WO2019004067A1 - Manufacturing method for layered structure, and layered structure - Google Patents

Manufacturing method for layered structure, and layered structure Download PDF

Info

Publication number
WO2019004067A1
WO2019004067A1 PCT/JP2018/023738 JP2018023738W WO2019004067A1 WO 2019004067 A1 WO2019004067 A1 WO 2019004067A1 JP 2018023738 W JP2018023738 W JP 2018023738W WO 2019004067 A1 WO2019004067 A1 WO 2019004067A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin sheet
reinforcing material
molten resin
sheet
resin
Prior art date
Application number
PCT/JP2018/023738
Other languages
French (fr)
Japanese (ja)
Inventor
祥 中島
Original Assignee
キョーラク株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by キョーラク株式会社 filed Critical キョーラク株式会社
Publication of WO2019004067A1 publication Critical patent/WO2019004067A1/en

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements

Definitions

  • the present invention relates to a method of manufacturing a laminated structure and a laminated structure.
  • a laminated structure is obtained by laminating two resin sheets.
  • a rib is formed by causing one resin sheet to protrude to the other resin sheet.
  • a reinforcing material unit is disposed between a front wall and a back wall which are two resin sheets.
  • Cited Reference 1 in the case of forming a resin panel in Cited Reference 1, as shown in FIG. 7 of Cited Reference 1, a reinforcing material unit held by a manipulator is used for a resin sheet adsorbed in a cavity of a mold. It is described to move and press horizontally.
  • the reinforcing material unit of Patent Document 1 is made of metal such as aluminum or hard plastic, and even if the reinforcing material unit of such material is pressed against the molten resin, the adhesion between the reinforcing material unit and the molten resin is It is weak, and the reinforcement unit may fall before the mold clamping of the subsequent mold.
  • the hole may be a cosmetic material sheet etc. after inserting the reinforcing material. It is not good for aesthetics.
  • the present invention has been proposed in view of the problems of the prior art as described above, and when manufacturing a laminated structure in which a reinforcing material is interposed between two resin sheets, the reinforcing material is stable. It is an object of the present invention to make it possible to intervene between resin sheets and to provide a laminated structure.
  • a method of manufacturing a laminated structure according to the present invention is a method of manufacturing a laminated structure in which a reinforcing material intervenes between a first resin sheet and a second resin sheet, Attaching a temporary holding material to the surface on the front side or the back side of the reinforcing material, and a first molten resin sheet between the first divided mold and the second divided mold facing each other
  • a fabric is used, and the
  • the laminated structure of the present invention is a laminated structure in which a reinforcing material intervenes between the first resin sheet and the second resin sheet, and a non-woven fabric intervenes between the reinforcing material and at least one of the resin sheets.
  • the nonwoven fabric has a basis weight of 50 g / m 2 to 300 g / m 2 .
  • the adhesive force between the reinforcing material unit and the molten resin becomes strong.
  • the fabric weight is important, and by setting the fabric weight of the non-woven fabric to 50 g / m 2 to 300 g / m 2 , the reinforcing material is reliably held.
  • the reinforcing material when manufacturing a laminated structure in which a reinforcing material is interposed between two resin sheets, the reinforcing material can be stably interposed between the resin sheets.
  • FIG. 3 is a cross-sectional view taken along lines AA, BB and CC in FIG.
  • FIG. 1 It is a figure which shows the manufacturing method of the resin-made board of embodiment, and shows the insertion process of a reinforcing material.
  • A) is a figure which shows the state in which the reinforcing material is hold
  • (b) is a figure which shows the state which the nonwoven fabric extended and the inclination produced in the reinforcing material.
  • A) is a figure which shows the state which inserted the reinforcement in the direction (lateral direction) orthogonal to the hanging-down direction of a molten resin sheet, (b) is parallel to the hanging-down direction of a molten resin sheet It is a figure which shows the state inserted in a certain direction (vertical direction).
  • FIG. 1 is a perspective view of a resin board 1 according to the present embodiment.
  • FIG. 2 is a plan view of the resin board 1 of the present embodiment.
  • FIG. 3 is a cross-sectional view taken along lines AA, BB and CC of FIG.
  • FIG. 4 is a perspective view of the reinforcing material 3 disposed inside the resin board 1 of the present embodiment.
  • the external shape, the internal shape, and the shape, arrangement, and the like of the reinforcing member 3 of the resin board 1 shown in FIGS. 1 to 4 are exemplary for explaining the method of manufacturing a laminated structure according to the present invention. It is only a thing.
  • the resin board 1 has a front surface FS and a back surface BF, and has a substantially rectangular parallelepiped shape.
  • the resin board 1 has a resin laminate 2 in which a first resin sheet 21 and a second resin sheet 22 are laminated, and a front surface of the first resin sheet 21.
  • a cosmetic material sheet 23 provided on the surface side.
  • the front surface of the cosmetic material sheet 23 constitutes the front surface FS of the resin board 1.
  • a hollow portion H is formed between the first resin sheet 21 and the second resin sheet 22.
  • a parting line PL at the time of molding of the resin is formed. Note that providing the cosmetic material sheet 23 is not essential.
  • the cosmetic material sheet 23 may not be provided.
  • the first resin sheet 21 and the second resin sheet 22 are thermoplastic resins.
  • the resin material is not limited and may be a foamed resin or a non-foamed resin, but in order to secure the rigidity of the resin board 1, it is preferable to be formed from the non-foamed resin. It is preferable to use a resin material with high melt tension from the viewpoint of preventing the occurrence of thickness variation due to draw-down, neck-in, etc. during molding, and on the other hand, the transferability to the mold and the followability are good. Therefore, it is preferable to use a highly fluid resin material.
  • resin materials of the first resin sheet 21 and the second resin sheet 22 include polyolefins such as polypropylene and polyethylene, and acrylic derivatives such as polyamide, polystyrene and polyvinyl chloride, or a mixture of two or more of them. It can be mentioned.
  • the first resin sheet 21 and the second resin sheet 22 may be molded using a resin material mixed with a glass filler in order to increase the rigidity and the strength.
  • a glass filler include glass fibers, glass fiber cloth such as glass cloth and glass nonwoven fabric, glass beads, glass flakes, glass powder, milled glass and the like.
  • the glass include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, quartz, low dielectric constant glass, high dielectric constant glass and the like.
  • glass fillers but also talc, calcium carbonate, wollastonite, inorganic fillers such as magnesium based materials, carbon fibers, etc. may be mixed to increase the rigidity.
  • the cosmetic material sheet 23 is configured for the purpose of improving the appearance or decoration of the resin board 1 or protecting an object that comes in contact with the resin board 1.
  • a fibrous surface material sheet-like surface material, a film-like surface material, or the like is applied as a material of the cosmetic material sheet 23 .
  • the material of the fiber covering material includes synthetic fibers such as polyester, polypropylene, polyamide, polyurethane, acrylic and vinylon, semi-synthetic fibers such as acetate and rayon, regenerated fibers such as viscose rayon and copper ammonia rayon, cotton, hemp, Natural fibers such as wool and silk, or blends of these fibers may be mentioned.
  • rib groups R11 to R16 and R21 to R26 are formed on the resin board 1.
  • the surface on the front side of the second resin sheet 22 protrudes toward the first resin sheet 21, and the ribs of the first resin sheet 21 are formed. It is formed to be welded to the surface on the back side (the surface opposite to the surface on which the cosmetic material sheet 23 is disposed).
  • the elongated reinforcing member 3 is disposed in the hollow portion H between the rib group R11 to R16 and the rib group R21 to R26.
  • the material of the reinforcing material 3 is not particularly limited, in order to secure the strength and rigidity of the resin board 1, it is preferably made of metal such as aluminum or hard plastic.
  • the reinforcing material 3 is formed by, for example, extrusion molding.
  • the reinforcing member 3 is a connecting plate shape connecting the first plate portion 31 and the second plate portion 32 parallel to each other, and the first plate portion 31 and the second plate portion 32. It has a portion 33 and has an H-shaped cross section.
  • the surface facing the first resin sheet 21 in the first plate-like portion 31 is the first surface 311, and the surface facing the second resin sheet 22 in the second plate-like portion 32 is the second surface 321.
  • the reinforcing material 3 is temporarily held by the molten resin sheet by pressing the first surface 311 of the reinforcing material 3 against the molten resin sheet at the time of molding a resin described later.
  • the non-woven fabric 5 is attached to the first surface 311 of the reinforcing material 3.
  • the non-woven fabric 5 include polyethylene, polypropylene, polystyrene, polyester, polyurethane, mixtures of these, and hairs (felt etc.).
  • FIGS. 5 to 12 are views for sequentially explaining the method of manufacturing the resin board of the present embodiment.
  • 6 to 8 and 11 to 12 show the clamping device 140 and the molten resin sheet cut at a position corresponding to the cross section CC in FIG.
  • the cosmetic material sheet 23 is omitted in each of FIGS. 6 to 12.
  • the molding apparatus 100 for a resin molded product has an extrusion device 120 and a mold clamping device 140 disposed below the extrusion device 120.
  • the extrusion device 120 is composed of a two-system extrusion mechanism for molten resin. That is, the extrusion device 120 includes cylinders 18A and 18B to which hoppers 16A and 16B are respectively attached, hydraulic motors 20A and 20B respectively connected to the cylinders 18A and 18B, and accumulators 24A whose insides respectively communicate with the cylinders 18A and 18B. , 24B and plungers 26A, 26B.
  • Plungers 26A and 26B are respectively inserted into accumulators 24A and 24B, and by driving plungers 26A and 26B, plungers 26A and 26B are advanced and retracted within accumulators 24A and 24B, whereby the contents of accumulators 24A and 24B are obtained. Make the product variable.
  • the push-out device 120 is additionally provided with a hydraulic cylinder (not shown) for driving the plungers 26A, 26B.
  • the thermoplastic resin introduced from the hoppers 16A and 16B is melted and kneaded in the cylinders 18A and 18B by the rotation of the screws by the hydraulic motors 20A and 20B, and a molten resin (hereinafter referred to as "molten resin") ) Are transferred to the accumulators 24A and 24B and stored in a fixed amount.
  • molten resin molten resin
  • the molten resin stored in the accumulators 24A and 24B is supplied to the T-die 28 through the valve 27 by the actuation of the plungers 26A and 26B.
  • the plungers 26A and 26B are driven to reduce the internal volume of the accumulators 24A and 24B, and the molten resin stored in the accumulators 24A and 24B is pressurized and fed to the T dies 28A and 28B, thereby making the molten resin To generate an extrusion pressure.
  • the T dies 28A and 28B push the supplied molten resin downward from the extrusion slits as continuous sheet-like molten resin sheets P and P.
  • the extruded molten resin sheets P and P are fed downward while being pressed by a pair of rollers 40AA and 40AB and a pair of rollers 40BA and 40BB which are arranged at an interval, and the divided molds 42A and 42B are obtained. Dropped between.
  • corresponds to the longitudinal direction of FIG.
  • the mold clamping device 140 has divided molds 42A and 42B. Sliding parts 43A and 43B are provided on the split molds 42A and 42B, respectively.
  • the sliding portions 43A and 43B face each other.
  • the sliding portion 43A can slide in a direction perpendicular to the molten resin sheet P (that is, in the horizontal direction), so that relative movement is possible relative to the forming surface 116A (see FIG. 6) of the split mold 42A. It is configured.
  • the sliding portion 43B can slide in a direction (that is, a horizontal direction) orthogonal to the molten resin sheet P, thereby being relative to the forming surface 116B (see FIG. 6) of the split mold 42B. It is configured to be movable.
  • the reinforcing material 3 in which the non-woven fabric 5 is attached to the first surface 311 is prepared.
  • Any adhesive may be used as the adhesive when the non-woven fabric 5 is attached to the reinforcing material 3 as long as the reinforcing material 3 does not fall off from the non-woven fabric 5 by its own weight.
  • the non-woven fabric 5 used as a temporary holding material only needs to exhibit an anchor effect with the molten resin, and thus may be made of a different material from the molten resin sheet as the base material.
  • the non-woven fabric 5 to be used needs to be appropriately set in basis weight, and the basis weight of the non-woven fabric 5 is set to 50 g / m 2 to 300 g / m 2 . If the basis weight of the non-woven fabric 5 is less than 50 g / m 2 , the function as a temporary holding material may be insufficient, and the effect of improving the adhesive strength may not be sufficiently obtained. On the contrary, if the basis weight of the non-woven fabric 5 exceeds 300 g / m 2 , the amount of extension of the non-woven fabric 5 becomes large, which may cause inconveniences such as inclination of the reinforcing material 3 and the like.
  • the non-woven fabric 5 is 0.3 mm to 1.5 mm.
  • the cosmetic material sheet 23 is temporarily fixed so as to cover the formation surface of the divided mold 42A by a temporary fixing pin (not shown) provided on the divided mold 42A. That is, the decorative material sheet 23 is disposed between the split mold 42A and the molten resin sheet P.
  • the molten resin sheets P and P (one example of the first molten resin sheet and the second molten resin sheet, respectively) extruded from the T dies 28A and 28B are divided into molds 42A, 42B (respectively an example of a first split mold, an example of a second split mold).
  • the sliding portions 43A and 43B are moved (slided) in the direction in which the sliding portions 43A and 43B approach each other, thereby bringing the ends of the sliding portions 43A and 43B into contact with the molten resin sheets P and P.
  • a closed space SP1 is formed between the forming surface 116A of the split mold 42A and the molten resin sheet P
  • a closed space SP2 is formed between the forming surface 116B of the split mold 42B and the molten resin sheet P.
  • each of the divided molds 42A and 42B has a built-in vacuum chamber, and a communication path for vacuum suction is provided between the vacuum chamber and the formation surfaces 116A and 116B. Then, the air in the sealed spaces SP1 and SP2 is sucked from the communication passage by the vacuum chamber. By this suction, as shown in FIG. 7, the pair of molten resin sheets P and P are pressed against the forming surfaces 116A and 116B, respectively, and are shaped (shaped) along the forming surfaces 116A and 116B. At this time, the molten resin sheet P on the left side is shaped, and the cosmetic material sheet 23 is pressed together with the molten resin sheet P against the forming surface 116B of the split mold 42B. Thereby, the cosmetic material sheet 23 is welded to the molten resin sheet P.
  • the reinforcing material 3 to which the non-woven fabric 5 is attached is disposed between the split molds 42A and 42B while being held by the manipulator 90. Then, the surface (the first surface 311 in FIG. 4) to which the nonwoven fabric 5 of the reinforcing material 3 is attached is pressed against the molten resin sheet P adsorbed to the forming surface 116B of the split mold 42B. Then, the molten resin enters the fine irregularities on the material surface of the non-woven fabric 5 to increase the adhesion of the reinforcing material 3 to the molten resin sheet P (anchor effect), and the reinforcing material 3 is made by the molten resin sheet P via the non-woven fabric 5.
  • FIG. 9 is a figure which shows the state in which the reinforcing material is normally hold
  • the non-woven fabric 5 having a basis weight of more than 300 g / m 2 is used, as shown in (b) of FIG. If molding is performed while being held in this state, the shape of the corner portion of the reinforcing material 3 is transferred to the molten resin sheet P, which causes the appearance of the laminated structure to be impaired.
  • the reinforcing material 3 is in a direction (lateral direction) perpendicular to the hanging direction of the molten resin sheet P, and FIG. As shown to b), the case where the reinforcement 3 is made into the direction (longitudinal direction) parallel to the hanging-down direction of the molten resin sheet P is considered.
  • a direction (longitudinal direction) parallel to the drooping direction of the molten resin sheet P It is more advantageous to
  • the split molds 42A and 42B are clamped to sandwich the molten resin sheets P and P.
  • a pinch-off portion 118 is provided on the outer periphery of the split molds 42A and 42B so as to surround the forming surfaces 116A and 116B of the split molds 42A and 42B, and a pair of molten resin sheets P, The periphery of P is welded to form a parting line.
  • the split molds 42A and 42B are opened to take out a resin molded product having a hollow portion.
  • the burr formed around the parting line is cut and removed by a cutter or the like.
  • the resin board 1 is completed.
  • the non-woven fabric 5 is attached to the surface of the reinforcing material 3 in contact with the molten resin sheet, and the reinforcing material 3 is melted resin via the non-woven fabric 5 It was made to press on the sheet. Therefore, it is possible to prevent the reinforcing material 3 from being detached from the molten resin sheet at least until after the mold clamping of the divided mold (that is, sandwiching the reinforcing material 3 between the two molten resin sheets). Further, by setting the basis weight of the non-woven fabric 5 in an appropriate range, the reinforcing material 3 does not have an inclination or the like. Therefore, the resin board 1 having the reinforcing material 3 in the hollow portion H between the two resin sheets can be stably manufactured.
  • the cosmetic material sheet 23 is stacked on the front surface of the first resin sheet 21 has been described, but providing the cosmetic material sheet 23 is not essential. That is, the cosmetic material sheet 23 may not be disposed between the split molds 42A and 42B, and the cosmetic material sheet 23 may not be pressed to the forming surface 116A of the split mold 42A together with the molten resin sheet P.
  • the cosmetic material sheet 23 it is assumed that a pressing mark is generated on the front surface of the first resin sheet 21 due to the reinforcing material 3 being pressed by the first resin sheet 21. Also, with the cosmetic material sheet 23, the pressing marks become difficult to see. Therefore, it is preferable to provide the cosmetic material sheet 23 from the aesthetic viewpoint of the resin board 1.
  • FIG. 13 is a partially enlarged view of the vicinity of the reinforcing material 3 in the B-B cross section of FIG.
  • the reinforcing material 3 when the reinforcing material 3 is pressed against the molten resin sheet P, the reinforcing material 3 is strongly pressed to such an extent that the raised portion 211 by the molten resin sheet P is formed on the periphery of the first surface 311 of the first plate-like portion 31 of the reinforcing material 3 It can also be done.
  • the formation of the raised portions 211 at the peripheral edge of the reinforcing material 3 restricts the movement of the reinforcing material 3 in the direction along the surface of the first resin sheet 21. That is, the raised portions 211 function as positioning of the reinforcing material 3 after molding.
  • the raised portions 211 are also formed at both end portions in the longitudinal direction of the reinforcing material 3, it is possible to prevent the reinforcing material 3 from being displaced in the longitudinal direction.
  • the protruding portion 211 is not formed, the first resin sheet 21 and / or the second resin sheet 22 corresponding to the side wall portion of the resin laminate 2 is damaged by movement of the reinforcing material 3 in the longitudinal direction, or Although there is a risk of breakage, the protuberances 211 prevent such a situation.
  • the protruding surface protrudes toward the forming surface of the divided mold 42B on the forming surface 116A of the divided mold 42A.
  • the part may be formed.
  • a BB cross section (a cross section corresponding to FIG. 3B) of the molded resin board is as shown in FIG. That is, the protrusions 221 are formed on the second resin sheet 22 in correspondence with the above-mentioned protruding portions of the forming surface 116A of the split mold 42A.
  • the projections 221 are in contact with the back surface of the reinforcing material 3A of FIG. 14, the plate-like portion of the reinforcing material 3A is formed on the back surface of the resin board (that is, the back surface of the second resin sheet 22). The appearance of the entire trace is prevented.
  • the manufacturing method of the laminated structure of this invention is not limited to the said embodiment, In the range which does not deviate from the main point of this invention, various improvement and change are made. Of course it is also good.
  • the shape of the reinforcing material 3 of the embodiment described above is H-shaped in cross section as shown in FIG. 4, the shape is not limited to such a form, and can be configured in any shape.
  • the reinforcing material may have a polygonal, circular, C-shaped or U-shaped cross section.
  • the reinforcing material may be solid or hollow.
  • the molding method of the resin may be performed by blow molding instead of vacuum molding.
  • blow molding a hole for blow molding is provided in the split mold, and in a state in which the split mold is clamped, molding is performed by pressing the foam parison against the cavity surface of the split mold.
  • compressed gas such as air is blown into the inside of the foam parison from holes for blow molding provided in the split mold, and blow molding is performed under a predetermined blow pressure.
  • molding may be performed by a method of combining blow molding and vacuum molding.
  • the non-woven fabric 5 is attached to the first surface 311 on the front side of the reinforcing material 3 and the first surface 311 is pressed against the molten resin sheet P in FIG.
  • the nonwoven fabric 5 may be attached to the second surface 321 on the back side of the reinforcing material 3, and the second surface 321 may be pressed against the molten resin sheet P on the right side (that is, pressed against the split mold 42A) in FIG.
  • a laminated structure was manufactured according to the above-mentioned manufacturing method.
  • a reinforcing material a square steel reinforcing material of 16 mm ⁇ 16 mm was used.
  • the thickness of steel used for the reinforcing material is 1.2 mm
  • the length of the reinforcing material is 1005 mm
  • the weight of the reinforcing material is 530 g.
  • Three such reinforcements were inserted.
  • the insert direction of the reinforcing material was horizontal and longitudinal.
  • the non-woven fabric used is as shown in Table 1.
  • the material of the non-woven fabric is polyethylene terephthalate (PET).
  • PET polyethylene terephthalate
  • the non-woven fabric having a basis weight of 75 g / m 2 or less is a non-woven fabric consisting of 39% of rayon fibers, 17% of polyester fibers, and 44% of acrylic ester fibers.
  • An acrylic pressure-sensitive adhesive was used as the adhesive, and the coating amount was 45 g / m 2 .
  • the evaluation criteria of "the product” measured the peeling strength of the reinforcing material from the surface which adhered the nonwoven fabric in a product, and evaluated it by the following criteria.
  • “(Circle)” The peeling strength at the time of lifting the edge part of a reinforcement was 30 N or more.
  • "X” Peeling strength when lifting the end of the reinforcing material was less than 30N.

