Method for manufacturing a structure and panel

Abstract

Provided is a manufacturing method of a structure that can more reliably cut off a burr portion. In the burr portion molding step, the burr portion is molded to the engaging portion by attracting the burr portion to the engaging portion via the attracting portion. In the cutting step, the movable portion is relatively moved with respect to the first split mold and the second split mold in a state in which the burr portion is molded to the engaging portion, and thereby the burr portion is cut off from the molded body main body in a manner along the cutting line.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a structure and a panel that can be bent via a hinge portion. Background Art

[0002] (Common to both the first and second viewpoints)

[0003] Patent Document 1 discloses a method for molding a resin panel using a mold having a pinch-off portion surrounding a cavity. In the molding method of Patent Document 1, a core material, such as a foam, a resin sheet covering the core material, and a skin material, such as a nonwoven fabric, are placed within the cavity and integrally molded within the cavity. The resulting molded body comprises a molded body formed within the cavity and a burr portion disposed outside the cavity.

[0004] Patent Document 1 discloses a method for cutting burrs using a movable portion attached to a mold. The movable portion of Patent Document 1 is configured to cut burrs from a resin sheet constituting a molded body by being driven to separate from the mold.

[0005] (Third Viewpoint)

[0006] Patent Document 2 discloses a method for manufacturing a resin structure using a mold and an outer frame disposed around the mold. The outer frame of Patent Document 2 protrudes from the mold, contacts a drooping resin sheet, and absorbs the resin sheet. When the outer frame absorbs the resin sheet, the space (cavity) between the resin sheet and the mold becomes a closed space. Therefore, by decompressing this space, the resin sheet can be shaped into the mold.

[0007] (Fourth Viewpoint)

[0008] Patent Document 3 discloses a resin panel having a thin hinge portion.

[0009] Prior art literature

[0010] Patent Literature

[0011] Patent Document 1: International Publication No. 2020 / 026928

[0012] Patent Document 2: Japanese Patent Application Publication No. 2018-122462

[0013] Patent Document 3: Japanese Patent Application Publication No. 2019-051649 Summary of the Invention

[0014] Problems to be solved by the invention

[0015] (First point of view)

[0016] Depending on the structure of the burr (e.g., material, shape, surface area, etc.), it may be difficult for the movable portion of Patent Document 1 to engage with the burr. In this case, when the movable portion is driven, the burr does not move with the movable portion, and there is a high possibility that the burr cannot be cut from the resin sheet.

[0017] The present invention has been made in view of such circumstances, and provides a method for manufacturing a structure capable of more reliably cutting off burrs.

[0018] (Second Viewpoint)

[0019] In Patent Document 1, a pinch-off portion is formed at the end of the mold. Furthermore, when the movable portion is in its initial position, the movable portion abuts against the pinch-off portion. Therefore, in Patent Document 1, the cutting line of the burr portion is located at a position corresponding to the pinch-off portion. While the shape of the pinch-off portion is determined by the shape of the molded article, if the movable portion does not smoothly connect to the portion abutting the pinch-off portion, the cutting line may be deformed, making it difficult to cut the burr portion.

[0020] The present invention has been made in view of such circumstances, and provides a method for manufacturing a structure that can suppress the difficulty in cutting off the burrs.

[0021] (Third Viewpoint)

[0022] The outer frame needs to be retreated to a certain extent from its advanced position in order to properly shape the resin sheet on the mold. Depending on the retreat amount of the outer frame, the shape of the mold, etc., there are cases where the resin sheet becomes difficult to follow the mold surface, the resin sheet peels off from the mold surface or the outer frame, and molding defects occur.

[0023] The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method for manufacturing a structure capable of suppressing molding defects.

[0024] (Fourth Viewpoint)

[0025] One approach to thinning the hinge to make it easier to bend is to make it thinner. However, it is difficult to stably manufacture thin hinges, and slight manufacturing variations can cause problems such as breakage. There are only so many ways to achieve thinner hinges.

[0026] The present invention has been made in view of such circumstances, and provides a panel having an improved bending ease of a hinge portion.

[0027] Means used to solve problems

[0028] (First point of view)

[0029] According to the present invention, a method for manufacturing a structure is provided, which includes a molding process, a burr shaping process, and a cutting process. In the molding process, a mold is used to mold a molded body, the mold having a movable part and a first split mold and a second split mold in a pair, the first split mold and the second split mold respectively having a cavity part and a pinch-off part, the movable part is attached to the first split mold and the second split mold in a manner that can move relative to the first split mold and the second split mold, and the movable part has an attraction part and a locking part, the molded body has a molded body main body, a cutting line and a burr part, the molded body main body is at the In the molding process, the molded part is molded in the cavity part, the cutting line is flattened by the pinching part in the molding process, the burr part is connected to the molded body main body via the cutting line, and is arranged on the movable part. In the burr part shaping process, the burr part is attracted to the engaging part by the suction part, so that the burr part is shaped on the engaging part. In the cutting process, the movable part is relatively moved relative to the first split mold and the second split mold in the state that the burr part is shaped on the engaging part, so that the burr part is cut off from the molded body main body along the cutting line.

[0030] In the present invention, during the burr shaping step, the burr is sucked toward the engaging portion of the movable portion via a suction portion. This burr is thus shaped on the movable portion, allowing it to engage more reliably with the movable portion. Consequently, when the movable portion is moved relative to the first and second split molds, the burr is prevented from sliding relative to the movable portion, allowing the burr to follow the movable portion. As a result, the burr is more reliably severed from the main body of the molded article.

[0031] Various embodiments of the present invention are exemplified below.

[0032] A method is provided, preferably, the first split mold has an end surface portion, the movable portion has a contact surface portion, and in the burr portion forming step, the contact surface portion contacts the end surface portion.

[0033] In providing a method, preferably, the mold further includes a sealing member installed on the end surface portion or the abutting surface portion.

[0034] A method is provided, preferably, the first split mold has a first outer portion, the pinch-off portion of the first split mold is formed on the first outer portion, and the end face portion is formed on the first outer portion, the second split mold has a second outer portion, the pinch-off portion of the second split mold is formed on the second outer portion, and the second outer portion is configured to be opposite to the first outer portion in the opening and closing direction of the first split mold and the second split mold.

[0035] A method is provided, preferably, the molded body has a resin sheet and a skin material, and the skin material is arranged on the outside of the resin sheet.

[0036] A method is provided, preferably, a decompression suction hole is formed on each of the first split mold and the second split mold, the decompression suction hole is formed in the cavity portion, and the decompression suction hole is formed in such a manner that the resin sheet is shaped to the first split mold and the second split mold, and in a state where the resin sheet is shaped to the first split mold and the second split mold, the skin material arranged in the cavity portion is disposed in a manner following the first split mold, and the decompression suction hole is not formed in the first outside portion of the first split mold.

[0037] A method is provided, preferably, a skin material excess space is formed between the first outside portion and the second outside portion, and in the molding process, an end portion of the skin material is arranged in the skin material excess space.

[0038] (Second Viewpoint)

[0039] According to the present application, a method for manufacturing a structure is provided, which has a molding process, a fitting process, and a cutting process, in the molding process, a molded body is molded using a mold, the mold has a movable portion and a pair of first split mold and second split mold, the first split mold and the second split mold each have a cavity portion, an inside pinch portion, and an outside pinch portion, the inside pinch portion is connected to the cavity portion, the outside pinch portion is provided at a position further away from the cavity portion than the inside pinch portion, the movable portion is attached to the first split mold and the second split mold in a manner that allows relative movement with respect to the first split mold and the second split mold, and the movable portion has a fitting portion, the molded body has a molded body main body, an outside line portion, and an outside burr portion, the molded body main body has an inside line portion and an inside burr portion, the molded body main body is molded in the cavity portion in the molding process, the inside line portion is flattened by the inside pinch portion in the molding process, the inside burr portion is formed between the inside line portion and the outside line portion, the outside line portion is flattened by the outside pinch portion in the molding process, and the outside burr portion is connected to the outside line portion, in the fitting process, the outside burr portion is fitted to the fitting portion of the movable portion, and in the cutting process, the outside burr portion is cut from the inside burr portion in a manner following the outside line portion by relatively moving the movable portion with respect to the first split mold and the second split mold in a state where the outside burr portion is fitted to the fitting portion.

[0040] In the present invention, the first split mold and the second split mold each have an inner pinch-off portion connected to the cavity and an outer pinch-off portion provided at a position farther from the cavity than the inner pinch-off portion. The outer pinch-off portion is a portion that is not connected to the cavity and is a portion that separates the unnecessary inner burr portion from the outer burr portion. Therefore, the constraint that the outer pinch-off portion matches the shape of the peripheral portion of the molded body like the inner pinch-off portion is suppressed. Thus, in the present invention, since this constraint is suppressed, the pinch-off portion can be easily set to a shape that takes into account the connection with the movable portion, and as a result, the burr portion can be suppressed from becoming difficult to cut off.

[0041] Various embodiments of the present invention are exemplified below.

[0042] A method is provided, preferably, when the first split mold and the movable part are viewed from above, the outer pinch-off portion is formed along the engaging portion.

[0043] A method is provided, preferably, the top surface of the outer pinch-off portion is consistent with the top surface of the engaging portion.

[0044] A method is provided, preferably, the movable part further has a suction part, and in the engaging process, the outer burr part is sucked to the engaging part by the suction part, so that the outer burr part is shaped in the engaging part, thereby engaging the outer burr part with the engaging part.

[0045] A method is provided, preferably, the first split mold has an end surface portion, the movable portion has a contact surface portion, and in the engaging process, the outer burr portion is attracted to the engaging portion via the suction portion while the contact surface portion is in contact with the end surface portion.

[0046] In providing a method, preferably, the mold further includes a sealing member installed on the end surface portion or the abutting surface portion.

[0047] A method is provided, preferably, the first split mold has a first outer portion, on which the inner pinch-off portion and the outer pinch-off portion of the first split mold are formed, and the end face portion is formed, the second split mold has a second outer portion, on which the inner pinch-off portion and the outer pinch-off portion of the second split mold are formed, and the second outer portion is configured to be opposite to the first outer portion in the opening and closing direction of the first split mold and the second split mold.

[0048] A method is provided, wherein preferably, the molded body includes a resin sheet and a skin material, and the skin material is disposed outside the resin sheet.

[0049] A method is provided in which preferably a decompression suction hole is formed on each of a first split mold and a second split mold, the decompression suction hole is formed in a cavity portion, and the decompression suction hole is formed in such a manner that a resin sheet is shaped to the first split mold and the second split mold, in a state in which the resin sheet is shaped to the first split mold and the second split mold, the skin material disposed in the cavity portion is disposed along the first split mold, and the decompression suction hole is not formed in a first outer side portion of the first split mold.

[0050] A method is provided in which preferably a skin material excess space is formed between a first outer side portion and a second outer side portion, and in the molding process, an end portion of the skin material is disposed in the skin material excess space.

[0051] (Third Viewpoint)

[0052] According to the present application, a method for manufacturing a structure is provided, which uses a mold and an outer frame, in which a sag process, an adsorption process, and a shaping process are included, in the sag process, a molten resin sheet is sagged toward a front surface of the mold, the mold has a cavity portion, a pinch-off portion, and a chamfer portion, the chamfer portion is disposed between the outer frame and the pinch-off portion, and is formed so that a gap with the resin sheet that is sagged becomes wider in a direction from the pinch-off portion toward the outer frame, in the adsorption process, the outer frame is advanced, the resin sheet is adsorbed by the outer frame, and a closed space is formed between the outer frame, the resin sheet, and the mold, the outer frame is disposed around the mold, and is configured to be able to adsorb the resin sheet, and in the shaping process, the outer frame is retracted, and the closed space is decompressed so that the resin sheet is shaped to the cavity portion, the resin sheet moves together with the outer frame by the retraction of the outer frame so as to be disposed along the chamfer portion.

[0053] In the present application, since the mold has the chamfer portion, in the shaping process, when the resin sheet moves together with the outer frame, the resin sheet is smoothly disposed along the chamfer portion. Thus, peeling of the resin sheet from the mold or the outer frame can be suppressed, and formation of a molding defect can be avoided.

[0054] Hereinafter, various embodiments of the present application will be described.

[0055] A method is provided in which preferably the chamfer portion is constituted by a tapered surface.

[0056] A method is provided in which an inclination angle of the tapered surface is 60 degrees or less.

[0057] A method is provided in which preferably in the shaping process, the outer frame is retracted to a position of a rear end portion of the chamfer portion.

[0058] A method is provided, preferably, in the molding process, the outer frame has a retreat distance of 30 mm or more and 80 mm or less.

[0059] A method is provided, preferably, in the manufacturing method, a movable portion is further used, and the manufacturing method further has a molding process, the mold has a first split mold and a second split mold, the movable portion is configured to relatively move with respect to the first split mold, cut a portion of the resin sheet, and be attached around the first split mold, the second split mold has the chamfer portion, the outer frame is arranged around the second split mold, in the molding process, the first split mold and the second split mold are closed, and at least a portion of the movable portion is arranged at a position closer to the outer frame than a position of the front end portion of the chamfer portion in a state where the molding process is completed.

[0060] A method is provided, preferably, a width of the chamfer portion in an opening and closing direction of the mold is 10 mm or more and 63 mm or less.

[0061] A method is provided, preferably, a width of the chamfer portion in a direction from the pinch-off portion toward the outer frame is 5.7 mm or more.

[0062] (Fourth Viewpoint)

[0063] According to the present application, a panel is provided, having a resin panel body, wherein the resin panel body has a first body portion, a second body portion, and a hinge portion provided integrally, the hinge portion has a hinge sheet and a slit, the hinge sheet rotatably links the first body portion and the second body portion, and the slit is provided beside the hinge sheet to separate the first body portion and the second body portion.

[0064] In the present application, by providing the slit, the bending easiness of the hinge portion can be improved.

[0065] Hereinafter, various embodiments of the present application will be exemplified. The embodiments shown below can be combined with each other.

[0066] Preferably, a skin material is provided, which is attached to the first body portion and the second body portion across the hinge portion.

