US20130224448A1 - Resin panel and sandwich panel - Google Patents
Resin panel and sandwich panel Download PDFInfo
- Publication number
- US20130224448A1 US20130224448A1 US13/775,739 US201313775739A US2013224448A1 US 20130224448 A1 US20130224448 A1 US 20130224448A1 US 201313775739 A US201313775739 A US 201313775739A US 2013224448 A1 US2013224448 A1 US 2013224448A1
- Authority
- US
- United States
- Prior art keywords
- resin
- protrusions
- core material
- structures
- portions
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- 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
- B29C48/07—Flat, e.g. panels
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- B—PERFORMING OPERATIONS; TRANSPORTING
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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
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
- B29C48/11—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
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- B29C2049/2021—Inserts characterised by the material or type
- B29C2049/2065—Inserts characterised by the material or type for reinforcing specific areas of the final blow moulded article
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- B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3041—Trim panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/776—Walls, e.g. building panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24826—Spot bonds connect components
Abstract
The resin panel of the present invention includes a first structure 15A and a second structure 15B stacked on each other. The structures include reference surfaces that serve as the front surface and the back surface of the resin panel respectively. Each of the structures includes a plurality of protrusions 150 a , 150 b protruding inwardly from the reference surface. The protrusions 150 a of the structure 15A face the protrusions 150 b of the other structure 15B each other. Jutting portions Rb of linear shape are formed between adjacent protrusions of each of the structures. The structures 15A, 15B are joined such that apical portions of the protrusions of each structure abut one another.
Description
- This application claims priority to Japanese Patent Application No. 2012-040625 filed on Feb. 27, 2012, the entirety of which is hereby incorporated by reference in its entirety.
- 1. Field of the Invention
- The present invention relates to a resin panel, a sandwich panel in which the resin panel is covered by skin sheets, and relates to a molding technique therefor.
- 2. Description of the Related Art
- Conventionally, sandwich panels have been employed in a wide range of applications, from those in transportation machinery such as automobiles, airplanes, and the like, to those in construction, electrical equipment housings, sports and leisure, and so on. A sandwich panel has a core material of a resin panel covered by skin sheets; in some, only one surface of the core material is covered by skin sheets, while in others, both surfaces of the core material are covered by skin sheets. Sandwich panels in which only one surface of the core material is covered by skin sheets are employed, for example, in applications such as construction, in which it is not necessary for the other surface of the core material to be covered by skin sheets since it is not visible to the user. Sandwich panels in which both surfaces of the core material are covered by skin sheets are also referred to as sandwich panels. A sandwich panel has two skin sheets, and a core material interposed between both of the skin sheets. Specifically, the basic format of a sandwich panel is a stacked structure of one skin sheet, a core material, and another skin sheet.
- Sandwich panels of a core material of expanded resin (that is, resin foam) covered by skin sheets have been known (for example, see International Publication Pamphlet No. WO 2010/050242). The core material of this sandwich panel has a plurality of hollows that form voids in the interior, with appropriate setting of the number of hollows and the total opening area, thereby ensuring compressive stiffness.
- With conventional resin panels, and with sandwich panels in which a core material of a resin panel is covered by skin sheets, there is a need for further improvement in strength.
- It is therefore an object of the present invention to provide a resin panel and a sandwich panel of greater strength than in the past.
- A first aspect of the present invention is a resin panel including a first structure and a second structure stacked on each other, wherein: the structures include reference surfaces that serve as the front surface and the back surface of the resin panel respectively; each of the structures includes a plurality of protrusions protruding inwardly from the reference surface, the protrusions of one of the structures facing those of the other structure; the structures are joined such that apical portions of the protrusions of one of the structures abut apical portions of the protrusions of the other structure; and jutting portions of linear shape are formed between adjacent protrusions of each of the structures.
- In the aforedescribed resin panel, in a preferred embodiment, a plurality of the jutting portions of linear shape may be formed for each of the protrusions, such that at least two of the jutting portions do not extend in two opposite directions.
- In a preferred embodiment, the jutting portions of linear shape formed for each of the protrusions may extend in two opposite directions.
- In a preferred embodiment, the resin panel may be made from expanded material.
- A second aspect of the present invention is a sandwich panel including resin sheets, and the above-described resin panel sandwiched between the resin sheets.