Landscapes

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

Abstract

[Problem] When manufacturing a layered structure in which a reinforcing material is interposed between two resin sheets, to make it possible to stably interpose the reinforcing material between the resin sheets. [Solution] This manufacturing method is for a layered structure in which a reinforcing material is interposed between a first resin sheet and a second resin sheet. The method comprises: a step for attaching a temporary holding material to the front surface or the rear surface of a reinforcing material; a step for extruding a first molten resin sheet and a second molten resin sheet between a first split mold and a second split mold which face each other; a step for pressing the first molten resin sheet to the formation surface of the first split mold, and pressing the second molten resin sheet to the formation surface of the second split mold; a step for pressing the surface of the reinforcing material where the temporary holding member has been attached against the first molten resin sheet, thereby causing the reinforcing material to be held on the first molten resin sheet; and a step for mold clamping the first split mold and the second split mold. The temporary holding material is a nonwoven fabric, and the basis weight of said nonwoven fabric is set to 50 to 300g/m2.

Description

積層構造体の製造方法及び積層構造体Method of manufacturing laminated structure and laminated structure
本発明は、積層構造体の製造方法及び積層構造体に関する。 The present invention relates to a method of manufacturing a laminated structure and a laminated structure.
従来から、樹脂製の積層構造体が、自動車用、建材用、スポーツ・レジャー用等、多用途に用いられてきた。積層構造体は、２枚の樹脂シートを積層させたものである。積層構造体の強度および剛性を確保するため、一方の樹脂シートを他方の樹脂シートに突出させてリブを形成する場合もある。　 Heretofore, resin-made laminated structures have been used for various purposes such as for automobiles, building materials, sports and leisure. A laminated structure is obtained by laminating two resin sheets. In order to ensure the strength and rigidity of the laminated structure, there is also a case where a rib is formed by causing one resin sheet to protrude to the other resin sheet.
積層構造体の剛性および強度をさらに向上させるために、２枚の樹脂シートの間に補強材を介在させることが知られている。例えば引用文献１に記載された積層構造体としての樹脂製パネルでは、２枚の樹脂シートである表壁と裏壁の間に補強材ユニットを配置している。 In order to further improve the rigidity and strength of the laminated structure, it is known to interpose a reinforcing material between two resin sheets. For example, in a resin-made panel as a laminated structure described in Patent Document 1, a reinforcing material unit is disposed between a front wall and a back wall which are two resin sheets.
特開２０１３－１７６９０５号公報JP, 2013-176905, A
ところで、引用文献１には、樹脂製パネルを成形する場合、引用文献１の図７に示すように、金型のキャビティに吸着された樹脂シートに対して、マニピュレータに保持された補強材ユニットを水平方向に移動させて押し付けることが記載されている。　 Incidentally, in the case of forming a resin panel in Cited Reference 1, as shown in FIG. 7 of Cited Reference 1, a reinforcing material unit held by a manipulator is used for a resin sheet adsorbed in a cavity of a mold. It is described to move and press horizontally.
しかし、引用文献１の補強材ユニットはアルミニウム等の金属あるいは硬質プラスチックからなり、このような材料の補強材ユニットを溶融樹脂に押し付けたとしても、補強材ユニットと溶融樹脂との間の接着力が弱く、その後の金型の型締めまでの間に補強材ユニットが落下してしまう場合がある。　 However, the reinforcing material unit of Patent Document 1 is made of metal such as aluminum or hard plastic, and even if the reinforcing material unit of such material is pressed against the molten resin, the adhesion between the reinforcing material unit and the molten resin is It is weak, and the reinforcement unit may fall before the mold clamping of the subsequent mold.
なお、樹脂の成形時に補強材の挿入用の孔を設けておき、樹脂の成形後に当該孔から補強材を挿入することも考えられるが、その場合、補強材の挿入後に孔を化粧材シート等で塞がなければならず、美観上好ましくない。　 It is also conceivable to provide a hole for insertion of the reinforcing material at the time of molding of the resin and insert the reinforcing material from the hole after the molding of the resin, but in that case, the hole may be a cosmetic material sheet etc. after inserting the reinforcing material. It is not good for aesthetics.
本発明は、このような従来技術の有する課題に鑑みて提案されたものであり、２枚の樹脂シートの間に補強材を介在させた積層構造体を製造するときに、補強材を安定的に樹脂シート間に介在させることができるようにすることを目的とし、さらには積層構造体を提供することを目的とする。 The present invention has been proposed in view of the problems of the prior art as described above, and when manufacturing a laminated structure in which a reinforcing material is interposed between two resin sheets, the reinforcing material is stable. It is an object of the present invention to make it possible to intervene between resin sheets and to provide a laminated structure.
前述の目的を達成するために、本発明の積層構造体の製造方法は、第１の樹脂シートと第２の樹脂シートの間に補強材が介在する積層構造体の製造方法であって、前記補強材のおもて側の面または裏側の面に仮保持材を貼り付ける工程と、互いに対向する第１の分割金型と第２の分割金型の間に、第１の溶融樹脂シートと第２の溶融樹脂シートを押し出す工程と、第１の溶融樹脂シートを第１の分割金型の形成面に押圧させ、第２の溶融樹脂シートを第２の分割金型の形成面に押圧させる工程と、前記仮保持材が貼り付けられた前記補強材の面を第１の溶融樹脂シートに押圧させ、それによって前記補強材を第１の溶融樹脂シートに保持させる工程と、第１の分割金型と第２の分割金型の型締めを行う工程とを含み、　前記仮保持材として不織布を用い、当該不織布の目付けを５０ｇ／ｍ２～３００ｇ／ｍ２とすることを特徴とする。　 In order to achieve the above-mentioned object, a method of manufacturing a laminated structure according to the present invention is a method of manufacturing a laminated structure in which a reinforcing material intervenes between a first resin sheet and a second resin sheet, Attaching a temporary holding material to the surface on the front side or the back side of the reinforcing material, and a first molten resin sheet between the first divided mold and the second divided mold facing each other The step of extruding the second molten resin sheet, and pressing the first molten resin sheet against the formation surface of the first divided mold, and pressing the second molten resin sheet against the formation surface of the second divided mold And a step of pressing the surface of the reinforcing member to which the temporary holding member is attached to the first molten resin sheet, thereby holding the reinforcing member on the first molten resin sheet, and a first division. And a step of clamping a second divided mold, wherein the non-woven material is used as the temporary holding material. A fabric is used, and the basis weight of the non-woven fabric is 50 g / m 2 to 300 g / m 2 .
また、本発明の積層構造体は、第１の樹脂シートと第２の樹脂シートの間に補強材が介在する積層構造体であって、補強材と少なくとも一方の樹脂シートの間に不織布が介在され、前記不織布の目付けが５０ｇ／ｍ２～３００ｇ／ｍ２であることを特徴とする。　 The laminated structure of the present invention is a laminated structure in which a reinforcing material intervenes between the first resin sheet and the second resin sheet, and a non-woven fabric intervenes between the reinforcing material and at least one of the resin sheets. And the nonwoven fabric has a basis weight of 50 g / m 2 to 300 g / m 2 .
補強材に仮保持材として不織布を貼り付けて溶融樹脂シートに押し付けると、補強材ユニットと溶融樹脂との間の接着力が強くなる。ここで、使用する不織布について種々検討したところ、仮保持材に用いる不織布として適するものと適さないものがあることがわかってきた。具体的には、仮保持材に用いる不織布においては、目付けが重要であり、当該不織布の目付けを５０ｇ／ｍ２～３００ｇ／ｍ２とすることで、補強材が確実に保持される。 When a non-woven fabric as a temporary holding material is attached to the reinforcing material and pressed against the molten resin sheet, the adhesive force between the reinforcing material unit and the molten resin becomes strong. Here, when various examinations were carried out about the nonwoven fabric to be used, it turned out that there are a thing suitable as a nonwoven fabric used for temporary support material, and a thing unsuitable. Specifically, in the non-woven fabric used as the temporary holding material, the fabric weight is important, and by setting the fabric weight of the non-woven fabric to 50 g / m 2 to 300 g / m 2 , the reinforcing material is reliably held.
本開示によれば、２枚の樹脂シートの間に補強材を介在させた積層構造体を製造するときに、補強材を安定的に樹脂シート間に介在させることができる。 According to the present disclosure, when manufacturing a laminated structure in which a reinforcing material is interposed between two resin sheets, the reinforcing material can be stably interposed between the resin sheets.
実施形態の樹脂製ボードの斜視図である。It is a perspective view of the resin boards of embodiment. 実施形態の樹脂製ボードの平面図である。It is a top view of the resin boards of an embodiment. 図２のＡ－Ａ，Ｂ－Ｂ，Ｃ－Ｃの断面図である。FIG. 3 is a cross-sectional view taken along lines AA, BB and CC in FIG. 実施形態の樹脂製ボードの内部に配置される補強材の斜視図である。It is a perspective view of the reinforcing material arrange | positioned inside the resin board of embodiment. 実施形態の樹脂製ボードの製造方法を示す図であり、成形装置全体の概略構成を示す図である。It is a figure which shows the manufacturing method of the resin-made board of embodiment, and is a figure which shows schematic structure of the whole shaping | molding apparatus. 実施形態の樹脂製ボードの製造方法を示す図であり、樹脂シートを垂下させる工程を示す。It is a figure which shows the manufacturing method of the resin-made board of embodiment, and shows the process of making a resin sheet hang down. 実施形態の樹脂製ボードの製造方法を示す図であり、樹脂シートの賦形工程を示す。It is a figure which shows the manufacturing method of the resin-made board of embodiment, and shows the shaping process of a resin sheet. 実施形態の樹脂製ボードの製造方法を示す図であり、補強材の挿入工程を示す。It is a figure which shows the manufacturing method of the resin-made board of embodiment, and shows the insertion process of a reinforcing material. （ａ）は補強材が正常に保持されている状態を示す図であり、（ｂ）は不織布が伸びて補強材に傾きが生じた状態を示す図である。(A) is a figure which shows the state in which the reinforcing material is hold | maintained normally, (b) is a figure which shows the state which the nonwoven fabric extended and the inclination produced in the reinforcing material. （ａ）は補強材を溶融樹脂シートの垂下方向に対して直交する方向（横方向）にインサートした状態を示す図であり、（ｂ）は補強材を溶融樹脂シートの垂下方向に対して平行な方向（縦方向）にインサートした状態を示す図である。(A) is a figure which shows the state which inserted the reinforcement in the direction (lateral direction) orthogonal to the hanging-down direction of a molten resin sheet, (b) is parallel to the hanging-down direction of a molten resin sheet It is a figure which shows the state inserted in a certain direction (vertical direction). 実施形態の樹脂製ボードの製造方法を示す図であり、型締め工程を示す。It is a figure which shows the manufacturing method of the resin-made board of embodiment, and shows a clamping process. 実施形態の樹脂製ボードの製造方法を示す図であり、型開き工程を示す。It is a figure which shows the manufacturing method of the resin-made board of embodiment, and shows a mold opening process. 実施形態の樹脂製ボードの補強材の近傍を拡大して示す断面図である。It is sectional drawing which expands and shows the vicinity of the reinforcing material of the resin boards of embodiment. 実施形態の変形例に係る樹脂製ボードの断面図である。It is sectional drawing of the resin boards which concern on the modification of embodiment.
