WO2024090155A1

WO2024090155A1 - Processing method for panel structure, processing device for panel structure, and panel structure

Info

Publication number: WO2024090155A1
Application number: PCT/JP2023/036172
Authority: WO
Inventors: 帆乃花富▲崎▼; 明啓宮本; 智行岩本; 啓司新井
Original assignee: 三菱重工業株式会社
Priority date: 2022-10-27
Filing date: 2023-10-04
Publication date: 2024-05-02
Also published as: JP2024064118A

Abstract

This processing method for a panel structure, which comprises: a core member provided, on both surfaces thereof, with a plurality of protrusions extending in one direction and formed using a thermoplastic resin; and a face plate formed in a plate shape using a thermoplastic resin and disposed so as to sandwich the core member from the both sides in the height directions of the protrusions, includes an insertion step for inserting a rod-shaped member in one direction into a space formed between the face plate and the core member of the panel structure, and a bending step for heating and softening a target portion along the rod-shaped member of the panel structure in the state in which the rod-shaped member is inserted, and bending the panel structure along the rod-shaped member, thereby forming a bent portion at the target portion.

Description

Panel structure processing method, panel structure processing device, and panel structure

This disclosure relates to a method for processing a panel structure, a processing device for a panel structure, and a panel structure.

When bending a plastic corrugated cardboard panel structure, a processing method is known in which a heated blade is pressed against the surface of the panel structure to form a groove, and the panel structure is then bent along the groove (see, for example, Patent Document 1).

JP 2009-262943 A

When bending a panel structure by applying heat and pressure, as in the processing method of Patent Document 1, there is a possibility that peeling may occur at the bent portion, or that the panel structure at the bent portion may be crushed. In this case, there is a possibility that the strength of the panel structure at the bent portion may decrease.

The present disclosure has been made in consideration of the above, and aims to provide a processing method for a panel structure, a processing device for a panel structure, and a panel structure that can suppress a decrease in strength at the bent portion.

The processing method for a panel structure according to the present disclosure is a processing method for a panel structure including a core member formed of a thermoplastic resin and having a plurality of convex portions on both sides thereof that extend in one direction, and a face plate formed of a thermoplastic resin in a plate shape and arranged to sandwich the core member from both sides in the height direction of the convex portions, and includes an insertion step of inserting a rod-shaped member along the one direction into a space formed between the face plate and the core member of the panel structure, and a bending step of heating and softening a target portion of the panel structure along the rod-shaped member with the rod-shaped member inserted therein, and bending the panel structure along the rod-shaped member to form a bent portion in the target portion.

The processing device for panel structures according to the present disclosure is a processing device for panel structures comprising a core member formed of thermoplastic resin with multiple convex portions on both sides thereof extending in one direction, and a face plate formed of thermoplastic resin in a plate shape and arranged to sandwich the core member from both sides in the height direction of the convex portions, and is also provided with a holding section that holds the panel structure with a rod-shaped member inserted along the one direction in the space formed between the face plate and the core member, a heating section that heats and softens a target portion of the panel structure along the rod-shaped member, and a bending auxiliary section that is arranged along the target portion on the inside of the bending direction of the target portion when bending the panel structure along the rod-shaped member.

The panel structure according to the present disclosure comprises a core member formed of thermoplastic resin and having a plurality of protrusions on both sides thereof that extend in one direction, and a face plate formed of thermoplastic resin in a plate shape and arranged to sandwich the core member from both sides in the height direction of the protrusions, and has a bent portion that is bent along the one direction, and at the bent portion, the face plate and the core member are formed to surround a columnar space that is aligned along the one direction.

According to this disclosure, it is possible to suppress the decrease in strength at the bent portion.

FIG. 1 is a diagram showing an example of a panel structure to be processed in this embodiment. FIG. 2 is a flowchart showing an example of a processing method for the panel structure according to the present embodiment. FIG. 3 is a diagram showing an example of a rod-shaped member used in the insertion step. FIG. 4 is a diagram showing an example of the insertion process. FIG. 5 is a diagram showing an example of heating in the bending process. FIG. 6 is a diagram showing an example of folding the panel structure in the folding process. FIG. 7 is a diagram illustrating an example of the cooling process. FIG. 8 is a diagram showing an example of a panel structure after the removal step. FIG. 9 is a diagram showing another example of folding the panel structure in the folding process. FIG. 10 is a diagram showing another example of a rod-shaped member used in the insertion step. FIG. 11 is a diagram showing another example of the insertion process. FIG. 12 is a diagram showing another example of folding the panel structure in the folding process. FIG. 13 is a diagram showing another example of folding the panel structure in the folding process. FIG. 14 is a diagram showing another example of the insertion process. FIG. 15 is a diagram showing another example of folding the panel structure in the folding process. FIG. 16 is a diagram showing another example of folding the panel structure in the folding process. FIG. 17 is a diagram showing an example of a processing device according to the present embodiment. FIG. 18 is a diagram showing an example of a case where a bending process is performed using a processing device.

Below, embodiments of the processing method for a panel structure, the processing device for a panel structure, and the panel structure according to the present disclosure will be described with reference to the drawings. Note that the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are replaceable and easy for a person skilled in the art, or those that are substantially the same.

FIG. 1 is a diagram showing an example of a panel structure 10 to be processed in this embodiment. As shown in FIG. 1, the panel structure 10 includes a core member 12, a face plate 14, and a joint 16.