- Referring now to the attached drawings which form a part of this original disclosure:
-
FIG. 1 is an overall perspective view of a sandwich panel of an embodiment; -
FIG. 2 is a plan view of the core material of the sandwich panel of the embodiment; -
FIG. 3 is a drawing illustrating the A-A cross section inFIG. 2 ; -
FIG. 4A is a plan view of the structure of the lower side of the core material of a first example of the embodiment when cut at the joining surface; -
FIG. 4B is the X-X cross section and the Y-Y cross section inFIG. 4A ; -
FIG. 5A is a plan view of the structure of the lower side of the core material of a second example of the embodiment when cut at the joining surface; -
FIG. 5B is the Z-Z cross section inFIG. 5A ; -
FIG. 6 is a drawing illustrating a state prior to clamping of the mold in the molding step for the core material of the embodiment; -
FIG. 7 is a drawing illustrating a mold-clamped state in the molding step for the core material of the embodiment; -
FIG. 8 is a drawing illustrating a state subsequent to clamping of the mold in the molding step for the core material of the embodiment; -
FIG. 9 is a drawing illustrating the overall arrangement of the sandwich panel molding device of the embodiment; -
FIG. 10 is a drawing illustrating a state in which a cavity has formed between the resin sheet and the molding surface of the split mold in the molding process for the sandwich panel of the embodiment; -
FIG. 11 is a drawing illustrating a state in which the resin sheet has formed to a shape conforming to the molding surface of the split mold in the molding process for the sandwich panel of the embodiment; -
FIG. 12 is a drawing illustrating a state in which the core material has been inserted into the split mold in the molding process for the sandwich panel of the embodiment; -
FIG. 13 is a drawing illustrating a state in which the split mold has been moved to the closed position in the molding process for the sandwich panel of the embodiment; -
FIG. 14 is a drawing illustrating a state prior to pressing the core material against the molten resin sheet in a modification example of the embodiment; and -
FIG. 15 is a drawing illustrating a state after the core material has been pressed against the molten resin sheet until reaching the molding surface of the split mold in a modification example of the embodiment. - As an embodiment of the sandwich panel of the present invention, a sandwich panel, and a molding method therefor, are described below.
- The sandwich panel 1 of the embodiment is described below with reference to
FIGS. 1 and 2 . - As illustrated in
FIG. 1 by way of example, the sandwich panel 1 of the embodiment is equipped with an exterior shape that is approximately cuboid. This sandwich panel 1 is furnished on both the front surface side and the back surface side with resin sheets SA, SB of a thermoplastic resin, thereby providing a sandwich structure in which a core material 15 (resin panel) is sandwiched interposed between the resin sheets on the front surface side and the back surface side. The resin sheets SA, SB are served as the thin skin sheets of the sandwich panel 1, and are obtained by forming, within a mold, resin sheets (molten resin) extruded by an extrusion device. - In the sandwich panel 1 of the embodiment, the
core material 15 is molded from a thermoplastic resin, for example. The thermoplastic resin material is not limited, and may include, for example, polypropylene, polyethylene, or other polyolefins, polyamides, polystyrene, polyvinyl chloride, and other acrylic derivatives, and mixtures of two or more kinds of these. In preferred embodiment, thecore material 15 occupies a large proportion of the volume of the sandwich panel 1, and is made of expanded resin that has been expanded with a blowing agent for lighter weight. The expansion ratio of the expanded resin serving as thecore material 15 is in the range of 1.5 to 6, for example. Herein, the expansion ratio is a value obtained by dividing the density of the mixed resin prior to expansion, by the apparent density of the expanded resin after expansion. - The apparent expansion ratio of the entire expansion-molded article, including the hollow portions, may be in the range of 10 to 60, for example, and may be 30 as a representative value. This apparent expansion ratio is a value obtained by dividing the density of the mixed resin prior to expansion, by the density of the entire expansion-molded article, including the hollow portions.
- In the sandwich panel 1 of the embodiment, the resin sheets SA, SB are not limited as to the resin material thereof, but in preferred embodiment, will be formed from non-expanded resin in order to ensure rigidity of the sandwich panel 1. For example, in consideration of moldability, the resin sheets SA, SB may have polypropylene (PP) as the primary material, with polystyrene (PS) and a styrene-ethylene-butylene-styrene block copolymer resin (SEBS) mixed in.
- The resin sheets SA, SB and the
core material 15 may be molded from a resin material into which a glass filler has been admixed for the purpose of increasing the rigidity and strength. - As glass fillers, there may be cited glass fibers, glass fiber fabrics such as glass cloth or glass nonwoven fabric, glass beads, glass flakes, glass powder, milled glass, and the like. As types of glass, there may be cited E glass, C glass, A glass, S glass, D glass, NE glass, T glass, quartz, low-permittivity glass, high-permittivity glass, and the like.