以下、本発明の積層構造体の一実施形態である樹脂製ボードとその製造方法について説明する。　 Hereinafter, a resin board which is an embodiment of the laminated structure of the present invention and a method of manufacturing the same will be described.
（１）樹脂製ボードの構成　本実施形態の樹脂製ボード１の構成について、図１～４を参照して説明する。　図１は、本実施形態の樹脂製ボード１の斜視図である。図２は、本実施形態の樹脂製ボード１の平面図である。図３は、図２のＡ－Ａ，Ｂ－Ｂ，Ｃ－Ｃの断面図である。図４は、本実施形態の樹脂製ボード１の内部に配置される補強材３の斜視図である。　なお、図１～４に示す樹脂製ボード１の外観形状、内部の形状、および、補強材３の形状、配置等は、本発明に係る積層構造体の製造方法を説明するための例示的なものに過ぎない。　 (1) Configuration of Resin Board The configuration of the resin board 1 of the present embodiment will be described with reference to FIGS. FIG. 1 is a perspective view of a resin board 1 according to the present embodiment. FIG. 2 is a plan view of the resin board 1 of the present embodiment. FIG. 3 is a cross-sectional view taken along lines AA, BB and CC of FIG. FIG. 4 is a perspective view of the reinforcing material 3 disposed inside the resin board 1 of the present embodiment. The external shape, the internal shape, and the shape, arrangement, and the like of the reinforcing member 3 of the resin board 1 shown in FIGS. 1 to 4 are exemplary for explaining the method of manufacturing a laminated structure according to the present invention. It is only a thing.
図１および図２に示すように、樹脂製ボード１は、おもて面ＦＳと裏面ＢＦとを有し、概ね直方体の形状をなしている。図１に拡大破断図で示すように、樹脂製ボード１は、第１の樹脂シート２１と第２の樹脂シート２２が積層された樹脂積層体２と、第１の樹脂シート２１のおもて面側に設けられた化粧材シート２３とを含む。化粧材シート２３のおもて面は、樹脂製ボード１のおもて面ＦＳを構成する。第１の樹脂シート２１と第２の樹脂シート２２の間には中空部Ｈが形成されている。第１の樹脂シート２１と第２の樹脂シート２２の境界には、樹脂の成形時のパーティングラインＰＬが形成されている。　なお、化粧材シート２３を設けることは必須ではない。化粧材シート２３は設けなくてもよい。　 As shown in FIGS. 1 and 2, the resin board 1 has a front surface FS and a back surface BF, and has a substantially rectangular parallelepiped shape. As shown in the enlarged broken view in FIG. 1, the resin board 1 has a resin laminate 2 in which a first resin sheet 21 and a second resin sheet 22 are laminated, and a front surface of the first resin sheet 21. And a cosmetic material sheet 23 provided on the surface side. The front surface of the cosmetic material sheet 23 constitutes the front surface FS of the resin board 1. A hollow portion H is formed between the first resin sheet 21 and the second resin sheet 22. At the boundary between the first resin sheet 21 and the second resin sheet 22, a parting line PL at the time of molding of the resin is formed. Note that providing the cosmetic material sheet 23 is not essential. The cosmetic material sheet 23 may not be provided.
第１の樹脂シート２１および第２の樹脂シート２２は熱可塑性樹脂である。その樹脂材料を限定せず、発泡樹脂でもよいし、非発泡樹脂でもよいが、樹脂製ボード１の剛性を確保するために非発泡樹脂から形成されることが好ましい。成形時のドローダウン、ネックインなどにより肉厚のバラツキが発生することを防止する観点から溶融張力の高い樹脂材料を用いることが好ましく、一方で金型への転写性、追従性を良好とするため流動性の高い樹脂材料を用いることが好ましい。第１の樹脂シート２１および第２の樹脂シート２２の樹脂材料の例として、ポリプロピレン、ポリエチレン等のポリオレフィンや、ポリアミド、ポリスチレン、ポリ塩化ビニル等のアクリル誘導体のいずれか、又は２種類以上の混合物が挙げられる。　 The first resin sheet 21 and the second resin sheet 22 are thermoplastic resins. The resin material is not limited and may be a foamed resin or a non-foamed resin, but in order to secure the rigidity of the resin board 1, it is preferable to be formed from the non-foamed resin. It is preferable to use a resin material with high melt tension from the viewpoint of preventing the occurrence of thickness variation due to draw-down, neck-in, etc. during molding, and on the other hand, the transferability to the mold and the followability are good. Therefore, it is preferable to use a highly fluid resin material. Examples of resin materials of the first resin sheet 21 and the second resin sheet 22 include polyolefins such as polypropylene and polyethylene, and acrylic derivatives such as polyamide, polystyrene and polyvinyl chloride, or a mixture of two or more of them. It can be mentioned.
第１の樹脂シート２１および第２の樹脂シート２２は、剛性及び強度を増加させる目的で、ガラスフィラーを混入した樹脂材料を用いて成形するようにしてもよい。　ガラスフィラーとしては、ガラス繊維、ガラスクロスやガラス不織布などのガラス繊維布、ガラスビーズ、ガラスフレーク、ガラスパウダー、ミルドガラスなどが挙げられる。ガラスの種類としては、Ｅガラス、Ｃガラス、Ａガラス、Ｓガラス、Ｄガラス、ＮＥガラス、Ｔガラス、クオーツ、低誘電率ガラス、高誘電率ガラスなどが挙げられる。　なお、ガラスフィラーに限らず、剛性を上げるためのタルク、炭酸カルシウム、珪灰石（Wollastonite）、マグネシウム系材料等の無機フィラー、カーボンファイバー等を混入させてもよい。　 The first resin sheet 21 and the second resin sheet 22 may be molded using a resin material mixed with a glass filler in order to increase the rigidity and the strength. Examples of the glass filler include glass fibers, glass fiber cloth such as glass cloth and glass nonwoven fabric, glass beads, glass flakes, glass powder, milled glass and the like. Examples of the glass include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, quartz, low dielectric constant glass, high dielectric constant glass and the like. Not only glass fillers, but also talc, calcium carbonate, wollastonite, inorganic fillers such as magnesium based materials, carbon fibers, etc. may be mixed to increase the rigidity.
化粧材シート２３は、樹脂製ボード１の美観向上若しくは装飾性、又は、樹脂製ボード１と接触する物の保護を目的として構成されるものである。化粧材シート２３の材質は、繊維表皮材シート状表皮材、フィルム状表皮材等が適用される。かかる繊維表皮材の素材としては、ポリエステル、ポリプロピレン、ポリアミド、ポリウレタン、アクリル、ビニロン等の合成繊維、アセテート、レーヨン等の半合成繊維、ビスコースレーヨン、銅アンモニアレーヨン等の再生繊維、綿、麻、羊毛、絹等の天然繊維、又はこれらのブレンド繊維が挙げられる。　 The cosmetic material sheet 23 is configured for the purpose of improving the appearance or decoration of the resin board 1 or protecting an object that comes in contact with the resin board 1. As a material of the cosmetic material sheet 23, a fibrous surface material sheet-like surface material, a film-like surface material, or the like is applied. The material of the fiber covering material includes synthetic fibers such as polyester, polypropylene, polyamide, polyurethane, acrylic and vinylon, semi-synthetic fibers such as acetate and rayon, regenerated fibers such as viscose rayon and copper ammonia rayon, cotton, hemp, Natural fibers such as wool and silk, or blends of these fibers may be mentioned.
図２および図３に示すように、樹脂製ボード１には、リブ群Ｒ１１～Ｒ１６，Ｒ２１～Ｒ２６が形成されている。図３（ａ），（ｂ）に示すように、各リブは、第２の樹脂シート２２のおもて側の面が第１の樹脂シート２１に向かって突出し、第１の樹脂シート２１の裏面側の面（化粧材シート２３が配置されている面とは反対側の面）に溶着するようにして形成されている。　 As shown in FIGS. 2 and 3, rib groups R11 to R16 and R21 to R26 are formed on the resin board 1. As shown in FIGS. 3A and 3B, in each rib, the surface on the front side of the second resin sheet 22 protrudes toward the first resin sheet 21, and the ribs of the first resin sheet 21 are formed. It is formed to be welded to the surface on the back side (the surface opposite to the surface on which the cosmetic material sheet 23 is disposed).
図２および図３（ｃ）に示すように、リブ群Ｒ１１～Ｒ１６とリブ群Ｒ２１～Ｒ２６の間の中空部Ｈには、長尺状の補強材３が配置される。補強材３の材料は特に限定するものではないが、樹脂製ボード１の強度および剛性を確保するために、好ましくはアルミニウムなどの金属製あるいは硬質のプラスチック製である。補強材３は、例えば押出成形によって成形される。　図４に示すように、補強材３は、互いに平行な第１板状部３１と第２板状部３２、および、第１板状部３１と第２板状部３２を連結する連結板状部３３を有し、断面がＨ型の形状をなしている。第１板状部３１において第１の樹脂シート２１と対向する面が第１面３１１であり、第２板状部３２において第２の樹脂シート２２と対向する面が第２面３２１である。　 As shown in FIG. 2 and FIG. 3C, the elongated reinforcing member 3 is disposed in the hollow portion H between the rib group R11 to R16 and the rib group R21 to R26. Although the material of the reinforcing material 3 is not particularly limited, in order to secure the strength and rigidity of the resin board 1, it is preferably made of metal such as aluminum or hard plastic. The reinforcing material 3 is formed by, for example, extrusion molding. As shown in FIG. 4, the reinforcing member 3 is a connecting plate shape connecting the first plate portion 31 and the second plate portion 32 parallel to each other, and the first plate portion 31 and the second plate portion 32. It has a portion 33 and has an H-shaped cross section. The surface facing the first resin sheet 21 in the first plate-like portion 31 is the first surface 311, and the surface facing the second resin sheet 22 in the second plate-like portion 32 is the second surface 321.
本実施形態では、後述する樹脂の成形時において溶融樹脂シートに対して補強材３の第１面３１１を押し付けることで一時的に溶融樹脂シートに補強材３を保持させる。そのときの保持力を確保するために、図４に示すように、補強材３の第１面３１１に不織布５が貼り付けられている。不織布５としては、ポリエチレン、ポリプロピレン、ポリスチレン、ポリエステル、ポリウレタン又はこれらを混合したものや毛類（フェルト等）が挙げられる。　 In the present embodiment, the reinforcing material 3 is temporarily held by the molten resin sheet by pressing the first surface 311 of the reinforcing material 3 against the molten resin sheet at the time of molding a resin described later. In order to ensure the holding power at that time, as shown in FIG. 4, the non-woven fabric 5 is attached to the first surface 311 of the reinforcing material 3. Examples of the non-woven fabric 5 include polyethylene, polypropylene, polystyrene, polyester, polyurethane, mixtures of these, and hairs (felt etc.).
