. It is 89, 0.9, 0.91, 0.92, 0.93, 0.94, 0.95, and may be within the range between any two of the numerical values exemplified here.
２．成形体１の製造方法
　第２節では、成形体１の製造方法について説明する。図３は、成形体１を製造するための成形機３の態様を示している。図４は、成形体１の製造において、金型７１，７２が開放された態様を示している。図５は、成形体１の製造において、金型７１，７２が閉じられた態様を示している。 2. Manufacturing Method of Molded Body 1 Section 2 describes a manufacturing method of the molded body 1. FIG. 3 shows an aspect of a molding machine 3 for manufacturing a molded body 1. FIG. 4 shows a mode in which the molds 71 and 72 are opened in the production of the molded product 1. FIG. 5 shows a mode in which the molds 71 and 72 are closed in the production of the molded product 1.
２－１．成形機３の構成
　成形機３は、樹脂供給装置４と、Ｔダイ５と、一対の金型７１，７２を備える。樹脂供給装置４は、ホッパー４１と、押出機４２と、アキュームレータ４５とを備える。押出機４２とアキュームレータ４５は、連結管６１を介して連結される。アキュームレータ４５とＴダイ５は、連結管６２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。 2-1. Configuration of Molding Machine 3 The molding machine 3 includes a resin supply device 4, a T-die 5, and a pair of molds 71 and 72. The resin supply device 4 includes a hopper 41, an extruder 42, and an accumulator 45. The extruder 42 and the accumulator 45 are connected via a connecting pipe 61. The accumulator 45 and the T-die 5 are connected via a connecting pipe 62. Hereinafter, each configuration will be described in detail.
＜ホッパー４１、押出機４２＞
　ホッパー４１は、原料樹脂Ｍ１を押出機４２のシリンダ４３内に投入するために用いられる。原料樹脂Ｍ１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Ｍ１は、ホッパー４１からシリンダ４３内に投入された後、シリンダ４３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４３内に配置されたスクリューの回転によってシリンダ４３の先端に向けて搬送される。スクリューは、シリンダ４３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４３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 41, extruder 42>
The hopper 41 is used to put the raw material resin M1 into the cylinder 43 of the extruder 42. The form of the raw material resin M1 is not particularly limited, but is usually in the form of pellets. The raw material resin M1 is charged into the cylinder 43 from the hopper 41 and then melted by being heated in the cylinder 43 to become a molten resin. Further, it is conveyed toward the tip of the cylinder 43 by the rotation of the screw arranged in the cylinder 43. The screw is arranged in the cylinder 43, and the molten resin is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device. The number of screws arranged in the cylinder 43 may be one or two or more.
＜アキュームレータ４５、Ｔダイ５＞
　溶融混練されてなる樹脂Ｍ２は、シリンダ４３の樹脂押出口から押し出され、連結管６１を通じてアキュームレータ４５内に注入される。アキュームレータ４５は、シリンダ４６とその内部で摺動可能なピストン４７を備えており、シリンダ４６内に溶融された樹脂Ｍ２が貯留可能になっている。そして、シリンダ４６内に樹脂Ｍ２が所定量貯留された後にピストン４７を移動させることによって、連結管６２を通じて樹脂Ｍ２をＴダイ５内に設けられたスリットから押し出して垂下させて一対の樹脂シート２１，２２を形成する。 <Accumulator 45, T-die 5>
The melt-kneaded resin M2 is extruded from the resin extrusion port of the cylinder 43 and injected into the accumulator 45 through the connecting pipe 61. The accumulator 45 includes a cylinder 46 and a piston 47 slidable inside the cylinder 46, so that the molten resin M2 can be stored in the cylinder 46. Then, by moving the piston 47 after a predetermined amount of the resin M2 is stored in the cylinder 46, the resin M2 is pushed out from the slit provided in the T die 5 through the connecting pipe 62 and hung down to form a pair of resin sheets 21. , 22 is formed.
＜一対の金型７１，７２＞
　一対の樹脂シート２１，２２は、一対の金型７１，７２間に導かれる。一対の金型７１，７２には、それぞれ多数の減圧吸引孔（不図示）が設けられており、樹脂シート２１，２２を減圧吸引して一対の金型７１，７２に沿った形状に賦形することが可能になっている。金型７１，７２は、凹部７１ｃ，７２ｃを有する形状になっており、凹部７１ｃ，７２ｃを取り囲むようにピンチオフ部７１ｐ，７２ｐが設けられている。後述の型締工程において、ピンチオフ部７１ｐ，７２ｐによって樹脂シート２１，２２が食い切られる。 <A pair of molds 71, 72>
The pair of resin sheets 21 and 22 are guided between the pair of molds 71 and 72. The pair of dies 71 and 72 are each provided with a large number of decompression suction holes (not shown), and the resin sheets 21 and 22 are decompressed and suctioned to form a shape along the pair of dies 71 and 72. It is possible to do. The molds 71 and 72 have a shape having recesses 71c and 72c, and pinch-off portions 71p and 72p are provided so as to surround the recesses 71c and 72c. In the mold clamping step described later, the resin sheets 21 and 22 are cut off by the pinch-off portions 71p and 72p.
２－２．製造方法の流れ
　成形体１の製造方法は、準備工程と、垂下工程と、配置工程と、成形工程とを備える。以下、詳細に説明する。 2-2. Flow of Manufacturing Method The manufacturing method of the molded product 1 includes a preparation step, a hanging step, an arrangement step, and a molding step. Hereinafter, a detailed description will be given.
＜準備工程＞
　準備工程では、芯材１２の表面の少なくとも一部に補強部材１３を貼付する。具体的には、図２に示されるように、発泡体であってパネル形状の芯材１２の表面及び裏面の少なくとも一方に繊維強化プラスチックを含む補強部材１３を接着剤等で接着して（接着層１４を介して）貼付することで、インサート部材１５が構成される。 <Preparation process>
In the preparatory step, the reinforcing member 13 is attached to at least a part of the surface of the core material 12. Specifically, as shown in FIG. 2, a reinforcing member 13 containing a fiber reinforced plastic is adhered (adhered) to at least one of the front surface and the back surface of the panel-shaped core material 12 which is a foam. By sticking (via the layer 14), the insert member 15 is configured.
＜垂下工程＞
　垂下工程では、溶融状態の２本の樹脂シートを一対の金型７１，７２間に垂下させる。具体的には、図３に示されるように、芯材１２に補強部材１３を接着層１４によって貼付し、準備工程で用意されたインサート部材１５を、一対の金型７１，７２間に配置し、さらに図４に示されるように、インサート部材１５の両面に２つの樹脂シート２１，２２を垂下させる。 <Dripping process>
In the hanging step, the two molten resin sheets are hung between the pair of molds 71 and 72. Specifically, as shown in FIG. 3, the reinforcing member 13 is attached to the core material 12 by the adhesive layer 14, and the insert member 15 prepared in the preparatory step is arranged between the pair of molds 71 and 72. Further, as shown in FIG. 4, two resin sheets 21 and 22 are hung on both sides of the insert member 15.