- There is no limitation to the glass fillers; other inorganic fillers, such as talc, calcium carbonate, wollastonite, magnesium based materials, or carbon fibers or the like, may be admixed in order to raise the rigidity.
- The thickness of the
core material 15 is determined, as appropriate, according to the target thickness of the sandwich panel 1, as well as to the thickness of the resin sheets for ensuring that the sandwich panel 1 has the target rigidity. The thickness may be, but not particularly limited to, about 10 mm, for example. The thickness of the resin sheets SA, SB may be preferably within the range of 0.1 mm to 0.6 mm, and may be 0.5 mm as a representative value. - Next, the structure of the
core material 15 serving as the resin panel is described with reference toFIGS. 2 to 5 . -
FIG. 2 is a fragmentary plan view of thecore material 15 of the sandwich panel 1 of the embodiment.FIG. 3 is a drawing illustrating the A-A cross section inFIG. 2 .FIGS. 4A , 4B and 5A, 5B are drawings illustrating examples of the structure when thecore material 15 of the embodiment has been cut at the joining surface.FIG. 4A illustrates a plan view, whileFIG. 4B is the X-X cross section and the Y-Y cross section inFIG. 4A .FIG. 5A illustrates a plan view, whileFIG. 5B is the Z-Z cross section inFIG. 5A . - As illustrated in
FIG. 3 , in thecore material 15, afirst structure 15A and asecond structure 15B are joined at a joining surface, thereby producing a structure in which thefirst structure 15A and thesecond structure 15B are stacked on each other. A reference surface 15Sa of thefirst structure 15A is corresponding to the front surface of thecore material 15, while a reference surface 15Sb of thesecond structure 15B is corresponding to the back surface of thecore material 15. - On the
first structure 15A are formed a plurality ofprotrusions 150 a that protrude inwardly from the reference surface 15Sa. In a preferred embodiment, the plurality ofprotrusions 150 a are furnished so as to be aligned in rows in a predetermined pattern over the entire face of the reference surface 15Sa corresponding to the front surface of thecore material 15, as illustrated inFIG. 2 . With this arrangement, the rigidity and strength in the direction of compression against the front surface of thecore material 15 can be increased. While the front surface is illustrated inFIG. 2 , the back surface has a comparable structure. That is, in a preferred embodiment, the plurality ofprotrusions 150 b are furnished so as to be aligned in rows in a predetermined pattern over the entire face of the reference surface 15Sb corresponding to the back surface of thecore material 15, whereby the rigidity and strength in the direction of compression against the back surface of thecore material 15 can be increased. - Referring to the
first structure 15A inFIG. 3 , theprotrusions 150 a have a taperedsurface 1501 a formed so as to taper off towards the inward side, and anapical portion 1502 a. By tapering off the taperedsurface 1501 a of eachprotrusion 150 a towards the inward side, theprotrusions 150 a are more resistant to buckling in response to a large load on the front surface of thecore material 15, thereby increasing the strength in the direction of compression against the front surface of thecore material 15. - Referring to the
second structure 15B inFIG. 3 , theprotrusions 150 b have a taperedsurface 1501 b formed so as to taper off towards the inward side, and anapical portion 1502 b. By tapering off the taperedsurface 1501 b of eachprotrusion 150 b towards the inward side, theprotrusions 150 b are more resistant to buckling in response to a large load on the back surface of thecore material 15, thereby increasing the strength in the direction of compression against the back surface of thecore material 15. - As illustrated in
FIG. 3 , theprotrusion 150 a of thefirst structure 15A and theprotrusions 150 b of thesecond structure 15B are joined such that their respectiveapical portions core material 15 is constructed such that thefirst structure 15A and thesecond structure 15B are stacked with the both structured joined. - In the
first structure 15A and thesecond structure 15B which form thecore material 15 of the present embodiment, jutting portions (raised folds) of linear shape are formed between adjacent protrusions of each of the structures; this feature is described with reference toFIGS. 4A , 4B and 5A, 5B.FIGS. 4A , 4B and 5A, 5B illustrate specific examples of the structures of thecore material 15 of the present embodiment. InFIGS. 4A , 4B and 5A, 5B, only thesecond structure 15B is illustrated, and only thesecond structure 15B is mentioned below; however, thefirst structure 15A is comparable in structure. - In
FIGS. 4A and 5A , illustrated is a plan view of the cut joining surface of thecore material 15, seen from the inward side (that is, seen from the side of theapical portion 1502 b of theprotrusions 150 b). InFIGS. 4B and 5B , illustrated is a cross sectional view of thesecond structure 15B when cut along the direction of the jutting portions which are furnished between the protrusions. InFIGS. 4 and 5 , the jutting portions are furnished along the reference surface 15Sb corresponding to the back surface of thecore material 15. - Firstly, in the example illustrated in