The core member 12 and the face plate 14 are formed using a thermoplastic resin. Examples of the thermoplastic resin include composite materials, polypropylene, and the like. Examples of composite materials include thermoplastic fiber reinforced plastics (FRP: Fiber Reinforced Plastics) that contain reinforcing fibers. Examples of fiber reinforced plastics include glass fiber reinforced plastics (GFRP: Glass Fiber Reinforced Plastics) and carbon fiber reinforced plastics (CFRP: Carbon Fiber Reinforced Plastics). Note that the fiber reinforced plastics are not limited to the above. The core member 12 and the face plate 14 may be formed of the same material or different materials.

The core member 12 is formed, for example, in a wave shape. The core member 12 has a plurality of convex portions 18 on both sides. Each convex portion 18 extends in an extension direction (one direction) D1, which is a linear direction. The core member 12 has a concave portion at a position corresponding to the convex portion 18 on the side opposite to the protruding direction of the convex portion 18. Such a core member 12 may also be called a corrugated shape. Note that the core member 12 may be configured such that the convex portions 18 are repeatedly provided in the same shape in a direction intersecting the extension direction D1 along each side of the core member 12. Therefore, the core member 12 is not limited to a wave shape or a corrugated shape, and may have other shapes. Other shapes include, for example, a so-called harmonica shape (or harmonica structure) used in the cross-sectional shape of plastic cardboard.

The faceplate 14 is arranged so as to sandwich the core member 12 from both sides in the height direction of the convex portion 18. The faceplate 14 is arranged on the convex portion 18 of the core member 12. In this embodiment, the faceplate 14 is, for example, rectangular. The shape of the faceplate 14 may be a shape other than rectangular. By arranging the faceplate 14, a space K1 is formed between the faceplate 14 and the convex portion 18 along one direction.

The joint 16 connects the core member 12 and the face plate 14. The joint 16 is formed between the top of the protrusion 18 and the face plate 14. The joint 16 is selectively formed, for example, between the tops of the multiple protrusions 18 and the face plate 14. The joint 16 is formed, for example, according to the rigidity and impact resistance characteristics required for the panel structure 10. The joint 16 can be formed by heating and melting the joint between the top of the protrusion 18 and the face plate 14, and then placing the face plate 14 and cooling it. Heating can be performed, for example, using a heat source such as a heater or an electric heating wire, ultrasonic vibration, electromagnetic induction by a magnetic field, and laser, but is not limited to these methods. The joint 16 may be configured such that the protrusion 18 and the face plate 14 are joined using an adhesive not shown.

FIG. 2 is a flow chart showing an example of a processing method for the panel structure 10 according to this embodiment. As shown in FIG. 2, the processing method for the panel structure 10 according to this embodiment includes an insertion process S10, a bending process S20, a cooling process S30, and a removal process S40.

In the insertion step S10, the rod-shaped member 30 is inserted along the extension direction D1 into the space K1 formed between the face plate 14 and the protrusion 18 of the panel structure 10.

FIG. 3 is a diagram showing an example of a rod-shaped member 30 used in the insertion process S10. As shown in FIG. 3, the rod-shaped member 30 has a heating member 32, a protective layer 34, and a commingling material 36.

The heating member 32 is formed into a cylindrical shape using a conductive material such as metal. The heating member 32 generates heat, for example, by passing an electric current through it. The heating member 32 is formed to a length such that both ends protrude from the space K1 when inserted into the space K1 of the panel structure 10. For example, electrodes or the like can be connected to both ends protruding from the heating member 32.

The protective layer 34 is formed using a resin material such as polyimide. The protective layer 34 is arranged so as to cover the portion of the heating member 32 that is housed within the space K1 of the panel structure 10. The protective layer 34 is provided so as to be separable from the heating member 32. In this embodiment, for example, a film member is used as the protective layer 34. The protective layer 34 is not limited to a film member and may be a tape member.

The commingle material 36 is formed, for example, in a linear shape using a mixture of reinforced fibers and thermoplastic resin fibers. The shape of the commingle material is not limited to cleaning, and may be other shapes such as a tape (strip) or a sheet. The commingle material 36 is arranged in a wound state around the portion of the heating member 32 that is covered by the protective layer 34. The thermoplastic resin fibers are melted by applying heat to the commingle material 36.

The rod-shaped member 30 is, for example, cylindrical when the heating member 32, protective layer 34, and commingle material 36 are provided. The shape of the rod-shaped member 30 may be other types of columnar, such as a rectangular column. When the rod-shaped member 30 is inserted into the space K1, the diameter of the rod-shaped member 30 can be set so that it contacts the face plate 14 surrounding the space K1 and the portions of the protrusions 18 extending on both sides in the extension direction D1.

FIG. 4 is a diagram showing an example of the insertion step S10. As shown in FIG. 4, in the insertion step S10, a rod-shaped member 30 having a heating member 32, a protective layer 34, and a commingle material 36 is inserted along an extension direction D1 into a space K1 between the face plate 14 and the protrusion 18 of the panel structure 10. The rod-shaped member 30 is inserted so that both longitudinal ends of the heating member 32 protrude from the space K1 in the extension direction D1. The rod-shaped member 30 is also inserted so that the entire portion of the heating member 32 wrapped with the commingle material 36 is accommodated in the space K1.