　そして、一対の金型７１，７２間に、溶融状態の樹脂Ｍ２をＴダイ５のスリットから押し出して垂下させて形成した一対の樹脂シート２１，２２を垂下する。本実施形態では、Ｔダイ５から押し出された一対の樹脂シート２１，２２をそのまま使用するダイレクト真空成形が行われるので、一対の樹脂シート２１，２２は、成形前に室温にまで冷却されて固化されることがなく、固化された一対の樹脂シート２１，２２が成形前に加熱されることもない。ここで、図３では、垂下工程中において、一対の樹脂シート２１，２２の間にインサート部材１５を図示しているが、垂下工程では、インサート部材１５を他の場所に待機させておいてもよい。 Then, between the pair of molds 71 and 72, a pair of resin sheets 21 and 22 formed by extruding the molten resin M2 from the slit of the T die 5 and hanging the resin sheets 21 and 22 are hung. In the present embodiment, direct vacuum forming is performed using the pair of resin sheets 21 and 22 extruded from the T die 5 as they are, so that the pair of resin sheets 21 and 22 are cooled to room temperature and solidified before molding. The solidified pair of resin sheets 21 and 22 are not heated before molding. Here, in FIG. 3, the insert member 15 is shown between the pair of resin sheets 21 and 22 during the hanging step, but in the hanging step, the insert member 15 may be kept on standby at another place. Good.
＜賦形工程＞
　次に、賦形工程では、一対の樹脂シート２１，２２をそれぞれ一対の金型７１，７２の一部に当接させた後、一対の金型７１，７２の両方によって２枚の樹脂シート２１，２２を減圧吸引して一対の金型７１，７２に沿った形状に賦形する。 <Shaping process>
Next, in the shaping step, after the pair of resin sheets 21 and 22 are brought into contact with a part of the pair of molds 71 and 72, respectively, the two resin sheets 21 are provided by both of the pair of molds 71 and 72. , 22 are sucked under reduced pressure to form a shape along the pair of molds 71 and 72.
＜配置工程＞
　次に、配置工程では、２本の樹脂シートの間に芯材１２及び補強部材１３を配置する。そして、インサート部材１５を一対の樹脂シート２１，２２に溶着させる。 <Placement process>
Next, in the arranging step, the core material 12 and the reinforcing member 13 are arranged between the two resin sheets. Then, the insert member 15 is welded to the pair of resin sheets 21 and 22.
＜成形工程＞
　最後に、成形工程では、一対の金型７１，７２を型締めし、その後これを開放することで、２本の樹脂シートが表皮部材１１ａ，１１ｂとなって成形体１が製造される。具体的には、図５に示されるように、一対の金型７１，７２を型締めする。すなわち、インサート部材１５が２つの樹脂シート２１，２２に挟まれた位置に配置される。これによって、樹脂シート２１，２２が、図１に示される成形体１における表皮部材１１ａ，１１ｂとなる。最後に、一対の金型７１，７２から成形体を取り出し、バリ２５を除去することによって、図５に示される成形体１が得られる。 <Molding process>
Finally, in the molding step, the pair of dies 71 and 72 are molded and then opened, so that the two resin sheets become the skin members 11a and 11b to manufacture the molded body 1. Specifically, as shown in FIG. 5, the pair of molds 71 and 72 are molded. That is, the insert member 15 is arranged at a position sandwiched between the two resin sheets 21 and 22. As a result, the resin sheets 21 and 22 become the skin members 11a and 11b in the molded body 1 shown in FIG. Finally, by taking out the molded product from the pair of molds 71 and 72 and removing the burr 25, the molded product 1 shown in FIG. 5 is obtained.
３．変形例
　第３節では、成形体１に係る変形例について説明する。すなわち、下記のような態様によって成形体１や成形体１を実施してもよい。 3. 3. Modification Example Section 3 describes a modification of the molded body 1. That is, the molded body 1 or the molded body 1 may be carried out according to the following aspects.
　成形体１はパネル状であるものの、必ずしても直方体状でなくてもよい。例えば、図６に示されるように、成形体１（インサート部材１５をなす芯材１２）がヌスミ１２ｓをさらに備えるように構成されてもよい。かかる場合は、ヌスミ１２ｓを避けるように補強部材１３が芯材１２に貼付されることとなる。 Although the molded body 1 has a panel shape, it does not necessarily have to be a rectangular parallelepiped shape. For example, as shown in FIG. 6, the molded body 1 (core material 12 forming the insert member 15) may be configured to further include the eggplant 12s. In such a case, the reinforcing member 13 is attached to the core material 12 so as to avoid the shavings 12s.
　芯材１２に補強部材１３が貼付されていれば、補強部材１３の個数、配置、形状等は限定されない。以下に様々な例を示す。もちろん、これらに限定されるものではない。
（１）芯材１２の中央線Ｘから離れた位置に２本貼付してもよい。
（２）芯材１２の２本の対角線に沿って貼付してもよい。
（３）図２では長手方向にテープ状の補強部材１３が貼付されているが、これに代えて又はこれとともに短手方向にも補強部材１３が貼付されてもよい。
（４）図２では、長手方向において、芯材１２の長さよりも補強部材１３が短いものとなっているが、芯材１２と補強部材１３の長さが同一であってもよい。 As long as the reinforcing member 13 is attached to the core material 12, the number, arrangement, shape, etc. of the reinforcing member 13 are not limited. Various examples are shown below. Of course, it is not limited to these.
(1) Two may be attached at a position away from the center line X of the core material 12.
(2) It may be attached along the two diagonal lines of the core material 12.
(3) Although the tape-shaped reinforcing member 13 is attached in the longitudinal direction in FIG. 2, the reinforcing member 13 may be attached in place of or together with the reinforcing member 13 in the lateral direction.
(4) In FIG. 2, the reinforcing member 13 is shorter than the length of the core material 12 in the longitudinal direction, but the lengths of the core material 12 and the reinforcing member 13 may be the same.
　芯材１２は、ビーズ発泡成形による発泡体に代えてハニカム構造体であってもよい。 The core material 12 may be a honeycomb structure instead of the foam formed by bead foam molding.
４．結言
　このように、強度を担保しつつも軽量な成形体を実現することができる成形体を提供することができる。 4. Conclusion As described above, it is possible to provide a molded product capable of realizing a lightweight molded product while ensuring strength.
