WO2015033780A1 - 樹脂製パネル及び成形方法 - Google Patents
樹脂製パネル及び成形方法 Download PDFInfo
- Publication number
- WO2015033780A1 WO2015033780A1 PCT/JP2014/071797 JP2014071797W WO2015033780A1 WO 2015033780 A1 WO2015033780 A1 WO 2015033780A1 JP 2014071797 W JP2014071797 W JP 2014071797W WO 2015033780 A1 WO2015033780 A1 WO 2015033780A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- resin
- back wall
- molten resin
- front wall
- panel
- Prior art date
Links
- 229920005989 resin Polymers 0.000 title claims abstract description 610
- 239000011347 resin Substances 0.000 title claims abstract description 610
- 238000000034 method Methods 0.000 title claims description 27
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- 238000000465 moulding Methods 0.000 claims description 51
- 238000010298 pulverizing process Methods 0.000 claims description 13
- 239000000454 talc Substances 0.000 claims description 11
- 229910052623 talc Inorganic materials 0.000 claims description 11
- 238000007493 shaping process Methods 0.000 claims description 5
- 230000000994 depressogenic effect Effects 0.000 abstract 1
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- 239000010445 mica Substances 0.000 description 3
- 229910052618 mica group Inorganic materials 0.000 description 3
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Natural products C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 2
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 2
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 2
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- 229920002994 synthetic fiber Polymers 0.000 description 2
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- 229920002397 thermoplastic olefin Polymers 0.000 description 2
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- 239000013585 weight reducing agent Substances 0.000 description 2
- JMMZCWZIJXAGKW-UHFFFAOYSA-N 2-methylpent-2-ene Chemical compound CCC=C(C)C JMMZCWZIJXAGKW-UHFFFAOYSA-N 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
- B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29B11/06—Making preforms by moulding the material
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- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
- B29C51/02—Combined thermoforming and manufacture of the preform
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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
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- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/30—Extrusion nozzles or dies
- B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
- B29C48/31—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets being adjustable, i.e. having adjustable exit sections
- B29C48/313—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets being adjustable, i.e. having adjustable exit sections by positioning the die lips
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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
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
- B29C48/388—Plasticisers, homogenisers or feeders comprising two or more stages using a screw extruder and a ram or piston
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
- B29C51/006—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 for making articles having hollow walls
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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- B29L2031/00—Other particular articles
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- B29L2031/3005—Body finishings
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Definitions
- the present invention relates to a resin panel such as a package tray, a deck board, or a floor board installed in a luggage compartment of a vehicle.
- Patent Document 1 Japanese Patent Laid-Open No. 10-235720 discloses a technique for blow molding a cylindrical molten resin and molding a panel with skin.
- Patent Document 1 a skin material is thermally welded to the outer surface of one wall portion with a blow pressure at the time of blow molding, and an inner rib is formed on the other wall portion so as to protrude until it contacts the inner surface of the one wall portion, The panel with skin is to be molded.
- the thickness (wall thickness) of the cylindrical molten resin becomes uniform. Further, when the split mold is clamped, the pressing force for pressing the cylindrical parison against the split mold is uniform over the entire surface of the cylindrical parison. For this reason, the parison pressed against one split mold that forms a rib such as an inner rib is stretched due to the blow ratio corresponding to the rib, and a locally thin portion is generated. Moreover, since the rib is not formed in the other divided mold, a thin portion is not generated. As a result, the thickness of the cylindrical parison needs to be set in accordance with the thin portion generated on one split mold side forming the ribs, thereby generating an extra thickness on the other split mold side.
- the thickness of the wall portion where the rib is not formed becomes thicker than the thickness of the wall portion where the rib is formed after blow molding. Therefore, there is a problem that it is difficult to reduce the weight of the resin panel to be molded.
- one wall portion and the other wall portion are made of the same material. For this reason, there is also a problem that it is difficult to partially improve the impact resistance with only the resin material constituting the one wall portion and the other wall portion. For this reason, it is necessary to obtain a resin panel that is lighter and has improved impact resistance.
- the weight reduction of the resin panel can be realized, for example, by using a pair of thermoplastic resin sheets extruded from an extrusion device as in Patent Document 2 (Japanese Patent Laid-Open No. 2010-201662). It is.
- Patent Document 2 Japanese Patent Laid-Open No. 2010-201662.
- a pair of thermoplastic resin sheets extruded from an extrusion device is arranged in a pair of split molds. Therefore, the thickness of the thermoplastic resin extruded into one split mold that forms the ribs and the thickness of the thermoplastic resin extruded into the other split mold that does not form the ribs are individually adjusted, and the ribs are not formed.
- An object of the present invention is to obtain a resin panel with improved resin panel weight and impact resistance.
- the resin panel is made lighter and more rigid and has no warpage. There is to get a panel.
- the resin panel according to one aspect of the present invention is: A resin panel having a back wall, a front wall facing the back wall at an interval, and a rib welded to the inner surface of the front wall with a part of the back wall recessed toward the front wall Because The melted first molten resin mixed with the plate-like filler constituting the back wall extruded from the extrusion apparatus, and the molten state second mixed with the plate-like filler constituting the front wall The molten resin is clamped with a split mold to form the back wall, the front wall, and the rib, and the longitudinal direction of the rib is the first molten resin and the second It is characterized by being non-parallel to the flow direction of the molten resin.
- the resin panel according to one aspect of the present invention is: A resin panel having a back wall and a front wall facing the back wall at an interval, The first molten resin in the molten state constituting the back wall extruded from the extrusion device and the second molten resin in the molten state constituting the front wall are clamped with a split mold, A back wall and the front wall are formed, the second molten resin is formed of a material having higher impact resistance than the first molten resin, and the front wall is more resistant than the back wall. It is composed of a material having a high impact property.
- FIG. 1 is a diagram illustrating a configuration example of a molding apparatus that molds a resin panel 1 of the present embodiment.
- FIG. 3 is a first view showing an example of a molding process for the resin panel 1.
- FIG. 4 is a second view showing an example of a molding process for the resin panel 1.
- FIG. 6 is a third diagram showing an example of a molding process for the resin panel 1.
- FIG. 10 is a fourth view showing an example of a molding process for the resin panel 1.
- FIG. 10 is a fifth diagram illustrating an example of a molding process for the resin panel 1.
- FIG. 10 is a sixth diagram illustrating an example of a molding process for the resin panel 1.
- FIG. 10 is a seventh diagram illustrating an example of a molding process for the resin panel 1.
- FIG. 10 is an eighth diagram illustrating an example of a molding process for the resin panel 1.
- FIG. 5 is a diagram showing a configuration example of a resin panel when a longitudinal direction of a rib 3a is formed in parallel with a resin flow direction.
- FIG. 1 shows a configuration example of a resin panel 1 according to one embodiment of the present invention
- FIG. 2 shows a configuration example of a molding apparatus for molding the resin panel 1 shown in FIG. 1
- FIGS. 2 shows a part of the molding process of the resin panel 1.
- a resin panel 1 As shown in FIG. 1, a resin panel 1 according to one embodiment of the present invention includes a back wall 3, a front wall 2 that is opposed to the back wall 3 with a space therebetween, and a part of the back wall 3 is a front wall 2. And a rib 3a welded to the inner surface of the front wall 2 so as to be recessed toward the surface.
- the resin panel 1 is, for example, a first molten resin P1 in a molten state in which plate-like fillers constituting the back wall 3 that has been extruded and flowed out from the extrusion device 12 shown in FIG. 2 are mixed. And the second molten resin P2 in a molten state mixed with the plate-like filler constituting the front wall 2 are clamped by the split mold 32, so that the back wall 3, the front wall 2, and the rib 3a Thus, the resin panel 1 is obtained in which the longitudinal direction of the rib 3a is not parallel to the flow direction of the first molten resin P1 and the second molten resin P2.
- the longitudinal portion 3a1 constituting the longitudinal direction of the rib 3a shown in FIG. 1 is formed in an orthogonal direction that is not parallel to the flow directions of the first molten resin P1 and the second molten resin P2.
- the flow direction of the first molten resin P1 and the second molten resin P2 is the BB ′ direction, which is the longitudinal direction of the resin panel 1.
- the direction orthogonal to the flow direction is the AA ′ direction, which is the short direction of the resin panel 1.