After inserting the rod-shaped member 30 into the space K1, the bending process S20 is performed. In the bending process S20, the target portion of the panel structure 10 along the rod-shaped member 30 with the rod-shaped member 30 inserted is heated and softened, and the panel structure 10 is bent along the rod-shaped member 30 to form a bent portion in the target portion.

FIG. 5 is a diagram showing an example of heating in the bending process S20. As shown in FIG. 5, in the bending process S20, the target portion 20 is heated from inside the panel structure 10 by a heating member 32 inserted into the space K1 of the panel structure 10. The target portion 20 is a portion including the face plate 14 and the protrusion 18 that surround the space K1 into which the rod-shaped member 30 is inserted.

When an electric current is passed through the heating element 32, the heating element 32 generates heat. The heat generated by the heating element 32 heats and softens the target portion 20. The heat generated by the heating element 32 also melts the thermoplastic resin fibers 36a of the commingle material 36, and the fibers adhere to the face plate 14 and the protruding portion 18 of the panel structure 10. The melted thermoplastic resin fibers 36a also adhere to the protective layer 34.

After softening the target portion 20, the panel structure 10 is bent along the rod-shaped member 30 to form a bent portion in the target portion 20. Figure 6 is a diagram showing an example of bending the panel structure 10 in the bending process. Figure 6 shows an example of bending the panel structure 10 so that the protrusion 18 is positioned inside the rod-shaped member 30 in the bending direction D2.

As shown in FIG. 6, when the panel structure 10 is folded so that the protrusion 18 is positioned on the inside of the folding direction D2 relative to the rod-shaped member 30, a compressive force is generated in the protrusion 18 and face plate 14B that are positioned on the inside of the folding direction D2. The compressive force generated in the protrusion 18 and face plate 14B presses the rod-shaped member 30 against the face plate 14A on the outside of the folding direction D2. Since the rod-shaped member 30 is positioned in the space K1, the deformation of the protrusion 18 and face plate 14B toward the inside of the space K1 due to the compressive force is suppressed. Therefore, the crushing of the space K1 and the peeling of the joint 16 due to the folding are suppressed. This compressive force causes the tip side of the protruding direction of the protrusion 18 to deform so as to expand laterally relative to the extension direction D1.

In addition, when the panel structure 10 is bent, a tensile force is generated in the face plate 14A located on the outside of the bending direction D2. The face plate 14A on the outside of the bending direction D2 is efficiently heated and softened by the rod-shaped member 30, and is deformed so as to extend laterally in the extension direction D1 without breaking due to the tensile force.

In addition, the thermoplastic resin fibers 36a of the commingle material 36 provided on the rod-shaped member 30 melt when heated and adhere to the face plate 14A and the protrusion 18.

After forming the bent portion 22 in the panel structure 10, a cooling step S30 is performed. In the cooling step S30, the bent portion 22 is cooled. FIG. 7 is a diagram showing an example of the cooling step S30. In the cooling step S30, for example, the heating of the heating member 32 is stopped, and the panel structure 10 including the bent portion 22 is cooled by natural cooling. The panel structure 10 may be cooled using a cooling device or the like.

The cooling step S30 hardens the softened or melted thermoplastic resin. For example, the face plate 14 and the protrusions 18 that have been heated and softened by the heating member 32 are hardened. As a result, the panel structure 10 maintains the shape in which the bent portions 22 are formed. In addition, the thermoplastic resin fibers 36a of the commingle material 36 that have been heated and melted by the heating member 32 and attached to the face plate 14 and the protrusions 18 are hardened. The hardening of the thermoplastic resin fibers 36a reinforces the face plate 14 and the protrusions 18. For example, the face plate 14A on the outer side of the bending direction D2 may be stretched by being bent in the bending step S20, and the plate thickness may become smaller. In this embodiment, the thermoplastic resin fibers 36a harden while attached to the face plate 14A, thereby reinforcing the face plate 14A.

After cooling the bent portion 22, a removal process S40 is performed. In the removal process S40, at least a portion of the rod-shaped member 30 is removed from the panel structure 10 with the bent portion 22 cooled.

In this embodiment, the thermoplastic resin fibers 36a of the comingle material 36 harden while attached to the protective layer 34. In other words, the protective layer 34 is adhered to the face plate 14 and the protrusion 18 via the thermoplastic resin fibers 36a. Therefore, in the removal step S40, a part of the rod-shaped member 30 can be easily removed by separating and removing the heating member 32 from the protective layer 34. Depending on the state of attachment between the thermoplastic resin fibers 36a and the protective layer 34, the protective layer 34 may be removable from the thermoplastic resin fibers 36a without destroying the shape of the bent portion 22. In this case, the protective layer 34 may be removed from the thermoplastic resin fibers 36a, and the heating member 32 may be removed together with the protective layer 34.

FIG. 8 is a diagram showing an example of the panel structure 10 after the removal process S40. As shown in FIG. 9, by performing the removal process S40, the panel structure 10 has a folded portion 22 that is folded in a folding direction D2 along the extension direction D1. Furthermore, the panel structure 10 is formed such that the face plate 14 and the protruding portion 18 surround a columnar space K2 along the extension direction D1 at the folded portion 22.