　次に記載の各態様で提供されてもよい。
　前記成形体において、前記補強部材は、細長のテープ状に形成され、前記芯材の表面における中央線に沿って貼付されるもの。
　前記成形体において、前記芯材の厚さをｔ１、前記補強部材の厚さをｔ２とすると、０．０１≦ｔ２／ｔ１≦０．３を満たすもの。
　前記成形体において、前記芯材の幅をｗ１、前記補強部材の幅をｗ２とすると、０．０５≦ｗ２／ｗ１≦０．９５を満たすもの。
　前記成形体において、前記補強部材は、ガラス繊維強化プラスチック、又は炭素繊維強化プラスチックを含むもの。
　前記成形体において、前記補強部材の引張弾性率が１２ＧＰａ以上４００ＧＰａ以下であるもの。
　前記成形体において、前記補強部材は、前記芯材の表面及び裏面の両側に貼付されるように構成されるもの。
　前記成形体において、前記芯材は、前記補強部材を貼付するための凹部を有し、前記補強部材がこの凹部に収容されるもの。
　前記成形体において、ヌスミをさらに備えるもの。
　前記成形体の製造方法であって、準備工程と、垂下工程と、配置工程と、成形工程とを備え、前記準備工程では、前記芯材の表面の少なくとも一部に前記補強部材を貼付し、前記垂下工程では、溶融状態の２本の樹脂シートを一対の金型間に垂下させ、前記配置工程では、前記２本の樹脂シートの間に前記芯材及び補強部材を配置し、前記成形工程では、前記一対の金型を型締めし、その後これを開放することで、前記２本の樹脂シートが前記表皮部材となって前記成形体を製造する方法。
　もちろん、この限りではない。 It may be provided in each of the following aspects.
In the molded body, the reinforcing member is formed in an elongated tape shape and is attached along the center line on the surface of the core material.
In the molded body, assuming that the thickness of the core material is t1 and the thickness of the reinforcing member is t2, 0.01 ≦ t2 / t1 ≦ 0.3 is satisfied.
In the molded body, assuming that the width of the core material is w1 and the width of the reinforcing member is w2, 0.05 ≦ w2 / w1 ≦ 0.95 is satisfied.
In the molded product, the reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic.
In the molded body, the tensile elastic modulus of the reinforcing member is 12 GPa or more and 400 GPa or less.
In the molded body, the reinforcing member is configured to be attached to both the front surface and the back surface of the core material.
In the molded body, the core material has a recess for attaching the reinforcing member, and the reinforcing member is housed in the recess.
In the molded product, one further provided with a shaving.
The method for manufacturing a molded product includes a preparation step, a hanging step, an arrangement step, and a molding step. In the preparation step, the reinforcing member is attached to at least a part of the surface of the core material. In the hanging step, two molten resin sheets are hung between a pair of molds, and in the placement step, the core material and the reinforcing member are placed between the two resin sheets, and the molding step is performed. Then, a method of manufacturing the molded body in which the two resin sheets serve as the skin member by molding the pair of molds and then opening the molds.
Of course, this is not the case.
（第２の実施形態）
１．全体構成
　第１節では、本実施形態に係るパネル状の成形体１０１について説明する。図８は、成形体１の構成を示す断面図である。図９は、図８の分解断面図である。図１０は、芯材１１２に補強部材１１３を仮留めしてなるインサート部材１１５の平面図である。 (Second Embodiment)
1. 1. Overall Configuration Section 1 describes the panel-shaped molded body 101 according to the present embodiment. FIG. 8 is a cross-sectional view showing the structure of the molded body 1. FIG. 9 is an exploded cross-sectional view of FIG. FIG. 10 is a plan view of the insert member 115 formed by temporarily fixing the reinforcing member 113 to the core material 112.
　図８及び図９に示されるように、パネル状の成形体１０１は、表皮部材１１１と、芯材１１２と、補強部材１１３とを備える。以下、各構成について詳細に説明する。 As shown in FIGS. 8 and 9, the panel-shaped molded body 101 includes a skin member 111, a core member 112, and a reinforcing member 113. Hereinafter, each configuration will be described in detail.
＜表皮部材１１１＞
　図８及び図９に示されるように、表皮部材１１１は、樹脂のシートであり、後述の芯材１１２の両面に配置されることで、本成形体１０１の外観を構成する。換言すると、成形体１０１では、表皮部材１１１における外面２１１が視認される。また、表皮部材１１１の内面２１２には補強部材１１３が一体溶着化される。具体的には、表皮部材１１１の材料としては、第１の実施形態の表皮部材１１と同様のものが使用可能である。 <Skin member 111>
As shown in FIGS. 8 and 9, the skin member 111 is a resin sheet, and is arranged on both sides of the core material 112, which will be described later, to form the appearance of the molded body 101. In other words, in the molded body 101, the outer surface 211 of the skin member 111 is visually recognized. Further, the reinforcing member 113 is integrally welded to the inner surface 212 of the skin member 111. Specifically, as the material of the skin member 111, the same material as that of the skin member 11 of the first embodiment can be used.
＜芯材１１２＞
　芯材１１２としては、第１の実施形態の芯材１２と同様のものが使用可能である。 <Core material 112>
As the core material 112, the same core material 12 as that of the first embodiment can be used.
　なお、芯材１１２に後述の補強部材１１３が両面テープ１１４で仮留めされることで、インサート部材１１５が構成される。なお、あくまでも製造に際しての仮留めであり、前述の通り、補強部材１１３は表皮部材１１１の内面２１２に一体化溶着されるものである。インサート部材１１５については、第２節における成形体１０１の製造方法において、改めて説明する。 The insert member 115 is formed by temporarily fixing the reinforcing member 113, which will be described later, to the core material 112 with the double-sided tape 114. It should be noted that this is only temporary fastening at the time of manufacturing, and as described above, the reinforcing member 113 is integrally welded to the inner surface 212 of the skin member 111. The insert member 115 will be described again in the method for manufacturing the molded body 101 in Section 2.
＜補強部材１１３＞
　成形体１０１においては、補強部材１１３は、ガラス繊維強化プラスチック、又は炭素繊維強化プラスチックを含む、又はこれらを採用することが好ましい。繊維強化プラスチックを採用していることから、軽量な成形体１を実現することができる。 <Reinforcing member 113>
In the molded body 101, the reinforcing member 113 contains glass fiber reinforced plastic or carbon fiber reinforced plastic, or it is preferable to use these. Since the fiber reinforced plastic is used, a lightweight molded body 1 can be realized.
　補強部材１１３は、シート又はテープ状に形成される。補強部材１１３は、熱可塑性を有し、補強部材１１３における表面２３１が表皮部材１１１の内面２１２の少なくとも一部に一体溶着化されてなることに留意されたい。一方で、補強部材１１３は、その裏面２３２が芯材１１２の表面及び裏面の両側で仮留めされるように構成される。なお、図１０では、補強部材１１３が細長のテープ状に形成される例が示されている。このようにテープ状に形成されていることから軽量な成形体１０１を製造することができる。 The reinforcing member 113 is formed in the form of a sheet or tape. It should be noted that the reinforcing member 113 has thermoplasticity, and the surface 231 of the reinforcing member 113 is integrally welded to at least a part of the inner surface 212 of the skin member 111. On the other hand, the reinforcing member 113 is configured such that its back surface 232 is temporarily fastened on both the front surface and the back surface of the core material 112. Note that FIG. 10 shows an example in which the reinforcing member 113 is formed in the shape of an elongated tape. Since it is formed in a tape shape in this way, a lightweight molded body 101 can be manufactured.