- the resin panel 1 according to one embodiment of the present invention When the resin panel 1 according to one embodiment of the present invention is molded, first, as shown in FIG. 2, a molten state in which plate-like fillers constituting the back wall 3 that has been extruded and flowed out from the extrusion device 12 are mixed.
- the first molten resin P1 and the second molten resin P2 in a molten state in which the plate-like fillers constituting the front wall 2 are mixed are suspended between the pair of split molds 32.
- the first molten resin P1 and the second molten resin P2 are sucked into the surface of the cavity 116 of the split mold 32, and the first molten resin P1 and the second molten resin P2 are sucked. Are formed into a shape along the cavity 116.
- the split mold 32 is clamped, and the longitudinal direction of the rib 3a is formed in a non-parallel manner with the flow directions of the first molten resin P1 and the second molten resin P2. Panel 1 is formed.
- the resin panel 1 includes a first molten resin P1 in a molten state in which a plate-like filler constituting the back wall 3 extruded from the extrusion device 12 and flows out, and a front wall 2
- the back wall 3, the front wall 2, and the rib 3a are constituted by clamping the second molten resin P2 in a molten state mixed with the plate-shaped filler to be configured with the split mold 32, A resin panel 1 in which the longitudinal direction of the rib 3a is not parallel to the flow direction of the first molten resin P1 and the second molten resin P2 is formed.
- the resin panel 1 according to one embodiment of the present invention can reduce the weight of the resin panel 1 by using the molding apparatus shown in FIG.
- it is usually preferable to mold by mixing a highly anisotropic filler such as glass fiber with the resin.
- a resin panel 1 having ribs 3a is formed by extruding a resin mixed with a highly anisotropic filler such as glass fiber from the extrusion device 12, warping occurs in the finally formed resin panel 1. May end up. This warp occurs remarkably when the longitudinal direction of the rib 3a formed on the resin panel 1 is parallel to the flow direction of the resin that has been pushed out of the extrusion device 12 and flowed out.
- the resin panel 1 formed by extruding the resin mixed with the plate-like filler from the extrusion device 12 and the longitudinal direction of the rib 3a being extruded from the extrusion device 12 and flowing in parallel with the flow direction of the resin flows out.
- the resin panel 1 can be reduced in weight and high rigidity, and the resin panel 1 without warping can be obtained.
- a resin panel 1 according to one embodiment of the present invention will be described in detail with reference to the accompanying drawings.
- FIG. 1 is a diagram showing a configuration example of a resin panel 1
- FIG. 1 (a) is an overall perspective view of the resin panel 1
- FIG. 1 (b) is a resin shown in FIG. 1 (a).
- FIG. 1 (c) is a cross-sectional view of the resin panel 1 shown in FIGS. 1 (a) and 1 (b)
- FIG. 1 (d) is a cross-sectional view of FIG. It is BB 'sectional drawing of the resin panels 1 shown to (a), (b).
- the resin panel 1 of the present embodiment includes a front wall 2, a back wall 3, a peripheral wall 4, and a reinforcing material unit 5 as shown in FIG. 1 (a).
- the resin panel 1 of the present embodiment has a front wall 2 and a back wall 3 facing each other at a predetermined interval. Are connected by a peripheral wall 4. Further, a hollow portion 6 is provided between the front wall 2 and the back wall 3, and the reinforcing material unit 5 is disposed between the front wall 2 and the back wall 3.
- the resin panel 1 of the present embodiment has a decorative member 7 attached to the surface of the front wall 2 for decoration, etc.
- the back wall 3, the front wall 2, and the decorative member 7 constitute a laminated structure. It is also possible not to attach the decorative member 7.
- the resin panel 1 of the present embodiment is configured to have a plurality of ribs 3a in which a part of the back wall 3 is recessed toward the front wall 2 and is welded to the inner surface of the front wall 2. 1 to improve the rigidity and strength.
- the rib 3a of the present embodiment has a bottom, and the bottom of the rib 3a is welded to the inner surface of the front wall 2.
- FIG. 1 shows an example in which slit ribs are provided as the ribs 3a, inner ribs can also be provided.
- the number of ribs 3a is not particularly limited, and an arbitrary number of ribs 3a can be provided according to the shape of the resin panel 1.
- any shape can be used as long as the rib 3a has a long portion 3a1 and a short portion 3a2 on the outer surface of the back wall 3.
- the longitudinal part 3a1 is a part constituting the longitudinal direction of the rib 3a.
- the short part 3a2 is a part constituting the short direction of the rib 3a.
- the rib 3a can be configured in a shape having a long portion and a short portion, such as a linear shape, a curved shape, a rectangular shape, and an elliptical shape.
- the short part 3a2 of the rib 3a is in the direction BB ′.
- the direction of BB ′ is the flow direction of the resin constituting the back wall 3 and the front wall 2.
- the longitudinal portion 3a1 of the rib 3a is in the direction of AA ′.
- the direction of AA ′ is a direction orthogonal to the resin flow direction BB ′.
- the resin panel 1 of the present embodiment is made of a resin containing a plate-like filler, and the longitudinal portion 3a1 of the rib 3a is formed in a direction AA ′ orthogonal to the resin flow direction BB ′. Yes. For this reason, it is possible to obtain the resin panel 1 without warping.
- the plate-like filler include talc and mica, which are less anisotropic than glass fibers.
- the number of ribs 3a provided apart from each other in the direction AA ′ orthogonal to the resin flow direction BB ′ is not particularly limited, and an arbitrary number of ribs 3a can be arranged.
- the resin panel 1 of the present embodiment has a contact surface 31 on the back wall 3.
- the contact surface 31 is, for example, a portion that comes into contact with another member when the resin panel 1 is placed on another member in the automobile.
- the contact surface 31 contacts the other member, and the resin panel 1 Is placed on another member.
- the strength of the resin panel 1 can be improved by arranging the reinforcing material unit 5 so as to span the contact surface 31.
- the strength of the reinforcing material unit 5 in the direction orthogonal to the longitudinal direction can be improved.
- the shape and position of the contact surface 31 are not limited to the flat shape and position shown in FIGS. 1A and 1B, and the resin panel 1 when the resin panel 1 is placed on another member.
- the resin panel 1 of FIG. 1 has a configuration in which the reinforcing material unit 5 is disposed but the reinforcing material unit 5 is not disposed.
- the contact surface 31 is formed on the extension line in the longitudinal direction of the rib 3a. Thereby, the strength of the resin panel 1 can be improved.
- the resin panel 1 of the present embodiment is formed with a plurality of ribs 3a on the back wall 3 having the contact surface 31 while reducing the weight of the resin panel 1. For this reason, in order to make the contact surface 31 of the back wall 3 difficult to deform and crack, the average thickness of the back wall 3 is configured in the range of 1.1 mm to 1.7 mm. Further, unlike the back wall 3, the front wall 2 does not form the ribs 3a, and thus the average thickness of the front wall 2 is configured in the range of 0.7 mm to 1.2 mm. Thereby, the resin panel 1 can be reduced in weight, and the resin panel 1 which is difficult to be deformed and is difficult to break can be obtained.
- the average thickness of the back wall 3 is configured to be 1.1 mm or more. Further, if the average thickness of the back wall 3 is greater than 1.7 mm, it becomes uselessly thick and it becomes difficult to reduce the weight of the resin panel 1. In addition, the thickness difference between the back wall 3 and the front wall 2 is increased, the distance between the back wall 3 and the front wall 2 is changed, and the contact surface 31 is easily deformed.
- the average thickness of the back wall 3 is configured in the range of 1.1 mm to 1.7 mm.
- the front wall 2 has an average wall thickness of 0.7 mm or more and 1.2 mm or less for the same reason as the back wall 3.
- the resin panel 1 of the present embodiment is configured with an average thickness of the back wall 3 in a range of 1.1 mm to 1.7 mm, and an average thickness of the front wall 2 in a range of 0.7 mm to 1.2 mm.
- the weight of the molded product without the decorative member 7 can be reduced to 2.5 to 4.2 kg / m 2 to reduce the weight of the resin panel 1, and the contact surface 31 of the back wall 3 can be reduced. It is possible to make it difficult to deform and break. However, the weight of the molded product is lighter on the front wall 2 than on the back wall 3.
- the average wall thickness of the front wall 2 and the back wall 3 is at least 10 locations (provided that the rib 3a is provided) at substantially equal intervals along the longitudinal direction of the front wall 2 and the back wall 3. It means the average value of the thickness measured at 10 points a1 to a10 shown in FIG. For example, in the case of the configuration example of the resin panel 1 shown in FIG. 1, as shown in FIG. 1 (b), the measurement was made at 10 locations a1 to a10 on the front wall 2 where the ribs 3a were not provided. It is the average thickness.