（２）樹脂製ボードの製造方法　次に、本実施形態の樹脂製ボード１の製造方法について、図５～１２を参照して説明する。図５～１２はそれぞれ、本実施形態の樹脂製ボードの製造方法を順に説明するための図である。図６～図８、図１１～図１２は、図２のＣ－Ｃ断面に相当する位置で型締装置１４０および溶融樹脂シートを切断したときの図を示している。なお、図６～１２の各図には、化粧材シート２３は図示を省略している。　 (2) Method of Manufacturing Resin Board Next, a method of manufacturing the resin board 1 of the present embodiment will be described with reference to FIGS. 5 to 12 are views for sequentially explaining the method of manufacturing the resin board of the present embodiment. 6 to 8 and 11 to 12 show the clamping device 140 and the molten resin sheet cut at a position corresponding to the cross section CC in FIG. The cosmetic material sheet 23 is omitted in each of FIGS. 6 to 12.
（２－１）成形装置の構成　図５に示すように、樹脂成形品の成形装置１００は、押出装置１２０と、押出装置１２０の下方に配置された型締装置１４０とを有する。　 (2-1) Configuration of Molding Apparatus As shown in FIG. 5, the molding apparatus 100 for a resin molded product has an extrusion device 120 and a mold clamping device 140 disposed below the extrusion device 120.
図５に示すように、押出装置１２０は、２系統の溶融樹脂の押出機構からなる。すなわち、押出装置１２０は、ホッパ１６Ａ，１６Ｂがそれぞれ付設されたシリンダ１８Ａ，１８Ｂと、シリンダ１８Ａ，１８Ｂにそれぞれ連結された油圧モータ２０Ａ，２０Ｂと、シリ
ンダ１８Ａ，１８Ｂと内部がそれぞれ連通したアキュムレータ２４Ａ，２４Ｂと、プランジャ２６Ａ，２６Ｂとを備える。プランジャ２６Ａ，２６Ｂは、それぞれアキュムレータ２４Ａ，２４Ｂに内挿されており、プランジャ２６Ａ，２６Ｂを駆動することにより、プランジャ２６Ａ，２６Ｂをアキュムレータ２４Ａ，２４Ｂ内で進退させ、それによってアキュムレータ２４Ａ，２４Ｂの内容積を可変とする。押出装置１２０には、プランジャ２６Ａ，２６Ｂを駆動するための油圧シリンダ（図示せず）が付設されている。　 As shown in FIG. 5, the extrusion device 120 is composed of a two-system extrusion mechanism for molten resin. That is, the extrusion device 120 includes cylinders 18A and 18B to which hoppers 16A and 16B are respectively attached, hydraulic motors 20A and 20B respectively connected to the cylinders 18A and 18B, and accumulators 24A whose insides respectively communicate with the cylinders 18A and 18B. , 24B and plungers 26A, 26B. Plungers 26A and 26B are respectively inserted into accumulators 24A and 24B, and by driving plungers 26A and 26B, plungers 26A and 26B are advanced and retracted within accumulators 24A and 24B, whereby the contents of accumulators 24A and 24B are obtained. Make the product variable. The push-out device 120 is additionally provided with a hydraulic cylinder (not shown) for driving the plungers 26A, 26B.
押出装置１２０では、ホッパ１６Ａ，１６Ｂから投入された熱可塑性樹脂が、シリンダ１８Ａ，１８Ｂ内で油圧モータ２０Ａ，２０Ｂによるスクリューの回転により溶融、混練され、溶融状態の樹脂（以下、「溶融樹脂」ともいう。）がアキュムレータ２４Ａ，２４Ｂに移送されて一定量貯留される。アキュムレータ２４Ａ，２４Ｂに貯留された溶融樹脂は、プランジャ２６Ａ，２６Ｂの駆動によりバルブ２７を通してＴダイ２８に供給される。すなわち、プランジャ２６Ａ，２６Ｂを駆動してアキュムレータ２４Ａ，２４Ｂの内容積を小さくして、アキュムレータ２４Ａ，２４Ｂの内部に貯留された溶融樹脂を加圧してＴダイ２８Ａ，２８Ｂに送り込むことで、溶融樹脂への押出圧力を発生させるようにしている。　 In the extrusion device 120, the thermoplastic resin introduced from the hoppers 16A and 16B is melted and kneaded in the cylinders 18A and 18B by the rotation of the screws by the hydraulic motors 20A and 20B, and a molten resin (hereinafter referred to as "molten resin") ) Are transferred to the accumulators 24A and 24B and stored in a fixed amount. The molten resin stored in the accumulators 24A and 24B is supplied to the T-die 28 through the valve 27 by the actuation of the plungers 26A and 26B. That is, the plungers 26A and 26B are driven to reduce the internal volume of the accumulators 24A and 24B, and the molten resin stored in the accumulators 24A and 24B is pressurized and fed to the T dies 28A and 28B, thereby making the molten resin To generate an extrusion pressure.
Ｔダイ２８Ａ，２８Ｂは、供給された溶融樹脂を押出スリットから連続的なシート状の溶融樹脂シートＰ，Ｐとして下方に押し出す。押し出された溶融樹脂シートＰ，Ｐは、間隔を隔てて配置された一対のローラ４０ＡＡ，４０ＡＢおよび一対のローラ４０ＢＡ，４０ＢＢによって挟圧されながら下方に向かって送り出されて分割金型４２Ａ，４２Ｂの間に垂下される。なお、溶融樹脂シートＰ，Ｐの押出方向は、図２の長手方向に対応している。　 The T dies 28A and 28B push the supplied molten resin downward from the extrusion slits as continuous sheet-like molten resin sheets P and P. The extruded molten resin sheets P and P are fed downward while being pressed by a pair of rollers 40AA and 40AB and a pair of rollers 40BA and 40BB which are arranged at an interval, and the divided molds 42A and 42B are obtained. Dropped between. In addition, the extrusion direction of molten resin sheet P, P respond | corresponds to the longitudinal direction of FIG.
型締装置１４０は、分割金型４２Ａ，４２Ｂを有する。分割金型４２Ａ，４２Ｂには、それぞれ摺動部４３Ａ，４３Ｂが設けられている。摺動部４３Ａ，４３Ｂは互いに対向している。摺動部４３Ａは溶融樹脂シートＰに対して直交する方向（つまり、水平方向）に摺動可能であり、それによって分割金型４２Ａの形成面１１６Ａ（図６参照）に対して相対移動可能に構成されている。同様に、摺動部４３Ｂは溶融樹脂シートＰに対して直交する方向（つまり、水平方向）に摺動可能であり、それによって分割金型４２Ｂの形成面１１６Ｂ（図６参照）に対して相対移動可能に構成されている。　 The mold clamping device 140 has divided molds 42A and 42B. Sliding parts 43A and 43B are provided on the split molds 42A and 42B, respectively. The sliding portions 43A and 43B face each other. The sliding portion 43A can slide in a direction perpendicular to the molten resin sheet P (that is, in the horizontal direction), so that relative movement is possible relative to the forming surface 116A (see FIG. 6) of the split mold 42A. It is configured. Similarly, the sliding portion 43B can slide in a direction (that is, a horizontal direction) orthogonal to the molten resin sheet P, thereby being relative to the forming surface 116B (see FIG. 6) of the split mold 42B. It is configured to be movable.
（２－２）樹脂製ボードの製造方法　以下、上述した成形装置１００を用いて樹脂製ボード１を製造する方法について説明する。　 (2-2) Method of Manufacturing Resin Board Hereinafter, a method of manufacturing the resin board 1 using the above-described molding apparatus 100 will be described.
先ず、図４に示したように、第１面３１１に不織布５を貼り付けた補強材３を用意する。不織布５を補強材３に貼り付けるときの接着剤は、補強材３が自重で不織布５から脱落しない程度の接着力があれば如何なるものでもよい。仮保持材とし使用する不織布５は、溶融樹脂との間でアンカー効果を発揮すればよいので、基材である溶融樹脂シートと異材質であってよい。　 First, as shown in FIG. 4, the reinforcing material 3 in which the non-woven fabric 5 is attached to the first surface 311 is prepared. Any adhesive may be used as the adhesive when the non-woven fabric 5 is attached to the reinforcing material 3 as long as the reinforcing material 3 does not fall off from the non-woven fabric 5 by its own weight. The non-woven fabric 5 used as a temporary holding material only needs to exhibit an anchor effect with the molten resin, and thus may be made of a different material from the molten resin sheet as the base material.
ただし、使用する不織布５は、目付けを適正に設定する必要があり、当該不織布５の目付けを５０ｇ／ｍ２～３００ｇ／ｍ２とする。不織布５の目付けが５０ｇ／ｍ２未満であると、仮保持材としての機能が不足し、接着力向上の効果が十分に得られないおそれがある。逆に、不織布５の目付けが３００ｇ／ｍ２を越えると、不織布５の伸び量が大きくなって、補強材３に傾きが生ずる等の不都合が発生するおそれがあり、外観を損なう原因となる。好ましくは７５ｇ／ｍ２～３００ｇ／ｍ２であり、より好ましくは７５ｇ／ｍ２～１５０ｇ／ｍ２である。目付けを７５ｇ／ｍ２～１５０ｇ／ｍ２とすることで、補強材のインサート方向によらず、確実に保持することが可能となり、製品の品質も優れたものとなる。なお、不織布５の厚さの最適値としては、０．３ｍｍ～１．５ｍｍである。　 However, the non-woven fabric 5 to be used needs to be appropriately set in basis weight, and the basis weight of the non-woven fabric 5 is set to 50 g / m 2 to 300 g / m 2 . If the basis weight of the non-woven fabric 5 is less than 50 g / m 2 , the function as a temporary holding material may be insufficient, and the effect of improving the adhesive strength may not be sufficiently obtained. On the contrary, if the basis weight of the non-woven fabric 5 exceeds 300 g / m 2 , the amount of extension of the non-woven fabric 5 becomes large, which may cause inconveniences such as inclination of the reinforcing material 3 and the like. Preferably, it is 75 g / m 2 to 300 g / m 2 , more preferably 75 g / m 2 to 150 g / m 2 . By setting the basis weight to 75 g / m 2 to 150 g / m 2 , it becomes possible to reliably hold the reinforcing material regardless of the insertion direction of the reinforcing material, and the product quality becomes excellent. The optimum thickness of the non-woven fabric 5 is 0.3 mm to 1.5 mm.
次に、化粧材シート２３を分割金型４２Ａに設けた仮止めピン（図示せず）により、分割金型４２Ａの形成面を覆うように仮止めする。つまり、分割金型４２Ａと溶融樹脂シートＰの間に化粧材シート２３を配置させる。　 Next, the cosmetic material sheet 23 is temporarily fixed so as to cover the formation surface of the divided mold 42A by a temporary fixing pin (not shown) provided on the divided mold 42A. That is, the decorative material sheet 23 is disposed between the split mold 42A and the molten resin sheet P.
次に、図５に示したように、Ｔダイ２８Ａ，２８Ｂから押し出した溶融樹脂シートＰ，Ｐ（それぞれ、第１の溶融樹脂シート、第２の溶融樹脂シートの一例）を分割金型４２Ａ，４２Ｂ（それぞれ、第１の分割金型、第２の分割金型の一例）の間に垂下させる。　 Next, as shown in FIG. 5, the molten resin sheets P and P (one example of the first molten resin sheet and the second molten resin sheet, respectively) extruded from the T dies 28A and 28B are divided into molds 42A, 42B (respectively an example of a first split mold, an example of a second split mold).
その後、図６に示すように、摺動部４３Ａ，４３Ｂを互いに近接する方向に移動（スライド）させることで、摺動部４３Ａ，４３Ｂの先端を溶融樹脂シートＰ，Ｐに接触させる。それによって、分割金型４２Ａの形成面１１６Ａと溶融樹脂シートＰの間に密閉空間ＳＰ１が形成され、分割金型４２Ｂの形成面１１６Ｂと溶融樹脂シートＰの間に密閉空間ＳＰ２が形成される。　 Thereafter, as shown in FIG. 6, the sliding portions 43A and 43B are moved (slided) in the direction in which the sliding portions 43A and 43B approach each other, thereby bringing the ends of the sliding portions 43A and 43B into contact with the molten resin sheets P and P. As a result, a closed space SP1 is formed between the forming surface 116A of the split mold 42A and the molten resin sheet P, and a closed space SP2 is formed between the forming surface 116B of the split mold 42B and the molten resin sheet P.