FIG. 4A , four jutting portions Rb1 to Rb4 of linear shape (referred to collectively as “jutting portions Rb” when appropriate) are furnished between eachprotrusion 150 b andother protrusions 150 b. Of these four jutting portions Rb1 to Rb4, at least two jutting portions are formed so as to not extend in two mutually opposite directions. For example, the jutting portions Rb1 and Rb2 do not extend in two mutually opposite directions, and the jutting portions Rb1 and Rb4 do not extend in two mutually opposite directions. That is, in the example illustrated inFIG. 4 , the jutting portions Rb are formed betweenprotrusions 150 b that are adjacent in at least two non-opposite directions in plan view, whereby the jutting portions Rb function as reinforcing ribs against bending moment exerted in any direction on the reference surface 15Sb. This allows a structure resistant to collapse of theprotrusions 150 b in response to bending moment acting on the back surface, and therefore the bending rigidity and bending strength can be increased. In the example illustrated inFIG. 4A , the jutting portions Rb constituting interstices between theprotrusions 150 b are formed to extend in two intersecting directions overall. This allows a structure that is strong with respect to bending moment centered on any straight line in the longitudinal direction or lateral direction inFIG. 4A . - Next, in the example of
FIG. 5A , two jutting portions Rb1, Rb2 of linear shape are furnished between eachprotrusion 150 b andother protrusions 150 b. These two jutting portions Rb1, Rb2 of linear shape extend in two mutually opposite directions. That is, inFIG. 5A , the jutting portions Rb constituting interstices between theprotrusions 150 b extend in a single longitudinal direction overall. Therefore, the jutting portions Rb1, Rb2 function as reinforcing ribs against bending moment the action of which is centered on a line in the lateral direction inFIG. 5A , thereby providing a structure extremely resistant to the bending moment. The structure is relatively low in bending rigidity with respect to bending moment centered on a line in the direction of overall extension of the jutting portions Rb. Consequently, the structure illustrated inFIGS. 5A and 5B is particularly useful in cases in which higher bending rigidity and bending strength are desired in a specific direction. - The
first structure 15A and thesecond structure 15B are formed in individual blow molding processes, by forcing the molten resin against the respective split molds. Protrusions corresponding to theprotrusions FIGS. 4A , 4B and 5A, 5B are formed through the arrangement of the protrusions formed on the split molds in correspondence with theprotrusions - For example, in a case in which t1>t2, there are formed jutting portions of intersecting shape overall as illustrated in
FIG. 4A , whereas in a case in which t1<t2, there readily form jutting portions of linear shape overall in a single direction as illustrated inFIG. 5A . InFIGS. 4A and 5A , the direction extending from the top towards the bottom on the plane of the page corresponds to the direction of injection of the molten resin, and in this case, examples of preferred dimensions of the jutting portions when formed to the shapes as illustrated inFIGS. 4A , 4B and 5A, 5B are as follows. - Specifically, with regard to distances between the centers of
adjacent protrusions 150 b in the case ofFIGS. 4A and 4B , the distance t1 in the injection direction is 11 mm for example, and the distance t2 in a direction orthogonal to the injection direction is 5.5 mm, for example. In a case in which the height of the protrusions (equal to the width of the structure) is 12 mm, the height Rh of the jutting portions formed therebetween is 0.5 to 3 mm. In the case ofFIGS. 5A and 5B on the other hand, t1=5.5 mm and t2=11 mm, and in a case in which the height of the protrusions (equal to the width of the structure) is 12 mm, the height Rh of the jutting portions formed therebetween is 1 to 5 mm. - As mentioned previously, in
FIGS. 4 and 5 , the direction from the top towards the bottom on the plane of the page corresponds to the direction of injection of the molten resin in the molding step, to be discussed below. By introducing filler into the molten resin, the bending rigidity and bending strength against bending moment centered on the direction of injection, that is, on a line in a horizontal direction inFIG. 4 or 5, can be increased further. As the introduced filler, in addition to the various glass fillers mentioned previously, inorganic fillers, such as talc, calcium carbonate, wollastonite, magnesium based materials, or carbon fibers or the like, may be admixed. - In the sandwich panel 1 of the present embodiment, any of the widely known physical blowing agents or chemical blowing agents, or mixtures of these, can be cited as examples of blowing agents that may be used in the