The space K2 has a shape corresponding to the shape of the rod-shaped member 30 removed in the removal process S40. The shape of the space K2 is different from the shape of the space K1 in the portion of the panel structure 10 other than the bent portion 22. For example, in a cross-sectional view along a plane perpendicular to the extension direction D1, the space K2 has substantially the same shape in any portion of the extension direction D1. In a cross-sectional view along a plane perpendicular to the extension direction D1, the dimensions of the space K2 correspond to the dimensions of the rod-shaped member 30 removed in the removal process S40. The space forming portion 24 is formed when the face plate 14 and the protrusion 18 are softened by heat and hardened into a shape that conforms to the rod-shaped member 30.

In addition, in this embodiment, the thermoplastic resin fibers 36a of the commingle material 36 are provided in a hardened state in the folded portion 22 of the panel structure 10. In this case, the thermoplastic resin fibers 36a form part of the space forming portion 24 that surrounds the space K2. In addition, when the heating member 32 is separated and removed from the protective layer 34 in the removal step S40, the protective layer 34 remains in the folded portion 22 of the panel structure 10. In this case, the protective layer 34 forms part of the space forming portion 24 that surrounds the space K2.

In this way, according to the above-mentioned processing method for the panel structure 10, the panel structure 10 is folded with the rod-shaped member 30 disposed in the space K1, so deformation of the protrusion 18 and the face plate 14B toward the inside of the space K1 is suppressed. Therefore, crushing of the space K1 and peeling of the joint 16 due to folding are suppressed. This makes it possible to suppress a decrease in strength at the folded portion.

The panel structure 10 has a bent portion 22 that is bent in one direction, and in the bent portion 22, the face plate 14 and the protruding portion 18 are formed to surround a columnar space K1 that is aligned in one direction. Therefore, it is possible to provide a panel structure 10 in which the reduction in strength in the bent portion 22 is suppressed.

9 is a diagram showing another example of bending the panel structure 10 in the bending step S20. FIG. 9 shows a case where the panel structure 10 is bent so that the convex portion 18 is positioned outside the bending direction D2 relative to the rod-shaped member 30. As shown in FIG. 9, when the panel structure 10 is bent so that the convex portion 18 is positioned outside the bending direction D2 relative to the rod-shaped member 30, a compressive force is generated in the face plate 14B, which is positioned inside the bending direction D2. Due to the compressive force generated in the face plate 14B, the rod-shaped member 30 is pressed against the convex portion 18 and the face plate 14A on the outside of the bending direction D2. Due to this pressing, the tip side of the protruding direction of the convex portion 18 is deformed so as to spread laterally in the extension direction D1. In addition, since the rod-shaped member 30 is placed in the space K1, the deformation of the face plate 14B toward the inside of the space K1 due to the compressive force is suppressed. Therefore, the crushing of the space K1 and the peeling of the joint 16 due to the bending are suppressed. In the example shown in FIG. 9, the rod-shaped member 30 is pressed against the joint 16, which more reliably prevents the joint 16 from peeling off.

In addition, when the panel structure 10 is bent, a tensile force is generated in the face plate 14A and the protrusions 18 arranged on the outside of the bending direction D2. The face plate 14A and the protrusions 18 on the outside of the bending direction D2 are efficiently heated and softened by the rod-shaped member 30, and are deformed so as to extend laterally in the extension direction D1 without breaking due to the tensile force.

FIG. 10 is a diagram showing another example of a rod-shaped member used in the insertion process S10. As shown in FIG. 10, the rod-shaped member 40 has a heating member 42, a protective layer 44, and a commingling material 46.

The heating member 42 has, for example, a rod-shaped core member 42a and a sheet heating element 42b wound around the core member 42a. The core member 42a is formed using a material that can maintain its rigidity even when exposed to heat. The sheet heating element 42b is configured with a wiring layer 42d made of metal or the like formed on a film member 42c made of, for example, resin. Heat is generated by passing a current through the wiring layer 42d. The protective layer 44 and the commingle material 46 can be configured in the same way as the protective layer 34 and the commingle material 36 described above. The film member 42c may be configured to have the same function as the protective layer 34. In this case, the protective layer 44 may not be provided.

FIG. 11 is a diagram showing another example of the insertion process S10. FIG. 11 shows an example in which multiple rod-shaped members 30 are used in the insertion process S10. As shown in FIG. 11, in the insertion process S10, the rod-shaped members 30 can be inserted into three adjacent spaces K1 in the panel structure 10 that are separated by protrusions 18. The rod-shaped members 30 inserted into each space K1 may have the same configuration, or at least one of them may have a different configuration.

12 is a diagram showing another example of bending the panel structure 10 in the bending step S20. FIG. 12 shows an example of bending the panel structure 10 into which a plurality of rod-shaped members 30 are inserted. As shown in FIG. 12, in the bending step S20, the panel structure 10 is bent at the convex portion 18 of the central space K1 in the adjacent direction among the three spaces K1. FIG. 13 shows an example of bending the panel structure 10 so that the convex portion 18 is located inside the bending direction D2 relative to the rod-shaped member 30. As shown in FIG. 12, the rod-shaped members 30 are arranged in each of the three spaces K1, so that the face plate 14 and the convex portion 18 can be prevented from being deformed inwardly of the space K1 due to the compressive force. Therefore, the collapse of the space K1 and the peeling of the joint portion 16 due to the bending can be more reliably prevented.