- the back wall 3 is an average value of the thicknesses measured at the respective portions at positions facing the respective portions a1 to a10 measured at the front wall 2.
- the resin sheets P1 and P2 constituting the front wall 2 and the back wall 3 are, for example, polyethylene resin, polypropylene resin, ethylene-vinyl acetate copolymer, vinyl chloride resin, ABS resin (acrylonitrile-styrene-butadiene resin). Further, a resin such as a polyamide resin, a polystyrene resin, a polyester resin, a polycarbonate resin, a modified polyphenylene ether, or a mixed resin obtained by blending these resins is used to form a material in which a plate-like filler is mixed. Examples of the plate-like filler include talc and mica, which are less anisotropic than glass fibers.
- the front wall 2 and the back wall 3 are preferably made of a resin material having a high melt tension from the viewpoint of preventing thickness variation due to drawdown, neck-in, etc.
- a resin material with high fluidity In order to improve transferability and followability, it is preferable to use a resin material with high fluidity.
- a plate-like filler In order to achieve high rigidity of the resin panel 1, it is preferable to use a plate-like filler. This is because it was discovered by repeating various experiments that the rigidity of the resin panel 1 can be improved by using a plate-like filler.
- a known material can be applied to the material constituting the decorative member 7.
- a thermoplastic elastomer (TPE) such as a thermoplastic polyolefin elastomer (TPO), a resin sheet made of a thermoplastic resin such as a polyethylene polyolefin resin, and a laminate sheet thereof can be appropriately selected.
- the material constituting the reinforcing material unit 5 known materials can be applied. For example, metal (aluminum or the like) or hard plastic is applicable.
- the shape of the reinforcing material unit 5 is not limited to the shape shown in FIG. 1 and can be configured in an arbitrary shape. For example, it may be configured in a cylindrical shape, a C shape, a U shape, or the like. However, since the resin panel 1 shown in FIG. 1 forms the rib 3a on the back wall 3, it is necessary to dispose the reinforcing material unit 5 at a location where the rib 3a is not formed.
- FIG. 2 shows a configuration example of a molding apparatus for molding the resin panel 1
- FIGS. 3 to 10 are diagrams showing an example of a process for molding the resin panel 1.
- the T of the extrusion apparatus 12 shown in FIG. A state in which the resin sheet P and the split mold 32 are viewed from the die 28 side is shown.
- the resin panel 1 of this embodiment can be molded using a molding apparatus shown in FIG.
- the molding apparatus shown in FIG. 2 has an extrusion apparatus 12 and a mold clamping apparatus 14, and sends molten resin sheets P 1 and P 2 extruded from the extrusion apparatus 12 to the mold clamping apparatus 14. Then, the resin sheets P1 and P2 are clamped to form the resin panel 1 shown in FIG.
- the resin sheet P1 constitutes the back wall 3, and the resin sheet P2 constitutes the front wall 2.
- the protrusion 33 for forming the rib 3a forms the back wall 3 side as shown in FIGS.
- a plurality of cavities 116B of one split mold 32B are provided.
- the projecting portion 33 is formed in a shape corresponding to the rib 3a formed on the back wall 3, and is provided in the cavity 116B so as to project toward the other split mold 32A configuring the front wall 2 side.
- the protrusion 33 shown in FIG. 2 forms a rib 3a in the longitudinal direction of the resin panel 1 shown in FIG. 1, and the protrusion 33 shown in FIGS. 3 to 10 is the resin panel 1 shown in FIG.
- the rib 3a in the short direction is formed.
- the resin panel 1 of the present embodiment is configured by making the thickness of the back wall 3 relatively thicker than the front wall 2, the back wall 3 is configured rather than the resin sheet P2 constituting the front wall 2.
- the thickness of the resin sheet P1 to be increased is increased.
- the sheet-like decorative member 7 is divided by a temporary fixing pin provided in the divided mold 32A. Temporarily fix the cavity 116A of the mold 32A.
- the resin sheets P1 and P2 are extruded from the T-die 28 of the extrusion device 12, and the extruded resin sheets P1 and P2 are passed through a pair of rollers 30 so that the thickness of the resin sheets P1 and P2 is increased. The thickness is adjusted and suspended between the pair of split molds 32.
- the extrusion capability of the extrusion device 12 is appropriately selected from the viewpoint of the size of the resin panel 1 to be molded, the draw-down of the resin sheets P1 and P2, and the prevention of neck-in occurrence. More specifically, from a practical viewpoint, the amount of extrusion per shot in intermittent extrusion is preferably 1 to 10 kg, and the extrusion speed of the resin sheets P1 and P2 from the extrusion slit is several hundred kg / hour or more, More preferably, it is 700 kg / hour or more.
- the resin sheet P1, P2 extrusion process is preferably as short as possible, depending on the type of resin, MFR value, MT value, In addition, the extrusion process should be completed within 40 seconds, more preferably within 10 to 20 seconds. For this reason, the extrusion amount of the resin sheets P1 and P2 per unit area and unit time from the extrusion slit is 50 kg / hour cm 2 or more, more preferably 150 kg / hour cm 2 or more.
- the extrusion device 12 of the present embodiment is such that the thickness of the front wall 2 is substantially the same as the thickness of the back wall 3 or thin, and the front wall 2 is lighter than the back wall 3.
- the thickness of the second molten resin sheet P2 constituting the front wall 2 is made thinner than the thickness of the first molten resin sheet P1 constituting the back wall 3 and extruded.
- the thickness of the resin sheet P2 constituting the front wall 2 is adjusted so that the average thickness of the front wall 2 of the resin panel 1 of the final molded product is in the range of 0.7 mm to 1.2 mm.
- the resin sheet P1 constituting the back wall 3 is adjusted so that the average thickness of the back wall 3 of the resin panel 1 of the final molded product is in the range of 1.1 mm to 1.7 mm.
- the thickness of the resin sheets P1 and P2 can be changed by adjusting the interval between the extrusion slits, the interval between the rollers 30, and the rotation speed of the rollers 30.
- the resin sheets P1 and P2 are preferably made of a resin material having a high melt tension from the viewpoint of preventing thickness variation due to drawdown, neck-in, etc. It is preferable to use a resin material with high fluidity in order to improve the property and followability.
- the resin sheets P1 and P2 are polyolefins (for example, polypropylene and high-density polyethylene) that are homopolymers or copolymers of olefins such as ethylene, propylene, butene, isoprenepentene, and methylpentene, and are 230 ° C.
- MFR (measured according to JIS K-7210 at a test temperature of 230 ° C and a test load of 2.16 kg) of 3.0 g / 10 min or less, more preferably 0.3 to 1.5 g / 10 min, or Amorphous resin such as acrylonitrile / butadiene / styrene copolymer, polystyrene, high impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), MFR at 200 ° C.
- HIPS resin high impact polystyrene
- AS resin acrylonitrile / styrene copolymer
- the molding apparatus of this embodiment can stretch and thin the resin sheets P1 and P2 by sending the resin sheets P1 and P2 sandwiched between the pair of rollers 30 downward by the rotation of the pair of rollers 30.
- by adjusting the relative speed difference between the extrusion speed of the resin sheets P1, P2 and the delivery speed at which the resin sheets P1, P2 are sent downward by the pair of rollers 30 by the rotational speed of the pair of rollers 30, It is possible to prevent the occurrence of drawdown or neck-in. For this reason, the restriction
- the resin sheets P1 and P2 are arranged between the divided molds 32, and the frame member 128 is moved toward the corresponding resin sheets P1 and P2 by the frame member driving device, as shown in FIG. As described above, the frame member 128 is brought into contact with the resin sheets P1 and P2, and the resin sheets P1 and P2 are held by the frame member 128.
- the frame member 128 has an opening 130, and the frame member 128 holds the resin sheets P1 and P2.
- the frame member 128 is moved toward the split mold 32, and as shown in FIG. 5, the resin sheets P1 and P2 are brought into contact with the pinch-off portion 118 of the split mold 32, and the resin sheets P1, P2 and the pinch-off portion are contacted. 118 and the cavity 116 form a sealed space 117.
- the reinforcing material unit 5 (see FIG. 1) held by the suction disk 119 of the manipulator is inserted between the divided molds 32 as shown in FIG.