図示しないが、分割金型４２Ａ，４２Ｂにはそれぞれ真空チャンバが内蔵され、当該真空チャンバと形成面１１６Ａ，１１６Ｂの間には真空吸引のための連通路が設けられている。そして、真空チャンバによって連通路から密閉空間ＳＰ１，ＳＰ２内の空気を吸引する。この吸引により、図７に示すように、一対の溶融樹脂シートＰ，Ｐがそれぞれ形成面１１６Ａ，１１６Ｂに押圧させられ、形成面１１６Ａ，１１６Ｂに沿った形状に成形（賦形）される。　このとき、左側の溶融樹脂シートＰについては賦形されるとともに、化粧材シート２３を溶融樹脂シートＰとともに分割金型４２Ｂの形成面１１６Ｂに押圧させる。それによって、化粧材シート２３が溶融樹脂シートＰに溶着する。　 Although not shown, each of the divided molds 42A and 42B has a built-in vacuum chamber, and a communication path for vacuum suction is provided between the vacuum chamber and the formation surfaces 116A and 116B. Then, the air in the sealed spaces SP1 and SP2 is sucked from the communication passage by the vacuum chamber. By this suction, as shown in FIG. 7, the pair of molten resin sheets P and P are pressed against the forming surfaces 116A and 116B, respectively, and are shaped (shaped) along the forming surfaces 116A and 116B. At this time, the molten resin sheet P on the left side is shaped, and the cosmetic material sheet 23 is pressed together with the molten resin sheet P against the forming surface 116B of the split mold 42B. Thereby, the cosmetic material sheet 23 is welded to the molten resin sheet P.
次いで、図８に示すように、不織布５を貼り付けた補強材３を、マニピュレータ９０によって保持された状態で分割金型４２Ａ，４２Ｂの間に配置させる。そして、補強材３の不織布５を貼り付けた面（図４の第１面３１１）を、分割金型４２Ｂの形成面１１６Ｂに吸着された溶融樹脂シートＰに押圧させる。すると、不織布５の材料表面の微細な凹凸に溶融樹脂が入り込むことで補強材３の溶融樹脂シートＰに対する接着力が高まり（アンカー効果）、溶融樹脂シートＰによって不織布５を介して補強材３が保持された状態となる。この状態では、マニピュレータ９０による補強材３の保持を解除しても、少なくとも分割金型４２Ａ，４２Ｂの型締めを行うまでの短い期間内では、補強材３が溶融樹脂シートＰから離脱して落下することはない。　 Next, as shown in FIG. 8, the reinforcing material 3 to which the non-woven fabric 5 is attached is disposed between the split molds 42A and 42B while being held by the manipulator 90. Then, the surface (the first surface 311 in FIG. 4) to which the nonwoven fabric 5 of the reinforcing material 3 is attached is pressed against the molten resin sheet P adsorbed to the forming surface 116B of the split mold 42B. Then, the molten resin enters the fine irregularities on the material surface of the non-woven fabric 5 to increase the adhesion of the reinforcing material 3 to the molten resin sheet P (anchor effect), and the reinforcing material 3 is made by the molten resin sheet P via the non-woven fabric 5. It will be in the held state. In this state, even if the holding of the reinforcing material 3 by the manipulator 90 is released, the reinforcing material 3 separates from the molten resin sheet P and falls at least within a short period of time until clamping of the split molds 42A and 42B is performed. There is nothing to do.
特に、不織布５として目付けが５０ｇ／ｍ２～３００ｇ／ｍ２の不織布を用いているので、補強材３が傾くなどの障害が発生することもない。図９の（ａ）は、補強材が正常に保持されている状態を示す図であり、不織布５の目付けを前記適正範囲とすることで、図９（ａ）に示すような正常な保持状態が実現される。これに対し、例えば目付けが３００ｇ／ｍ２を越える不織布５を用いると、図９の（ｂ）に示すように、不織布５が伸びて補強材３に傾きが生ずる。この状態で保持されたまま成形を行うと、補強材３の角部の形状が溶融樹脂シートＰに転写される等、積層構造体の外観を損なう原因となる。　 In particular, since a non-woven fabric having a basis weight of 50 g / m 2 to 300 g / m 2 is used as the non-woven fabric 5, no trouble such as tilting of the reinforcing material 3 occurs. (A) of FIG. 9 is a figure which shows the state in which the reinforcing material is normally hold | maintained, and by making the fabric weight of the nonwoven fabric 5 into the said appropriate range, the normal holding state as shown to FIG. 9 (a) Is realized. On the other hand, when, for example, the non-woven fabric 5 having a basis weight of more than 300 g / m 2 is used, as shown in (b) of FIG. If molding is performed while being held in this state, the shape of the corner portion of the reinforcing material 3 is transferred to the molten resin sheet P, which causes the appearance of the laminated structure to be impaired.
また、補強材３のインサート方向としては、図１０（ａ）に示すように、補強材３を溶融樹脂シートＰの垂下方向に対して直交する方向（横方向）とする場合と、図１０（ｂ）に示すように、補強材３を溶融樹脂シートＰの垂下方向に対して平行な方向（縦方向）とする場合が考えられる。ここで、不織布５の伸び量が補強材３の傾きや落下に及ぼす影響を考慮すると、図１０（ｂ）に示すように、溶融樹脂シートＰの垂下方向に対して平行な方向（縦方向）とする方が有利である。　 Further, as the insert direction of the reinforcing material 3, as shown in FIG. 10A, the reinforcing material 3 is in a direction (lateral direction) perpendicular to the hanging direction of the molten resin sheet P, and FIG. As shown to b), the case where the reinforcement 3 is made into the direction (longitudinal direction) parallel to the hanging-down direction of the molten resin sheet P is considered. Here, in consideration of the influence of the amount of elongation of the non-woven fabric 5 on the inclination and fall of the reinforcing material 3, as shown in FIG. 10B, a direction (longitudinal direction) parallel to the drooping direction of the molten resin sheet P It is more advantageous to
次に、図１１に示すように、分割金型４２Ａ，４２Ｂの型締めを行って、溶融樹脂シートＰ，Ｐを挟み込む。分割金型４２Ａ，４２Ｂの外周には、分割金型４２Ａ，４２Ｂの形成面１１６Ａ，１１６Ｂを取り囲むようにピンチオフ部１１８が設けられており、型締めによりピンチオフ部１１８において一対の溶融樹脂シートＰ，Ｐの周縁が溶着させられ、パーティングラインが形成される。　 Next, as shown in FIG. 11, the split molds 42A and 42B are clamped to sandwich the molten resin sheets P and P. A pinch-off portion 118 is provided on the outer periphery of the split molds 42A and 42B so as to surround the forming surfaces 116A and 116B of the split molds 42A and 42B, and a pair of molten resin sheets P, The periphery of P is welded to form a parting line.
次に、図１２に示すように、分割金型４２Ａ，４２Ｂを開型して中空部を有する樹脂成形品を取り出す。パーティングラインまわりに形成されたバリを、カッター等で切断して除去する。以上で、樹脂製ボード１が完成する。　 Next, as shown in FIG. 12, the split molds 42A and 42B are opened to take out a resin molded product having a hollow portion. The burr formed around the parting line is cut and removed by a cutter or the like. Thus, the resin board 1 is completed.
以上説明したように、本実施形態の樹脂製ボード１の製造方法によれば、補強材３の溶融樹脂シートと接触する面に不織布５を貼り付け、不織布５を介して補強材３を溶融樹脂シートに押圧させるようにした。そのため、少なくとも後の分割金型の型締め（つまり、補強材３を２枚の溶融樹脂シートで挟み込む）までの間、補強材３が溶融樹脂シートから離脱することを防止できる。また、不織布５の目付けを適正範囲とすることで、補強材３に傾き等が生ずることもない。従って、２枚の樹脂シートの間の中空部Ｈに補強材３を有する樹脂製ボード１を安定的に製造することができる。　 As explained above, according to the method of manufacturing the resin board 1 of this embodiment, the non-woven fabric 5 is attached to the surface of the reinforcing material 3 in contact with the molten resin sheet, and the reinforcing material 3 is melted resin via the non-woven fabric 5 It was made to press on the sheet. Therefore, it is possible to prevent the reinforcing material 3 from being detached from the molten resin sheet at least until after the mold clamping of the divided mold (that is, sandwiching the reinforcing material 3 between the two molten resin sheets). Further, by setting the basis weight of the non-woven fabric 5 in an appropriate range, the reinforcing material 3 does not have an inclination or the like. Therefore, the resin board 1 having the reinforcing material 3 in the hollow portion H between the two resin sheets can be stably manufactured.
上述した実施形態では、第１の樹脂シート２１のおもて面に化粧材シート２３を重ねた場合を説明したが、化粧材シート２３を設けることは必須ではない。すなわち、分割金型４２Ａ，４２Ｂの間に化粧材シート２３を配置させ、当該化粧材シート２３を溶融樹脂シートＰとともに分割金型４２Ａの形成面１１６Ａに押圧させなくてもよい。しかし、化粧材シート２３を設けることで、補強材３が第１の樹脂シート２１に押圧されたことに起因して第１の樹脂シート２１のおもて側の面に押圧痕が生じたとしても、化粧材シート２３によってその押圧痕が見え難くなる。そのため、樹脂製ボード１の美観上の観点から化粧材シート２３を設けることが好ましい。　 In the embodiment described above, the case where the cosmetic material sheet 23 is stacked on the front surface of the first resin sheet 21 has been described, but providing the cosmetic material sheet 23 is not essential. That is, the cosmetic material sheet 23 may not be disposed between the split molds 42A and 42B, and the cosmetic material sheet 23 may not be pressed to the forming surface 116A of the split mold 42A together with the molten resin sheet P. However, by providing the cosmetic material sheet 23, it is assumed that a pressing mark is generated on the front surface of the first resin sheet 21 due to the reinforcing material 3 being pressed by the first resin sheet 21. Also, with the cosmetic material sheet 23, the pressing marks become difficult to see. Therefore, it is preferable to provide the cosmetic material sheet 23 from the aesthetic viewpoint of the resin board 1.
上述した実施形態において、補強材３の不織布５を貼り付けた面を、分割金型４２Ｂの形成面１１６Ｂに吸着された溶融樹脂シートＰに押圧させるときには、当該溶融樹脂シートＰに対応する第１の樹脂シート２１に***部が形成される程度に強く行うこともできる。それによって、図１３に示すように、補強材３の第１板状部３１の第１面３１１の周縁に***部２１１を形成することができる。図１３は、図３のＢ－Ｂ断面の補強材３近傍の部分拡大図である。すなわち、補強材３を溶融樹脂シートＰに押圧するときには、補強材３の第１板状部３１の第１面３１１の周縁に溶融樹脂シートＰによる***部２１１が形成される程度に強く押圧することもできる。補強材３の周縁に***部２１１が形成されることで、補強材３の第１の樹脂シート２１の面に沿った方向の移動が規制される。つまり、***部２１１は、成形後の補強材３の位置決めとして機能する。　 In the embodiment described above, when the surface to which the nonwoven fabric 5 of the reinforcing material 3 is attached is pressed against the molten resin sheet P adsorbed to the forming surface 116B of the split mold 42B, the first corresponding to the molten resin sheet P The resin sheet 21 can be made as strong as the ridges are formed. As a result, as shown in FIG. 13, the raised portion 211 can be formed on the periphery of the first surface 311 of the first plate-like portion 31 of the reinforcing material 3. FIG. 13 is a partially enlarged view of the vicinity of the reinforcing material 3 in the B-B cross section of FIG. That is, when the reinforcing material 3 is pressed against the molten resin sheet P, the reinforcing material 3 is strongly pressed to such an extent that the raised portion 211 by the molten resin sheet P is formed on the periphery of the first surface 311 of the first plate-like portion 31 of the reinforcing material 3 It can also be done. The formation of the raised portions 211 at the peripheral edge of the reinforcing material 3 restricts the movement of the reinforcing material 3 in the direction along the surface of the first resin sheet 21. That is, the raised portions 211 function as positioning of the reinforcing material 3 after molding.