Figure 13 is a diagram showing another example of bending the panel structure 10 in the bending process S20. Figure 13 shows another example of bending the panel structure 10 into which multiple rod-shaped members 30 are inserted, where the panel structure 10 is bent so that the protrusions 18 are positioned outside the rod-shaped members 30 in the bending direction D2. As shown in Figure 13, the rod-shaped members 30 are disposed in each of the three spaces K1, so that deformation of the face plate 14 and the protrusions 18 toward the inside of the spaces K1 due to compressive force can be suppressed. This makes it possible to more reliably suppress the collapse of the spaces K1 and the peeling of the joints 16 due to bending.

FIG. 14 is a diagram showing another example of the insertion step S10. FIG. 14 is a diagram showing another example in which multiple rod-shaped members 30 are used in the insertion step S10. As shown in FIG. 14, in the insertion step S10, the rod-shaped members 30 can be inserted into three adjacent spaces K1 in the panel structure 10 that are separated by the protrusions 18. In this case, the rod-shaped members 30 inserted into each of the three spaces K1 are provided with the commingle material 36 wrapped around them so that they overlap in the radial direction. Also, the amount of the commingle material 36 wrapped around the rod-shaped members 30 inserted into the spaces K1 on both sides in the adjacent direction is greater than the amount of the rod-shaped member 30 inserted into the central space K1 in the adjacent direction among the three spaces K1.

FIG. 15 is a diagram showing another example of bending the panel structure 10 in the bending step S20. FIG. 15 shows another example of bending the panel structure 10 into which a plurality of rod-shaped members 30 are inserted. Specifically, an example of bending is shown in which the convex portion 18 of the central space K1 in adjacent directions among the three spaces K1 is positioned inside the bending direction D2 relative to the rod-shaped member 30. As shown in FIG. 15, since the rod-shaped members 30 are disposed in each of the three spaces K1, it is possible to suppress deformation of the face plate 14 and the convex portion 18 toward the inside of the space K1 due to compression force. Therefore, it is possible to more reliably suppress crushing of the space K1 and peeling of the joint 16 due to bending.

In addition, by wrapping the commingle material 36 around the rod-shaped member 30 inserted into each space K1 so that it overlaps in the radial direction, the surface layer of the rod-shaped member 30 becomes soft and easier to deform. Therefore, when the panel structure 10 is bent, it becomes easier to accommodate the deformation of the face plate 14 and the protrusions 18, improving the conformability of the face plate 14 and the protrusions 18.

In addition, the comingle material 36 of the rod-shaped member 30 inserted into the space K1 on both sides reinforces the joint 16 between the protrusion 18 and the face plate 14 and its surrounding area. This makes it possible to prevent the space K1 from collapsing due to bending and the joint 16 from peeling off. In addition, the weight of the reinforced portion provided by the comingle material 36 is greater than when the rod-shaped member 30 is inserted only into the central space K1, improving the reinforcing strength.

Also, by making the amount of winding of the commingle material 36 of the rod-shaped member 30 inserted into the spaces K1 on both sides greater than the amount of winding of the commingle material 36 of the rod-shaped member 30 inserted into the central space K1, the joint 16 between the convex portion 18 and the face plate 14 and its surroundings can be sufficiently reinforced in the spaces K1 on both sides, thereby suppressing crushing of the space K1 and peeling of the joint 16 due to bending. Also, the rod-shaped member 30 inserted into the central space K1 is pressed outward in the bending direction D2 in the bending process S20. Therefore, the reinforcement of the inner portion (the joint 16 between the face plate 14 and the convex portion 18 and its surroundings) is less than the reinforcement of the outer portion in the bending direction D2. In response to this, by making the amount of winding of the commingle material 36 of the rod-shaped member 30 inserted into the spaces K1 on both sides greater than the amount of winding of the commingle material 36 of the rod-shaped member 30 inserted into the central space K1, it is possible to reinforce the inner portion of the central space K1 in the bending direction D2, i.e., the joint 16 and its surrounding area, from both sides.

FIG. 16 is a diagram showing another example of bending the panel structure 10 in the bending step S20. FIG. 16 shows another example of bending the panel structure 10 into which multiple rod-shaped members 30 are inserted. Specifically, this shows an example of bending the convex portion 18 of the central space K1 in adjacent directions among the three spaces K1 so that the convex portion 18 is positioned outside the bending direction D2 relative to the rod-shaped member 30. As shown in FIG. 16, since the rod-shaped members 30 are disposed in each of the three spaces K1, it is possible to suppress deformation of the face plate 14 and the convex portion 18 toward the inside of the space K1 due to compression force. Therefore, it is possible to more reliably suppress the crushing of the space K1 and the peeling of the joint 16 due to bending.

Also, in the same way as when bending the rod-shaped member 30 so that the protrusions 18 are positioned on the inside of the bending direction D2, the commingle material 36 is wrapped around the rod-shaped member 30 inserted into each space K1 so as to overlap in the radial direction, making the surface layer of the rod-shaped member 30 soft and easier to deform. Therefore, when the panel structure 10 is bent, it becomes easier to accommodate the deformation of the face plate 14 and the protrusions 18, improving the conformability of the face plate 14 and the protrusions 18.

In addition, by making the amount of winding of the commingle material 36 of the rod-shaped member 30 inserted into the spaces K1 on both sides greater than the amount of winding of the commingle material 36 of the rod-shaped member 30 inserted into the central space K1, the joint 16 between the protrusion 18 and the face plate 14 and its surroundings in the spaces K1 on both sides can be sufficiently reinforced, thereby preventing the space K1 from collapsing due to bending and the joint 16 from peeling off.