[0067] Preferably, when a length of both ends of the hinge portion is set as a total length L0, and a total length of the slit is set as a slit total length L S , L S / L0 is 0.50 to 0.99.

[0068] Preferably, the hinge sheet includes end portion hinge sheets respectively provided at both ends of the hinge portion.

[0069] Preferably, the hinge piece comprises a middle hinge piece, and the middle hinge piece is arranged between the end hinge pieces. BRIEF DESCRIPTION OF THE DRAWINGS

[0070] Figure 1A It is a perspective view of the resin panel 1 according to the embodiment of the first viewpoint to the third viewpoint. Figure 1B It is a perspective view of the core material 3 according to the embodiment of the first viewpoint to the third viewpoint.

[0071] Figure 2A It is an exploded perspective view of the core material 3 according to the embodiment of the first aspect to the third aspect. Figure 2B yes Figure 2A Magnified view of area B in FIG. Figure 2C is an end view of the reinforcing member 3c.

[0072] Figure 3 This is a front view showing the structure of the molding machine 10 according to the first and second viewpoints (the first split mold 21 and the second split mold 22 and their adjacent components are cross-sectional views). Figure 3 In, omitted Figure 5 A diagram of the drive mechanism 24 is shown.

[0073] Figure 4A It is a perspective view of the insertion device 19 of the embodiment of the first viewpoint and the second viewpoint, Figure 4B A state in which the core material 3 is installed in the insertion device 19 is shown.

[0074] Figure 5 It is a perspective view of the first split mold 21 and the second split mold 22 in the state of being opened according to the embodiment of the first viewpoint and the second viewpoint.

[0075] Figure 6 yes Figure 5 An enlarged view of area A is shown.

[0076] Figure 7 It is from Figure 5 Perspective views of the first split mold 21 and the second split mold 22 when viewed from different directions.

[0077] Figure 8 yes Figure 7 An enlarged view of area A is shown.

[0078] Figure 9A It is a perspective view of a pair of movable parts 23 according to the first viewpoint and the second viewpoint. Figure 9B yes Figure 9A An enlarged view of area B is shown.

[0079] Figure 10A as well as Figure 10BIt is a front view showing the operation of the movable portion 23 when the first cutting step of the embodiment according to the first viewpoint and the second viewpoint is performed.

[0080] Figure 11 It is used to explain the molding process of the embodiment of the first viewpoint and the second viewpoint. Figure 3 Corresponding illustration.

[0081] Figure 12 This is an end view showing a state in which the first split mold 21 and the second split mold 22 are closed and the movable portion 23 is located at the initial position in the embodiment of the first viewpoint and the second viewpoint. Figure 12 and Figure 3 The AA end shown corresponds.

[0082] Figure 13 In the embodiments of the first and second aspects, the state is shown after the engaging step (burr forming step) and at the start of the first cutting step. Figure 13 is with Figure 12 Area A shown corresponds to an end view.

[0083] Figure 14 This is an operation diagram for explaining the first cutting step according to the first and second viewpoints. Figure 14 , the movable portion 23 moves away from the first split mold 21 , and the outer burr portion 5bc2 is cut from the inner burr portion 5bc1 .

[0084] Figure 15 The front views of the molded body 5 according to the first to third aspects of the embodiment are shown.

[0085] Figure 16 It is schematically shown in the first viewpoint and the second viewpoint, Figure 13 The front view of the molded body 5 is shown in a state where the outer burr portion 5bc2 is cut from the inner burr portion 5bc1. Figure 16 , in the first viewpoint and the second viewpoint, the outer burr portion 5bc2 is pulled by the movable portion 23 and is torn along the right line 5cr and the left line 5cl. Figure 16 The figure schematically shows a state in which the outer burr portion 5bc2 of the molded body 5 is cut from the inner burr portion 5bc1 by performing the first cutting step in the third aspect.

[0086] Figure 17 It is an end view of the first split mold 21 and the second split mold 22 of the modification of the embodiment of the first viewpoint and the second viewpoint. Figure 17 The state at the start of the first cutting step is shown.

[0087] Figure 18It is an operation explanatory diagram of the first cutting step in the modification of the embodiment of the first viewpoint and the second viewpoint.

[0088] Figure 19 It is a cross-sectional view of a first split mold 21 and a second split mold 22 used when manufacturing a resin panel having a hinge portion in the embodiment of the first viewpoint and the second viewpoint. Figure 19 This is a cross-sectional view taken along a plane passing through the hinge portion of the resin panel and parallel to the extending direction of the hinge portion.

[0089] Figure 20A It is an exploded perspective view of the first split mold 21 and the movable portion 23 of Modification 2 of the embodiment of the first viewpoint and the second viewpoint. Figure 20B It is from Figure 20A Exploded stereograms when viewed from different directions. Figure 20C The movable portion 23 is shown in a state where it is supported by the support portion 21 f.

[0090] Figure 21 This is a front view showing the structure of the molding machine 10 according to the embodiment of the third viewpoint (the first split mold 21 and the second split mold 22 , the outer frame 31 , the core material 3 , etc. are cross-sectional views).

[0091] Figure 22 This is a perspective view showing the first split mold 21 and the second split mold 22 and the outer frames 31 and 32 in a state where the first split mold 21 and the second split mold 22 are being opened according to the embodiment of the third aspect.

[0092] Figure 23 yes Figure 22 An enlarged view of area A is shown.

[0093] Figure 24 It is from Figure 22 The three-dimensional diagram of the first split mold 21 and the second split mold 22 and the outer frames 31 and 32 when viewed from different directions. Figures 28 to 34 In the figure, the first split mold 21 and the second split mold 22 are shown. Figure 24 The end face is cut by a horizontal plane passing through the upper and lower points P1. Figure 26 as well as Figure 27 In the figure, the first split mold 21 and the second split mold 22 are shown. Figure 24 The end face is cut by a vertical plane passing through the upper and lower points P2.

[0094] Figures 25A to 25C The operation of the movable portion 23 when the first cutting step of the embodiment according to the third aspect is performed will be described.

[0095] Figure 26The embodiment according to the third aspect shows a state in which the skin material attaching step is completed and the hanging step is being performed.

[0096] Figure 27 The diagram shows a state in which the adsorption step according to the embodiment of the third aspect is being performed.

[0097] Figure 28 yes Figure 27 Horizontal end views of the first split mold 21 and the second split mold 22 are shown.

[0098] Figure 29 yes Figure 28 The enlarged view of area A is shown. Figure 29 In FIG. 1 , the dotted lines L1 and L5 correspond to the position of the rear end portion 22 ab , the dotted lines L2 and L4 correspond to the position of the front end portion 22 af , and the dotted line L3 corresponds to the position of the front end surface of the outer frame 32 .

[0099] Figure 30 A state in which the shaping step of the embodiment according to the third aspect is performed is shown.

[0100] Figure 31 A state in which the core material welding step according to the embodiment of the third aspect is performed is shown.

[0101] Figure 32 A state in which the molding step of the embodiment according to the third aspect is performed is shown.

[0102] Figure 33 yes Figure 32 The main parts of the first split mold 21 and the second split mold 22 are enlarged. Figure 33 In FIG. 1 , the dotted line T1 corresponds to the position of the front end surface of the outer frame 32 , the dotted line T2 corresponds to the position of the front end surface of the suction portion 23 g , and the dotted line T3 corresponds to the position of the facing surface portion 23 a .

[0103] Figure 34 The state in which the first cutting step of the embodiment of the third viewpoint is performed is shown. Figure 34 , the movable portion 23 moves away from the first split mold 21 , and the outer burr portion 5bc2 is cut from the inner burr portion 5bc1 .

[0104] Figure 35A This is a top view of the panel from the surface side (skin material side). Figure 35B is a side view of the panel.

[0105] Figure 36A This is a top view of the panel from the back side. Figure 36B It is a cross-sectional view along line AA.

[0106] Figure 37It is an enlarged plan view of parts B1 to B3 of FIG. 36 on the back surface of the panel.

[0107] Figure 38 It is along Figure 37 Cross-sectional view of the CC line.

[0108] Figure 39 is a cross-sectional view showing an example of a state in which the hinge portion bends.

[0109] Figure 40 This is a structural diagram of a molding machine 10 that can be used for manufacturing panels (a longitudinal cross-sectional view of molds 121 and 131 and their adjacent components).

[0110] Figure 41 It is shown in Figure 40 The dotted line D is a cross-sectional view showing the situation when the mold is closed. DETAILED DESCRIPTION

[0111] The following describes the embodiments of the present invention. The various features described in the embodiments below can be combined with each other. In addition, each feature can independently establish the invention.

[0112] (Common to both the first and second viewpoints)

[0113] 1. About resin panel 1

[0114] As shown in FIG. 1 , a resin panel 1 (an example of a “structure”) according to one embodiment of the present invention is a panel covered with a resin molded body 2 having a substantially rectangular shape in a plan view.

[0115] As shown in Figure 1~ Figure 2C As shown, the resin panel 1 includes a hollow resin molded body 2 and a core material 3, with the core material 3 being disposed within the resin molded body 2. A skin material 4 is attached to one side of the resin molded body 2 so as to extend to the parting line PL. The skin material 4 is, for example, a nonwoven fabric and is integrally formed with the resin molded body 2 during molding.

[0116] Both surfaces of the core material 3 are in close contact with the resin molded body 2. The core material 3 is composed of base bodies 3a and 3b and a reinforcing member 3c connecting them. The reinforcing member 3c is an elongated member with a fixed cross-sectional shape. The base bodies 3a and 3b are composed of, for example, foam.

[0117] The reinforcing member 3c is roughly H-shaped and consists of an upper wall 3c1, a lower wall 3c2, and a column 3c3 connecting them. At both ends of the upper wall 3c1 in the width direction, protrusions 3c11 are provided that protrude toward the lower wall 3c2. At both ends of the lower wall 3c2 in the width direction, protrusions 3c21 are provided that protrude toward the upper wall 3c1. The protrusions 3c11 and 3c21 engage with the bases 3a and 3b, integrating the bases 3a and 3b with the reinforcing member 3c. At the ends of the bases 3a and 3b, recessed one-level recesses 3a1 and 3b1 are provided. By accommodating the upper wall 3c1 and lower wall 3c2 in the recesses 3a1 and 3b1, the upper and lower surfaces of the bases 3a and 3b and the reinforcing member 3c become roughly flush.

[0118] 2. Method for Manufacturing Resin Panel 1

[0119] 2-1. Description of manufacturing apparatus

[0120] like Figure 3 As shown, in the manufacturing method of the embodiment, a molding machine 10 and an inserting device 19 are used to form Figure 15 The molded body 5 shown. Figure 3 As shown in FIG. 9 , the molding machine 10 includes a pair of sheet forming devices 14 , a first split mold 21 , a second split mold 22 , a movable portion 23 , and a drive mechanism 24 .

[0121] 2-1-1. Structure of the sheet forming device 14

[0122] like Figure 3 As shown, the sheet forming device 14 includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18. The extruder 13 and the accumulator 17 are connected via a connecting pipe 15. The accumulator 17 and the T-die 18 are connected via a connecting pipe 16. Each structure will be described in detail below.

[0123] <Hopper 12, Extruder 13>

[0124] The hopper 12 is used to feed the raw resin 11 into the cylinder 13a of the extruder 13. The form of the raw resin 11 is not particularly limited, but is generally in a granular form. The raw resin is, for example, a thermoplastic resin such as polyolefin. Examples of polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer, and mixtures thereof. The raw resin 11 may also include recycled raw materials produced by crushing the burrs with a grinder. After the raw resin 11 is fed from the hopper 12 into the cylinder 13a, it is heated and melted in the cylinder 13a to become a molten resin. In addition, it is transported toward the front end of the cylinder 13a by the rotation of the screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and its rotation mixes the molten resin while transporting it. A gear device is provided at the base end of the screw, and the screw is driven to rotate by the gear device.

[0125] <Accumulator 17, T-die 18>

[0126] The raw resin is extruded from the resin extruder in cylinder 13a and injected into accumulator 17 through connecting tube 15. Accumulator 17 comprises cylinder 17a and a piston 17b slidable therein. Molten resin 11a can be stored in cylinder 17a. After a predetermined amount of molten resin 11a is stored in cylinder 17a, piston 17b is moved, forcing molten resin 11a through slits provided in T-die 18 via connecting tube 16, causing it to droop and form molten resin sheets p1 and p2.

[0127] 2-1-2. First split mold 21 and second split mold 22

[0128] like Figure 11 As shown, the resin sheets p1 and p2 are guided between the first split mold 21 and the second split mold 22. The first split mold 21 and the second split mold 22 can be split by the parting surface that abuts when the mold is closed, and the molded body 5 is formed by the first split mold 21 and the second split mold 22. That is, in the molding process, the molded body 5 is formed using a pair of split first split molds 21 and second split molds 22. In addition, in the embodiment, a skin margin space sp is formed between the first split mold 21 and the second split mold 22 (refer to Figure 13 ). During the forming process, the end of the skin material 4 is arranged in the skin margin space sp.

[0129] <First split mold 21>

[0130] like Figure 7 、 Figure 8 、 Figure 13 as well as Figure 14As shown, the first split mold 21 includes a main body 21a1, a pair of first outer sides 21a2, and an end face 21a3. A cavity cvt (see Figure 12 ). When the first split mold 21 and the second split mold 22 are closed, the cavity portion cvt is a closed space formed between the first split mold 21 and the second split mold 22, and is a space for molding the molded body. The first outer portion 21a2 is connected to the end portion (left and right end portion) of the main body 21a1 in the transverse width direction. In addition, the so-called transverse width direction is a direction that is perpendicular to the opening and closing direction of the first split mold 21 and the second split mold 22 and perpendicular to the up and down direction. A surface for the movable portion 23 to abut is formed on the end surface portion 21a3. In an embodiment, the end surface portion 21a3 is formed on the side surface of the first outer portion 21a2.

[0131] The first split mold 21 is provided with a plurality of pressure reducing and suction holes h1 (refer to Figure 13 ), the resin sheet p1 can be vacuum-sucked and shaped into a shape along the inner surface 21b of the first split mold 21. In addition, the inner surface 21b faces the cavity portion cvt.