　また、図１０に示されるように、補強部材１１３は、芯材１１２の表面における中央線Ｘに沿って裏面２３２が芯材１１２に仮留めされるとよい。換言すると、芯材１１２の表面における中央線Ｘに沿って仮留めされることで、中央線Ｘに沿って表皮部材１１１に一体溶着化される。補強部材１１３が表皮部材１１１に一体溶着化されているため、補強部材１１３の剛性が表皮部材１１１にダイレクトに影響し、補強部材１１３に比して相対的に伸びやすい表皮部材１１１の強度を強化することができる。これにより表皮部材１１１の繊維方向の伸びを抑制し、時間の経過とともに発生しうる成形体１０１のたわみを少なくすることができる、という有利な効果を奏する。 Further, as shown in FIG. 10, it is preferable that the back surface 232 of the reinforcing member 113 is temporarily fastened to the core material 112 along the center line X on the front surface of the core material 112. In other words, by temporarily fixing along the center line X on the surface of the core material 112, it is integrally welded to the skin member 111 along the center line X. Since the reinforcing member 113 is integrally welded to the skin member 111, the rigidity of the reinforcing member 113 directly affects the skin member 111, and the strength of the skin member 111, which is relatively easy to stretch as compared with the reinforcing member 113, is strengthened. can do. As a result, the elongation of the skin member 111 in the fiber direction can be suppressed, and the deflection of the molded body 101 that may occur with the passage of time can be reduced, which is an advantageous effect.
　さらに具体的には、補強部材１１３がＵＤ（Ｕｎｉ－Ｄｉｒｅｃｔｉｏｎ）シート又はＵＤテープであることが好ましい。これらは、繊維を一方向に引きそろえて熱可塑性樹脂を含浸させたシート又はテープである。ＵＤシート又はＵＤテープは、長い繊維を使用した繊維強化プラスチックで、繊維が配向する方向の引張強度が高いことに留意されたい。これにより表皮部材１１１の繊維方向の伸びを顕著に抑制することができる。 More specifically, it is preferable that the reinforcing member 113 is a UD (Uni-Direction) sheet or a UD tape. These are sheets or tapes in which fibers are aligned in one direction and impregnated with a thermoplastic resin. It should be noted that the UD sheet or UD tape is a fiber reinforced plastic using long fibers and has high tensile strength in the direction in which the fibers are oriented. As a result, the elongation of the skin member 111 in the fiber direction can be remarkably suppressed.
　成形体１０１において、補強部材１１３の引張弾性率は先の第１の実施形態の補強部材１３と同様である。 In the molded body 101, the tensile elastic modulus of the reinforcing member 113 is the same as that of the reinforcing member 13 of the first embodiment.
　また、成形体１０１においては、芯材１１２の厚さをｔ１、補強部材１１３の厚さをｔ２とすると、０．０１≦ｔ２／ｔ１≦０．３を満たすことが好ましい（図８参照）。補強部材１１３はシート状またはテープ状であり、インサート部材１１５を準備する上で、作業者が簡単に仮留めできる程度に、補強部材１１３を薄いものにすることが好ましいからである。具体的には例えば、ｔ２／ｔ１の値が０．０１，０．０１５，０．０２，０．０２５，０．０３，０．０３５，０．０４，０．０４５，０．０５，０．０５５，０．０６，０．０６５，０．０７，０．０７５，０．０８，０．０８５，０．０９，０．０９５，０．１，０．１０５，０．１１，０．１１５，０．１２，０．１２５，０．１３，０．１３５，０．１４，０．１４５，０．１５，０．１５５，０．１６，０．１６５，０．１７，０．１７５，０．１８，０．１８５，０．１９，０．１９５，０．２，０．２０５，０．２１，０．２１５，０．２２，０．２２５，０．２３，０．２３５，０．２４，０．２４５，０．２５，０．２５５，０．２６，０．２６５，０．２７，０．２７５，０．２８，０．２８５，０．２９，０．２９５，０．３であり、ここで例示した数値の何れか２つの間の範囲内であってもよい。 Further, in the molded body 101, assuming that the thickness of the core material 112 is t1 and the thickness of the reinforcing member 113 is t2, it is preferable that 0.01 ≦ t2 / t1 ≦ 0.3 is satisfied (see FIG. 8). This is because the reinforcing member 113 is in the form of a sheet or a tape, and when preparing the insert member 115, it is preferable that the reinforcing member 113 is thin enough to be easily temporarily fastened by an operator. Specifically, for example, the value of t2 / t1 is 0.01,0.015,0.02,0.025,0.03,0.035,0.04,0.045,0.05,0. 055, 0.06, 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, 0.095, 0.1, 0.105, 0.11, 0.115, 0.12, 0.125, 0.13, 0.135, 0.14, 0.145, 0.15, 0.155, 0.16, 0.165, 0.17, 0.175, 0. 18, 0.185, 0.19, 0.195, 0.2, 0.205, 0.21, 0.215, 0.22, 0.225, 0.23, 0.235, 0.24 It is 0.245, 0.25, 0.25, 0.26, 0.265, 0.27, 0.275, 0.28, 0.285, 0.29, 0.295, 0.3. It may be within the range between any two of the numerical values exemplified here.