また、補強材３の長手方向の両端部においても***部２１１が形成されるため、補強材３がその長手方向にずれることが防止される。***部２１１が形成されない場合には、補強材３の長手方向の移動により、樹脂積層体２の側壁部分に相当する第１の樹脂シート２１および／または第２の樹脂シート２２が傷付き、あるいは破損する虞があるが、***部２１１によりそのような状況が防止される。　 Further, since the raised portions 211 are also formed at both end portions in the longitudinal direction of the reinforcing material 3, it is possible to prevent the reinforcing material 3 from being displaced in the longitudinal direction. When the protruding portion 211 is not formed, the first resin sheet 21 and / or the second resin sheet 22 corresponding to the side wall portion of the resin laminate 2 is damaged by movement of the reinforcing material 3 in the longitudinal direction, or Although there is a risk of breakage, the protuberances 211 prevent such a situation.
本実施形態の変形例において、分割金型４２Ａの形成面１１６Ａには、不織布５が貼り付けられた補強材３の面に対向する領域において、分割金型４２Ｂの形成面に向けて突出する突出部が形成されていてもよい。このような突出部を設けることで、成形された樹脂製ボードのＢ－Ｂ断面（図３（ｂ）に相当する断面）は、図１４に示すようなものになる。つまり、分割金型４２Ａの形成面１１６Ａの上記突出部に対応して、第２の樹脂シート２２には突起２２１が形成される。この場合、図１４の補強材３Ａの裏側の面に突起２２１が接触することになるため、樹脂製ボードの裏面（つまり、第２の樹脂シート２２の裏面）に、補強材３Ａの板状部全体の痕跡が現れることが防止される。　 In the modified example of the present embodiment, in the area opposite to the surface of the reinforcing material 3 to which the non-woven fabric 5 is attached, the protruding surface protrudes toward the forming surface of the divided mold 42B on the forming surface 116A of the divided mold 42A. The part may be formed. By providing such a projecting portion, a BB cross section (a cross section corresponding to FIG. 3B) of the molded resin board is as shown in FIG. That is, the protrusions 221 are formed on the second resin sheet 22 in correspondence with the above-mentioned protruding portions of the forming surface 116A of the split mold 42A. In this case, since the projections 221 are in contact with the back surface of the reinforcing material 3A of FIG. 14, the plate-like portion of the reinforcing material 3A is formed on the back surface of the resin board (that is, the back surface of the second resin sheet 22). The appearance of the entire trace is prevented.
以上、本発明の実施形態について詳細に説明したが、本発明の積層構造体の製造方法は上
記実施形態に限定されず、本発明の主旨を逸脱しない範囲において、種々の改良や変更をしてもよいのは勿論である。　 As mentioned above, although embodiment of this invention was described in detail, the manufacturing method of the laminated structure of this invention is not limited to the said embodiment, In the range which does not deviate from the main point of this invention, various improvement and change are made. Of course it is also good.
例えば、上述した実施形態の補強材３の形状は、図４に示したように断面がＨ型のものであるが、このような形態に限られず、任意の形状で構成することができる。例えば、断面が多角形、円形、Ｃ型、Ｕ字型の補強材であってもよい。また、補強材は、中実であっても中空であってもよい。　 For example, although the shape of the reinforcing material 3 of the embodiment described above is H-shaped in cross section as shown in FIG. 4, the shape is not limited to such a form, and can be configured in any shape. For example, the reinforcing material may have a polygonal, circular, C-shaped or U-shaped cross section. Also, the reinforcing material may be solid or hollow.
上述した実施形態において、樹脂の成形方法を、真空成形に代えてブロー成形によって行ってもよい。ブロー成形を行う場合、分割金型には、ブロー成形用の孔が設けられており、分割金型を型締めした状態で、発泡パリソンを分割金型のキャビティ面に押し付けることで賦形する。具体的には、分割金型に設けられたブロー成形用の孔から空気等の圧縮気体を発泡パリソンの内部に吹き込み、所定のブロー圧にてブロー成形を行う。また、ブロー成形と真空成形とを組み合わせる方法で成形を行ってもよい。　 In the embodiment described above, the molding method of the resin may be performed by blow molding instead of vacuum molding. When blow molding is performed, a hole for blow molding is provided in the split mold, and in a state in which the split mold is clamped, molding is performed by pressing the foam parison against the cavity surface of the split mold. Specifically, compressed gas such as air is blown into the inside of the foam parison from holes for blow molding provided in the split mold, and blow molding is performed under a predetermined blow pressure. In addition, molding may be performed by a method of combining blow molding and vacuum molding.
上述した実施形態では、図４に示したように補強材３のおもて側の第１面３１１に不織布５を貼り付け、図８において第１面３１１を溶融樹脂シートＰに押し付ける場合について説明したが、この限りではない。補強材３の裏側の第２面３２１に不織布５を貼り付け、図８において第２面３２１を右側の（つまり、分割金型４２Ａに押圧されている）溶融樹脂シートＰに押し付けてもよい。 In the embodiment described above, as shown in FIG. 4, the case where the non-woven fabric 5 is attached to the first surface 311 on the front side of the reinforcing material 3 and the first surface 311 is pressed against the molten resin sheet P in FIG. However, this is not the case. The nonwoven fabric 5 may be attached to the second surface 321 on the back side of the reinforcing material 3, and the second surface 321 may be pressed against the molten resin sheet P on the right side (that is, pressed against the split mold 42A) in FIG.
次に、本発明の具体的な実施例について、実験結果に基づいて説明する。　 Next, specific examples of the present invention will be described based on experimental results.
積層構造体の試作　前述の製造方法に従って積層構造体を作製した。補強材としては、１６ｍｍ×１６ｍｍの角型のスチール製補強材を使用した。補強材に使用したスチールの厚さは１．２ｍｍ、補強材の長さは１００５ｍｍ、補強材の重さは５３０ｇである。係る補強材を３本インサートした。補強材のインサート方向は、横方向及び縦方向とした。　 Trial manufacture of laminated structure A laminated structure was manufactured according to the above-mentioned manufacturing method. As a reinforcing material, a square steel reinforcing material of 16 mm × 16 mm was used. The thickness of steel used for the reinforcing material is 1.2 mm, the length of the reinforcing material is 1005 mm, and the weight of the reinforcing material is 530 g. Three such reinforcements were inserted. The insert direction of the reinforcing material was horizontal and longitudinal.
また、使用した不織布は表１に示す通りである。不織布の材質はポリエチレンテレフタレート（ＰＥＴ）である。ただし、目付けが７５ｇ／ｍ２以下の不織布は、レーヨン繊維３９％、ポリエステル繊維１７％、アクリル酸エステル繊維４４％からなる不織布である。接着剤としては、アクリル系粘着剤を用い、その塗布量は４５ｇ／ｍ２とした。　 The non-woven fabric used is as shown in Table 1. The material of the non-woven fabric is polyethylene terephthalate (PET). However, the non-woven fabric having a basis weight of 75 g / m 2 or less is a non-woven fabric consisting of 39% of rayon fibers, 17% of polyester fibers, and 44% of acrylic ester fibers. An acrylic pressure-sensitive adhesive was used as the adhesive, and the coating amount was 45 g / m 2 .
成形結果　不織布の目付けを変えて成形を行い、補強材の保持状態を評価した。結果を表１に示す。表１の成形結果における「成形」の評価基準は下記の通りである。「○」：問題なく成形できた。「×」：成形において、補強材が落下又は傾くことで、製品を得ることができないか、製品が得られたとしても、得られた製品の外観が不良で商品性が無かった。　 As a result of molding, the nonwoven fabric was changed in weight and molded, and the holding state of the reinforcing material was evaluated. The results are shown in Table 1. The evaluation criteria of "molding" in the molding result of Table 1 are as follows. "○": It could be molded without problems. "X": In the molding, a product could not be obtained by dropping or tilting the reinforcing material, or even if the product was obtained, the appearance of the obtained product was poor and the productability was not commercial.
また、「製品」の評価基準は、製品における不織布を接着した面からの補強材の引きはがし強度を測定して、下記の基準により評価した。「○」：補強材の端部を持ち上げた際の引きはがし強度が３０Ｎ以上であった。「×」：補強材の端部を持ち上げた際の引きはがし強度が３０Ｎ未満であった。なお、「成形」の評価が「×」の場合は、「製品」の評価に耐える製品を得られないことから、「製品」の評価を「×」とした。　 Moreover, the evaluation criteria of "the product" measured the peeling strength of the reinforcing material from the surface which adhered the nonwoven fabric in a product, and evaluated it by the following criteria. "(Circle)": The peeling strength at the time of lifting the edge part of a reinforcement was 30 N or more. "X": Peeling strength when lifting the end of the reinforcing material was less than 30N. In addition, when the evaluation of "molding" is "x", since the product which endures evaluation of a "product" can not be obtained, evaluation of a "product" was made into "x".
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
表１から明らかな通り、仮保持材である不織布の目付けが大きすぎると、補強材の傾きが生じて外観不良が発生し、極端な場合には補強材が落下してしまった。不織布の目付けが小さすぎると、アンカー効果が損なわれ、補強材の落下が見られたり、成形は可能であっても使用中に補強材が脱落する等の問題が発生した。目付けを７５ｇ／ｍ２～１５０ｇ／ｍ２とすることで、補強材のインサート方向を横方向とした場合でも、確実に保持することが可能となり、良好な成形が実現されるとともに、補強材が脱落することのない優れた品質の製品を得ることができた。 As apparent from Table 1, when the basis weight of the non-woven fabric as the temporary holding material is too large, the reinforcing material is inclined to cause appearance failure, and in an extreme case, the reinforcing material falls. If the basis weight of the non-woven fabric is too small, the anchor effect is impaired, and the reinforcement may be dropped, or the reinforcement may fall off during use even though it can be molded. By setting the basis weight to 75 g / m 2 to 150 g / m 2 , even when the insert direction of the reinforcing material is set to the lateral direction, it becomes possible to securely hold it, and good molding is realized and the reinforcing material is It was possible to obtain an excellent quality product without falling off.
１　樹脂製ボード２　樹脂積層体３　補強材３１　第１板状部３１１　第１面３２　第２板状部３２１　第２面３３　連結板状部５　不織布２１　第１の樹脂シート２２　第２の樹脂シート２３　化粧材シート１００　成形装置１２０　押出装置１４０　型締装置１６Ａ，１６Ｂ　ホッパ１８Ａ，１８Ｂ　シリンダ２０Ａ，２０Ｂ　油圧モータ２４Ａ，２４Ｂ　アキュムレータ２６Ａ，２６Ｂ　プランジャ２８Ａ，２８Ｂ　Ｔダイ４０ＡＡ，４０ＡＢ，４０ＢＡ，４０ＢＢ　ローラ４２Ａ，４２Ｂ　分割金型４４３Ａ，４３Ｂ　摺動部９０　マニピュレータ１１８　ピンチオフ部Ｒ１１～Ｒ１６，Ｒ２１～Ｒ２６　リブＦＳ　おもて面ＢＦ　裏面Ｐ　溶融樹脂シートＨ　中空部ＰＬ　パーティングライン   DESCRIPTION OF SYMBOLS 1 resin board 2 resin laminated body 3 reinforcing material 31 1st plate-like part 311 1st surface 32 2nd plate-like part 321 2nd surface 33 connection plate-like part 5 nonwoven fabric 21 1st resin sheet 22 2nd resin sheet 23 cosmetic material sheet 100 molding device 120 extrusion device 140 clamping device 16A, 16B hopper 18A, 18B cylinder 20A, 20B hydraulic motor 24A, 24B accumulator 26A, 26B plunger 28A, 28B T die 40AA, 40AB, 40BA, 40BB roller 42A, 42B Divided mold 443A, 43B Sliding part 90 Manipulator 118 Pinch off parts R11 to R16, R21 to R26 Rib FS Front surface BF Back surface P Molten resin sheet H Hollow part PL Parting line