core material 15. For example, as the physical blowing agents, air, carbon dioxide gas, nitrogen gas, or other such inorganic physical blowing agents, as well as butane, pentane, hexane, dichloromethane, dichloroethane, and other such organic physical blowing agents can be applied. As the chemical blowing agents, there may be cited, for example, organic blowing agents such as azodicarbonamide (ADCA), N,N′-dinitrosopentamethylene tetramine, 4,4′-oxybis(benzenesulfonyl hydrazide), diphenylsulfone-3,3′-disulfonyl hydrazide, p-toluenesulfonyl semicarbazide, trihydrazinotriazine, azobisisobutyronitrile, and the like; as well inorganic blowing agents such as mixtures of polycarboxylic acids, such as citric acid, oxalic acid, fumaric acid, phthalic acid, malic acid, tartaric acid, cyclohexane-1,2-dicarboxylic acid, camphoric acid, ethylenediaminetetraacetic acid, triethylenetetramine hexaacetic acid, nitrilo acid, and the like, with inorganic carbonic acid compounds such as sodium hydrogen carbonate, aluminum sodium hydrogen carbonate, potassium hydrogen carbonate, ammonium hydrogen carbonate, ammonium carbonate, and the like; or sodium dihydrogen citrate, potassium oxalate, and other salts of polycarboxylic acids. - The molding method for the
core material 15 is described next. - Firstly, a polyolefin based resin, for example, is fed to an extruder (not illustrated), in which, after kneading the material while heating and melting it, a predetermined amount of a blowing agent is added, continuing to further knead within the extruder to give an expandable molten resin. While maintaining the expandable molten resin at a resin temperature suitable for expansion, but at a pressure such that the expandable molten resin does not begin to expand, the material is packed into an accumulator (not illustrated). Next, with the gate at the distal end of the die of the
extrusion head 40 open, the ram of the accumulator (not illustrated) is pushed in order to release the expandable molten resin into a low-pressure zone, forming an expandable cylindrical parison P. A substantially constant expansion ratio is maintained throughout the molding step bysplit molds - Next, as illustrated in
FIG. 6 , the cylindrical parison P in a molten state is extruded vertically downward through a slit die by the known-art extrusion head 40, and the cylindrical parison P is continuously fed in a molten state between the twosplit molds - Next, as illustrated in
FIG. 7 , the twosplit molds split molds molding surfaces - In further detail, in the case of blow molding, in a manner comparable to known prior art methods, a blow pin (not illustrated) is inserted into the
core material 15, and a pressurized fluid is introduced into the interior, pressing the parison P towards the molding surfaces 52A, 52B of thesplit molds split molds split molds structures protrusions protrusions structures split molds protrusions protrusions structures protrusions split molds apical portions protrusions respective structures portions individual split molds - As mentioned previously, through appropriate arrangement of the plurality of
protrusions split molds protrusions adjacent protrusions 150 a and theadjacent protrusions 150 b, in each of the pair ofstructures - Next, as illustrated in
FIG. 8 , the twosplit molds split molds core material 15 is thereby released from the twosplit molds - This completes the molding of the
expandable core material 15. - Next, the device and method for employing a mold to mold the sandwich panel 1 of the embodiment is described with reference to
FIGS. 9 to 15 . - Firstly, the molding device for the sandwich panel 1 of the embodiment is described.
- As illustrated in
FIG. 9 , themolding device 90 of the embodiment has anextrusion device 60, and amold clamping device 70 arranged below theextrusion device 60. Resin sheets P in the molten state extruded from theextrusion device 60 are delivered to themold clamping device 70, and the resin sheets P in the molten state are molded in themold clamping device 70.FIG. 9 illustrates in cross section only themold clamping device 70 and the resin sheets P in the molten state. - The
extrusion device 60 is equipped with T-dies 61A, 61B,accumulators plungers extruders resin feed hoppers extrusion device 60, the extruders are employed to plasticize and melt a resin feedstock, and this molten resin is then extruded out from the T-dies 61A, 61B. In theextrusion device 60, the extrusion capability of theextruders - In the
extrusion device 60, the rate at which the resin sheet is extruded is set by the T-dies 61A, 61B and theaccumulators accumulators - Referring back to
FIG. 9 , themold clamping device 70 has a pair ofsplit molds split molds - In each of the pair of
split molds portions portions split mold split molds portions - The pair of
split molds portions portions split molds - The pair of
split molds house vacuum chambers vacuum chambers vacuum chambers - The pair of
split molds split molds portions split molds split molds split molds - Next, the molding method of the sandwich panel 1 is described.