- the reinforcing material unit 5 shown in FIG. 5 is the reinforcing material unit 5 shown in FIG.
- the position where the reinforcing material unit 5 is held by the suction disk 119 is not particularly limited, and can be held at an arbitrary position.
- a vacuum suction chamber is provided inside the split mold 32B of the present embodiment.
- the vacuum suction chamber communicates with the cavity 116B through a suction hole, and sucks from the vacuum suction chamber through the suction hole.
- the resin sheet P1 is adsorbed toward the cavity 116B, and the resin sheet P1 is shaped into a shape along the outer surface of the cavity 116B.
- ribs 3a are formed on the outer surface of the resin sheet P1 by the protrusions 33 provided on the outer surface of the cavity 116B. Thereby, a plurality of ribs 3a are formed on the resin sheet P1.
- the manipulator is moved toward the divided mold 32B, and as shown in FIG. 7, the reinforcing material unit 5 is pressed against the resin sheet P1 adsorbed by the cavity 116B of the divided mold 32B, and the reinforcing material unit 5 is moved to the resin sheet. Paste to P1. At this time, the reinforcing material unit 5 is attached to the resin sheet P1 so that both ends of the reinforcing material unit 5 are positioned on the contact surface 31 (see FIG. 1) of the back wall 3.
- the resin sheets P1 and P2 of the present embodiment contain a large amount of plate-like fillers in order to improve the rigidity of the resin panel 1. If a resin containing a large amount of filler is used in blow molding, the resin does not stretch well, and it is difficult to form a resin panel 1 having ribs 3a as shown in FIG. In particular, if the filler contains 20% or more in blow molding, it becomes difficult to mold the resin panel 1. On the other hand, in the present embodiment, the molten resin sheets P1 and P2 extruded from the extrusion device 12 using the molding apparatus shown in FIG. 2 are sucked into the cavity 116 surface of the split mold 32, and the resin sheets P1 and P2 are sucked.
- the resin panel 1 is formed by shaping P2 into a shape along the cavity 116. For this reason, the resin panel 1 having the ribs 3a shown in FIG. 1 can be easily formed even if it contains a large amount of filler. When the molding apparatus shown in FIG. 2 is used, a plate-like filler can be contained in a range of 20 to 50%.
- Examples of the plate-like filler used when the resin panel 1 of the present embodiment is molded include talc and mica having a smaller anisotropy than glass fibers.
- the plate-like filler is mixed with the molding resin in an amount of 20 wt% to 50 wt%, preferably 25 to 40 wt%.
- the resin used for the resin sheets P1 and P2 includes a resin that can withstand the drying temperature (about 80 ° C.) in the drying process of the dry blend.
- this type of resin include PP (polypropylene resin) and PE (polyethylene resin).
- PP polypropylene resin
- PE polyethylene resin
- HDPE high density polyethylene
- LLDPE linear low density polyethylene
- the suction platen 119 is detached from the reinforcing material unit 5, the manipulator is pulled out from between the two divided molds 32, and the resin sheet P2 constituting the front wall 2 is pressed against the cavity 116A, as shown in FIG. As shown, the resin sheet P2 is shaped into a shape along the cavity 116A.
- a vacuum suction chamber is also provided inside the split mold 32A of the present embodiment, and the vacuum suction chamber communicates with the cavity 116A through the suction hole and sucks from the vacuum suction chamber through the suction hole. By doing so, the resin sheet P2 is adsorbed toward the cavity 116A, and the resin sheet P2 is shaped into a shape along the outer surface of the cavity 116A.
- the two divided molds 32 are clamped by the mold driving device, and the reinforcing material unit 5 and the rib 3a are pressed against the resin sheet P2 adsorbed in the cavity 116A of the divided mold 32A as shown in FIG. Then, the reinforcing material unit 5 and the rib 3a are attached to the resin sheet P2. Further, the periphery of the two resin sheets P1 and P2 is welded to form a parting line PL.
- the reinforcing material unit 5 when the resin panel 1 in which the reinforcing material unit 5 and the resin sheets P1, P2 are integrated is clamped with the split mold 32, the reinforcing material unit 5 is used with the split mold 32. It is preferable to compress the resin sheets P1 and P2. Thereby, the adhesive strength between the reinforcing material unit 5 and the resin sheets P1 and P2 can be further improved.
- the resin panel 1 formed by sandwiching the reinforcing material unit 5 between the molten resin sheets P1 and P2 is completed.
- the two split molds 32 are opened, the cavity 116 is separated from the completed resin panel 1, and the burrs formed around the parting line PL are removed. This completes the molding of the resin panel 1 shown in FIG.
- the first resin sheet P1 is shaped into a shape along the cavity 116B of the split mold 32B, and the first resin sheet P1 is stretched into a shape along the protruding portion 33. Ribs 3a are formed. Thereby, the rib 3a is formed in the 1st resin sheet P1 which comprises the back wall 3.
- FIG. 6
- the reinforcing material unit 5 is attached to the first resin sheet P1 on which the rib 3a is formed.
- a pair of split molds 32 are clamped to form a first resin sheet P1 constituting the back wall 3, a second resin sheet P2 constituting the front wall 2,
- the edges of the ribs 3a formed on the first resin sheet P1 are welded to the second resin sheet P2.
- the reinforcing material unit 5 is attached to the second resin sheet P2.
- the resin panel 1 of the present embodiment includes a first resin sheet P1 in a molten state mixed with a plate-like filler constituting the back wall 3 that has been extruded from the extrusion device 12 and flowed out, and a plate constituting the front wall 2
- the second resin sheet P2 in a molten state mixed with a filler in the shape of a mold is clamped with a split mold 32 to form a back wall 3, a front wall 2, and a rib 3a.
- the longitudinal direction constitutes the resin panel 1 that is not parallel to the flow direction of the first resin sheet P1 and the second resin sheet P2.
- the resin panel 1 according to one aspect of the present embodiment can reduce the weight and the rigidity of the resin panel 1 and can obtain the resin panel 1 without warping.
- FIG. 11 is a diagram showing the configuration of the resin panel 1 of this example.
- A is an overall perspective view of the resin panel 1 and shows a state in which the back wall 3 is an upper surface.
- (B) is FF 'sectional drawing shown to (a)
- (c) is EE' sectional drawing shown to (a).
- the resin panel 1 shown in FIG. 11 can be molded using the molding apparatus shown in FIG.
- T indicates the flow direction of the resin for molding the resin panel 1
- R indicates the direction orthogonal to the flow direction of the resin.
- R also indicates the longitudinal direction of the rib 3a.
- the resin panel 1 of this embodiment has a front wall 2, a back wall 3, and a peripheral wall 4.
- the front wall 2 and the back wall 3 face each other at a predetermined interval, and the front wall 2 and the back wall 3 Are connected by a peripheral wall 4.
- a hollow portion 6 is provided between the front wall 2 and the back wall 3.
- the resin panel 1 of the present embodiment is configured without using the reinforcing material unit 5 and the decorative member 7 like the resin panel 1 shown in FIG.
- the longitudinal direction of the rib 3a is formed in the direction R perpendicular to the resin flow direction T on the outer surface of the back wall 3.
- a plurality of ribs 3a are formed apart from each other in a direction R perpendicular to the resin flow direction T. Further, the plurality of ribs 3a formed so as to be spaced apart are alternately formed in the resin flow direction T.
- the resin panel 1 of the present embodiment has an outer shape of about 1080 mm ⁇ 510 mm and has a contact surface 31 on the entire circumference.
- Example 1 A resin panel 1 shown in FIG. 11 having a recommended product weight of 3000 g / m 2 was molded using resin sheets P1 and P2 of materials having the following talc composition.
- the resin panel 1 of Example 1 did not warp.
- the resin panel 1 was supported by abutting against other members at a contact surface 31 having an inner dimension of 1000 mm ⁇ 440 mm provided on the entire circumference of the back wall 3 of the resin panel 1 of Example 1. Then, a load of a predetermined weight is applied to the center position of the resin panel 1 shown in FIG. 11 (a) with a ⁇ 60 mm loader under a normal temperature environment (23 ° C. ⁇ 2 ° C.), and the resin panel 1 after a few seconds. The displacement of was measured. Further, it was tested whether the resin panel 1 had a desired rigidity.
- the center position of the resin panel 1 is the position of the intersection where the center in the longitudinal direction of the resin panel 1 and the center in the short direction of the resin panel 1 intersect.