[0132] The first split mold 21 has a pinch-off portion 21d, which is provided so as to surround the cavity portion cvt. The pinch-off portion 21d is a protrusion formed from the first split mold 21 side toward the second split mold 22 side. The pinch-off portion 21d has an inner pinch-off portion 21d1 and an outer pinch-off portion 21d2. Figure 13 As shown, the inner pinch-off portion 21d1 and the outer pinch-off portion 21d2 are formed on the first outer portion 21a2.

[0133] The inner pinch-off portion 21d1 is provided so as to face the cavity portion cvt. The inner pinch-off portion 21d1 is formed into a shape corresponding to the shape of the resin panel 1. Specifically, in the embodiment, the top surface of the inner pinch-off portion 21d1 is a flat surface. Furthermore, in the embodiment, the inner pinch-off portion 21d1 extends in a curved, straight line.

[0134] The outer pinch-off portion 21d2 is provided at a position farther from the cavity portion cvt than the inner pinch-off portion 21d1. The outer pinch-off portion 21d2 is formed to match the shape of the movable portion 23. Specifically, the outer pinch-off portion 21d2 is formed to fit the engaging portion 23d (see FIG. 2 ) of the movable portion 23 described later. Figure 8 ) is a shape that matches the shape of the engaging portion 23d (hereinafter referred to as the closest engaging portion 23d) closest to the first split mold 21. In addition, when the first split mold 21 and the movable portion 23 are viewed from above (from Figure 11(When viewing the first split mold 21 and movable portion 23 in the direction of arrow C2, the outer pinch-off portion 21d2 is formed along the closest engaging portion 23d. In other words, when viewing the first split mold 21 and movable portion 23 from above, the outer pinch-off portion 21d2 is formed parallel to the closest engaging portion 23d. This prevents deformation of the cutting line of the burr portion, making it difficult to cut the burr portion.)

[0135] In addition, in the embodiment, the closest engaging portion 23d is described as being located at the end of the facing surface portion 23a of the movable portion 23, which will be described later. However, the present invention is not limited thereto. The closest engaging portion 23d may also be located at a position that is further inward than the end of the facing surface portion 23a in the driving direction of the movable portion 23.

[0136] Furthermore, the top surface of the outer pinch-off portion 21d2 coincides with the top surface of the closest engaging portion 23d. In other words, when the top surface of the outer pinch-off portion 21d2 is extended, it overlaps with the top surface of the closest engaging portion 23d. Therefore, the top surface of the outer pinch-off portion 21d2 smoothly connects to the top surface of the closest engaging portion 23d. Therefore, in this embodiment, deformation of the cutoff line of the burr portion is more effectively avoided, effectively preventing the burr portion from becoming difficult to cut.

[0137] Furthermore, in the embodiment, the shape of the inner pinch-off portion 21d1 corresponds to the shape of the closest engaging portion 23d, and therefore the outer pinch-off portion 21d2 is formed parallel to the inner pinch-off portion 21d1. However, the shape of the outer pinch-off portion 21d2 need not be limited to the shape of the inner pinch-off portion 21d1. In other words, the shape of the outer pinch-off portion 21d2 can be determined to match the shape of the movable portion 23. In other words, while the shape of the inner pinch-off portion 21d1 is limited by the shape of the resin panel 1, the outer pinch-off portion 21d2 is not limited by the shape of the resin panel 1 and can adopt a shape that matches the shape of the movable portion 23.

[0138] The first split mold 21 has a male protrusion 21e. The male protrusion 21e is provided at a position facing a female protrusion 19c (described later) of the insertion device 19. The male protrusion 21e is slidable relative to the first split mold 21 and is housed within the first split mold 21.

[0139] <Second split mold 22>

[0140] like Figure 13 As shown, the second split mold 22 has a main body 22a1, a pair of second outer sides 22a2, and a pair of opposing parts 22a3. A cavity cvt (see Figure 12The second outer portion 22a2 is connected to the ends (left and right ends) of the main body 22a1 in the lateral direction. Furthermore, each opposing portion 22a3 is connected to the ends of each second outer portion 22a2 in the lateral direction. The opposing portion 22a3 is arranged so as to face the movable portion 23.

[0141] The second split mold 22 is provided with a plurality of pressure reducing and suction holes h1 (refer to Figure 13 ), the resin sheet p2 can be vacuum-sucked and shaped into a shape along the inner surface 22b of the second split mold 22. In addition, the inner surface 22b faces the cavity portion cvt.

[0142] The second split mold 22 has a pinch-off portion 22d, which is provided so as to surround the cavity portion cvt. The pinch-off portion 22d is a protrusion formed so as to protrude from the second split mold 22 side toward the first split mold 21 side. The pinch-off portion 22d has an inner pinch-off portion 22d1 and an outer pinch-off portion 22d2. Figure 13 As shown, the inner pinch-off portion 22d1 and the outer pinch-off portion 22d2 are formed on the second outer portion 22a2.

[0143] The inner pinch-off portion 22d1 and the outer pinch-off portion 22d2 have the same structure as the inner pinch-off portion 21d1 and the outer pinch-off portion 21d2. The inner pinch-off portion 22d1 is positioned facing the cavity portion cvt. The inner pinch-off portion 22d1 is formed into a shape corresponding to the shape of the resin panel 1. Specifically, the top surface of the inner pinch-off portion 22d1 is flat. The inner pinch-off portion 22d1 also extends in a curved, straight line.

[0144] The outer pinch-off portion 22d2 is positioned farther from the cavity portion cvt than the inner pinch-off portion 22d1. Like the outer pinch-off portion 21d2, the outer pinch-off portion 22d2 is formed to match the shape of the movable portion 23. The top surface of the outer pinch-off portion 22d2 coincides with the top surface of the closest engaging portion 23d. Therefore, the top surface of the outer pinch-off portion 22d2 smoothly connects to the top surface of the closest engaging portion 23d.

[0145] <Surface material margin space sp>

[0146] The skin material excess space sp is a space for arranging excess skin material 4. Furthermore, the end portion of the skin material 4 is arranged in the skin material excess space sp. The skin material excess space sp is formed between the first split mold 21 and the second split mold 22. Specifically, the skin material excess space sp is the space between the first outer portion 21a2 and the second outer portion 22a2, and between the inner pinch-off portions 21d1 and 22d1 and the outer pinch-off portions 21d2 and 22d2.

[0147] The skin material 4 used during molding is larger than the size of the cavity portion cvt. Therefore, during molding, excess skin material 4 is generated. In addition, the excess skin material 4 is cut off by the operator in the subsequent process. In addition, the raw resin 11 that constitutes the burr portion can be reused, but once the excess skin material 4 adheres to the resin sheet p1 corresponding to the raw resin 11, it will stick together, and there may be a case where it is difficult to peel the skin material 4 from the resin sheet p1. In the case where it cannot be peeled off, the burr portion will be discarded, so the resin cannot be reused. Therefore, in the embodiment, a skin material margin space sp is formed on the first split mold 21 and the second split mold 22.

[0148] Here, when the thickness of the resin sheet p1 and the thickness of the resin sheet p2 are 0.6 (mm) to 1.7 (mm), Figure 13 The following description will be given with reference to the width w1 of the skin material allowance space sp and the depth w2 of the skin material allowance space sp shown.

[0149] The horizontal width dimension w1 is preferably set to 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, 20.0, 20.5, 21.0, 21.5, 22.0, 22.5, 23.0, 23.5, 24.0, 24.5, 25.0 (mm), and the horizontal width dimension w1 can also be within the range between any two values ​​exemplified here.

[0150] In addition, the depth dimension w2 of the surface material margin space sp is preferably set to 4.0, 4.2, 4.4, 4.6, 4.8, 5.0, 5.2, 5.4, 5.6, 5.8, 6.0, 6.2, 6.4, 6.6, 6.8, 7.0, 7.2, 7.4, 7.6, 7.8, 8.0 (mm), for example. In addition, the depth dimension w2 can also be within the range between any two values ​​exemplified here.

[0151] By setting the width w1 and the depth w2 of the skin material allowance space sp in this manner, it is possible to suppress adhesion of the skin material 4 and the resin sheet p1 .

[0152] Furthermore, the first outer portion 21a2 is not provided with pressure-reducing and suction holes h1. In other words, while the cavity portions cvt of the first and second split molds 21 and 22 are formed with pressure-reducing and suction holes h1, the first outer portion 21a2 is not provided with pressure-reducing and suction holes h1. This effectively prevents adhesion between the skin material 4 and the resin sheet p1. Furthermore, while the embodiment describes the provision of pressure-reducing and suction holes h1 on the second outer portion 22a2, this is not limiting and the provision of pressure-reducing and suction holes h1 is also possible.

[0153] 2-1-3. Structure of the movable portion 23

[0154] The movable portion 23 has the function of engaging with the burr portion and cutting the burr portion. The movable portion 23 is configured to be movable relative to the first split mold 21 and the second split mold 22. Figures 9A to 10B as well as Figure 13 As shown, the movable portion 23 is attached to the side of the first outer portion 21a2 of the first split mold 21. The movable portion 23 includes a facing surface portion 23a, a contact surface portion 23b, a suction portion 23c, an engaging portion 23d, and a sealing member 23e.

[0155] like Figure 13 As shown, the facing surface portion 23a is provided so as to face the facing portion 22a3 of the second split mold 22. A plurality of engaging portions 23d are formed on the facing surface portion 23a.

[0156] like Figure 14 As shown, the contact surface portion 23b is formed so as to be able to contact the end surface portion 21a3 of the first split mold 21. The contact surface portion 23b is formed along the end surface portion 21a3. Therefore, when the contact surface portion 23b contacts the end surface portion 21a3 and air is decompressed and sucked through the decompression suction hole h1, air can be prevented from flowing from between the contact surface portion 23b and the end surface portion 21a3 into the portion where the resin is formed. The portion where the resin is formed includes, for example, the space within the cavity portion cvt and the gap between the burr portion and the surface of the engaging portion 23d.

[0157] like Figure 13 As shown, the suction portion 23c is a hole formed in the opposing surface portion 23a and opens in the area where the engaging portion 23d is formed. By decompressing and drawing air through the suction portion 23c, the burr portion (outer burr portion 5bc2) is shaped by the engaging portion 23d. This allows the burr portion (outer burr portion 5bc2) to be more securely hooked onto the movable portion 23, preventing the burr portion from sliding relative to the movable portion 23 when the movable portion 23 is driven. As a result, in the embodiment, the burr portion appropriately follows the movable portion 23 when the movable portion 23 is driven, enabling more reliable cutting of the burr portion.

[0158] For example, when the resin sheet p1 is formed into the cavity cvt, if the suction unit 23c applies reduced pressure, wrinkles, etc., may form on the resin sheet p1, potentially impairing moldability. Therefore, the reduced pressure suction system in the suction unit 23c is independent of the reduced pressure suction system in the reduced pressure suction holes h1 of the first split mold 21. This allows for separate control of the timing of reduced pressure suction in the suction unit 23c and the timing of reduced pressure suction in the reduced pressure suction holes h1, thus preventing impairment of moldability.

[0159] The engaging portion 23d has the function of engaging with the burr portion. The engaging portion 23d is a protrusion formed so as to protrude toward the second split mold 22. Multiple engaging portions 23d are formed on the opposing surface portion 23a, so the area of ​​the opposing surface portion 23a where the engaging portions 23d are formed has a concave-convex shape. Furthermore, in the embodiment, the suction portion 23c is described as opening in the area between two adjacent engaging portions 23d on the opposing surface portion 23a, but this is not limiting. The suction portion 23c may also open on the surface of the engaging portion 23d.

[0160] like Figure 9B As shown, the sealing member 23e is attached to the abutting surface portion 23b. Specifically, a groove is formed in the abutting surface portion 23b, and the sealing member 23e is installed in the groove. This effectively prevents air from flowing between the abutting surface portion 23b and the end surface portion 21a3 into the portion where the resin is shaped. Furthermore, while the embodiment illustrates the case where the sealing member 23e is attached to the abutting surface portion 23b, this is not limiting. The sealing member 23e may also be attached to the end surface portion 21a3 of the first split mold 21.

[0161] 2-1-4. Structure of the drive mechanism 24

[0162] like Figure 5 As shown in FIG. 2 , the driving mechanism 24 is arranged on the back side of the first split mold 21. The driving mechanism 24 is configured to drive the movable portion 23. Figure 5 As shown, the drive mechanism 24 includes a pair of upper drive mechanisms 24a and a pair of lower drive mechanisms 24b. Each of the upper drive mechanisms 24a and the lower drive mechanisms 24b can be composed of, for example, a cylinder. Each of the upper drive mechanisms 24a and the lower drive mechanisms 24b is arranged astride the first split mold 21 and the movable portion 23, and each of the upper drive mechanisms 24a and the lower drive mechanisms 24b is fixed to the first split mold 21 and the movable portion 23. The movable portion 23 moves as the cylinders of the upper drive mechanisms 24a and the lower drive mechanisms 24b extend.

[0163] Each upper drive mechanism 24a and each lower drive mechanism 24b can be controlled independently. Figure 10A as well as Figure 10BAs shown, the drive mechanism 24 can move the lower portion of the movable portion 23 after moving the upper portion of the movable portion 23. This makes the force for tearing the burrs localized, and the movable portion 23 can tear the burrs smoothly.

[0164] 2-1-5. Insertion device 19

[0165] The insertion device 19 is configured to be movable by a driving mechanism (not shown). Figure 4A As shown, the inserting device 19 includes a base 19a, a suction pad 19b, and a female protrusion 19c. Each component is held by the base 9a. The suction pad 9b is used to absorb and hold the core material 3. The female protrusion 19c can hold the skin material 4 and is used to attach the skin material 4 to the first split mold 21.

[0166] 2-2. Molded body 5

[0167] The resin panel 1 is formed by forming a molded body 5 (see Figure 15 ) is obtained by removing the burrs. That is, the molded body 5 is a molded body in a state before the burrs are removed after being molded with a mold.