- Firstly, as illustrated in
FIG. 9 , the resin sheets P in the molten state are extruded vertically downward by theextrusion device 60, from each of the die slits. The extruded resin sheets P respectively pass throughrollers split molds split molds - In a case in which a decorative sheet (for example, a decorative sheet made of fabric) is to be applied to the surface of the sandwich panel 1, the descending resin sheets P and the decorative sheet can be bonded to one another by the
rollers rollers - Alternatively, a decorative sheet may be positioned in advance on the molding surface of the split mold, inducing the decorative sheet to adhere the resin sheet P simultaneously with molding of the resin sheet P.
- Decorative sheets made of fabric are preferably of nonwoven fabric. In terms of improving the adhesive strength, it is especially preferable to employ a needle-punched nonwoven fabric in which the fibers have been mechanically entangled by pricking with barbed needles.
- Next, as illustrated in
FIG. 10 , the slidingportions split molds vacuum chambers split molds FIG. 11 . - By adopting a process whereby air present on the resin sheet P side can be suctioned out from the distal ends of the sliding
portions portions - Next, employing a manipulator (not illustrated), the
core material 15 is positioned between the pair ofsplit molds FIG. 12 (inFIG. 12 , thesplit mold 71B). Thecore material 15 is thereby affixed to a resin sheet P. Subsequent to molding, the resin sheets P may shrink by about 1% due to cooling, depending on the resin material. The shapes of the molding surfaces 72A, 72B of thesplit molds core material 15, which is in a normal temperature state, can be inserted into the split molds with some room to spare. - Next, as illustrated in
FIG. 13 , the pair ofsplit molds core material 15 which had been affixed to one of the resin sheets P (the one on the right side in the drawing) is thereby affixed to the other resin sheet P (the one on the left side in the drawing) as well. Furthermore, the peripheral edges of the pair of resin sheets are affixed by the pinch-offportions split molds core material 15, which is in a normal-temperature state, is affixed to the resin sheets P in the molten state, thecore material 15 is positioned beforehand so as to not experience deformation due to mold clamping. - Finally, the pair of
split molds portions core material 15, and the resin sheet SB which are stacked in order. - As mentioned previously, a glass filler, inorganic filler, or carbon filler may be admixed into the resin sheets P, with the object of increasing rigidity and strength.
- By adopting the above method of sandwiching the core material between the split molds, and bringing about adhesion prior to solidification of the extruded resin sheets in the molten state, molding costs can be reduced. The reason is that, as compared for example to a method in which the solidified resin sheets are reheated and melted, then affixed to the core material, the need for a reheating step is obviated, and molding costs can be reduced.
- By adopting a process whereby the resin sheets are extruded vertically downward in a molten state, the area occupied by the manufacturing devices can be reduced. The reason is that, in a case of molding by extrusion in the horizontal direction for example, a separate conveyance device is necessary to convey the resin sheets in the horizontal direction, and it is moreover necessary for the conveyance device and the molds to be positioned in-line with the extrusion device in the horizontal direction.
- The sandwich panel molding method discussed above may be modified as appropriate. Modification examples of the sandwich panel molding method of the embodiment are described below.
- Whereas the sandwich panel molding method discussed above described a case of extrusion of resin sheets in a molten state from a pair of T-dies, resin sheets could also be obtained by extruding a cylindrical parison, while cutting it.
- Whereas the sandwich panel molding method discussed above described a case in which the cavities are formed between the resin sheets P and the molding surfaces 72A, 72B of the pair of
split molds split molds split molds - Whereas the sandwich panel molding method discussed above described a case of suctioning the air inside the cavities in order to press the resin sheets P against the molding surfaces 72A, 72B of the pair of
split molds split molds - In the sandwich panel molding method discussed above, the step of pressing the outer layer of the resin sheets in a molten state against the molding surfaces of the split molds employed a method of suctioning from the cavities, or a method relying on blow molding; however, there is no limitation to these methods. It is also acceptable to apply a method in which the
core material 15 is employed to press the resin sheets in a molten state against the cavities of the split molds, without forming cavities. This method is described with reference toFIGS. 14 and 15 . -
FIG. 14 is a drawing illustrating thecore material 15 in a state prior to being pressed against the resin sheets in a molten state.FIG. 15 is a drawing illustrating thecore material 15 in a state after being pressed against a resin sheet in a molten state, until reaching the molding surfaces of a split mold. - In the method of the present modification example, firstly, as illustrated in
FIG. 14 , in a state in which the resin sheets P have been extruded vertically downward in a molten state from the extrusion device 60 (the same state as inFIG. 9 ), thecore material 15, retained by amanipulator 120, is positioned at a position in opposition to thesplit mold 71B, with a resin sheet P therebetween. Once thecore material 15 has been positioned, themanipulator 120 retaining thecore material 15 is moved towards themolding surface 72B of thesplit mold 71B. Thereupon, thecore material 15 is brought into contact with the resin sheet P in the molten state, affixing thecore material 15 and the resin sheet P. At the moment of contact with thecore material 15, the resin sheet P in the molten state is kept at relatively high temperature due to the lack of contact with thesplit mold 71B, which has high thermal conductivity. Therefore, thecore material 15 and the resin sheet P adhere tightly. - As the
manipulator 120 is moved further along, and the outer layer of the resin sheet P reaches themolding surface 72B of thesplit mold 71B, the state illustrated inFIG. 15 is assumed. At this time, the outer layer of the resin sheet P is pressed by themanipulator 120 against themolding surface 72B, with thecore material 15 therebetween. Themanipulator 120 is then detached from thecore material 15. - Subsequent steps are the same as those discussed previously.