- the resin panel 1 of Example 1 had little deflection. It was also found that the resin panel 1 has a desired rigidity.
- Comparative Example 1 A resin panel shown in FIG. 13 having a recommended product weight of 3000 g / m 2 was molded using resin sheets P1 and P2 of materials having the same talc composition as in Example 1.
- the resin panel shown in FIG. 13 differs from the resin panel 1 shown in FIG. 11 in that the longitudinal direction R of the rib 3a is formed in parallel with the resin flow direction T.
- the longitudinal direction of the rib 3a of Example 1 is merely parallel to the resin flow direction T.
- the resin panel of Comparative Example 1 did not warp.
- the resin panel was supported by abutting against other members at an abutting surface 31 having an inner dimension of 1000 mm ⁇ 440 mm provided on the entire circumference of the back wall 3 of the resin panel of Comparative Example 1.
- a load of a predetermined weight was applied to the center position of the resin panel shown in FIG. 13 with a ⁇ 60 mm loader under a normal temperature environment (23 ° C. ⁇ 2 ° C.), and the displacement of the resin panel after several seconds was measured. .
- the resin panel of Comparative Example 1 had more deflection than Example 1. It was also found that the resin panel does not have the desired rigidity.
- Comparative Example 2 Using a resin sheet P1, P2 of the material below the glass formulation, the recommended weight of the product was molded fender panel shown in FIG. 11 of 3000 g / m 2.
- the talc mixed in the resin sheets P1 and P2 of Example 1 is simply made of short glass fibers. Glass compounding: PP (polypropylene resin) + PE (polyethylene resin) mixed resin mixed with 30% short glass fiber.
- the short glass fiber is a glass fiber having a fiber length of 0.2 to 0.5 mm.
- the resin panel of Comparative Example 2 did not warp.
- the resin panel was supported by abutting against other members at an abutting surface 31 having an inner dimension of 1000 mm ⁇ 440 mm provided on the entire circumference of the back wall 3 of the resin panel of Comparative Example 2.
- a load of a predetermined weight is applied to the central position of the resin panel shown in FIG. 11 (a) with a ⁇ 60 mm load element in a normal temperature environment (23 ° C. ⁇ 2 ° C.), and the displacement of the resin panel after a few seconds. was measured.
- the resin panel of Comparative Example 2 had more deflection than Example 1. It was also found that the resin panel does not have the desired rigidity.
- Comparative Example 3 A resin panel shown in FIG. 13 having a recommended product weight of 3000 g / m 2 was molded using resin sheets P1 and P2 made of the same glass composition as in Comparative Example 2.
- the resin panel shown in FIG. 13 differs from the resin panel 1 shown in FIG. 11 in that the longitudinal direction R of the rib 3a is formed in parallel with the resin flow direction T.
- the longitudinal direction of the rib 3a of Comparative Example 2 is merely parallel to the resin flow direction T.
- the resin panel of Comparative Example 3 was warped.
- the resin panel was supported by abutting against other members at a contact surface 31 having an inner dimension of 1000 mm ⁇ 440 mm provided on the entire circumference of the back wall 3 of the resin panel of Comparative Example 3.
- a load of a predetermined weight was applied to the center position of the resin panel shown in FIG. 13 with a ⁇ 60 mm loader under a normal temperature environment (23 ° C. ⁇ 2 ° C.), and the displacement of the resin panel after several seconds was measured. .
- the resin panel of Comparative Example 3 had more deflection than Example 1. It was also found that the resin panel had the desired rigidity.
- the resin panel of Comparative Example 3 has the desired rigidity because the anisotropic glass fibers are oriented in the resin flow direction T, and the orientation direction of the glass fibers and the longitudinal direction of the ribs 3a are parallel. It is. However, in the case of the resin panel of Comparative Example 3, warpage occurs remarkably, which is not preferable for the product.
- Example 1 and Comparative Examples 1 to 3 are shown in FIG.
- the longitudinal direction of the rib 3a is formed in the direction R orthogonal to the resin flow direction T, as shown in FIG. 11, in the resin sheets P1 and P2 mixed with talc. It has been found that by molding the resin panel 1, the resin panel 1 having a desired rigidity is obtained without warping the resin panel 1.
- FIG. 1 shows a configuration example of the resin panel 1
- FIG. 2 shows a configuration example of a molding apparatus for molding the resin panel 1 shown in FIG. 1
- FIGS. 8 and 9 show molding of the resin panel 1. A part of the process is shown.
- the resin panel 1 of the present embodiment is a resin panel 1 having a back wall 3 and a front wall 2 facing the back wall 3 at a distance.
- the resin panel 1 of the present embodiment includes, for example, a molten resin sheet P1 constituting the back wall 3 extruded from the extrusion device 12 shown in FIG. 2, and a molten resin sheet P2 constituting the front wall 2.
- the back wall 3 and the front wall 2 are configured by clamping with a split mold 32, and the resin sheet P2 is configured with a material having higher impact resistance than the resin sheet P1, and the front wall 2 Is made of a material having higher impact resistance than the back wall 3.
- the molten resin sheet P1 constituting the back wall 3 extruded from the extrusion device 12 and the front wall 2 are constituted.
- the molten resin sheet P2 is suspended between the pair of split molds 32.
- the resin sheet P1 and the resin sheet P2 are sucked into the surface of the cavity 116 of the split mold 32, and the resin sheet P1 and the resin sheet P2 are shaped into a shape along the cavity 116. .
- the split mold 32 is clamped to mold the resin panel 1.
- the resin sheet P2 constituting the front wall 2 is made of a material having higher impact resistance than the resin sheet P1 constituting the back wall 3, so that the weight of the resin panel 1 is reduced.
- the resin panel 1 having improved impact resistance can be obtained.
- FIG. 1 is a diagram showing a configuration example of a resin panel 1
- FIG. 1 (a) is an overall perspective view of the resin panel 1
- FIG. 1 (b) is a resin shown in FIG. 1 (a).
- FIG. 1 (c) is a cross-sectional view of the resin panel 1 shown in FIGS. 1 (a) and 1 (b)
- FIG. 1 (d) is a cross-sectional view of FIG. It is BB 'sectional drawing of the resin panels 1 shown to (a), (b).
- the resin panel 1 of the present embodiment includes a front wall 2, a back wall 3, a peripheral wall 4, and a reinforcing material unit 5 as shown in FIG. 1 (a).
- the resin panel 1 of the present embodiment has a front wall 2 and a back wall 3 facing each other at a predetermined interval. Are connected by a peripheral wall 4. Further, a hollow portion 6 is provided between the front wall 2 and the back wall 3, and the reinforcing material unit 5 is disposed between the front wall 2 and the back wall 3.
- the resin sheet P2 constituting the front wall 2 of the present embodiment is a resin material having higher impact resistance than the resin sheet P1 constituting the back wall 3 in order to withstand strong impact while ensuring rigidity.
- the resin sheet P2 constituting the front wall 2 is, for example, polyethylene resin, polypropylene resin, ethylene-vinyl acetate copolymer, vinyl chloride resin, ABS resin (acrylonitrile-styrene-butadiene resin), polyamide resin, polystyrene resin, polyester resin. , Polycarbonate resin, modified polyphenylene ether resin, or a mixed resin obtained by blending these materials is used.
- the fibrous filler of long fiber means a filler having a fiber length of 3 to 12 mm.
- Examples of this type of filler include long glass fibers having a fiber length of 3 to 12 mm.
- the resin sheet P2 constituting the front wall 2 can also be constituted by using a pulverized material obtained by pulverizing burrs generated when the resin panel 1 is molded.
- the burr may be used by separating the resin sheet P2 constituting the front wall 2 and the resin sheet P1 constituting the back wall 3, but may be used without being separated. When using separately, the burr
- the resin sheet P2 constituting the front wall 2 for example, 30% glass fiber of polypropylene resin + long fiber (fiber length 3 to 12 mm) + 50% of a pulverized material with respect to a virgin material made of elastomer Mixed materials can be mentioned.
- a virgin material it is possible to ensure the inclusion of a filler having a long fiber length.
- the resin sheet P1 constituting the back wall 3 is superior to the resin sheet P2 constituting the front wall 2 in order to obtain the moldability necessary for forming the rib 3a while ensuring rigidity. It is made of resin material.