[0168] like Figure 15 As shown, the molded article 5 is composed of a molded article body 5a and a large burr portion 5b connected by a cut line 5c provided so as to surround the molded article body 5a. The cut line 5c corresponds to the portion crushed by the pinch-off portions 21d and 22d. By cutting the molded article 5 along the cut line 5c along the entire circumference of the molded article body 5a, the molded article 5 can be separated into the molded article body 5a and the large burr portion 5b.

[0169] like Figure 15 as well as Figure 16 As shown, the molded body 5a is composed of a portion (molded product 5d) corresponding to the above-mentioned resin panel 1, and a small burr portion 5e and an inner burr portion 5bc1 connected to the portion. In other words, the resin panel 1 can be obtained by removing the small burr portion 5e and the inner burr portion 5bc1 from the molded body 5a.

[0170] The large burr portion 5b is composed of an upper burr portion 5bu located above the molded body 5a, a lower burr portion 5bb located below the molded body 5a, and an outer burr portion 5bc2 located between the upper burr portion 5bu and the lower burr portion 5bb. The outer burr portion 5bc2 is connected to the inner burr portion 5bc1 before being cut by the movable portion 23.

[0171] like Figure 13As shown, the inner burr portion 5bc1 is composed of the resin sheets p1 and p2 and the skin material 4. On the other hand, the outer burr portion 5bc2 is composed of the resin sheets p1 and p2. In other words, the outer burr portion 5bc2 does not include the skin material 4. In other words, the skin material 4 is positioned so that its end is located between the inner pinch-off portions 21d1 and 22d1 and the outer pinch-off portions 21d2 and 22d2.

[0172] The cutting line 5c includes a left line 5cl (an example of an outer line portion), a right line 5cr (an example of an outer line portion), an upper line 5cu, and a lower line 5cb. The left line 5cl, the right line 5cr, the upper line 5cu, and the lower line 5cb are arranged from Figure 11 The closing direction of the second split mold 22 shown ( Figure 11 When observing the molded body 5 in the direction of arrow C2, they are respectively arranged on the left side, right side, upper side and lower side of the molded body main body 5a.

[0173] In this embodiment, a first cutting step is performed to cut the molded article 5 along the right line 5cr and the left line 5cl using the first and second split molds 21, 22, and the movable portion 23. After the molded article 5 is removed from the first and second split molds 21, 22, a second cutting step is performed to cut the molded article 5 along the remaining portion of the cutting line 5c (that is, the upper line 5cu and the lower line 5cb).

[0174] The molded body 5a is formed by connecting the molded product 5d (equivalent to the resin panel 1), the small burrs 5e, and the inner burrs 5bc1 via a parting line 5f. In other words, the molded body 5a comprises the molded product 5d, the small burrs 5e, the inner burrs 5bc1, and a portion of the parting line 5f (the left line 5f1 and the right line 5fr). Therefore, by cutting the molded body 5a along the parting line 5f along the entire circumference of the molded product 5d, the small burrs 5e and the inner burrs 5bc1 can be separated from the molded product 5d.

[0175] The parting line 5f includes a left line 5f1 (an example of an inner line portion), a right line 5fr (an example of an inner line portion), an upper line 5fu, and a lower line 5fb. The left line 5f1, the right line 5fr, the upper line 5fu, and the lower line 5fb are arranged from Figure 11 The second split molds 22 shown are arranged on the left side, right side, upper side, and lower side of the molded body main body 5 a when viewing the molded body 5 in the mold closing direction (arrow C2 ).

[0176] Furthermore, in the embodiment, the lower line 5cb of the cutting line 5c and the lower line 5fb of the parting line 5f overlap.

[0177] Further, the upper line 5cu of the cut line 5c is provided adjacent to the upper side of the upper line 5fu of the parting line 5f. Therefore, the molded product 5d and the small flash portion 5e are joined via the upper line 5fu.

[0178] Further, the left line 5cl and the right line 5cr of the cut line 5c are provided adjacent to the left line 5fl and the right line 5fr of the parting line 5f, respectively. Therefore, the molded product 5d and the inner side flash portion 5bc1 are joined via the left line 5cl and the right line 5cr.

[0179] The upper line 5fu of the parting line 5f is not linear. Therefore, for example, the operator needs to cut the molded body 5 along the upper line 5fu using a cutter. Therefore, in the present embodiment, the upper line 5cu which is linear is provided adjacent to the upper side of the upper line 5fu. Further, in the present embodiment, the lower line 5fb of the parting line 5f is also linear. Such a linear line can be cut using a cutter of a flash cutting device. In this way, after the left line 5cl and the right line 5cr are cut, the upper line 5cu and the lower line 5cb are cut, and the molded body main portion 5a is separated from the large flash portion 5b.

[0180] 2-3. Explanation of each process of the manufacturing method

[0181] The manufacturing method of the resin-made panel 1 of the present embodiment has a skin material installation process, a sag process, a resin sheet molding process, a core material welding process, a molding process, an engagement process, a first cutting process, a molded body extraction process, a second cutting process, and a post-process.

[0182] 2-3-1. Skin material installation process

[0183] In the skin material installation process, the skin material 4 is installed to the first split mold 21. Specifically, the female protrusion 19c is inserted into the through hole formed in the skin material 4 in advance, and the skin material 4 is held to the insertion device 19 as shown in FIG. 2B. In the skin material installation process, after the female protrusion 19c and the male protrusion 21e are opposed, the two are engaged, and in this state, the skin material 4 is moved toward the male protrusion 21e by pressing the skin material 4 toward the male protrusion 21e. Thus, as shown in FIG. 2C, the skin material 4 is installed to the first split mold 21. Figure 3 Figure 11

[0184] 2-3-2. Sag process

[0185] In the sag process, as shown in FIG. 2D, the first split mold 21 is moved downward, and the skin material 4 is sagged. Thus, as shown in FIG. 2E, the skin material 4 is sagged to the first split mold 21. Figure 11 ​​As shown, resin sheets p1 and p2 extruded from the T-die 18 are allowed to droop between the first split die 21 and the second split die 22. Resin sheet p1 droops between the core material 3 and the skin material 4. Resin sheet p2 droops between the insert device 19 and the second split die 22. In this embodiment, direct vacuum forming is performed using the resin sheets p1 and p2 extruded from the T-die 18. Therefore, the resin sheets p1 and p2 do not need to be cooled to room temperature and hardened before molding, nor do they need to be heated before molding.

[0186] 2-3-3. Resin sheet shaping process

[0187] When implementing the resin sheet shaping process, the resin sheet p1 is preliminarily brought into close contact with the protruding portion (for example, the pinch-off portion) of the first split mold 21, and a closed space is formed between the resin sheet p1 and the first split mold 21. The same applies to the resin sheet p2 and the second split mold 22. In addition, when forming a closed space, an outer frame (not shown) that is separate from the first split mold 21 and the second split mold 22 can also be used. Each outer frame is arranged on the peripheral surface of the first split mold 21 and the second split mold 22. Moreover, each outer frame is free to move in the opening and closing direction of the first split mold 21 and the second split mold 22, and is formed with a decompression suction hole. The outer frame of the first split mold 21 is in close contact with the resin sheet p1 by attracting the resin sheet p1, and a closed space is formed between the first split mold 21, the resin sheet p1 and the outer frame. The same applies to the outer frame of the second split mold 22.

[0188] Then, in the resin sheet shaping process, the air in the enclosed space is decompressed and sucked through the decompression and suction holes h1 in the first and second split molds 21, 22, respectively, to shape the resin sheets p1 and p2 in the first and second split molds 21, 22. In the first split mold 21, the resin sheet p1 is shaped to conform to the outer shape of the inner surface 21b of the cavity. The resin sheet p2 is shaped to conform to the shape of the inner surface 22b of the cavity. The timing of shaping the resin sheets p1 and p2 can be staggered. For example, the resin sheet p2 can be shaped after the core material welding process or during the mold closing process.

[0189] Furthermore, the first outer portion 21a2 does not have a pressure-reducing suction hole h1. Therefore, even during the resin sheet forming step, adhesion between the skin material 4 and the resin sheet p1 is suppressed. Consequently, when the inner burr portion 5bc1 is removed from the molded body 5a, the resin forming the inner burr portion 5bc1 can be reused.

[0190] 2-3-4. Core material welding process

[0191] In the core material welding step, the core material 3 is welded to the resin sheet p1. Figure 11 As shown, the insertion device 19 has attached the skin material 4 to the first split mold 21, so the core material 3 remains on the insertion device 19. In this state, the core material 3 can be fused to the resin sheet p1 by moving the insertion device 19 toward the resin sheet p1. After the core material 3 is fused to the resin sheet p1, the insertion device 19 is moved to a position outside the movement trajectory of the first split mold 21 and the second split mold 22.

[0192] The timing of placing the core material 3 between the resin sheets p1 and p2 is not limited, and the core material 3 may be placed between the resin sheets p1 and p2 during the drooping step or the shaping step. Alternatively, the core material 3 may be welded to the resin sheet p2 first.

[0193] 2-3-5. Molding process

[0194] In the molding process, the first split mold 21 and the second split mold 22 are moved along the Figure 11 Move in the direction of arrows C1 and C2 in the figure to close the first split mold 21 and the second split mold 22. As a result, the resin sheets p1 and p2 are flattened and welded at the locations corresponding to the pinch-off portions 21d and 22d, forming Figure 15 The molded body 5 is shown.

[0195] 2-3-6. Engaging process (burr shaping process)

[0196] The engaging step is a step of shaping the outer burr portion 5bc2 of the molded body 5 to the movable portion 23 so that the outer burr portion 5bc2 is engaged with the movable portion 23 (burr portion shaping step). Figure 13 As shown, by sucking the outer burr portion 5bc2 toward the engaging portion 23d via the suction portion 23c, the resin piece p1 of the outer burr portion 5bc2 is shaped so as to be along the engaging portion 23d.

[0197] In the molding process, the resins (resin sheets p1 and p2) constituting the outer burr portion 5bc2 are welded to each other in a state where the first split mold 21 and the second split mold 22 are closed (see FIG. 2 ). Figure 13 In this state, by performing the engagement step (burr shaping step), the unfused portions of the resin sheets p1 and p2 are easily separated, resulting in the outer burr portion 5bc2 becoming hollow. Thus, even if the resin sheets p1 and p2 are relatively thin, the outer burr portion 5bc2 (resin sheet p1) is clearly formed with recesses and projections along the engagement portion 23d, making it easier for the engagement portion 23d to hook onto the outer burr portion 5bc2 (resin sheet p1). As a result, the movable portion 23 can effectively tear the outer burr portion 5bc2 from the inner burr portion 5bc1.

[0198] Furthermore, as described above, the resin sheets p1 and p2 constituting the outer burr portion 5bc2 are welded to each other, thereby increasing the rigidity of the outer burr portion 5bc2. As a result, the force of the engaging portion 23d pulling the outer burr portion 5bc2 is easily transmitted to the outer burr portion 5bc2, making it easier to tear the outer burr portion 5bc2 from the inner burr portion 5bc1.

[0199] 2-3-7. First cutting process

[0200] After the engagement process, the molded body 5a is housed in the first split mold 21 and the second split mold 22, and the large burr portion 5b is engaged with the engagement portion 23d of the movable portion 23 provided in the first split mold 21. Figure 10A As shown, when the upper side of the movable portion 23 is tilted away from the main body portion 22a1, the molded body 5 is cut along the left line 5cl and the right line 5cr of the cutting line 5c from the upper side. Figure 10B As shown, when the movable part 23 is moved so that the lower side of the movable part 23 is separated from the first split mold 21, the crack of the molded body 5 develops downward, and the first cutting process is completed (refer to Figure 15 ).

[0201] 2-3-8. Molded body removal process

[0202] In the molded body removal process, the first split mold 21 and the second split mold 22 are opened by a clamping device (not shown) while clamping the burrs such as the upper burrs 5bu. Then, the molded body 5 is transported by the clamping device to a desired position for the next process. Figure 16 As shown, the molded article 5 is cut along the left line 5cl and the right line 5cr of the cutting line 5c. On the other hand, the molded article 5 is not cut along the upper line 5cu and the lower line 5cb of the cutting line 5c. If the molded article 5 is cut along either the upper line 5cu or the lower line 5cb, the molded article body 5a is likely to wobble relative to the large burr portion 5b, making it difficult to handle. However, in this embodiment, the molded article 5 is cut only along the left line 5cl and the right line 5cr at this point in time, making it easier to handle the molded article 5.

[0203] 2-3-9. Second cutting process

[0204] In the second cutting step, the molded body 5 is cut along the upper line 5cu and the lower line 5cb to separate the molded body 5a and the large burr portion 5b. In the second cutting step, for example, a cutting device that can recognize the positions of the upper line 5cu and the lower line 5cb and automatically cut the cutting line can be used.

[0205] 2-3-10. Post-process

[0206] In a subsequent step, the small burrs 5e and the inner burrs 5bc1 are removed to obtain the resin panel 1. This step can be performed by an operator.

[0207] 3. Effects of implementation methods

[0208] 3-1. Regarding the Decompression and Suction Function of the Movable Section 23

[0209] In the engaging step (burr forming step) of the embodiment, the outer burr portion 5bc2 is attracted to the engaging portion 23d of the movable portion 23 via the suction portion 23c. This forms the outer burr portion 5bc2 on the movable portion 23, allowing the outer burr portion 5bc2 to be more reliably engaged with the movable portion 23. Therefore, when the movable portion 23 is moved relative to the first split mold 21 and the second split mold 22, the outer burr portion 5bc2 is prevented from sliding relative to the movable portion 23, and the outer burr portion 5bc2 moves so as to follow the movable portion 23. As a result, the outer burr portion 5bc2 is more reliably severed from the molded body 5a.