In addition, the rod-shaped member 30 inserted into the central space K1 is pressed outward in the bending direction D2 in the bending process S20. This allows the joint 16 between the protrusion 18 and the face plate 14 to be reinforced. On the other hand, when bending the rod-shaped member 30 so that the protrusion 18 is positioned outward in the bending direction D2, the face plate 14 on both sides of the joint 16 may be stretched and the plate thickness may become smaller due to the tensile force generated outward in the bending direction D2. In response to this, by making the winding amount of the commingle material 36 of the rod-shaped member 30 inserted into the spaces K1 on both sides greater than the winding amount of the commingle material 36 of the rod-shaped member 30 inserted into the central space K1, the face plate 14 on both sides of the joint 16 can be sufficiently reinforced by the commingle material 36 of the rod-shaped member 30 placed in the spaces K1 on both sides.

FIG. 17 is a diagram showing an example of a processing device 50 according to this embodiment. The processing device 50 is used when performing the above-mentioned bending process S20. As shown in FIG. 17, the processing device 50 includes a holding unit 52, a heating unit 54, and a bending assistant unit 56.

The holding portion 52 holds the panel structure 10 in which the rod-shaped member 30 is inserted along the extension direction D1 into the space K1 formed between the face plate 14 and the protrusion 18 of the panel structure 10. The base end 52a of the holding portion 52 is fixed. The holding portion 52 holds the panel structure 10 so that it is in a cantilevered state, for example.

The heating unit 54 heats and softens the target portion 20 along the rod-shaped member 30 of the panel structure 10. The heating unit 54 is, for example, a power source for passing a current through the rod-shaped member 30. By passing a current through the rod-shaped member 30 with the heating unit 54, the rod-shaped member 30 generates heat, and the target portion 20 can be heated. The heating unit 54 may be a heater or the like provided outside the panel structure 10. In this case, the heater can heat the target portion 20 from outside the panel structure 10.

The bending assist part 56 is arranged along the target part 20 on the inside of the bending direction D2 of the target part 20 when the panel structure 10 with the softened target part 20 is bent along the rod-shaped member 30. The bending assist part 56 can be a columnar member having various shapes, such as a cylinder, a rectangular prism, or a triangular prism. An appropriate shape can be selected for the bending assist part 56 depending on the bending angle of the panel structure 10, the shape of the bent part, etc. At least one end of the bending assist part 56 in the longitudinal direction is fixed.

FIG. 18 is a diagram showing an example of performing the bending process S20 using a processing device 50. As shown in FIG. 18, first, with the surface of the panel structure 10 that is on the inside of the bending direction D2 facing downward, one end of the panel structure 10 in the direction in which the protrusions 18 are aligned is held by a holding unit 52. Then, the target portion 20 is heated and softened by a heating unit 54.

After the target portion 20 has softened, the bending assist portion 56 is placed on top of the target portion 20 along the extension direction D1, and the bending assist portion 56 is fixed so that it does not move in the vertical direction. From this state, the other end of the panel structure 10 in the direction in which the convex portions 18 are lined up, i.e., the end that is not held by the holding portion 52, is grasped and lifted upward. This allows the panel structure 10 to be bent appropriately.

As described above, the processing method for a panel structure according to the first aspect of the present disclosure is a processing method for a panel structure 10 including a core member 12 formed of a thermoplastic resin and provided with a plurality of convex portions 18 extending in one direction on both sides thereof, and a face plate 14 formed in a plate shape using a thermoplastic resin and arranged to sandwich the core member 12 from both sides in the height direction of the convex portions 18, and includes an insertion step S10 of inserting a rod-shaped member 30 in one direction into a space K1 formed between the face plate 14 and the core member 12 of the panel structure 10, and a folding step S20 of heating and softening a target portion 20 along the rod-shaped member 30 of the panel structure 10 in a state in which the rod-shaped member 30 is inserted, and folding the panel structure 10 along the rod-shaped member 30 to form a folded portion 22 in the target portion 20.

With this configuration, the panel structure 10 is folded with the rod-shaped member 30 disposed in the space K1, so deformation of the protrusion 18 and the face plate 14B toward the inside of the space K1 is suppressed. Therefore, crushing of the space K1 and peeling of the joint 16 due to folding are suppressed. This makes it possible to suppress a decrease in strength at the folded portion.

The processing method for a panel structure according to the second aspect of the present disclosure is the same as the processing method for a panel structure according to the first aspect, except that a thermoplastic composite material is used as the thermoplastic resin for the panel structure 10. Therefore, in the panel structure 10 using the composite material, it is possible to suppress a decrease in strength at the bent portion.

The processing method for a panel structure according to the third aspect of the present disclosure is the same as the processing method for a panel structure according to the first or second aspect, except that a rod-shaped heating member 32 is used as the rod-shaped member 30, and in the bending step S20, the heating member 32 heats the target portion 20 from inside the panel structure 10. Therefore, the target portion 20 of the panel structure 10 can be efficiently heated.

The processing method for a panel structure according to the fourth aspect of the present disclosure is the processing method for a panel structure according to the third aspect, except that the heating member 42 has a rod-shaped core member 42a and a planar heating element 42b wound around the core member 42a. Therefore, the target portion 20 of the panel structure 10 can be efficiently heated.