- Specifically, as illustrated in
FIG. 13 , the pair ofsplit molds core material 15 which has been affixed to one of the resin sheets P (the one on the right side in the drawing) is now affixed to the other resin sheet P as well (the one on the left side in the drawing). The pair of resin sheets are then pressed against the molding surfaces 72A, 72B of the pair ofsplit molds FIG. 11 . Furthermore, in the pinch-offportions split molds split molds core material 15, and the resin sheet SB which are stacked in order. - While the present invention has been described in detail above in terms of the present preferred embodiment, the resin panel and sandwich panel of the present invention are not limited to the aforedescribed embodiment, and various improvements and modifications of the present invention are possible without departing from the scope and spirit thereof. For example, in the present embodiment, a case of use as the core material of a sandwich panel was described as an example of the resin panel of the present invention; however, applications for the resin panel are not limited thereto. In applications where skin sheets are not necessary, the resin panel could be used by itself.
- 1 Sandwich panel
- SA, SB Resin sheet
- 15 Core material (resin panel)
- 15A First structure
- 15B Second structure
- 150 a, 150 b Protrusions
- 60 Extrusion device
- 70 Mold clamping device
- 61A, 61B T die
- 65A, 65B Roller
- 71A, 71B Split mold
- 72A, 72B Molding surface
- 73A, 73B Vacuum chamber
- 74A, 74B Pinch-off portion
- 75A, 75B Sliding portion
- 90 Molding device
- P Resin sheet
Claims (5)
1. A resin panel including a first structure and a second structure stacked on each other, wherein:
the structures include reference surfaces that serve as the front surface and the back surface of the resin panel respectively;
each of the structures includes a plurality of protrusions protruding inwardly from the reference surface, the protrusions of one of the structures facing those of the other structure;
the structures are joined such that apical portions of the protrusions of one of the structures abut apical portions of the protrusions of the other structure; and
jutting portions of linear shape are formed between adjacent protrusions of each of the structures.
2. The resin panel according to claim 1 , wherein a plurality of the jutting portions of linear shape are formed for each of the protrusions, at least two of the jutting portions not extending in two opposite directions.
3. The resin panel according to claim 1 , wherein the jutting portions of linear shape formed for each of the protrusions extend in two opposite directions.
4. The resin panel according to claim 1 , wherein the resin panel is made from expanded material.
5. A sandwich panel comprising resin sheets and a resin panel sandwiched between the resin sheets, the resin panel including a first structure and a second structure stacked on each other, wherein:
the structures include reference surfaces that serve as the front surface and the back surface of the resin panel respectively;
each of the structures includes a plurality of protrusions protruding inwardly from the reference surface, the protrusions of one of the structures facing those of the other structure;
the structures are joined such that apical portions of the protrusions of one of the structures abut apical portions of the protrusions of the other structure; and
jutting portions of linear shape are formed between adjacent protrusions of each of the structures.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/673,513 US10022903B2 (en) | 2012-02-27 | 2015-03-30 | Method of making a resin panel |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2012-040625 | 2012-02-27 | ||
JP2012040625A JP5966429B2 (en) | 2012-02-27 | 2012-02-27 | Manufacturing method of resin panel, manufacturing method of sandwich panel |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/673,513 Division US10022903B2 (en) | 2012-02-27 | 2015-03-30 | Method of making a resin panel |
Publications (1)
Publication Number | Publication Date |
---|---|
US20130224448A1 true US20130224448A1 (en) | 2013-08-29 |
Family
ID=47754352