[0210] 3-2. Double pinch-off section

[0211] In an embodiment, the first split mold 21 and the second split mold 22 have a double pinch-off structure. That is, the first split mold 21 and the second split mold 22 respectively have inner pinch-off portions 21d1 and 22d1 connected to the cavity portion cvt and outer pinch-off portions 21d2 and 22d2 arranged at a position farther away from the cavity portion cvt than the inner pinch-off portions 21d1 and 22d1. Among them, the inner pinch-off portions 21d1 and 22d1 need to have a shape corresponding to the shape of the molded body main body 5a. On the other hand, the outer pinch-off portions 21d2 and 22d2 are arranged at a position that divides the inner burr portion 5bc1 and the outer burr portion 5bc2. Moreover, the inner burr portion 5bc1 and the outer burr portion 5bc2 are cut together and are unnecessary parts of the product. In other words, the outer pinch-off portions 21d2 and 22d2 are portions not connected to the cavity portion CVT. Furthermore, since they demarcate the inner burr portion 5bc1 and the outer burr portion 5bc2, which are not necessary for the product, the outer pinch-off portions 21d2 and 22d2 are less likely to be formed to match the molded body 5a, as the inner pinch-off portions 21d1 and 22d1 are. Therefore, in this embodiment, the outer pinch-off portions 21d2 and 22d2 can be easily shaped to take into account the connection with the movable portion 23. This prevents deformation of the cutting line of the burr portion, preventing the burr portion from becoming difficult to cut.

[0212] In the embodiment, the case where the top surface of the inner pinch-off portions 21d1 and 22d1 is a flat surface is described, but it is not limited to this. The top surface of the inner pinch-off portions 21d1 and 22d1 may also extend in a concave-convex (wavy) manner. When describing the shape of such inner pinch-off portions 21d1 and 22d1, a resin panel having a shape different from that of the resin panel described in the embodiment is used as an example. That is, the resin panel may also be a structure in which, for example, a hinge portion is arranged between two bases 3a and 3b covered with a resin sheet and is crushed by a mold. The hinge portion is formed by utilizing the pinch-off portions 21dd and 22dd (see Figure 19 ) The thin-walled portion formed by flattening the resin sheets p1 and p2 is formed, and the resin panel can be bent via the hinge portion. In addition, the hinge portion is formed to be close to one side of the thickness direction of the resin panel. In this form of resin panel, the parting line in the base 3a, 3b is the center of the thickness direction of the resin panel, and in contrast, the parting line in the hinge portion is the hinge portion itself, and therefore close to one side of the thickness direction of the resin panel. That is, in the parting line of the resin panel, the portion connecting the base 3a, 3b to the hinge portion becomes a complex structure. In other words, in order to manufacture this resin panel, the shapes of the pinch-off portions 21d, 22d of the first split mold 21 and the second split mold 22 become a complex structure. Specifically, as Figure 19 As shown, in the cross section of the first split mold 21 and the second split mold 22 at the hinge portion, the inner pinch-off portion 22d1 has a convex portion, and the inner pinch-off portion 21d1 has a concave portion.

[0213] This embodiment is suitable for a resin panel having such a hinge portion.

[0214] When a resin panel having a hinge portion such as the above is manufactured using a mold that does not have the outer pinch-off portions 21d2 and 22d2 as in the conventional mold, the cutting line of the burr portion in the hinge portion will be deformed, and the mold design will become complicated. In response to this, in an embodiment, the shape of the outer pinch-off portions 21d2 and 22d2 can be determined without being restricted by the shape of the inner pinch-off portions 21d1 and 22d1. Therefore, in an embodiment, the deformation of the cutting line of the burr portion can be avoided, and the burr portion can be prevented from becoming difficult to cut. In addition, since the structures of the first split mold 21 and the second split mold 22 can be avoided from becoming complicated structures, mold design is facilitated.

[0215] In conventional manufacturing methods, the movable portion is configured to cut the portion corresponding to the connection between the molded body 5a and the inner burr portion 5bc1 in the embodiment. In such a manufacturing method, if this portion cannot be cut, the resin sheet may peel or curl from this portion when the molded body is removed from the mold, resulting in the molded body being defective. Because the embodiment is configured to cut the connection between the inner burr portion 5bc1 and the outer burr portion 5bc2, even if the outer burr portion 5bc2 cannot be cut from the inner burr portion 5bc1, the portion that peels or curls is the unnecessary inner burr portion 5bc1. Therefore, the embodiment can prevent the molded body from being defective and improve the yield rate. Furthermore, as described above, the embodiment employs a double pinch-off structure, making the burr portion itself difficult to cut, further improving the yield rate.

[0216] Conventional manufacturing methods involve a structure in which the movable portion also cuts the skin material. However, even if the resin sheet is cut, the skin material may not be cut. In such cases, when the molded body is removed from the mold, the skin material may curl up, starting from the uncut skin material, resulting in a defective molded body.

[0217] In the embodiment, the ends of the skin material 4 are located inside the outer pinching portions 21d2 and 22d2, so the movable portion 23 does not cut the skin material 4 itself. Therefore, the embodiment can prevent the molded body 5a from becoming defective and improve the yield.

[0218] Furthermore, assuming that the skin material 4 extends to the outer burr portion 5bc2, even if the skin material 4 is not cut by the movable portion 23, the portion that is rolled up is the unnecessary inner burr portion 5bc1. In other words, the embodiment adopts a double pinch-off structure, and even if the skin material 4 extends to the outer burr portion 5bc2, it is possible to prevent the molded body from becoming a defective product, thereby improving the yield rate.

[0219] 4. Modifications

[0220] 4-1. Modification 1

[0221] like Figure 17 As shown, even if the outer pinch-off portions 21d2 and 22d2 described in the embodiment are not provided on the first split mold 21 and the second split mold 22, the decompression and suction function of the movable portion 23 described in the embodiment can be obtained. Figure 17 In the illustrated embodiment, the outer burr portion 5bc2 is also more reliably engaged with the movable portion 23, and the outer burr portion 5bc2 is more reliably cut off from the molded body main body 5a.

[0222] In addition, in this modification example 1, since the outer pinch-off portions 21d2 and 22d2 are not provided on the first split mold 21 and the second split mold 22, Figure 18 As shown, during the cutting process, the inner burrs 5bc1 and outer burrs 5bc2 are not cut, and the inner burrs 5bc1 are severed from the molded body 5a. Since the first outer portion 21a2 lacks the pressure-reducing suction holes h1, adhesion between the resin sheet p1 and the skin material 4 is suppressed. Even when the movable portion 23 is actuated, the skin material 4 and the burrs are prevented from being cut. Therefore, when the resin is reused, the effort of peeling the skin material 4 from the connected assembly of the severed inner burrs 5bc1 and outer burrs 5bc2 can be saved.

[0223] 4-2. Modification 2

[0224] The first split mold 21 and the movable portion 23 are connected via a drive mechanism 24. However, if the drive mechanism 24 has a long stroke, depending on the structure of the first split mold 21 and the movable portion 23, the movable portion 23 may fall off the first split mold 21, making it difficult for the movable portion 23 to return to its initial position. For example, if the drive mechanism 24 has a long stroke, the movable portion 23 may not contact the first split mold 21 and fall off the first split mold 21. In this case, the movable portion 23 is connected to the first split mold 21 via the drive mechanism 24, so the movable portion 23 does not fall to the ground. However, when the drive mechanism 24 is driven to return the movable portion 23 to its original initial position, the movable portion 23 may interfere with the side of the first split mold 21, preventing it from returning to its initial position. In this case, for example, the operator is required to move the movable portion 23 back to its initial position each time it falls off.

[0225] In this modification 2, if Figure 20A as well as Figure 20B As shown, the first split mold 21 has a supporting portion 21f, and the movable portion 23 has a supported portion 23f. Figure 20A as well as Figure 20B In the figure, the driving mechanism 24 is omitted.

[0226] The support portion 21f is configured to prevent the movable portion 23 from falling off from the first split mold 21, and the support portion 21f is formed to protrude in the direction from the first split mold 21 toward the movable portion 23. The support portion 21f is connected to the lateral side of the first split mold 21. Specifically, in this modification, the support portion 21f is connected to the first outer side portion 21a2. In addition, when the first split mold 21 and the movable portion 23 are viewed from the front side (from the front side), the support portion 21f is connected to the first outer side portion 21a2. Figure 20AWhen viewed in the direction of arrow Ar), the support portion 21f is provided to protrude toward the movable portion 23 from the end surface portion 21a3 of the first split mold 21. In other words, Figure 20A When viewed in the direction of arrow Ar, the support portion 21f is provided to protrude further toward the movable portion 23 than the outermost pinch-off portion (outer pinch-off portion 21d2) in the width direction. Furthermore, the support portion 21f is positioned further inward than the front portion of the first split mold 21 in the thickness direction Dr of the first split mold 21. The front portion of the first split mold 21 refers to, for example, the portion where the inner pinch-off portion 21d1, the outer pinch-off portion 21d2, and the inner surface 21b are formed.

[0227] The supported portion 23f is configured to be supported by the supporting portion 21f. The supported portion 23f is a concave portion into which the supporting portion 21f is inserted. Figure 20C As shown, the supporting portion 21f is inserted into the supported portion 23f, so when the movable portion 23 is driven, the supported portion 23f is supported on the upper surface of the supporting portion 21f. This prevents the movable portion 23 from falling off from the first split mold 21.

[0228] In addition, if Figure 10A as well as Figure 10B As shown, the movable part 23 moves in a swinging manner, so the size of the supported part 23f is larger than the size of the supporting part 21f. Therefore, when the movable part 23 moves in a swinging manner, interference between the supporting part 21f and the supported part 23f can be avoided, so that the movable part 23 moves smoothly.

[0229] This modification example 2 can also be applied to the form of modification example 1.

[0230] (Third Viewpoint)

[0231] 1. About resin panel 1

[0232] The structure of the resin panel 1 (an example of a “structure”) of the embodiment of the third aspect is the same as that of the resin panel 1 of the embodiment of the first aspect and the second aspect (see “1. About the resin panel 1” of the first aspect and the second aspect), so the description is omitted.

[0233] 2. Method for Manufacturing Resin Panel 1

[0234] 2-1. Description of manufacturing apparatus

[0235] like Figure 21 As shown, in the manufacturing method of the embodiment, a molding machine 10 and an inserting device 19 are used to form Figure 15 The molded body 5 shown. Figures 21 and 22As shown, the molding machine 10 includes a pair of sheet forming devices 14, molds (a first split mold 21 and a second split mold 22), outer frames 31, 32, and a movable portion 23. Although not shown in the figure, the molding machine 10 is as shown in FIG. Figures 25A to 25C As shown, the movable portion 23 is further provided with a driving mechanism (not shown) for moving the movable portion 23 away from the first split mold 21. Figure 5 The drive mechanism 24) can be Figure 25B as well as Figure 25C As shown, after the upper portion of the movable portion 23 is moved, the lower portion of the movable portion 23 is moved, whereby the burr portion (a portion of the resin sheet) can be torn smoothly.

[0236] 2-1-1. Structure of the sheet forming device 14

[0237] Figure 21 The sheet forming device 14 and the resin used in the embodiment of the third viewpoint shown are the same as the sheet forming device 14 and the resin used in the embodiments of the first viewpoint and the second viewpoint (refer to "2-1-1. Structure of the sheet forming device 14" of the first viewpoint and the second viewpoint), so the description is omitted.

[0238] 2-1-2. Molds (First Split Mold 21 and Second Split Mold 22) and Outer Frames 31 and 32

[0239] like Figure 26 As shown, the resin sheets p1 and p2 are guided between the first split mold 21 and the second split mold 22. The first split mold 21 and the second split mold 22 can be split by the parting surface abutting when the mold is closed, and the molded body 5 is formed by the first split mold 21 and the second split mold 22 (see Figure 15 That is, in the molding process, a pair of split first and second split molds 21 and 22 are used to form the molded body 5. In addition, in the embodiment, a skin margin space sp is formed between the first and second split molds 21 and 22 (see Figure 33 as well as Figure 34 The skin margin space sp is used to arrange the end of the skin material 4 during molding.

[0240] <First split mold 21>

[0241] like Figure 24 As shown, the first split mold 21 includes a main body portion 21a1, a pair of first outer portions 21a2, and an end surface portion 21a3 (see Figure 34). A cavity portion cvt is formed on the main body portion 21a1. When the first split mold 21 and the second split mold 22 are closed, the cavity portion cvt is a closed space formed between the first split mold 21 and the second split mold 22, and is a space for molding the molded body. The first outer portion 21a2 is connected to the end portions (left and right ends) of the main body portion 21a1 in the transverse direction. In addition, the so-called transverse direction is a direction that is perpendicular to the opening and closing direction of the first split mold 21 and the second split mold 22 and perpendicular to the up and down direction. A surface for the movable portion 23 to abut is formed on the end surface portion 21a3. In an embodiment, the end surface portion 21a3 is formed on the side of the first outer portion 21a2.

[0242] The first split mold 21 is provided with a plurality of pressure reducing and suction holes h1 (refer to Figure 29 ), the resin sheet p1 can be decompressed and sucked to form it into a shape along the inner surface 21b of the first split mold 21. Figure 24 As shown, the inner surface 21b faces the cavity portion cvt.

[0243] like Figure 24 As shown, the first split mold 21 has a pinch-off portion 21d, which is provided to surround the cavity portion cvt. The pinch-off portion 21d is a protrusion formed in a manner protruding from the first split mold 21 side to the second split mold 22 side. Figure 29 As shown, the pinch-off portion 21d includes an inner pinch-off portion 21d1 and an outer pinch-off portion 21d2. The inner pinch-off portion 21d1 and the outer pinch-off portion 21d2 are formed on the first outer portion 21a2.

[0244] The inner pinch-off portion 21d1 is disposed facing the cavity portion cvt. The inner pinch-off portion 21d1 is formed into a shape corresponding to the shape of the resin panel 1. Specifically, in the embodiment, the top surface of the inner pinch-off portion 21d1 is flat. Furthermore, in the embodiment, the inner pinch-off portion 21d1 extends in a curved, straight line.

[0245] The outer pinch-off portion 21d2 is provided at a position farther from the cavity portion cvt than the inner pinch-off portion 21d1. The outer pinch-off portion 21d2 is formed to match the shape of the movable portion 23. Specifically, the outer pinch-off portion 21d2 is formed to fit the engaging portion 23d (see FIG. 2 ) of the movable portion 23 described later. Figures 24 to 25C ) matches the shape of the engaging portion 23d closest to the first split mold 21 (hereinafter referred to as the closest engaging portion 23d). Furthermore, when viewing the first split mold 21 and movable portion 23 from above, the outer pinch-off portion 21d2 is formed along the closest engaging portion 23d. This prevents deformation of the cutting line of the burr portion, preventing the burr portion from becoming difficult to cut.