- the resin sheet P1 constituting the back wall 3 is made of, for example, a fibrous filler having a fiber length shorter than that of the long fiber fibrous filler contained in the resin sheet P2 for the same resin as the resin sheet P2 described above. Use mixed materials. Examples of this type of filler include glass fibers obtained by pulverizing glass fibers having a fiber length of 3 to 12 mm used for the resin sheet P2 to shorten the fiber length, and short glass fibers having a fiber length of 0.2 to 0.5 mm.
- the resin sheet P1 constituting the back wall 3 can also be constituted by using a pulverized material obtained by pulverizing burrs generated when the resin panel 1 is molded.
- the resin sheet P1 includes more pulverized material than the resin sheet P2.
- the burr can be used without separating the resin sheet P2 constituting the front wall 2 and the resin sheet P1 constituting the back wall 3.
- a material suitable as the resin sheet P1 constituting the back wall 3 for example, a material composed only of a pulverized material can be mentioned.
- the fibrous filler of long fibers contained in the resin sheet P2 has a short fiber length in the course of kneading, extruding, and crushing burrs generated after molding in the extrusion apparatus 12 described later.
- the resin sheet P1 is not composed only of a pulverized material, but can also be composed by adding a virgin material composed of polypropylene resin + 30% glass fiber (fiber length 0.2 to 0.5 mm) + elastomer + elastomer. is there.
- the resin panel 1 of the present embodiment can be molded using the molding apparatus shown in FIG. 2 as in the first embodiment.
- the molding apparatus shown in FIG. 2 has an extrusion apparatus 12 and a mold clamping apparatus 14, and sends molten resin sheets P 1 and P 2 extruded from the extrusion apparatus 12 to the mold clamping apparatus 14. Then, the resin sheets P1 and P2 are clamped to form the resin panel 1 shown in FIG.
- the resin sheet P1 constitutes the back wall 3, and the resin sheet P2 constitutes the front wall 2.
- the resin sheet P2 constituting the front wall 2 and the resin sheet P1 constituting the back wall 3 can be mixed with different materials.
- the resin sheet P2 constituting the front wall 2 is made of a material mixed with a fibrous filler of long fibers in order to withstand a strong impact while ensuring rigidity.
- the fibrous filler of long fiber means a filler having a fiber length of 3 to 12 mm. Examples of this type of filler include long glass fibers having a fiber length of 3 to 12 mm.
- the resin sheet P1 constituting the back wall 3 has a longer fiber length than the fibrous filler of the long fibers contained in the resin sheet P1 in order to obtain the moldability necessary to form the rib 3a while ensuring rigidity.
- a material mixed with a short fibrous filler is used. Examples of this type of filler include glass fibers obtained by pulverizing glass fibers having a fiber length of 3 to 12 mm used for the resin sheet P2 to shorten the fiber length, and short glass fibers having a fiber length of 0.2 to 0.5 mm.
- the molten resin sheets P1 and P2 extruded from the extrusion device 12 using the molding apparatus shown in FIG. 2 are sucked into the cavity 116 surface of the split mold 32, and the resin sheets P1 and P2 are sucked.
- the resin panel 1 is formed by shaping P2 into a shape along the cavity 116. For this reason, the resin panel 1 having the ribs 3a shown in FIG. 1 can be easily formed even if it contains a large amount of filler.
- the filler is mixed in an amount of 20 wt% to 50 wt%, preferably 25 to 40 wt%, with respect to the molding resin.
- the fibrous filler is oriented in the extrusion direction of the resin sheets P1 and P2.
- the resin sheet P2 constituting the front wall 2 is, for example, pulverized by pulverizing a virgin material 60% composed of polypropylene resin + long glass fiber 30% + elastomer, and burrs generated when the resin panel 1 is molded. A material composed of 40% material.
- the resin sheet P1 constituting the back wall 3 is, for example, a material composed of 100% pulverized material obtained by pulverizing burrs generated when the resin panel 1 is molded.
- resin sheets P1 and P2 are formed using a pulverized material obtained by pulverizing the burrs.
- the fibers contained in the resin sheets P1 and P2 have a short fiber length in the course of kneading, extrusion, and burr grinding in the extrusion device 12. For this reason, burrs generated when the resin panel 1 is molded can be used as a recycled material. It is not necessary to separate burrs between the resin sheet P2 constituting the front wall 2 and the resin sheet P1 constituting the back wall 3.
- the resin sheet P2 constituting the front wall 2 extruded from the extrusion device 12 is 100
- the resin sheet P1 constituting the back wall 3 is 100.
- 70 out of 100 of the resin sheets P2 constituting the front wall 2 extruded from the extrusion device 12 become burrs.
- 70 out of 100 of the resin sheet P1 constituting the back wall 3 are burrs.
- 60 of the resin sheets P1 and P2 is the resin panel 1 and the remaining 140 is the burr.
- a pulverized material obtained by pulverizing 100 burrs is used for the resin sheet P1 constituting the back wall 3.
- the resin sheet P1 is made of 100% pulverized material, mixing of raw materials becomes unnecessary, and the equipment cost can be reduced. Further, the pulverized material obtained by pulverizing the remaining 40 burrs is used for the resin sheet P2 constituting the front wall 2.
- the remaining 60 of the resin sheet P2 uses a virgin material composed of polypropylene resin + 30% glass fiber (fiber length 3 to 12 mm) + elastomer. By using the virgin material, it is possible to prevent the resin constituting the resin panel 1 from being deteriorated.
- the polypropylene resin constituting the virgin material a polyethylene resin or a mixed resin of a polypropylene resin and a polyethylene resin can be used.
- a pulverized material obtained by pulverizing 90 burrs out of 140 burrs is used for the resin sheet P1 constituting the back wall 3.
- the remaining 10 of the resin sheet P1 uses a virgin material composed of polypropylene resin + short fiber (fiber length 0.2 to 0.5 mm) 30% glass fiber + elastomer.
- the polypropylene resin constituting the virgin material a polyethylene resin or a mixed resin of a polypropylene resin and a polyethylene resin can be used.
- the pulverized material obtained by pulverizing the remaining 50 burrs is used for the resin sheet P2 constituting the front wall 2.
- the remaining 50 of the resin sheet P2 uses a virgin material composed of polypropylene resin + 30% glass fiber (fiber length 3 to 12 mm) + elastomer.
- the amount of fiber added to the resin sheet P2 constituting the front wall 2 and the resin sheet P1 constituting the back wall 3 is made constant regardless of the length of the fiber to constitute the front wall 2. It is also possible for the resin sheet P2 to be made to differ from the resin sheet P1 constituting the back wall 3 only in the average fiber length.
- the first resin sheet P1 is shaped into a shape along the cavity 116B of the split mold 32B, and the first resin sheet P1 is stretched into a shape along the protruding portion 33. Ribs 3a are formed. Thereby, the rib 3a is formed in the 1st resin sheet P1 which comprises the back wall 3.
- FIG. 6
- the reinforcing material unit 5 is attached to the first resin sheet P1 on which the rib 3a is formed.
- a pair of split molds 32 are clamped to form a first resin sheet P1 constituting the back wall 3, a second resin sheet P2 constituting the front wall 2,
- the edges of the ribs 3a formed on the first resin sheet P1 are welded to the second resin sheet P2.
- the reinforcing material unit 5 is attached to the second resin sheet P2.
- the second resin sheet P2 constituting the front wall 2 is made of a material having higher impact resistance than the first resin sheet P1 constituting the back wall 3, and the front wall 2 is made of a material having higher impact resistance than the back wall 3.
- the second resin sheet P2 constituting the front wall 2 includes a long fiber filler, and the first resin sheet P1 constituting the back wall 3 is included in the second resin sheet P2. It comprises a filler having a fiber length shorter than that of the fiber.
- the 2nd resin sheet P2 which comprises the front wall 2 is comprised including the filler of a long fiber
- the 1st resin sheet P1 which comprises the back wall 3 is 2nd resin. It is assumed that the filler includes a filler having a fiber length shorter than that of the long fiber contained in the sheet P2. Thereby, the resin panel 1 in which the resin panel 1 is reduced in weight and impact resistance can be obtained.
- the thickness of the front wall 2 is substantially the same as the thickness of the back wall 3 or is thin.
- the front wall 2 can be made of a material having higher impact resistance than the back wall 3.
- the materials constituting the front wall 2 and the back wall 3 are made different from each other, and the front wall 2 is made of a material having higher impact resistance than the back wall 3. For this reason, the thickness can be reduced and the weight can be reduced as compared with the case where the front wall 2 and the back wall 3 are made of the same material. As a result, it is possible to obtain a resin panel in which the weight of the resin panel is reduced and the impact resistance is improved.