　さらに、成形体１０１においては、芯材１１２の幅をｗ１、補強部材１１３の幅をｗ２とすると、０．０５≦ｗ２／ｗ１≦０．９５を満たすことが好ましい（図１０参照）。これはコストとの兼ね合いであり、たわみ防止の効果を高く望む場合は、ｗ２／ｗ１の値を相対的に高くするとよく、コスト削減を考えるのであれば、ｗ２／ｗ１の値を相対的に低くするとよい。具体的には例えば、ｗ２／ｗ１の値が０．０５，０．０６，０．０７，０．０８，０．０９，０．１，０．１１，０．１２，０．１３，０．１４，０．１５，０．１６，０．１７，０．１８，０．１９，０．２，０．２１，０．２２，０．２３，０．２４，０．２５，０．２６，０．２７，０．２８，０．２９，０．３，０．３１，０．３２，０．３３，０．３４，０．３５，０．３６，０．３７，０．３８，０．３９，０．４，０．４１，０．４２，０．４３，０．４４，０．４５，０．４６，０．４７，０．４８，０．４９，０．５，０．５１，０．５２，０．５３，０．５４，０．５５，０．５６，０．５７，０．５８，０．５９，０．６，０．６１，０．６２，０．６３，０．６４，０．６５，０．６６，０．６７，０．６８，０．６９，０．７，０．７１，０．７２，０．７３，０．７４，０．７５，０．７６，０．７７，０．７８，０．７９，０．８，０．８１，０．８２，０．８３，０．８４，０．８５，０．８６，０．８７，０．８８，０．８９，０．９，０．９１，０．９２，０．９３，０．９４，０．９５であり、ここで例示した数値の何れか２つの間の範囲内であってもよい。 Further, in the molded body 101, assuming that the width of the core material 112 is w1 and the width of the reinforcing member 113 is w2, it is preferable that 0.05 ≦ w2 / w1 ≦ 0.95 is satisfied (see FIG. 10). This is a trade-off with cost, and if the effect of preventing deflection is desired to be high, the value of w2 / w1 should be relatively high, and if cost reduction is considered, the value of w2 / w1 should be relatively low. You should do it. Specifically, for example, the value of w2 / w1 is 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0. 14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0. 39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58, 0.59, 0.6, 0.61, 0.62, 0.63, 0. 64,0.65,0.66,0.67,0.68,0.69,0.7,0.71,0.72,0.73,0.74,0.75,0.76 0.77, 0.78, 0.79, 0.8, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0. It is 89, 0.9, 0.91, 0.92, 0.93, 0.94, 0.95, and may be within the range between any two of the numerical values exemplified here.
２．成形体１０１の製造方法
　第２節では、成形体１０１の製造方法について説明する。図１１は、成形体１０１を製造するための成形機３の態様を示している。図１２は、成形体１０１の製造において、金型７１，７２が開放された態様を示している。図１３は、成形体１０１の製造において、金型７１，７２が閉じられた態様を示している。 2. Method for Manufacturing Molded Body 101 Section 2 describes a method for manufacturing molded body 101. FIG. 11 shows an aspect of the molding machine 3 for manufacturing the molded body 101. FIG. 12 shows a mode in which the molds 71 and 72 are opened in the production of the molded product 101. FIG. 13 shows a mode in which the molds 71 and 72 are closed in the production of the molded product 101.
２－１．成形機３の構成
　成形機３の構成は、先の第１の実施形態と同様であり、ここではその説明は省略する。 2-1. Configuration of Molding Machine 3 The configuration of the molding machine 3 is the same as that of the first embodiment, and the description thereof will be omitted here.
２－２．製造方法の流れ
　成形体１０１の製造方法は、準備工程と、垂下工程と、配置工程と、成形工程とを備える。以下、詳細に説明する。 2-2. Flow of Manufacturing Method The manufacturing method of the molded product 101 includes a preparation step, a hanging step, an arrangement step, and a molding step. Hereinafter, a detailed description will be given.
＜準備工程＞
　準備工程では、芯材１１２の両面の少なくとも一部に補強部材１１３を仮留めする。具体的には、図１０に示されるように、発泡体であってパネル形状の芯材１１２の表面及び裏面の少なくとも一方に繊維強化プラスチックを含む補強部材１１３を両面テープ１１４で仮留めすることで、インサート部材１１５が構成される。 <Preparation process>
In the preparatory step, the reinforcing member 113 is temporarily fastened to at least a part of both sides of the core material 112. Specifically, as shown in FIG. 10, by temporarily fixing the reinforcing member 113 containing the fiber reinforced plastic to at least one of the front surface and the back surface of the panel-shaped core material 112 which is a foam, with double-sided tape 114. , The insert member 115 is configured.
＜垂下工程＞
　垂下工程では、溶融状態の２本の樹脂シート２１，２２を一対の金型７１，７２間に垂下させる。具体的には、図１１に示されるように、準備工程で用意されたインサート部材１１５を、一対の金型７１，７２間に配置し、さらに図１２に示されるように、インサート部材１１５の両面に２つの樹脂シート２１，２２を垂下させる。 <Dripping process>
In the hanging step, the two molten resin sheets 21 and 22 are hung between the pair of molds 71 and 72. Specifically, as shown in FIG. 11, the insert member 115 prepared in the preparation step is arranged between the pair of molds 71 and 72, and further, as shown in FIG. 12, both sides of the insert member 115. Two resin sheets 21 and 22 are hung down.
　そして、一対の金型７１，７２間に、溶融状態の樹脂Ｍ２をＴダイ５のスリットから押し出して垂下させて形成した一対の樹脂シート２１，２２を垂下する。本実施形態では、Ｔダイ５から押し出された一対の樹脂シート２１，２２をそのまま使用するダイレクト真空成形が行われるので、一対の樹脂シート２１，２２は、成形前に室温にまで冷却されて固化されることがなく、固化された一対の樹脂シート２１，２２が成形前に加熱されることもない。ここで、図４１１は、垂下工程中において、一対の樹脂シート２１，２２の間にインサート部材１１５を図示しているが、垂下工程では、インサート部材１１５を他の場所に待機させておいてもよい。 Then, between the pair of molds 71 and 72, a pair of resin sheets 21 and 22 formed by extruding the molten resin M2 from the slit of the T die 5 and hanging the resin sheets 21 and 22 are hung. In the present embodiment, direct vacuum forming is performed using the pair of resin sheets 21 and 22 extruded from the T die 5 as they are, so that the pair of resin sheets 21 and 22 are cooled to room temperature and solidified before molding. The solidified pair of resin sheets 21 and 22 are not heated before molding. Here, FIG. 411 illustrates the insert member 115 between the pair of resin sheets 21 and 22 during the hanging step, but in the hanging step, the insert member 115 may be kept waiting at another place. Good.
＜賦形工程＞
　次に、賦形工程では、一対の樹脂シート２１，２２をそれぞれ一対の金型７１，７２の一部に当接させた後、一対の金型７１，７２の両方によって２枚の樹脂シート２１，２２を減圧吸引して一対の金型７１，７２に沿った形状に賦形する。 <Shaping process>
Next, in the shaping step, after the pair of resin sheets 21 and 22 are brought into contact with a part of the pair of molds 71 and 72, respectively, the two resin sheets 21 are provided by both of the pair of molds 71 and 72. , 22 are sucked under reduced pressure to form a shape along the pair of molds 71 and 72.
＜配置工程＞
　次に、配置工程では、樹脂シート２１，２２の間に芯材１１２及びこれに仮留めされた補強部材１１３を配置する。そして、インサート部材１１５を一対の樹脂シート２１，２２に溶着させる。 <Placement process>
Next, in the arranging step, the core material 112 and the reinforcing member 113 temporarily fastened to the core material 112 are arranged between the resin sheets 21 and 22. Then, the insert member 115 is welded to the pair of resin sheets 21 and 22.