[0246] like Figure 24 As shown, the first split mold 21 has a pair of suction parts 21A. The suction parts 21A are respectively provided at the upper part and the lower part of the first split mold 21. The upper and lower suction parts 21A are respectively connected to the upper and lower ends of the main body 21a1. The suction part 21A is formed to protrude from the first split mold 21 side toward the second split mold 22 side. Thus, when the first split mold 21 moves forward, the suction part 21A contacts the resin sheet p1 before the pinch-off part 21d. A suction hole 21B is formed on the front end surface of the suction part 21A, and the suction part 21A can adsorb the resin sheet p1 by sucking air from the suction hole 21B. As shown Figure 24 As shown, the suction portion 21A is provided with an inclined surface 21C. When the resin sheet p1 is formed on the first split mold 21 , the resin sheet p1 easily follows the surface of the first split mold 21 .

[0247] like Figure 21 As shown, the first split mold 21 has a male protrusion 21e. The male protrusion 21e is provided at a position opposite to the female protrusion 19c (described later) of the insertion device 19. The male protrusion 21e can slide relative to the first split mold 21 and is received in a hole (not shown) in the first split mold 21.

[0248] <Second split mold 22>

[0249] like Figure 22 as well as Figure 23 As shown, the second split mold 22 has a main body 22a1, a pair of second outer sides 22a2, a pair of opposing parts 22a3 and four chamfered parts 22a4. A cavity part cvt is formed in the main body 22a1. The second outer sides 22a2 are connected to the end parts (left and right ends) of the main body 22a1 in the transverse direction. In addition, each opposing part 22a3 is connected to the end part of each second outer side 22a2 in the transverse direction. The opposing part 22a3 is configured to be opposite to the engaging part 23d of the movable part 23. Each opposing part 22a3 is composed of a flat surface and is connected to one of the upper and lower chamfered parts 22a4 and the left and right chamfered parts 22a4.

[0250] Chamfered portions 22a4 are formed on the periphery of the second split mold 22. In the embodiment, the second split mold 22 has a quadrilateral shape when viewed from above. Accordingly, chamfered portions 22a4 are provided on each of the four sides of the second split mold 22. Each chamfered portion 22a4 has a front end 22af and a rear end 22a. The front end 22af is the portion of the chamfered portion 22a4 closest to the first split mold 21 in the mold opening and closing direction. The rear end 22ab is the portion of the chamfered portion 22a4 farthest from the first split mold 21 in the mold opening and closing direction.

[0251] The left and right chamfered portions 22a4 are provided between the outer frame 32 and the pinch-off portion (outer pinch-off portion 22d2). When the left and right chamfered portions 22a4 are viewed while the resin sheet p2 is drooping, they are formed to increase the distance from the drooping resin sheet p2 in the direction from the outer pinch-off portion 22d2 toward the outer frame 32. In the embodiment, the chamfered portions 22a4 are formed as tapered surfaces (inclined surfaces). Specifically, the tapered surfaces (inclined surfaces) of the chamfered portions 22a4 extend from the front end portion 22af toward the rear end portion 22ab. Furthermore, the chamfered portions 22a4 do not have suction holes formed therein for adsorbing the resin sheet p2.

[0252] like Figure 29 As shown, the inclination angle θ of the tapered surface of the chamfered portion 22a4 is preferably greater than 0 degrees and less than 60 degrees. Specifically, for example, the inclination angle θ (degrees) is 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and 60 degrees. Furthermore, the inclination angle θ can also be defined within a range between any two values ​​exemplified here (for example, greater than 5 degrees and less than 60 degrees).

[0253] like Figure 29 As shown, the width w1 of the chamfered portion 22a4 in the mold opening and closing direction is preferably 10 mm or more and 63 mm or less. Specifically, for example, the width w1 (mm) is 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, or 63 mm, and can also be defined within a range between any two values ​​exemplified here.

[0254] like Figure 29 As shown, the width w2 from the pinch-off portion 22d of the chamfered portion 22a4 toward the outer frames 31 and 32 is preferably 5.7 mm or more and 70 mm or less. More preferably, the width w2 is 12 mm or more and 40 mm or less. Specifically, for example, the width w2 (mm) is 5.7, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, or 70. Alternatively, the width w2 can be defined within a range between any two of the values ​​exemplified here.

[0255] In the embodiment, the second split mold 22 has a total of four chamfered portions 22a4 (upper and lower chamfered portions 22a4 and left and right chamfered portions 22a4). The structures (inclination angle θ, width w1, width w2) of these chamfered portions 22a4 can be the same or different as long as they meet the above-mentioned numerical values ​​or numerical ranges. For example, the upper and lower chamfered portions 22a4 can have the same structure and the left and right chamfered portions 22a4 can have the same structure, but the upper and lower chamfered portions 22a4 can also have different structures from the left and right chamfered portions 22a4.

[0256] The second split mold 22 is provided with a plurality of pressure reducing and suction holes h1 (refer to Figure 29 ), the resin sheet p2 can be vacuum-sucked and shaped into a shape along the inner surface 22b of the second split mold 22. In addition, the inner surface 22b faces the cavity portion cvt.

[0257] The second split mold 22 includes a pinch-off portion 22d, which is provided to surround the cavity portion cvt. The pinch-off portion 22d is a protrusion that projects from the second split mold 22 toward the first split mold 21. The pinch-off portion 22d includes an inner pinch-off portion 22d1 and an outer pinch-off portion 22d2. The inner pinch-off portion 22d1 and the outer pinch-off portion 22d2 are formed on the second outer portion 22a2.

[0258] The inner pinch-off portion 22d1 and the outer pinch-off portion 22d2 have the same structure as the inner pinch-off portion 21d1 and the outer pinch-off portion 21d2. The inner pinch-off portion 22d1 is positioned facing the cavity portion cvt. The inner pinch-off portion 22d1 is formed into a shape corresponding to the shape of the resin panel 1. Specifically, the top surface of the inner pinch-off portion 22d1 is flat. The inner pinch-off portion 22d1 also extends in a curved, straight line.

[0259] The outer pinch-off portion 22d2 is provided at a position farther from the cavity portion cvt than the inner pinch-off portion 22d1. Similar to the outer pinch-off portion 21d2, the outer pinch-off portion 22d2 is formed in a shape that matches the shape of the movable portion 23.

[0260] <Outer frames 31, 32>

[0261] like Figure 22 as well as Figure 23 As shown, outer frames 31 and 32 are arranged around the second split mold 22. Specifically, outer frames 31 are attached to the upper and lower portions of the second split mold 22, respectively, and outer frames 32 are attached to the left and right sides of the second split mold 22, respectively. Outer frames 31 and 32 are configured to move parallel to the mold opening and closing direction. In other words, outer frames 31 and 32 are configured to move forward and backward in the mold opening and closing direction. Suction holes 31a and 32a are formed on the front ends of outer frames 31 and 32, respectively. The outer frames 31 and 32 absorb air through the suction holes 31a and 32a, respectively, to adsorb the resin sheet p2.

[0262] The outer frames 31 and 32 advance while adsorbing the resin sheet p2, and then, in the embodiment, retreat. This retreat allows the resin sheet p2 to be appropriately shaped on the second split mold 22, and prevents the outer frames 31 and 32 from interfering with the first split mold 21 and the movable portion 23 when the first split mold 21 and the second split mold 22 are closed.

[0263] Here, if Figure 29 As shown, the outer frame 32 is retracted to the position of the rear end portion 22ab of the chamfered portion 22a4. The same applies to the outer frame 31. The retracted distance w3 of the outer frames 31 and 32 is 30 mm or more and 80 mm or less. Specific examples of the retracted distance w3 (mm) of the outer frames 31 and 32 include 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, and 80 mm, but can also be defined within a range between any two of the values ​​exemplified here.

[0264] like Figure 33 As shown, when the outer frame 32 and the suction portion 23g are in closest proximity (when the molding process is complete), the distance t1 between the front end surface of the outer frame 32 and the front end surface of the suction portion 23g is preferably 5 mm or greater. Specifically, distance t1 (mm) can be 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 mm, and can also be defined within a range between any two of the values ​​exemplified here. The same applies to the outer frame 31 and the suction portion 21A. That is, the distance between the front end surface of the outer frame 31 and the front end surface of the suction portion 21A can also be defined in the same way as distance t1 described above.

[0265] <Surface material margin space sp>

[0266] Figure 33 as well as Figure 34 The skin material allowance space sp of the third embodiment is the same as the skin material allowance space sp described in the first and second embodiments (see “<Skin material allowance space sp>” in the first and second embodiments), and therefore description thereof is omitted.

[0267] 2-1-3. Structure of the movable portion 23

[0268] The movable portion 23 has the function of engaging with the burr portion and cutting off the burr portion. Figures 25A to 25C As shown, the movable portion 23 is configured to be able to move relative to the first split mold 21. Figure 25B As shown, the movable portion 23 is attached to the side of the first outer portion 21a2 of the first split mold 21. Figure 34 As shown, the movable portion 23 includes a facing surface portion 23a, a contact surface portion 23b, a suction portion 23c, an engaging portion 23d, a sealing member 23e, and a suction portion 23g.

[0269] The facing surface portion 23a is provided so as to face the facing portion 22a3 of the second split mold 22. A plurality of engaging portions 23d are formed on the facing surface portion 23a.

[0270] The abutting surface 23b is formed so as to be able to abut against the end surface 21a3 of the first split mold 21. The abutting surface 23b is formed along the end surface 21a3. Therefore, when the air is decompressed and sucked through the decompression suction hole h1 in a state where the abutting surface 23b abuts against the end surface 21a3, it is possible to suppress the air from flowing into the portion where the resin is shaped from between the abutting surface 23b and the end surface 21a3. In addition, the sealing member 23e is mounted on the abutting surface 23b. Specifically, a groove is formed in the abutting surface 23b, and the sealing member 23e is mounted in the groove. Thus, it is possible to effectively suppress the air from flowing into the portion where the resin is shaped from between the abutting surface 23b and the end surface 21a3. In addition, the so-called portion where the resin is shaped is, for example, the gap inside the cavity portion cvt, the gap between the burr portion and the surface of the engaging portion 23d, etc.

[0271] The suction portion 23c is a hole formed in the opposing surface portion 23a and opens in the area where the engaging portion 23d is formed. Air is decompressed and drawn in through the suction portion 23c, thereby shaping the burr portion (outer burr portion 5bc2) into the engaging portion 23d. This allows the burr portion (outer burr portion 5bc2) to be more securely hooked onto the movable portion 23, preventing the burr portion from sliding relative to the movable portion 23 when the movable portion 23 is driven. As a result, in the embodiment, the burr portion appropriately follows the movable portion 23 when the movable portion 23 is driven, enabling more reliable cutting of the burr portion.

[0272] The engaging portion 23d has the function of engaging with the burr portion. The engaging portion 23d is a protrusion formed so as to protrude toward the second split mold 22. Multiple engaging portions 23d are formed on the opposing surface portion 23a, so the area where the engaging portions 23d are formed on the opposing surface portion 23a is formed into a concave-convex shape. Furthermore, in the embodiment, the suction portion 23c is described as opening in the area between two adjacent engaging portions 23d on the opposing surface portion 23a, but this is not limiting. The suction portion 23c may also open on the surface of the engaging portion 23d.

[0273] The suction part 23g is in the movable direction (the movable part 23 Figure 25A Status Figure 25C The suction portion 23g is provided on the end side of the movable portion 23 in the direction of movement of the state. The suction portion 23g is formed in a manner protruding from the movable portion 23 side toward the outer frame 32 side. Thus, when the movable portion 23 moves forward together with the first split mold 21, the front end face of the suction portion 23g contacts the resin sheet p1 earlier than the engaging portion 23d. In addition, in the embodiment, the position of the front end face of the suction portion 23g is consistent with the position of the front end face of the suction portion 21A of the first split mold 21. A suction hole 23g1 is formed at the front end face of the suction portion 23g, and the suction portion 23g can adsorb the resin sheet p1 by sucking air from the suction hole 23g1. As Figure 29As shown, the suction portion 23g is formed with an inclined surface 23g2, which facilitates the resin sheet p1 to follow the surface of the movable portion 23 when the resin sheet p1 is formed on the movable portion 23. The inclined surface 23g2 is connected to the facing surface portion 23a.

[0274] like Figure 33 As shown, the protrusion amount t2 of the suction portion 23g (the distance between the position of the front end surface of the suction portion 23g and the position of the opposing surface portion 23a in the mold opening and closing direction) is preferably 15 mm or more. Specific examples of the protrusion amount t2 (mm) include 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 mm, but can also be defined within a range between any two of the values ​​exemplified here.

[0275] 2-1-4. Insertion device 19

[0276] The configuration of the insertion device 19 according to the embodiment of the third aspect is the same as that of the insertion device 19 according to the embodiment of the first aspect and the second aspect, and therefore, description thereof will be omitted.

[0277] 2-2. Molded body 5

[0278] The structure of the molded body 5 according to the embodiment of the third aspect is the same as that of the molded body 5 according to the embodiment of the first aspect and the second aspect (see “2-2. Molded body 5 ” of the first aspect and the second aspect), and therefore, description thereof will be omitted.

[0279] 2-3. Description of Each Step of the Manufacturing Method

[0280] The method for manufacturing the resin panel 1 of the present embodiment includes a skin material attaching step, a hanging step, an adsorption step, a shaping step, a core material welding step, a molding step, a first cutting step, a molded body removing step, a second cutting step, and a post-step.

[0281] 2-3-1. Surface material installation process

[0282] In the surface material installation process, the female protrusion 19c is inserted into the through hole formed in the surface material 4 in advance. Figure 21 As shown, the skin material 4 is held by the insertion device 19. Hereinafter, this step is the same as the "2-3-1. Skin material mounting step" of the first viewpoint and the second viewpoint, and therefore, the description thereof will be omitted.