- the front wall 2 includes a filler of long fibers (fiber length 3 to 12 mm), and the back wall 3 has a fiber length shorter than the filler of the long fibers constituting the front wall 2.
- the front wall 2 is made of a material having higher impact resistance than the back wall 3.
- the front wall 2 and the back wall 3 include a filler of short fibers (fiber length 0.2 to 0.5 mm), and the front wall 2 is a filler of short fibers (fiber length 0.2 to 0.5 mm) than the back wall 3.
- the front wall 2 can be made of a material having higher impact resistance than the back wall 3.
- the front wall 2 includes 10% short fiber (fiber length 0.2 to 0.5 mm) filler
- the back wall 3 includes 30% short fiber (fiber length 0.2 to 0.5 mm) filler.
- the elastic force of the front wall 2 is improved, it is possible to obtain a resin panel in which the resin panel is reduced in weight and impact resistance is improved. Further, it is possible to make the impact resistance higher than that of the back wall 3 by using an elastic material for the front wall 2.
- the elastic material include LLDPE (linear low density polyethylene), SEBS (hydrogenated styrene elastomer), and polyethylene elastomer. Also in this case, it is possible to obtain a resin panel in which the weight of the resin panel is reduced and the impact resistance is improved.
- one resin panel 1 has been described as an example. However, for example, it is possible to configure a resin panel in which a first resin panel and a second resin panel are connected via a hinge portion.
- the reinforcing material unit 5 is disposed inside the resin panel 1 by attaching the reinforcing material unit 5 to the molten resin sheets P1 and P2 and clamping the mold.
- the reinforcing material unit 5 can be inserted into the resin panel 1 by inserting the reinforcing material unit 5 from the side surface of the resin panel 1.
- the rectangular reinforcing material unit 5 as shown in FIG. 1 it can be inserted from the side surface of the molded resin panel 1, but is composed of a plurality of reinforcing materials facing different directions.
- the ladder-shaped reinforcing material unit In the case of the shape of a ladder-shaped reinforcing material unit or the like, it is preferable to form the ladder-shaped reinforcing material unit by attaching the ladder-shaped reinforcing material unit to the molten resin sheets P1 and P2, as in the molding method of the embodiment described above.
- the reinforcing material unit 5 is arranged inside the resin panel 1 as shown in FIG. However, as shown in FIG. 11, it is possible not to arrange the reinforcing material unit 5.
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Abstract
Description
裏壁と、前記裏壁と間隔をおいて対向する表壁と、前記裏壁の一部を前記表壁に向けて窪ませて前記表壁の内面に溶着したリブと、を有する樹脂製パネルであって、
押出装置から押し出されて流れ出た前記裏壁を構成する板状のフィラーを混合した溶融状態の第1の溶融樹脂と、前記表壁を構成する板状のフィラーを混合した溶融状態の第2の溶融樹脂と、を分割金型で型締めすることで、前記裏壁と、前記表壁と、前記リブと、を構成し、前記リブの長手方向は、前記第1の溶融樹脂及び前記第2の溶融樹脂の流れ方向と非平行である、ことを特徴とする。
裏壁と、前記裏壁と間隔をおいて対向する表壁と、を有する樹脂製パネルであって、
押出装置から押し出された前記裏壁を構成する溶融状態の第1の溶融樹脂と、前記表壁を構成する溶融状態の第2の溶融樹脂と、を分割金型で型締めすることで、前記裏壁と、前記表壁と、を構成し、前記第2の溶融樹脂は、前記第1の溶融樹脂よりも耐衝撃性の高い材料で構成し、前記表壁は、前記裏壁よりも耐衝撃性の高い材料で構成する、ことを特徴とする。
まず、図1、図2、図8、図9を参照しながら、本発明の一態様にかかる樹脂製パネル1の概要について説明する。図1は、本発明の一態様にかかる樹脂製パネル1の構成例を示し、図2は、図1に示す樹脂製パネル1を成形する成形装置の構成例を示し、図8、図9は、樹脂製パネル1の成形工程の一部を示す。
<樹脂製パネル1の構成例>
まず、図1を参照しながら、本実施形態の樹脂製パネル1の構成例について説明する。図1は、樹脂製パネル1の構成例を示す図であり、図1(a)は、樹脂製パネル1の全体斜視図であり、図1(b)は、図1(a)に示す樹脂製パネル1の上面図であり、図1(c)は、図1(a),(b)に示す樹脂製パネル1のA-A'断面図であり、図1(d)は、図1(a),(b)に示す樹脂製パネル1のB-B'断面図である。
次に、図2~図10を参照しながら、本実施形態の樹脂製パネル1の成形方法例について説明する。図2は、樹脂製パネル1を成形する成形装置の構成例を示し、図3~図10は、樹脂製パネル1を成形する工程例を示す図であり、図2に示す押出装置12のTダイ28側から樹脂シートPと分割金型32とを見た状態を示す。
このように、本実施形態の樹脂製パネル1を成形する場合は、まず、図2に示すように、最終的に成形される図1に示す樹脂製パネル1において、表壁2の肉厚は、裏壁3の肉厚と略同じ、または、薄肉となるように、また、表壁2が裏壁3よりも軽くなるように、表壁2を構成する第2の溶融樹脂シートP2の肉厚を、裏壁3を構成する第1の溶融樹脂シートP1の肉厚よりも薄肉にして押出装置12から押し出す。
次に、上述した樹脂製パネル1に関する具体的な実施例について説明する。但し、以下の実施例は、一例であり、本実施形態の技術思想は、以下の実施例のみに限定されるものではない。
以下のタルク配合の材料の樹脂シートP1,P2を用いて、製品の推奨重量が3000g/m2の図11に示す樹脂製パネル1を成形した。
タルク配合:PP(ポリプロピレン樹脂)+PE(ポリエチレン樹脂)の混合樹脂にタルク30%を混合。