＜成形工程＞
　最後に、成形工程では、一対の金型７１，７２を型締めし、その後これを開放することで、２本の樹脂シート２１，２２が表皮部材１１１となるとともに、補強部材１１３が表皮部材１１１と一体溶着化して成形体１０１が製造される。具体的には、図１３に示されるように、一対の金型７１，７２を型締めする。すなわち、インサート部材１１５が２つの樹脂シート２１，２２に挟まれた位置に配置される。これによって、樹脂シート２１，２２が、図８に示される成形体１０１における表皮部材１１１となる。これとともに、成形時の熱によって、熱可塑性を有する補強部材１１３の表面２３１が表皮部材１１１の内面２１２に溶着して一体化される。最後に、一対の金型７１，７２から成形体を取り出し、バリ２５を除去することによって、図１３に示される成形体１０１が得られる。 <Molding process>
Finally, in the molding step, the pair of dies 71 and 72 are molded and then opened, so that the two resin sheets 21 and 22 become the skin member 111 and the reinforcing member 113 becomes the skin member 111. The molded body 101 is manufactured by being integrally welded to the molded body 101. Specifically, as shown in FIG. 13, the pair of molds 71 and 72 are molded. That is, the insert member 115 is arranged at a position sandwiched between the two resin sheets 21 and 22. As a result, the resin sheets 21 and 22 become the skin member 111 in the molded body 101 shown in FIG. At the same time, due to the heat during molding, the surface 231 of the thermoplastic reinforcing member 113 is welded to the inner surface 212 of the skin member 111 and integrated. Finally, by taking out the molded product from the pair of molds 71 and 72 and removing the burr 25, the molded product 101 shown in FIG. 13 is obtained.
３．変形例
　第３節では、成形体１０１に係る変形例について説明する。すなわち、下記のような態様によって成形体１０１や成形体１０１を実施してもよい。 3. 3. Modification Example Section 3 describes a modification of the molded body 101. That is, the molded body 101 or the molded body 101 may be carried out according to the following aspects.
　表皮部材１１１に補強部材１１３が一体溶着化されていれば、補強部材１１３の個数、配置、形状等は限定されない。以下に様々な例を示す。もちろん、これらに限定されるものではない。
（１）芯材１１２の中央線Ｘから離れた位置において２本の補強部材１１３が表皮部材１１１に一体溶着化されてもよい。
（２）芯材１１２の２本の対角線に沿って２本の補強部材１１３が表皮部材１１１に一体溶着化されてもよい。
（３）図１０では長手方向にテープ状の補強部材１１３が仮留めされ且つ一体溶着化されているが、これに代えて又はこれとともに短手方向にも補強部材１１３が仮留めされ且つ一体溶着化されてもよい。
（４）図１０では、仮留めの際に、長手方向において、芯材１１２の長さと補強部材１１３の長さが略同一となっているが、芯材１１２の長さよりも補強部材１１３の長さを短くしてもよい。ただし、たわみの防止効果は略同一とするよりも低くなることに留意されたい。 As long as the reinforcing member 113 is integrally welded to the skin member 111, the number, arrangement, shape, etc. of the reinforcing member 113 are not limited. Various examples are shown below. Of course, it is not limited to these.
(1) The two reinforcing members 113 may be integrally welded to the skin member 111 at a position away from the center line X of the core material 112.
(2) Two reinforcing members 113 may be integrally welded to the skin member 111 along the two diagonal lines of the core material 112.
(3) In FIG. 10, the tape-shaped reinforcing member 113 is temporarily fastened and integrally welded in the longitudinal direction, but instead of or together with this, the reinforcing member 113 is temporarily fastened and integrally welded in the lateral direction. May be transformed.
(4) In FIG. 10, at the time of temporary fastening, the length of the core material 112 and the length of the reinforcing member 113 are substantially the same in the longitudinal direction, but the length of the reinforcing member 113 is larger than the length of the core material 112. The length may be shortened. However, it should be noted that the effect of preventing deflection is lower than that of the same.
　芯材１１２は、ビーズ発泡成形による発泡体に代えてハニカム構造体であってもよい。 The core material 112 may be a honeycomb structure instead of the foam formed by bead foam molding.
　両面テープ１１４は、補強部材１１３を芯材１１２に仮留めするにあたっての一例に過ぎず、接着剤や養生テープを上から貼り付けるようにして、仮留めを行ってもよい。 The double-sided tape 114 is only an example for temporarily fixing the reinforcing member 113 to the core material 112, and the adhesive or the curing tape may be attached from above to temporarily fix the reinforcing member 113.
４．結言
　このように、時間経過とともに発生しうる表皮部材の伸びを抑制し、たわみのおそれが少ない成形体、及び成形体の製造方法を提供することができる。 4. Conclusion As described above, it is possible to provide a molded product that suppresses the elongation of the epidermis member that may occur with the passage of time and has less risk of bending, and a method for manufacturing the molded product.
　次に記載の各態様で提供されてもよい。
　前記成形体において、前記補強部材は、細長のテープ状に形成され、前記芯材の中央線に沿って前記表皮部材に一体溶着化されるもの。
　前記成形体において、前記芯材の厚さをｔ１、前記補強部材の厚さをｔ２とすると、０．０１≦ｔ２／ｔ１≦０．３を満たすもの。
　前記成形体において、前記芯材の幅をｗ１、前記補強部材の幅をｗ２とすると、０．０５≦ｗ２／ｗ１≦０．９５を満たすもの。
　前記成形体において、前記補強部材は、ガラス繊維強化プラスチック、又は炭素繊維強化プラスチックを含むもの。
　前記成形体において、前記補強部材の引張弾性率が１２ＧＰａ以上４００ＧＰａ以下であるもの。
　前記成形体において、前記補強部材は、前記芯材の表面及び裏面の両側で仮留めされるように構成されるもの。
　前記成形体の製造方法であって、準備工程と、垂下工程と、配置工程と、成形工程とを備え、前記準備工程では、前記芯材の両面の少なくとも一部に前記補強部材を仮留めし、前記垂下工程では、溶融状態の２本の樹脂シートを一対の金型間に垂下させ、前記配置工程では、前記２本の樹脂シートの間に前記芯材及びこれに仮留めされた前記補強部材を配置し、前記成形工程では、前記一対の金型を型締めし、その後これを開放することで、前記２本の樹脂シートが前記表皮部材となるとともに、前記補強部材が前記表皮部材と一体溶着化して前記成形体を製造する方法。
　もちろん、この限りではない。 It may be provided in each of the following aspects.
In the molded body, the reinforcing member is formed in an elongated tape shape and integrally welded to the skin member along the center line of the core material.
In the molded body, assuming that the thickness of the core material is t1 and the thickness of the reinforcing member is t2, 0.01 ≦ t2 / t1 ≦ 0.3 is satisfied.
In the molded body, assuming that the width of the core material is w1 and the width of the reinforcing member is w2, 0.05 ≦ w2 / w1 ≦ 0.95 is satisfied.