[0283] 2-3-2. Drooping process

[0284] In the drooping process, Figure 26As shown, the resin sheets p1 and p2 extruded from the T-die 18 are allowed to droop between the first split die 21 and the second split die 22. Hereinafter, this step is the same as "2-3-2. Drooping Step" in the first and second aspects, and therefore its description is omitted.

[0285] 2-3-3. Adsorption process

[0286] In the adsorption process, Figures 27 to 29 As shown, the first split mold 21 and the movable part 23 move forward together, and the suction part 23g contacts the resin sheet p1. Then, the resin sheet p1 is attracted to the front end surface of the suction part 23g by the suction action of the suction hole 23g1 of the suction part 23g. In addition, the first split mold 21 also moves forward in the same manner, so as shown in FIG. Figure 27 As shown, the upper and lower suction parts 21A also come into contact with the resin sheet p1. Then, the resin sheet p1 is adsorbed on the front end surface of the suction part 21A by the suction action of the suction hole 21B of the suction part 21A. Figure 29 As shown, a sealed space SD1 is formed between the resin sheet p1 , the first split mold 21 , and the movable portion 23 .

[0287] In addition, if Figures 27 to 29 As shown, the outer frame 32 moves forward and contacts the resin sheet p2. Then, the resin sheet p2 is adsorbed on the front end surface of the outer frame 32 by the suction action of the suction holes 32a of the outer frame 32. Figure 27 As shown, the outer frame 31 also moves forward in the same manner. Then, the resin sheet p2 is adsorbed on the front end surface of the outer frame 31 by the suction action of the suction hole 31a of the outer frame 31. Figure 29 As shown, a sealed space SD1 is formed between the resin sheet p2 , the second split mold 22 , and the outer frames 31 , 32 .

[0288] 2-3-4. Shaping process

[0289] like Figure 30 As shown, during the shaping process, the air within the enclosed spaces SD1 and SD2 is decompressed and sucked via the decompression and suction holes h1 in the first and second split molds 21 and 22 and the suction portion 23c of the movable portion 23, thereby shaping the resin sheets p1 and p2 onto the first and second split molds 21 and 22 and the movable portion 23. Furthermore, during the shaping process, the outer frames 31 and 32, which were advanced during the suction process, are retracted. Specifically, the outer frames 31 and 32 are retracted until the front end surfaces of the outer frames 31 and 32 reach the rear end 22ab of the chamfered portion 22a4.

[0290] As the outer frames 31 and 32 retreat, the resin sheet p2 is shaped to conform to the surface of the second split mold 22. The second split mold 22 has chamfered portions 22a4, so as the resin sheet p1 moves along with the outer frames 31 and 32, it smoothly lies along the chamfered portions 22a4. This prevents the resin sheet p1 from peeling off from the second split mold 22 and the outer frames 31 and 32, thus preventing molding defects.

[0291] For example, in the case where the chamfered portion 22a4 is not formed on the second split mold 22 and the corner is a right angle, if the outer frames 31 and 32 retreat from the position of the corner, the resin sheet p1 extends in a manner that is bent at a right angle starting from the corner. However, depending on the physical properties of the resin sheet p1, sometimes the resin sheet p1 cannot smoothly follow the retreat of the outer frames 31 and 32, and the corner and its surrounding parts will separate (peel off) from the outer frames 31 and 32 and the second split mold 22. In other words, the resin sheet p1 is forcibly extended at the above-mentioned corner, and the resin sheet p1 cannot smoothly follow the retreat of the outer frames 31 and 32, and the resin sheet p1 will peel off from the outer frames 31 and 32 and the second split mold 22. In this case, the decompression shaping of the resin sheet p1 becomes inappropriate, resulting in leakage in the enclosed space SD1.

[0292] However, in the embodiment, since the second split mold 22 has the chamfered portion 22a4, when the outer frames 31 and 32 retreat and the resin sheet p1 moves together with the outer frames 31 and 32, the resin sheet p1 follows along the chamfered portion 22a4, thereby avoiding separation from the second split mold 22.

[0293] Alternatively, the retraction speed of the outer frames 31 and 32 can be reduced to improve the followability of the resin sheet p1. However, this method not only increases the molding time of the molded article 5 but also restricts the manufacturing conditions of other steps. However, in the manufacturing method of the embodiment, there is no need to reduce the retraction speed of the outer frames 31 and 32, thus avoiding not only an increase in the molding time of the molded article 5 but also any restrictions on the manufacturing conditions.

[0294] In addition, the timing of starting the decompression and suction and the timing of starting the retreat of the outer frames 31 and 32 may be simultaneous or may be staggered.

[0295] Furthermore, the timing of shaping the resin sheets p1 and p2 can be staggered. For example, the resin sheet p2 can be shaped after the core material welding step or during the mold closing step. Furthermore, the timing of decompressing the suction portion 23c can also be after the molding step described later.

[0296] 2-3-5. Core material welding process

[0297] like Figure 30 as well as Figure 31 As shown, the insertion device 19 has attached the skin material 4 to the first split mold 21, so the core material 3 remains on the insertion device 19. In this state, by moving the insertion device 19 toward the resin sheet p1, the core material 3 can be fused to the resin sheet p1. This step is the same as the "2-3-4. Core Material Welding Step" in the first and second viewpoints, so its description will be omitted.

[0298] 2-3-6. Molding process

[0299] In the molding process, the first split mold 21 and the second split mold 22 are closed. As a result, the resin sheets p1 and p2 are flattened and welded at the locations corresponding to the pinch-off portions 21d and 22d, forming Figure 15 The molded body 5 is shown.

[0300] Furthermore, when the molding process is complete, at least a portion of the movable portion 23 (the suction portion 23g in the embodiment) is positioned closer to the outer frame 32 than the tip 22af of the chamfered portion 22a4. Although not shown, the same applies to the suction portion 21A, which is positioned closer to the outer frame 31 than the tip 22af of the chamfered portion 22a4. During the molding process, the outer frames 31 and 32 are appropriately retracted, thereby preventing contact between the components.

[0301] 2-3-8. First Cutting Step, Molded Body Removing Step, Second Cutting Step, and Post-Steps These steps are the same as “2-3-7. First Cutting Step” to “2-3-10. Post-Step” in the first and second aspects, and therefore their descriptions are omitted.

[0302] 3. Other Implementation Methods

[0303] The chamfered portion 22a4 is not limited to a tapered surface. Any shape may be used as long as the distance between the chamfered portion 22a4 and the resin sheet P2 increases in the direction from the outer pinch-off portion 22d2 toward the outer frame 32. For example, the chamfered portion 22a4 may be composed of multiple tapered surfaces (multiple inclined surfaces) with different slopes.

[0304] In the embodiment, the tapered surface of the chamfered portion 22a4 is formed in a flat surface, but may be formed in a curved surface, or a flat surface portion and a curved surface portion may be combined.

[0305] Furthermore, the chamfered portion 22a4 may have one or more stepped portions (portions formed in a stepped shape) as long as the distance between the chamfered portion 22a4 and the resin sheet P2 increases in the direction from the outer pinch-off portion 22d2 toward the outer frame 32.

[0306] In the embodiment, the second split mold 22 is described as having four chamfered portions 22a4, but the present invention is not limited thereto. For example, the second split mold 22 may have only left and right chamfered portions 22a4, without having top and bottom chamfered portions 22a4, or vice versa. Furthermore, the second split mold 22 may have only one of the four chamfered portions 22a4, top and bottom, and left and right.

[0307] In the embodiment, the molding machine 10 is described as including the movable portion 23 , but the present invention is not limited thereto and may not include the movable portion 23 .

[0308] In the embodiment, a configuration in which a pair of movable portions 23 are arranged on the left and right sides of the first split mold 21 is described as an example, but the present invention is not limited thereto. Alternatively, the movable portions 23 may be arranged on the bottom surface of the first split mold 21 in addition to the left and right movable portions 23 of the first split mold 21. Alternatively, the movable portions 23 may be arranged on the bottom surface of the first split mold 21 in place of the left and right movable portions 23 of the first split mold 21.

[0309] (Fourth Viewpoint)

[0310] 1. Panel structure

[0311] Use Figure 35~ Figure 38 The structure of the panel 101 will be described. Figure 35A as well as Figure 35B As shown, the panel 101 includes a resin panel body 102 and a skin material 108. The resin panel body 102 is formed by integrally forming a first main body portion 102a, a second main body portion 102b, and a hinge portion 105. Figure 35A The front side of the resin panel body 102 is shown, and a skin material 108 is attached to cover the entire surface of the resin panel body 102. The skin material 108 is attached to the first body part 102a and the second body part 102b across the hinge part 105. The back side of the resin panel body 102 is exposed.

[0312] The panel 101 is a substantially rectangular flat panel having a total length L0 and a width W0. In the embodiment, as an example, the total lengths of the first body portion 102a, the second body portion 102b, and the hinge portion 105 are equal, and all have the same total length L0 as the panel 101. In the embodiment, as an example, the first body portion 102a has a width W a The second main body portion 102b has a width W b (W b <W a ). Including the width of the hinge portion 105 ( Figure 38 W h ), W0=W a +Wb +W h .

[0313] like Figure 36A As shown, the hinge portion 105 extends between the first main body portion 102a and the second main body portion 102b. In the embodiment, as an example, the hinge portion 105 has three hinge pieces 105h and two slits 105s. Figure 36A In the example, the length L of each hinge piece 105h is h The hinge 105 has a very small overall length L0. Three hinge pieces 105h rotatably connect the first and second body sections 102a and 102b. Slits 105s are provided adjacent to the hinge pieces 105h, separating the first and second body sections 102a and 102b. The provision of slits 105s enhances the flexibility of the hinge 105.

[0314] Figure 37 yes Figure 36A 1 to B3. As an example, the hinge piece 105h has a middle hinge piece 105h1 and two end hinge pieces 105h2. The two end hinge pieces 105h2 are provided at both ends of the hinge portion 105. The middle hinge piece 105h1 is provided at a position further inward than the ends of the hinge portion 105. In an embodiment, as an example, the middle hinge piece 105h1 is provided exactly at the center of the hinge portion 105 (i.e., at a position L0 / 2 away from the ends of the hinge portion 105).

[0315] Figure 38 Shown along Figure 37 The cross section along the CC line of the resin panel body 102 includes a front wall 103 and an inner wall 104. The front wall 103 and the inner wall 104 are opposed to each other with a gap therebetween. A hollow portion 107 is provided between the front wall 103 and the inner wall 104. In addition, the front wall 103 and the inner wall 104 are connected around by a peripheral wall (not shown). The surface of the front wall 103 is flat. The hinge portion 105 is formed by recessing the inner wall 104 toward the front wall 103. On the inner wall 104, an inclined portion 104a is provided at a position adjacent to the hinge portion 105, and the gap between the front wall 103 and the inner wall 104 becomes narrower on the inclined portion 104a as it approaches the hinge portion 105.

[0316] The hinge portion 105 has a width W h The slit 105s may be a cut formed by a single line, or may be a cut formed by cutting the hinge portion 105. The width (thickness) of the slit 105s is also referred to as the slit width W. S , when the slit 105s is a single-line cut, the slit width W S As an example, if the width W of the slit 105s is specifiedS The width W of the hinge h The ratio is W S / W h , then W S / W h For example, it is 0 to 1, specifically, 0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, and may be within the range between any two values ​​exemplified here. S It can be W S <W h , but it can also be set to become W S =W h The width of the hinge piece 105h is the same as that of the hinge portion 105, which is the width W. h In addition, the slit width W S In the case of a large size, a portion of the skin material 108 is exposed from the slit 105s.

[0317] like Figure 38 As shown, the skin material 108 is provided on the front wall 103 side of the panel 101. The skin material 108 is provided from the first body part 102a to the second body part 102b across the hinge part 105. The skin material 108 may be formed of a breathable carpet-like member such as nonwoven fabric.

[0318] The thickness of the front wall 103 and the back wall 104 of the first body 102a and the second body 102b is, for example, 0.5 to 2 mm, specifically, 0.5, 1.0, 1.5, or 2.0 mm, and may also be within the range between any two values ​​exemplified here.

[0319] like Figure 36A As shown, the hinge pieces 105h and the slits 105s are alternately arranged along the extending direction of the hinge portion 105. The two slits 105s have a slit length L S1 , L S2 In an embodiment, as an example, L S1 =L S2 In addition, in the embodiment, as an example, the three hinge pieces 105h have the same length L h L0=3L h +L S1 +L S2 In addition, L S1 +L S2 Also called the total slit length L S .

[0320] The thickness of the hinge piece 105h is, for example, 0.001 to 1.0 mm, specifically, 0.001, 0.01, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 mm, and may also be within the range between any two values ​​exemplified here. h (ie the width W of the hinge portion 105 h ) is, for example, 1 to 8 mm, specifically, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0 mm, and may be within the range between any two values ​​exemplified here.

[0321] In this specification, the thickness of the hinge portion 105 (i.e., the thickness of the hinge piece 105h) does not include the thickness of the skin material 108. The thickness and width of various components are average values ​​unless otherwise specified.

[0322] The total length L0 of the hinge portion 105 is the length extending across both ends of the hinge portion 105. S is the total length of the slits 105s. Their ratio is L S The larger the value of / L0, the larger the proportion of the slit 105s in the hinge portion 105 becomes, and the proportion of the hinge piece 105h in the hinge portion 105 (ie, the length L of the plurality of hinge pieces 105h) h The total of) becomes smaller. L S / L0 may be, for example, 0.50 to 0.99, or 0.70 to 0.97. S Specifically, / L0 is, for example, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99, and may also be within the range between any two of the values ​​exemplified here.

[0323] The length L of each hinge piece 105h h As an example, the length L of the hinge piece 105h is h The length L may be 10 mm, but is not limited thereto, and may be 5 to 15 mm, or 2 to 100 mm, for example. hSpecifically, for example, it is 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 70, 80, 90, 100 mm, and it can also be within the range between any two values ​​​​given here. In order to ensure a certain strength or more, the length L can also be h Increase to a certain extent.