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/775,739 Abandoned US20130224448A1 (en) | 2012-02-27 | 2013-02-25 | Resin panel and sandwich panel |
US14/673,513 Active 2034-08-01 US10022903B2 (en) | 2012-02-27 | 2015-03-30 | Method of making a resin panel |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/673,513 Active 2034-08-01 US10022903B2 (en) | 2012-02-27 | 2015-03-30 | Method of making a resin panel |
Country Status (3)
Country | Link |
---|---|
US (2) | US20130224448A1 (en) |
EP (1) | EP2631064B1 (en) |
JP (1) | JP5966429B2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20160221245A1 (en) * | 2013-09-26 | 2016-08-04 | Plastic Omnium Advanced Innovation And Research | Method for producing a fuel tank from plastic material |
WO2022103796A1 (en) * | 2020-11-13 | 2022-05-19 | Continental Structural Plastics, Inc. | Open area core sandwich structure manufacturing tool |
Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP6252749B2 (en) * | 2013-12-01 | 2017-12-27 | キョーラク株式会社 | Resin sandwich panel and method for manufacturing resin sandwich panel |
GB2530237B (en) * | 2014-06-04 | 2021-09-22 | Gridesic Holdings Ltd | Structural element |
EP3095584B1 (en) * | 2015-05-22 | 2020-02-19 | Sekisui Alveo AG | A process of manufacturing twin-sheet foam air duct with sound absorbing interlayer |
US11478026B2 (en) * | 2016-08-16 | 2022-10-25 | Timothy W. Markisen | Body limb protection system |
JP6829807B2 (en) * | 2017-02-28 | 2021-02-17 | キョーラク株式会社 | Molding method |
JP6985591B2 (en) * | 2017-07-31 | 2021-12-22 | キョーラク株式会社 | Resin panel and manufacturing method |
JP7257605B2 (en) * | 2019-01-30 | 2023-04-14 | キョーラク株式会社 | Foam core material, resin sandwich panel, and method for manufacturing resin sandwich panel |
WO2022044943A1 (en) * | 2020-08-25 | 2022-03-03 | キョーラク株式会社 | Resin panel and method for manufacturing resin panel |
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US3142599A (en) * | 1959-11-27 | 1964-07-28 | Sealed Air Corp | Method for making laminated cushioning material |
US20020017805A1 (en) * | 1998-02-04 | 2002-02-14 | Oakwood Energy Management, Inc. | Composite energy absorber |
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JPH06226889A (en) * | 1993-02-05 | 1994-08-16 | Sky Alum Co Ltd | Panel material and composite panel using the same |
JPH09141769A (en) * | 1995-11-27 | 1997-06-03 | Sumitomo Metal Ind Ltd | High rigidity panel |
EP0863056A1 (en) * | 1997-03-03 | 1998-09-09 | General Motors Corporation | Energy absorbing structure |
DE19709111C2 (en) | 1997-03-06 | 2003-01-02 | Sedra Asphalt Technik Biebrich | Rail chamber filling element for mechanical installation on rails and installation method and device |
JP3649380B2 (en) * | 1999-03-17 | 2005-05-18 | 本田技研工業株式会社 | Vehicle roofing |
JP2009107144A (en) * | 2007-10-26 | 2009-05-21 | Ube Nitto Kasei Co Ltd | Hollow structural plate |
CN102202881B (en) * | 2008-10-31 | 2018-04-24 | 京洛株式会社 | The manufacturing process of battenboard, the manufacturing process of core material for sandwich panel and battenboard |
-
2012
- 2012-02-27 JP JP2012040625A patent/JP5966429B2/en active Active
-
2013
- 2013-02-25 US US13/775,739 patent/US20130224448A1/en not_active Abandoned
- 2013-02-26 EP EP13156846.1A patent/EP2631064B1/en active Active
-
2015
- 2015-03-30 US US14/673,513 patent/US10022903B2/en active Active
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US3142599A (en) * | 1959-11-27 | 1964-07-28 | Sealed Air Corp | Method for making laminated cushioning material |
US20020017805A1 (en) * | 1998-02-04 | 2002-02-14 | Oakwood Energy Management, Inc. | Composite energy absorber |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160221245A1 (en) * | 2013-09-26 | 2016-08-04 | Plastic Omnium Advanced Innovation And Research | Method for producing a fuel tank from plastic material |
WO2022103796A1 (en) * | 2020-11-13 | 2022-05-19 | Continental Structural Plastics, Inc. | Open area core sandwich structure manufacturing tool |
Also Published As
Publication number | Publication date |
---|---|
EP2631064B1 (en) | 2016-02-24 |
JP2013173327A (en) | 2013-09-05 |
EP2631064A1 (en) | 2013-08-28 |
US20150202817A1 (en) | 2015-07-23 |
US10022903B2 (en) | 2018-07-17 |
JP5966429B2 (en) | 2016-08-10 |
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