In the molded product, the reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic.
In the molded body, the tensile elastic modulus of the reinforcing member is 12 GPa or more and 400 GPa or less.
In the molded body, the reinforcing member is configured to be temporarily fastened on both the front surface and the back surface of the core material.
The method for manufacturing a molded product includes a preparation step, a hanging step, an arrangement step, and a molding step. In the preparation step, the reinforcing member is temporarily fastened to at least a part of both sides of the core material. In the hanging step, two molten resin sheets are hung between a pair of molds, and in the arrangement step, the core material and the reinforcement temporarily fastened to the core material are placed between the two resin sheets. By arranging the members, molding the pair of molds in the molding process, and then opening the molds, the two resin sheets become the skin member, and the reinforcing member becomes the skin member. A method for producing the molded product by integrally welding.
Of course, this is not the case.
　最後に、本発明に係る種々の実施形態を説明したが、これらは、例として提示したものであり、発明の範囲を限定することは意図していない。当該新規な実施形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略、置き換え、変更を行うことができる。当該実施形態やその変形は、発明の範囲や要旨に含まれるとともに、特許請求の範囲に記載された発明とその均等の範囲に含まれるものである。 Finally, various embodiments according to the present invention have been described, but these are presented as examples and are not intended to limit the scope of the invention. The novel embodiment can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. The embodiment and its modifications are included in the scope and gist of the invention, and are included in the scope of the invention described in the claims and the equivalent scope thereof.
１：成形体、１１ａ：表皮部材、１１ｂ：表皮部材、１２：芯材、１２１：凹部、１２ｓ：ヌスミ、１３：補強部材、１４：接着層、１５：インサート部材、２１：樹脂シート、２２：樹脂シート、２５：バリ、３：成形機、４：樹脂供給装置、４１：ホッパー、４２：押出機、４３：シリンダ、４５：アキュームレータ、４６：シリンダ、４７：ピストン、５：Ｔダイ、６１：連結管、６２：連結管、７１：金型、７１ｃ：凹部、７１ｐ：ピンチオフ部、７２：金型、７２ｃ：凹部、７２ｐ：ピンチオフ部、９：成形体、９１ａ：表皮部材、９１ｂ：表皮部材、９２：芯材、９３：補強部材、Ｍ１：原料樹脂、Ｍ２：樹脂、Ｘ：中央線、１０１：成形体、１１１：表皮部材、２１１：外面、２１２：内面、１１２：芯材、１１３：補強部材、２３１：表面、２３２：裏面、１１５：インサート部材 1: Molded body, 11a: Skin member, 11b: Skin member, 12: Core material, 121: Recess, 12s: Nusumi, 13: Reinforcing member, 14: Adhesive layer, 15: Insert member, 21: Resin sheet, 22: Resin sheet, 25: burr, 3: molding machine, 4: resin supply device, 41: hopper, 42: extruder, 43: cylinder, 45: accumulator, 46: cylinder, 47: piston, 5: T die, 61: Connecting pipe, 62: Connecting pipe, 71: Mold, 71c: Recessed, 71p: Pinch-off part, 72: Mold, 72c: Recessed part, 72p: Pinch-off part, 9: Molded body, 91a: Skin member, 91b: Skin member , 92: Core material, 93: Reinforcing member, M1: Raw material resin, M2: Resin, X: Center line, 101: Molded body, 111: Skin member, 211: Outer surface, 212: Inner surface, 112: Core material, 113: Reinforcing member, 231: front surface, 232: back surface, 115: insert member

Claims (18)

  1. パネル状の成形体であって、
    　芯材と、補強部材と、表皮部材とを備え、
    　前記補強部材は、
    　　シート又はテープ状に形成され、
    　　前記芯材の表面又は裏面の少なくとも一部に貼付されるように構成され、
    　前記表皮部材は、
    　　樹脂のシートであり、
    　　前記芯材の両面に配置されるもの。     It is a panel-shaped molded body
    It is provided with a core material, a reinforcing member, and a skin member.
    The reinforcing member is
    Formed in the form of a sheet or tape,
    It is configured to be attached to at least a part of the front surface or the back surface of the core material.
    The skin member is
    It is a resin sheet,
    Those arranged on both sides of the core material.
  2. 請求項１に記載の成形体において、
    　前記補強部材は、
    　　細長のテープ状に形成され、
    　　前記芯材の表面における中央線に沿って貼付されるもの。     In the molded product according to claim 1,
    The reinforcing member is
    Formed in the form of an elongated tape,
    Those attached along the center line on the surface of the core material.
  3. 請求項１又は請求項２に記載の成形体において、
    　前記芯材の厚さをｔ１、前記補強部材の厚さをｔ２とすると、
    　　０．０１≦ｔ２／ｔ１≦０．３
    　を満たすもの。     In the molded product according to claim 1 or 2.
    Assuming that the thickness of the core material is t1 and the thickness of the reinforcing member is t2,
    0.01 ≤ t2 / t1 ≤ 0.3
    Those that meet.
  4. 請求項１～請求項３の何れか１つに記載の成形体において、
    　前記芯材の幅をｗ１、前記補強部材の幅をｗ２とすると、
    　　０．０５≦ｗ２／ｗ１≦０．９５
    　を満たすもの。     In the molded product according to any one of claims 1 to 3.
    Assuming that the width of the core material is w1 and the width of the reinforcing member is w2,
    0.05 ≦ w2 / w1 ≦ 0.95
    Those that meet.
  5. 請求項１～請求項４の何れか１つに記載の成形体において、
    　前記補強部材は、ガラス繊維強化プラスチック、又は炭素繊維強化プラスチックを含むもの。     In the molded product according to any one of claims 1 to 4.
    The reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic.
  6. 請求項１～請求項５の何れか１つに記載の成形体において、
    　前記補強部材の引張弾性率が１２ＧＰａ以上４００ＧＰａ以下であるもの。     In the molded product according to any one of claims 1 to 5.
    The reinforcing member has a tensile elastic modulus of 12 GPa or more and 400 GPa or less.
  7. 請求項１～請求項６の何れか１つに記載の成形体において、
    　前記補強部材は、前記芯材の表面及び裏面の両側に貼付されるように構成されるもの。     In the molded product according to any one of claims 1 to 6.
    The reinforcing member is configured to be attached to both the front surface and the back surface of the core material.
  8. 請求項１～請求項７の何れか１つに記載の成形体において、
    　前記芯材は、前記補強部材を貼付するための凹部を有し、前記補強部材がこの凹部に収容されるもの。     In the molded product according to any one of claims 1 to 7.
    The core material has a recess for attaching the reinforcing member, and the reinforcing member is housed in the recess.
  9. 請求項１～請求項８の何れか１つに記載の成形体において、
    　ヌスミをさらに備えるもの。     In the molded product according to any one of claims 1 to 8.