実施例1の樹脂製パネル1の裏壁3の全周に設けられた内寸1000mm×440mmの当接面31で他部材と当接し、樹脂製パネル1を支持した。そして、図11(a)に示す樹脂製パネル1の中心位置に常温環境下(23℃±2℃)でφ60mmの負荷子で所定の重さの加重を負荷し、数秒後の樹脂製パネル1の変位を測定した。また、樹脂製パネル1に所望の剛性があるか試験した。樹脂製パネル1の中心位置は、樹脂製パネル1の長手方向の中央と、樹脂製パネル1の短手方向の中央と、が交わる交点の位置である。実施例1の樹脂製パネル1は、たわみが少なかった。また、樹脂製パネル1に所望の剛性があることが判明した。
実施例1と同様のタルク配合の材料の樹脂シートP1,P2を用いて、製品の推奨重量が3000g/m2の図13に示す樹脂製パネルを成形した。図13に示す樹脂製パネルは、図11に示す樹脂製パネル1と異なり、リブ3aの長手方向Rが樹脂の流れ方向Tと平行に形成されている。比較例1は、実施例1のリブ3aの長手方向の向きを樹脂の流れ方向Tと平行にしただけである。
比較例1の樹脂製パネルの裏壁3の全周に設けられた内寸1000mm×440mmの当接面31で他部材と当接し、樹脂製パネルを支持した。そして、図13に示す樹脂製パネルの中心位置に常温環境下(23℃±2℃)でφ60mmの負荷子で所定の重さの加重を負荷し、数秒後の樹脂製パネルの変位を測定した。また、樹脂製パネルに所望の剛性があるか試験した。比較例1の樹脂製パネルは、実施例1に比べてたわみが多かった。また、樹脂製パネルに所望の剛性がないことが判明した。
以下のガラス配合の材料の樹脂シートP1,P2を用いて、製品の推奨重量が3000g/m2の図11に示す樹脂製パネルを成形した。比較例2は、実施例1の樹脂シートP1,P2に混合するタルクをガラス短繊維にしただけである。
ガラス配合:PP(ポリプロピレン樹脂)+PE(ポリエチレン樹脂)の混合樹脂にガラス短繊維30%を混合。ガラス短繊維は、繊維長0.2~0.5mmのガラス繊維である。
比較例2の樹脂製パネルの裏壁3の全周に設けられた内寸1000mm×440mmの当接面31で他部材と当接し、樹脂製パネルを支持した。そして、図11(a)に示す樹脂製パネルの中心位置に常温環境下(23℃±2℃)でφ60mmの負荷子で所定の重さの加重を負荷し、数秒後の樹脂製パネルの変位を測定した。また、樹脂製パネルに所望の剛性があるか試験した。比較例2の樹脂製パネルは、実施例1に比べてたわみが多かった。また、樹脂製パネルに所望の剛性がないことが判明した。
比較例2と同様のガラス配合の材料の樹脂シートP1,P2を用いて、製品の推奨重量が3000g/m2の図13に示す樹脂製パネルを成形した。図13に示す樹脂製パネルは、図11に示す樹脂製パネル1と異なり、リブ3aの長手方向Rが樹脂の流れ方向Tと平行に形成されている。比較例3は、比較例2のリブ3aの長手方向の向きを樹脂の流れ方向Tと平行にしただけである。
比較例3の樹脂製パネルの裏壁3の全周に設けられた内寸1000mm×440mmの当接面31で他部材と当接し、樹脂製パネルを支持した。そして、図13に示す樹脂製パネルの中心位置に常温環境下(23℃±2℃)でφ60mmの負荷子で所定の重さの加重を負荷し、数秒後の樹脂製パネルの変位を測定した。また、樹脂製パネルに所望の剛性があるか試験した。比較例3の樹脂製パネルは、実施例1に比べてたわみが多かった。また、樹脂製パネルに所望の剛性があることが判明した。比較例3の樹脂製パネルに所望の剛性があるのは、樹脂の流れ方向Tに異方性のあるガラス繊維が配向し、ガラス繊維の配向方向とリブ3aの長手方向とが平行になるためである。但し、この比較例3の樹脂製パネルの場合は、反りが顕著に発生するため、製品には好ましくない。
図12に示す試験結果から明らかなように、タルクを混合した樹脂シートP1,P2で、図11に示すように、リブ3aの長手方向が樹脂の流れ方向Tと直交する方向Rに形成された樹脂製パネル1を成形することで、樹脂製パネル1に反りが発生せず、所望の剛性がある樹脂製パネル1を得ることが判明した。
次に、第2の実施形態について説明する。
まず、図1を参照しながら、本実施形態の樹脂製パネル1の構成例について説明する。図1は、樹脂製パネル1の構成例を示す図であり、図1(a)は、樹脂製パネル1の全体斜視図であり、図1(b)は、図1(a)に示す樹脂製パネル1の上面図であり、図1(c)は、図1(a),(b)に示す樹脂製パネル1のA-A'断面図であり、図1(d)は、図1(a),(b)に示す樹脂製パネル1のB-B'断面図である。
このように、本実施形態の樹脂製パネル1を成形する場合は、まず、図2に示すように、最終的に成形される図1に示す樹脂製パネル1において、表壁2の肉厚は、裏壁3の肉厚と略同じ、または、薄肉となるように、また、表壁2が裏壁3よりも軽くなるように、表壁2を構成する第2の溶融樹脂シートP2の肉厚を、裏壁3を構成する第1の溶融樹脂シートP1の肉厚よりも薄肉にして押出装置12から押し出す。
2 表壁
3 裏壁
3a リブ
3a1 長手部分
3a2 短手部分
31 当接面
4 周囲壁
5 補強材ユニット
6 中空部
7 化粧部材
Claims (14)
- 裏壁と、前記裏壁と間隔をおいて対向する表壁と、前記裏壁の一部を前記表壁に向けて窪ませて前記表壁の内面に溶着したリブと、を有する樹脂製パネルであって、
押出装置から押し出されて流れ出た前記裏壁を構成する板状のフィラーを混合した溶融状態の第1の溶融樹脂と、前記表壁を構成する板状のフィラーを混合した溶融状態の第2の溶融樹脂と、を分割金型で型締めすることで、前記裏壁と、前記表壁と、前記リブと、を構成し、前記リブの長手方向は、前記第1の溶融樹脂及び前記第2の溶融樹脂の流れ方向と非平行である、ことを特徴とする樹脂製パネル。 - 前記板状のフィラーは、タルクである、ことを特徴とする請求項1記載の樹脂製パネル。
- 前記リブの長手方向は、前記流れ方向と直交する方向である、ことを特徴とする請求項1または請求項2記載の樹脂製パネル。
- 前記裏壁は、前記リブの長手方向の延長線上に、他部材と当接する当接面を有する、ことを特徴とする請求項1から請求項3の何れか1項に記載の樹脂製パネル。
- 裏壁と、前記裏壁と間隔をおいて対向する表壁と、を有する樹脂製パネルであって、
押出装置から押し出された前記裏壁を構成する溶融状態の第1の溶融樹脂と、前記表壁を構成する溶融状態の第2の溶融樹脂と、を分割金型で型締めすることで、前記裏壁と、前記表壁と、を構成し、前記第2の溶融樹脂は、前記第1の溶融樹脂よりも耐衝撃性の高い材料で構成し、前記表壁は、前記裏壁よりも耐衝撃性の高い材料で構成する、ことを特徴とする樹脂製パネル。 - 前記第2の溶融樹脂は、長繊維のフィラーを含んで構成し、
前記第1の溶融樹脂は、前記長繊維のフィラーよりも短い繊維長のフィラーを含んで構成する、ことを特徴とする請求項5記載の樹脂製パネル。 - 前記短い繊維長のフィラーは、前記長繊維のフィラーを粉砕したものを含む、ことを特徴とする請求項6記載の樹脂製パネル。
- 前記第1の溶融樹脂は、前記第1の溶融樹脂と、前記第2の溶融樹脂と、を前記分割金型で型締めして得られるバリを粉砕した粉砕材を含んで構成する、ことを特徴とする請求項5から請求項7の何れか1項に記載の樹脂製パネル。
- 前記第1の溶融樹脂は、前記粉砕材を前記第2の溶融樹脂よりも多く含んで構成する、ことを特徴とする請求項8記載の樹脂製パネル。
- 裏壁と、前記裏壁と間隔をおいて対向する表壁と、前記裏壁の一部を前記表壁に向けて窪ませて前記表壁の内面に溶着したリブと、を有する樹脂製パネルを、一対の分割金型を用いて成形する成形方法であって、
押出装置から押し出されて流れ出た前記裏壁を構成する板状のフィラーを混合した溶融状態の第1の溶融樹脂と、前記表壁を構成する板状のフィラーを混合した溶融状態の第2の溶融樹脂と、を一対の分割金型間に垂下させる垂下工程と、
前記第1の溶融樹脂と前記第2の溶融樹脂とを前記分割金型のキャビティ面に吸引し、前記第1の溶融樹脂と前記第2の溶融樹脂とを前記キャビティに沿った形状に賦形する賦形工程と、
前記分割金型を型締めし、前記リブの長手方向が、前記第1の溶融樹脂及び前記第2の溶融樹脂の流れ方向と非平行に形成された前記樹脂製パネルを成形する成形工程と、を有することを特徴とする成形方法。 - 前記板状のフィラーは、タルクである、ことを特徴とする請求項10記載の成形方法。
- 一方の分割金型のキャビティには、他方の分割金型に向かって突出する前記リブを形成するための突出部が設けられており、
前記賦形工程は、前記第1の溶融樹脂を前記突出部に沿った形状に引き伸ばして前記リブを形成する、ことを特徴とする請求項10または請求項11記載の成形方法。 - 裏壁と、前記裏壁と間隔をおいて対向する表壁と、を有する樹脂製パネルを、一対の分割金型を用いて成形する成形方法であって、
押出装置から押し出された前記裏壁を構成する溶融状態の第1の溶融樹脂と、前記表壁を構成する溶融状態の第2の溶融樹脂と、を一対の分割金型間に垂下させる垂下工程と、
前記第1の溶融樹脂と前記第2の溶融樹脂とを前記分割金型のキャビティ面に吸引し、前記第1の溶融樹脂と前記第2の溶融樹脂とを前記キャビティに沿った形状に賦形する賦形工程と、
前記分割金型を型締めし、前記樹脂製パネルを成形する成形工程と、を有し、
前記第2の溶融樹脂は、前記第1の溶融樹脂よりも耐衝撃性の高い材料で構成する、ことを特徴とする成形方法。 - 前記分割金型を型締めして得られるバリを粉砕して粉砕材を形成する粉砕工程を有し、
前記垂下工程は、前記粉砕材を含んだ前記第1の溶融樹脂を前記押出装置から押し出す、ことを特徴とする請求項13記載の成形方法。
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