Claims (6)

  1. 第１の樹脂シートと第２の樹脂シートの間に補強材が介在する積層構造体の製造方法であって、　前記補強材のおもて側の面または裏側の面に仮保持材を貼り付ける工程と、　互いに対向する第１の分割金型と第２の分割金型の間に、第１の溶融樹脂シートと第２の溶融樹脂シートを押し出す工程と、　第１の溶融樹脂シートを第１の分割金型の形成面に押圧させ、第２の溶融樹脂シートを第２の分割金型の形成面に押圧させる工程と、　前記仮保持材が貼り付けられた前記補強材の面を第１の溶融樹脂シートに押圧させ、それによって前記補強材を第１の溶融樹脂シートに保持させる工程と、第１の分割金型と第２の分割金型の型締めを行う工程とを含み、　前記仮保持材として不織布を用い、当該不織布の目付けを５０ｇ／ｍ２～３００ｇ／ｍ２とすることを特徴とする積層構造体の製造方法。 A manufacturing method of a laminated structure in which a reinforcing material intervenes between a first resin sheet and a second resin sheet, wherein a temporary holding material is attached to the front surface side or the back surface of the reinforcing material. A step of: extruding a first molten resin sheet and a second molten resin sheet between first and second divided molds facing each other; and Pressing the second molten resin sheet against the forming surface of the second divided mold, and pressing the surface of the reinforcing material to which the temporary holding material is attached. And a step of holding the reinforcing material on the first molten resin sheet, and a step of clamping the first and second divided dies. Non-woven fabric is used as a temporary holding material, and the basis weight of the non-woven fabric is 50 g / m 2 to 300 g / m The manufacturing method of the laminated structure characterized by setting it as 2 .
  2. 前記不織布の目付けを７５ｇ／ｍ２～１５０ｇ／ｍ２とすることを特徴とする、　請求項１に記載された、積層構造体の製造方法。 The method for producing a laminated structure according to claim 1, wherein the basis weight of the non-woven fabric is 75 g / m 2 to 150 g / m 2 .
  3. 前記押圧させる工程では、第１の分割金型と第１の溶融樹脂シートの間に化粧材シートを配置させ、当該化粧材シートを第１の溶融樹脂シートとともに第１の分割金型の形成面に押圧させることを特徴とする、　請求項１または２に記載された、積層構造体の製造方法。 In the pressing step, the decorative material sheet is disposed between the first divided mold and the first molten resin sheet, and the decorative material sheet is formed on the first divided mold together with the first molten resin sheet. The manufacturing method of the laminated structure described in Claim 1 or 2 characterized by making it press.
  4. 前記第２の分割金型の形成面には、前記仮保持材が貼り付けられた前記補強材の面に対向する領域において、第１の分割金型の形成面に向けて突出する突出部が形成されていることを特徴とする、　請求項１～３のいずれかに記載された、積層構造体の製造方法。 On the formation surface of the second divided mold, a protrusion projecting toward the formation surface of the first divided mold is in a region facing the surface of the reinforcing material to which the temporary holding material is attached. The method for producing a laminated structure according to any one of claims 1 to 3, characterized in that it is formed.
  5. 前記補強材を第１の溶融樹脂シートに保持させる工程は、前記仮保持材が貼り付けられた前記補強材の面の周縁に第１の溶融樹脂シートによる***部を形成することを特徴とする、　請求項１～４のいずれかに記載された、積層構造体の製造方法。 The step of holding the reinforcing material on the first molten resin sheet is characterized in that a raised portion by the first molten resin sheet is formed on the periphery of the surface of the reinforcing material to which the temporary holding material is attached. The method for producing a laminated structure according to any one of claims 1 to 4.
  6. 第１の樹脂シートと第２の樹脂シートの間に補強材が介在する積層構造体であって、補強材と少なくとも一方の樹脂シートの間に不織布が介在され、前記不織布の目付けが５０ｇ／ｍ２～３００ｇ／ｍ２であることを特徴とする積層構造体。 A laminated structure in which a reinforcing material intervenes between a first resin sheet and a second resin sheet, and a non-woven fabric is interposed between the reinforcing material and at least one resin sheet, and the basis weight of the non-woven fabric is 50 g / m A laminated structure characterized in that it is 2 to 300 g / m 2 .
PCT/JP2018/023738 2017-06-30 2018-06-22 Manufacturing method for layered structure, and layered structure WO2019004067A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2017129845A JP6916982B2 (en) 2017-06-30 2017-06-30 Manufacturing method of laminated structure and laminated structure
JP2017-129845 2017-06-30