The processing method for a panel structure according to the fifth aspect of the present disclosure is the processing method for a panel structure according to the third or fourth aspect, in which the rod-shaped member 30 has a commingle material 36 wrapped around a heating member 32, and in the bending step S20, a part of the commingle material 36 is melted by the heating member 32 and adhered to the panel structure 10. Therefore, the panel structure 10 can be reinforced by the part of the melted commingle material 36.

The processing method for the panel structure according to the sixth aspect of the present disclosure further includes a cooling step S30 for cooling the bent portion 22, and a removal step S40 for removing at least a part of the rod-shaped member 30 after cooling the bent portion 22. The heating member 32 is provided with a detachable protective layer 34 so as to cover the part around which the comingle material 36 is wound, and the comingle material 36 is provided in a state of being wound on the protective layer 34. In the bending step S20, the protective layer 34 is attached to a part of the melted comingle material 36, and in the removal step S40, the heating member 32 is separated from the protective layer 34 and removed. Therefore, when a part of the comingle material 36 is melted, it is attached to the protective layer 34 and does not directly adhere to the heating member 32, so that the heating member 32 can be easily removed in the removal step S40. In addition, the panel structure 10 can be reinforced by the protective layer 34.

The processing method for a panel structure according to the seventh aspect of the present disclosure is a processing method for a panel structure according to any one of the first to sixth aspects, in which in the bending step S20, the protrusion 18 is bent so as to be positioned on the inside of the bending direction D2 relative to the rod-shaped member 30. Therefore, the panel structure 10 can be folded efficiently while suppressing the collapse of the space K1 and the peeling of the joint 16.

The processing method for a panel structure according to the eighth aspect of the present disclosure is a processing method for a panel structure according to any one of the first to sixth aspects, in which in the bending step S20, the protrusion 18 is bent so as to be positioned outside the bending direction D2 relative to the rod-shaped member 30. Therefore, the panel structure 10 can be folded efficiently while suppressing the collapse of the space K1 and the peeling of the joint 16.

The processing method for a panel structure according to the ninth aspect of the present disclosure is the processing method for a panel structure according to the seventh or eighth aspect, in which, in the insertion step S10, a rod-shaped member 30 is inserted into three adjacent spaces K1 separated by a protrusion 18, and in the folding step S20, the panel structure 10 is folded along the rod-shaped member 30 inserted into the central space K1 of the three spaces K1. Therefore, in the central space K1 and the spaces K1 on both sides, crushing of the space K1 and peeling of the joints 16 due to folding are suppressed. This makes it possible to more reliably suppress a decrease in strength at the folded portion.

The processing method for a panel structure according to the tenth aspect of the present disclosure is the processing method for a panel structure according to the ninth aspect, in which the rod-shaped member 30 has a rod-shaped heating member 32 and a linear commingle material 36 wound around the heating member 32, and the rod-shaped member 30 inserted into the other two spaces K1 has a greater amount of the commingle material 36 wound around it than the rod-shaped member 30 inserted into the central space K1 of the three spaces K1. In the bending step S20, a part of the commingle material 36 is softened by the heating member 32 and attached to the panel structure 10. Therefore, the panel structure 10 can be reinforced by a part of the commingle material 36 in the central space K1 and the spaces K1 on both sides. In addition, since the reinforcing strength can be increased in the spaces K1 on both sides compared to the central space K1, it is possible to more reliably suppress a decrease in strength at the bent portion.

The processing method for a panel structure according to the eleventh aspect of the present disclosure is a processing method for a panel structure according to any one of the first to tenth aspects, in which in the bending step S20, the rod-shaped member 30 is bent so as to be pressed against the outside of the bending direction D2 of the panel structure 10. Therefore, the member on the outside of the bending direction D2 of the panel structure 10 can be efficiently heated, and can be reliably softened and deformed.

The processing device 50 for the panel structure 10 according to the twelfth aspect of the present disclosure is a processing device 50 for the panel structure 10, which includes a core member 12 formed of thermoplastic resin and provided with a plurality of convex portions 18 extending in one direction on both sides thereof, and a face plate 14 formed in a plate shape using thermoplastic resin and arranged to sandwich the core member 12 from both sides in the height direction of the convex portions 18, and includes a holding section 52 for holding the panel structure 10 with a rod-shaped member 30 inserted in one direction into the space K1 formed between the face plate 14 and the core member 12, a heating section 54 for heating and softening a target portion 20 of the panel structure 10 along the rod-shaped member 30, and a bending auxiliary section 56 arranged along the target portion 20 on the inside of the bending direction D2 of the target portion 20 when bending the softened target portion 20 of the panel structure 10 along the rod-shaped member 30.

Therefore, the panel structure 10 can be folded efficiently to prevent a decrease in strength at the folded portion.

The panel structure according to the thirteenth aspect of the present disclosure comprises a core member 12 formed using a thermoplastic resin and having a plurality of protrusions 18 extending in one direction on both sides thereof, and a face plate 14 formed in a plate shape using a thermoplastic resin and arranged to sandwich the core member 12 from both sides in the height direction of the protrusions 18, and has a bent portion 22 bent along one direction, where the face plate 14 and the core member 12 are formed to surround a columnar space K1 along one direction.

Therefore, it is possible to provide a panel structure 10 in which the reduction in strength at the bent portion 22 is suppressed.