    Those with more Nusumi.
  10. 請求項１～請求項９の何れか１つに記載の成形体の製造方法であって、
    　準備工程と、垂下工程と、配置工程と、成形工程とを備え、
    　前記準備工程では、前記芯材の表面の少なくとも一部に前記補強部材を貼付し、
    　前記垂下工程では、溶融状態の２本の樹脂シートを一対の金型間に垂下させ、
    　前記配置工程では、前記２本の樹脂シートの間に前記芯材及び補強部材を配置し、
    　前記成形工程では、前記一対の金型を型締めし、その後これを開放することで、前記２本の樹脂シートが前記表皮部材となって前記成形体を製造する方法。     The method for producing a molded product according to any one of claims 1 to 9.
    It has a preparation process, a hanging process, a placement process, and a molding process.
    In the preparatory step, the reinforcing member is attached to at least a part of the surface of the core material.
    In the hanging step, two molten resin sheets are hung between a pair of molds.
    In the arrangement step, the core material and the reinforcing member are arranged between the two resin sheets.
    In the molding step, a method of manufacturing the molded body in which the two resin sheets serve as the skin member by molding the pair of molds and then opening the molds.
  11. パネル状の成形体であって、
    　芯材と、表皮部材と、補強部材とを備え、
    　前記表皮部材は、
    　　樹脂のシートであり、
    　　前記芯材の両面に配置されることで、本成形体の外観を構成し、
    　前記補強部材は、
    　　シート又はテープ状に形成され、
    　　熱可塑性を有し、前記表皮部材の内面の少なくとも一部に一体溶着化されてなるもの。     It is a panel-shaped molded body
    It is provided with a core material, a skin member, and a reinforcing member.
    The skin member is
    It is a resin sheet,
    By arranging on both sides of the core material, the appearance of the molded body is formed.
    The reinforcing member is
    Formed in the form of a sheet or tape,
    It has thermoplasticity and is integrally welded to at least a part of the inner surface of the skin member.
  12. 請求項１１に記載の成形体において、
    　前記補強部材は、
    　　細長のテープ状に形成され、
    　　前記芯材の中央線に沿って前記表皮部材に一体溶着化されるもの。     In the molded product according to claim 11,
    The reinforcing member is
    Formed in the form of an elongated tape,
    A material that is integrally welded to the skin member along the center line of the core material.
  13. 請求項１１又は請求項１２に記載の成形体において、
    　前記芯材の厚さをｔ１、前記補強部材の厚さをｔ２とすると、
    　　０．０１≦ｔ２／ｔ１≦０．３
    　を満たすもの。     In the molded product according to claim 11 or 12.
    Assuming that the thickness of the core material is t1 and the thickness of the reinforcing member is t2,
    0.01 ≤ t2 / t1 ≤ 0.3
    Those that meet.
  14. 請求項１１～請求項１３の何れか１つに記載の成形体において、
    　前記芯材の幅をｗ１、前記補強部材の幅をｗ２とすると、
    　　０．０５≦ｗ２／ｗ１≦０．９５
    　を満たすもの。     In the molded product according to any one of claims 11 to 13.
    Assuming that the width of the core material is w1 and the width of the reinforcing member is w2,
    0.05 ≦ w2 / w1 ≦ 0.95
    Those that meet.
  15. 請求項１１～請求項１４の何れか１つに記載の成形体において、
    　前記補強部材は、ガラス繊維強化プラスチック、又は炭素繊維強化プラスチックを含むもの。     In the molded product according to any one of claims 11 to 14.
    The reinforcing member includes glass fiber reinforced plastic or carbon fiber reinforced plastic.
  16. 請求項１１～請求項１５の何れか１つに記載の成形体において、
    　前記補強部材の引張弾性率が１２ＧＰａ以上４００ＧＰａ以下であるもの。     In the molded product according to any one of claims 11 to 15.
    The reinforcing member has a tensile elastic modulus of 12 GPa or more and 400 GPa or less.
  17. 請求項１１～請求項１６の何れか１つに記載の成形体において、
    　前記補強部材は、前記芯材の表面及び裏面の両側で仮留めされるように構成されるもの。     In the molded product according to any one of claims 11 to 16.
    The reinforcing member is configured to be temporarily fastened on both the front surface and the back surface of the core material.
  18. 請求項１１～請求項１７の何れか１つに記載の成形体の製造方法であって、
    　準備工程と、垂下工程と、配置工程と、成形工程とを備え、
    　前記準備工程では、前記芯材の両面の少なくとも一部に前記補強部材を仮留めし、
    　前記垂下工程では、溶融状態の２本の樹脂シートを一対の金型間に垂下させ、
    　前記配置工程では、前記２本の樹脂シートの間に前記芯材及びこれに仮留めされた前記補強部材を配置し、
    　前記成形工程では、前記一対の金型を型締めし、その後これを開放することで、前記２本の樹脂シートが前記表皮部材となるとともに、前記補強部材が前記表皮部材と一体溶着化して前記成形体を製造する方法。     The method for producing a molded product according to any one of claims 11 to 17.
    It has a preparation process, a hanging process, a placement process, and a molding process.
    In the preparatory step, the reinforcing member is temporarily fastened to at least a part of both sides of the core material.
    In the hanging step, two molten resin sheets are hung between a pair of molds.
    In the arrangement step, the core material and the reinforcing member temporarily fastened to the core material are arranged between the two resin sheets.
    In the molding step, the pair of molds are molded and then opened to form the two resin sheets as the skin member, and the reinforcing member is integrally welded to the skin member to form the skin member. A method of manufacturing a molded product.
PCT/JP2020/038299 2019-10-15 2020-10-09 Molded body and molded-body producing method WO2021075375A1 (en)

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JP2019188988A JP7239831B2 (en) 2019-10-15 2019-10-15 Molded article and method for manufacturing molded article
JP2019-188988 2019-10-15

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001146506A (en) * 1999-09-06 2001-05-29 Nippon Shokubai Co Ltd Resin sheet and molded article using the same
JP2014098127A (en) * 2012-11-16 2014-05-29 Mitsubishi Rayon Co Ltd Carbon fiber-reinforced composite molding and method for producing the same
WO2018221484A1 (en) * 2017-05-29 2018-12-06 キョーラク株式会社 Resin panel and manufacturing method therefor, and structure and manufacturing method therefor

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001146506A (en) * 1999-09-06 2001-05-29 Nippon Shokubai Co Ltd Resin sheet and molded article using the same
JP2014098127A (en) * 2012-11-16 2014-05-29 Mitsubishi Rayon Co Ltd Carbon fiber-reinforced composite molding and method for producing the same
WO2018221484A1 (en) * 2017-05-29 2018-12-06 キョーラク株式会社 Resin panel and manufacturing method therefor, and structure and manufacturing method therefor

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