Publications (1)

Publication Number Publication Date
WO2019004067A1 true WO2019004067A1 (en) 2019-01-03

Family

ID=64741829

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2018/023738 WO2019004067A1 (en) 2017-06-30 2018-06-22 Manufacturing method for layered structure, and layered structure

Country Status (2)

Country Link
JP (1) JP6916982B2 (en)
WO (1) WO2019004067A1 (en)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11235129A (en) * 1998-02-24 1999-08-31 Hagiwara Kogyo Kk Light-shielding material for agriculture and horticulture
JPH11300818A (en) * 1998-04-16 1999-11-02 Nanba Press Kogyo Kk Skin monolithic molding of hollow body using olefinic resin composite material
WO2006043703A1 (en) * 2004-10-19 2006-04-27 Kyoraku Co., Ltd. Blow molded article with surface skin and method for production thereof
JP2007030773A (en) * 2005-07-28 2007-02-08 Howa Seni Kogyo Kk Method of manufacturing molded ceiling for vehicle
JP2010005872A (en) * 2008-06-25 2010-01-14 Kyoraku Co Ltd Composite resin molded article and its manufacturing method
WO2013047224A1 (en) * 2011-09-26 2013-04-04 キョーラク株式会社 Multilayer panel
WO2017119478A1 (en) * 2016-01-08 2017-07-13 キョーラク株式会社 Method for manufacturing laminated structure and laminated structure

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5590292B2 (en) * 2009-12-29 2014-09-17 キョーラク株式会社 Manufacturing method of resin laminate

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11235129A (en) * 1998-02-24 1999-08-31 Hagiwara Kogyo Kk Light-shielding material for agriculture and horticulture
JPH11300818A (en) * 1998-04-16 1999-11-02 Nanba Press Kogyo Kk Skin monolithic molding of hollow body using olefinic resin composite material
WO2006043703A1 (en) * 2004-10-19 2006-04-27 Kyoraku Co., Ltd. Blow molded article with surface skin and method for production thereof
JP2007030773A (en) * 2005-07-28 2007-02-08 Howa Seni Kogyo Kk Method of manufacturing molded ceiling for vehicle
JP2010005872A (en) * 2008-06-25 2010-01-14 Kyoraku Co Ltd Composite resin molded article and its manufacturing method
WO2013047224A1 (en) * 2011-09-26 2013-04-04 キョーラク株式会社 Multilayer panel
WO2017119478A1 (en) * 2016-01-08 2017-07-13 キョーラク株式会社 Method for manufacturing laminated structure and laminated structure

Also Published As

Publication number Publication date
JP2019010835A (en) 2019-01-24
JP6916982B2 (en) 2021-08-11

Similar Documents

Publication Publication Date Title
KR101579520B1 (en) Method for manufacturing a resin laminate
JP5004371B2 (en) Sandwich panel core, sandwich panel core molding method, and sandwich panel and sandwich panel molding method
US10179441B2 (en) Resin panel and molding method
JP5532522B2 (en) Sandwich panel, sandwich panel core molding method, and sandwich panel molding method
US10022903B2 (en) Method of making a resin panel
US10682804B2 (en) Molding method and molding apparatus for resin molded article
US10232584B2 (en) Resin sandwich panel, and method for manufacturing resin sandwich panel
JP6003009B2 (en) Resin sandwich panel and method for manufacturing resin sandwich panel
JP6283931B2 (en) Decorative molding method, decorative molding mold part with decorative sheet, decorative molding mold having the mold part, and decorative molding apparatus
JP6015921B2 (en) Resin sandwich panel and method for manufacturing resin sandwich panel
JP2014079899A (en) Made-of-resin sandwich panel and method for manufacturing a made-of-resin sandwich panel
JP6252749B2 (en) Resin sandwich panel and method for manufacturing resin sandwich panel
JP6268427B2 (en) Resin panel and molding method
JP5834797B2 (en) Manufacturing method of hollow thin panel structure made of bendable or bendable resin
JP6905664B2 (en) Laminated structure and its manufacturing method
WO2019004067A1 (en) Manufacturing method for layered structure, and layered structure
JP6424653B2 (en) Resin panel
JP6669550B2 (en) Manufacturing method of laminated structure
WO2017119478A1 (en) Method for manufacturing laminated structure and laminated structure
EP3042749A1 (en) Resin panel and forming method
JP5604997B2 (en) Manufacturing method of resin laminate having inner rib
WO2014058059A1 (en) Resin sandwich panel, and manufacturing method for resin sandwich panel
JP2019188615A (en) Molding method
JP2000167842A (en) Thermoplastic resin molded article molding die

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 18824027

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 18824027

Country of ref document: EP

Kind code of ref document: A1