The technical scope of the present invention is not limited to the above-described embodiments, and the above-described components include those that a person skilled in the art can easily imagine, those that are substantially the same, and those that are within the so-called equivalent range. Furthermore, the above-described components can be combined as appropriate. Furthermore, various omissions, substitutions, or modifications of the components can be made without departing from the spirit of the above-described embodiments.

For example, in the above embodiment, the rod-shaped

members

30, 40 are described as having

heating members

32, 42,

protective layers

34, 44, and commingle

materials

36, 46, but the present invention is not limited to this configuration. For example, the rod-shaped

members

30, 40 may not be provided with the

protective layers

34, 44. Furthermore, the rod-shaped

members

30, 40 may be configured such that neither the

protective layers

34, 44 nor the

commingle materials

36, 46 are provided.

10 Panel structure 12

Core member

14, 14A, 14B Face plate 16 Joint portion 18 Convex portion 20 Target portion 22 Bending portion 24

Space forming portion

30, 40 Rod-shaped

member

32, 42

Heating member

34, 44

Protective layer

36, 46 Comingle material 36a Thermoplastic resin fiber 42a Core member 42b Planar heating element

42c Film member

42d Wiring layer 50 Processing device 52 Holding portion 52a Base end portion 54 Heating portion 56 Bending auxiliary portion D1 Extension direction D2 Bending directions K1, K2 Space S10 Insertion process S20 Bending process S30 Cooling process S40 Removal process

Claims

A method for processing a panel structure comprising: a core member formed of a thermoplastic resin and having a plurality of protruding portions on both sides thereof, the protruding portions extending in one direction; and a face plate formed of a thermoplastic resin in a plate shape and disposed so as to sandwich the core member from both sides in a height direction of the protruding portions, the method comprising the steps of:
an inserting step of inserting a rod-shaped member along the one direction into a space formed between the face plate and the core member of the panel structure;
a bending step of heating and softening a target portion of the panel structure along the rod-shaped member in a state in which the rod-shaped member is inserted, and bending the panel structure along the rod-shaped member to form a bent portion in the target portion.
The method for processing a panel structure according to claim 1 , wherein the panel structure uses a thermoplastic composite material as the thermoplastic resin.
A rod-shaped heating member is used as the rod-shaped member,
The method for processing a panel structure according to claim 1 , wherein in the bending step, the target portion is heated from inside the panel structure by the heating member.
The method for processing a panel structure according to claim 3 , wherein the heating member has a rod-shaped core member and a sheet heating element wound around the core member.
The rod-shaped member has a commingle material wound around the heating member,
5. The method for processing a panel structure according to claim 3, wherein in the bending step, a part of the commingle material is melted by the heating member and adhered to the panel structure.
a cooling step of cooling the bent portion formed in the bending step;
and removing at least a part of the rod-shaped member after cooling the bent portion.
A protective layer is provided on the heating member so as to be detachable and cover a portion around which the commingle material is wound.
The commingle material is provided in a wound state on the protective layer,
In the bending step, the protective layer is attached to a part of the molten commingle material,
The method for processing a panel structure according to claim 5 , wherein in the removing step, the heating member is separated from the protective layer and removed.
The method for processing a panel structure according to claim 1 , wherein in the bending step, the bar-shaped member is bent so that the protrusion is positioned inside in a bending direction with respect to the bar-shaped member.
The method for processing a panel structure according to claim 1 , wherein in the bending step, the bar-shaped member is bent so that the protrusion is positioned outside in a bending direction with respect to the bar-shaped member.
In the inserting step, the rod-shaped members are inserted into three adjacent spaces separated by the protrusions,
9. The method for processing a panel structure according to claim 7 or 8, wherein in the bending step, the panel structure is bent along the rod-shaped member inserted into a central space among the three spaces.
The rod-shaped member has a rod-shaped heating member and a linear commingle material wound around the heating member,
The amount of winding of the commingle material is made larger in the rod-shaped members to be inserted into the other two spaces than in the rod-shaped member to be inserted into the central space among the three spaces;
The method for processing a panel structure according to claim 9, wherein in the bending step, a part of the commingle material is softened by the heating member to adhere to the panel structure.
The method for processing a panel structure according to claim 1 , wherein in the bending step, the rod-shaped member is bent so as to be pressed against an outer side in a bending direction of the panel structure.
A processing device for a panel structure, comprising: a core member formed of a thermoplastic resin and having a plurality of protrusions extending in one direction on both sides thereof; and a face plate formed of a thermoplastic resin in a plate shape and disposed so as to sandwich the core member from both sides in a height direction of the protrusions,
a holding portion for holding the panel structure in which a rod-shaped member is inserted along the one direction into a space formed between the face plate and the core member;
a heating unit that heats and softens a target portion of the panel structure along the rod-shaped member;
a bending assistant section that is positioned along the target portion on the inside of the bending direction of the target portion when the softened target portion of the panel structure is bent along the rod-shaped member.
a core member formed of a thermoplastic resin and having a plurality of protrusions on both sides thereof, the protrusions extending in one direction;
a face plate formed in a plate shape using a thermoplastic resin and disposed so as to sandwich the core member from both sides in a height direction of the protrusion,
A bent portion is bent along the one direction,
the face plate and the core member are formed at the bent portion to surround a columnar space extending in the one direction.