[0324] The number of hinge pieces 105h provided in the hinge portion 105 is not limited to 3, and may be 2 or 4 or more. Specifically, the number of hinge pieces 105h may be 5, 6, 7, 8, 9, or 10, or may be within the range between any two values ​​exemplified here. The plurality of hinge pieces 105h may all have the same length L. h , can also be different lengths. For example, the length L of a middle hinge piece 105h1 is h1 The length L of the hinge piece 105h2 at one end h2 In the case of comparison, it can be L h1 <L h2 , or L h1 >L h2 The length L of each hinge piece 105h h They may be different from each other within the above-mentioned numerical range.

[0325] The spacing between hinge pieces 105h is determined by the length of each slit 105s. The lengths of the slits 105s can be the same or different. Shortening the slits 105s so that the hinge pieces 105h are closer together increases strength. On the other hand, lengthening the slits 105s so that the hinge pieces 105h are farther apart increases the ease with which the hinge portion 105 bends.

[0326] The provision of slits 105s improves bending ease. Since the slits 105s can adjust bending ease, the hinge piece 105h does not need to be too thin, which has the advantage of preventing shearing and fragmentation of the hinge piece 105h. Furthermore, in the embodiment, the provision of the skin material 108 allows the first body portion 102a and the second body portion 102b to be rotatably connected using both the hinge piece 105h and the skin material 108. If the skin material 108 is constructed from a sufficiently thick material, high strength can be achieved.

[0327] The bending ease of the hinge portion 105 can be controlled in various ways. Depending on the desired degree of bending ease (flexibility), at least the number, length, width, depth, or thickness of the slits 105s and hinge piece 105h can be arbitrarily changed. Figure 39 The bending angle θ of the hinge portion 105 is exemplified. The bending angle θ caused by the weight of the second body portion 102b can be, for example, 45° or greater, 60° or greater, 70° or greater, or 85° or greater. Specifically, the bending angle θ caused by the weight of the second body portion 102b can be, for example, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, or 90°, and can also be within a range between any two of the values ​​exemplified here.

[0328] However, the hinge portion 105 is easily bent due to the weight of the second main body 102b, but the structure of the hinge portion 105 is not limited thereto. The hinge portion 105 may also not bend at all under the weight of the second main body 102b (i.e. Figure 39 The angle θ generated by the weight of the hinge 105 is substantially 0°), or the hinge 105 may bend only slightly (for example, 0°<θ≤15°, 0°<θ≤30°, or 0°<θ≤45°). Even in such a case, the slit 105s can be provided to facilitate bending of the hinge 105 when a force is applied to the second main body 102b.

[0329] Furthermore, the total length L0 of the panel 101 can be, for example, 500 to 1300 mm. Specifically, the total length L0 can be 500, 600, 700, 800, 900, 1000, 1100, 1200, or 1300 mm, or can be within a range between any two of the values ​​exemplified here. The panel 101 is provided as, for example, a luggage floor, a vehicle deck, or a floor for a luggage compartment.

[0330] Figure 35A The width W of the first main body portion 102a is a The width W of the second main body 102b b The relationship between can be set arbitrarily. If the width W of the second main body 102b is b If the hinge portion 105 is large, it is easy for the hinge portion 105 to bend due to the weight of the second main body portion 102b. b <W a In the case of width ratio W b / W a For example, it may be 0.20 to 0.80, or 0.40 to 0.60. b / W aSpecifically, for example, it is 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90 or 0.95, and may be within the range between any two of the values ​​exemplified here. However, it is not limited to the above conditions and may also be W b =W a (That is, W b / W a =1.0), or it can be W b >W a .

[0331] Any two or more of the various modifications described above may be used in combination with each other.

[0332] 2. Method for Manufacturing Panel 101

[0333] The following describes an example method for manufacturing panel 101. This method includes a preparation step, a slit cutting step, and an attachment step. Specifically, in the preparation step, a resin panel body 102 is prepared before slits are formed. Slits 105s are formed on this resin panel body 102, and the surface material 108 is attached.

[0334] 2-1. Molding machine structure

[0335] First, use Figure 40 The molding machine 10 that can be used to implement the method for manufacturing the resin panel body 102 will be described. The molding machine 10 includes a pair of sheet forming devices 14 and dies 121 and 131. Each sheet forming device 14 includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18. The extruder 13 and the accumulator 17 are connected via a connecting pipe 15. The accumulator 17 and the T-die 18 are connected via a connecting pipe 16.

[0336] Figure 40 The sheet forming device 14 and the resin used in the embodiment of the fourth viewpoint shown are the same as the sheet forming device 14 and the resin used in the embodiments of the first viewpoint and the second viewpoint (refer to "2-1-1. Structure of the sheet forming device 14" of the first viewpoint and the second viewpoint), so the description is omitted.

[0337] <Molds 121, 131>

[0338] The resin sheets 123 and 133 are extruded between the molds 121 and 131 while the molds 121 and 131 are open. Figure 40As shown, molds 121 and 131 have cavity surfaces 121a and 131a, and are provided with pinch-off portions 121b and 131b to surround cavity surfaces 121a and 131a. Vacuum holes (not shown) are provided within cavity surfaces 121a and 131a, through which the resin sheets 123 and 133 are subjected to reduced pressure and suction, thereby being shaped to conform to the shape of cavity surfaces 121a and 131a. The thickness of resin sheets 123 and 133 is, for example, 0.5 to 2 mm, specifically, 0.5, 1.0, 1.5, or 2.0 mm, or may be within the range between any two of the values ​​exemplified herein.

[0339] Mold 131 is provided with ridges 135 that form hinge portion 105. Ridges 135 are elongated protrusions, and are preferably configured so that the longitudinal direction of ridges 135 is not parallel to the extrusion direction of resin sheets 123, 133. More preferably, the longitudinal direction of ridges 135 is orthogonal to the extrusion direction of resin sheets 123, 133. In this case, variations in the thickness of resin sheets 123, 133 along the longitudinal direction of hinge portion 105 are suppressed.

[0340] 2-2. Preparation process (manufacturing process of panel body)

[0341] In the preparation step, the resin panel body 102 is prepared before the slits 105s are formed. More specifically, the preparation step of this embodiment includes an extrusion step, a shaping step, and a mold closing step.

[0342] In the extrusion process, Figure 38 As shown, resin sheets 123 and 133 are extruded between dies 121 and 131 . Resin sheet 133 is disposed between resin sheet 123 and die 131 .

[0343] Next, in the shaping step, the resin sheets 123 and 133 are shaped along the cavity surfaces 121a and 131a of the molds 121 and 131, respectively. This step can be performed by reducing and sucking the resin sheets 123 and 133 by the molds 121 and 131, respectively.

[0344] Next, in the mold closing process, the molds 121 and 131 are closed. When the molds 121 and 131 are closed, the resin sheets 123 and 133 are welded to each other along the pinch-off portions 121b and 131b, thereby obtaining a resin panel body 102 having a shape that conforms to the inner surface of the cavity formed by the pair of molds 121 and 131. The resin sheets 123 and 133 are compressed between the ridge 135 and the mold 121 to form the hinge portion 105 (see FIG. 1 ). Figure 41). The outer side of the pinch-off portion 121b, 131b becomes a burr. After that, the mold 121, 131 is opened to take out the resin panel body 102, and by removing the burr, a resin panel body 102 at a stage before the slit 105s is formed is obtained.

[0345] 2-3. Slit cutting step

[0346] Next, the slit 105s of a predetermined number and length is provided at the hinge portion 105 of the resin panel body 102. The specific method of forming the slit 105s is not limited, and for example, a punch press, an ultrasonic cutter, or a knife, or the like can be used.

[0347] 2-4. Skin material 108 attaching step

[0348] Next, by attaching the skin material 108 to the resin panel body 102 with an adhesive, the panel 101 is provided. Since such post-attaching is performed, in the embodiment, the raw material of the skin material 108 is not limited. The post-attaching does not require air permeability, and thus has the advantage that the variety of skin materials 108 that can be used is rich. For example, the skin material 108 can not be a nonwoven fabric, and can be a skin material such as synthetic leather or the like that does not have air permeability.

[0349] As explained above, according to the embodiment, by providing the slit 105s as a new method, the bending easiness of the hinge portion 105 can be improved. In particular, as in the various modifications disclosed in the embodiment, by appropriately designing the slit 105s and the hinge piece 105h, the advantage that the bending easiness of the hinge portion 105 can be controlled and durability can be ensured, and mass productivity can be taken into account, is obtained. That is, since the first body portion 102a and the second body portion 102b are linked by the hinge piece 105h, the first body portion 102a and the second body portion 102b do not have to be divided into different components. Thus, the post-attaching work of the skin material 108 in the post-process is easy, and in addition, the manufacturing variation in the size (width W0) of the panel 101 can be suppressed. In addition, by adjusting the length L h of the hinge piece 105h, the bending easiness of the hinge portion 105 can be easily controlled to a desired degree.

[0350] 3. Modification

[0351] Various modifications can be applied to the embodiment explained above. For example, the skin material 108 can be omitted from the panel 101.

[0352] The structure of the resin panel body 102 is an example, and various structures can be applied to the first main body 102a and the second main body 102b. As an example, a core material made of a foam body can be set in the hollow part 107. The foam body as the core material ensures the space between the outer wall 103 and the inner wall 104 in the hollow part 107, or improves the strength and heat insulation of the panel 101. In order to set the core material, an embedding process can be implemented between the shaping process and the mold closing process. In the embedding process, a thinner foam body is arranged at the position of the ridge 135 between the resin sheets 123 and 133, and then the mold closing process can be entered. As another example, the first main body 102a and the second main body 102b can also be constructed using a foam resin plate without a hollow part 107. As another example, reinforcing ribs can also be set at specified intervals at any position in the width direction of the first main body 102a and the second main body 102b. A plurality of reinforcing ribs may be provided by forming a portion of the inner wall 104 so as to be recessed toward the outer wall 103 and welded to the inner surface of the outer wall 103 , thereby increasing the rigidity and strength of the resin panel body 102 .

[0353] Description of Reference Numerals

[0354] (First to Third Viewpoints)

[0355] 1: Resin panel, 2: Resin molded body, 3: Core material, 3a: Base, 3a1: Recess, 3b: Base, 3b1: Recess, 3c: Reinforcement member, 3c1: Upper wall, 3c11: Protrusion, 3c2: Lower wall, 3c21: Protrusion, 3c3: Column, 4: Skin material, 5: Molded body, 5a: Molded body main body, 5b: Large burr, 5bb: Lower burr, 5bc1: Inner burr, 5bc2: Outer burr, 5bu: Upper burr, 5c: Cutting line, 5cb: Lower line, 5cl: Left line, 5cr: Right line, 5cu: Upper line, 5d: Molded product, 5e: Small burr, 5f: Parting line, 5fb: Lower line, 5 fl: Left line, 5fr: Right line, 5fu: Upper line, 9a: Base, 9b: Suction pad, 10: Molding machine, 11: Raw resin, 11a: Molten resin, 12: Hopper, 13: Extruder, 13a: Cylinder, 14: Sheet forming device, 15: Connecting pipe, 16: Connecting pipe, 17: Accumulator, 17a: Cylinder, 17b: Piston, 18: T-die, 19: Insertion device, 19a: Base, 19b: Suction pad, 19c: Female protrusion, 21: First split die, 21A: Suction portion, 21B: Suction hole, 21C: Inclined surface, 21a1: Main body, 21a2: First outer side, 21a3: End face, 21b: Inner surface Surface, 21d: Pinch-off portion, 21d1: Inner pinch-off portion, 21d2: Outer pinch-off portion, 21dd: Pinch-off portion, 21e: Male protrusion, 21f: Support portion, 22: Second split mold, 22a: Rear end portion, 22a1: Main body portion, 22a2: Second outer portion, 22a3: Opposing portion, 22a4: Chamfered portion, 22ab: Rear end portion, 22af: Front end portion, 22b: Inner surface, 22d: Pinch-off portion, 22d1: Inner pinch-off portion, 22d2: Outer pinch-off portion, 22dd: Pinch-off portion, 23: Movable portion, 23a: Opposing surface portion, 23b: Abutting surface portion, 23c: Suction portion, 23d: Engaging portion, 23e: Sealing structure Part, 23f: Supported part, 23g: Suction part, 23g1: Suction hole, 23g2: Inclined surface, 24: Driving mechanism, 24a: Upper driving mechanism, 24b: Lower driving mechanism, 31: Outer frame, 31a: Suction hole, 32: Outer frame, 32a: Suction hole, A: Area, Ar: Arrow, B: Area, C1: Arrow, C2: Arrow, Dr: Thickness direction, PL: Parting line, SD1: Confined space, SD2: Confined space, cvt: Cavity part, hl: Decompression suction hole, p1: Resin sheet, p2: Resin sheet, sp: Space, w1: Horizontal width dimension, w2: Depth dimension, t1: Distance, t2: Protrusion amount, w3: Retraction distance.

[0356] (Fourth Viewpoint)

[0357] 101: Panel, 102: Resin panel body, 102a: First main body, 102b: Second main body, 103: Surface wall, 104: Inner wall, 104a: Inclined portion, 105: Hinge, 105h: Hinge piece, 105h1: Middle hinge piece, 105h2: End hinge piece, 105s: Slit, 107: Hollow portion, 108: Surface material, 10: Molding machine, 11: Raw resin, 12: Hopper, 13: Extruder, 13a: Cylinder, 17: Accumulator, 17a: Cylinder, 17b: Piston, 18: T-die, 14: Sheet forming device, 121: Die, 121a: Cavity surface, 121b: Pinch-off portion, 123: Resin sheet, 15: Connecting tube, 16: Connecting tube, 131: Die, 131a: Cavity surface, 131b: Pinch-off portion, 133: Resin sheet, 135: Ribbon, L0: Total length of hinge, LS: Total length of slit, L S1 , L S2 : Slit length, L h : The length of the hinge, W S : Slit width.

Claims

1. A method for manufacturing a structure, wherein: It has forming process, burr shaping process and cutting process. In the molding process, a mold is used to mold the molded body. The mold has a movable portion and a first split mold and a second split mold that form a pair. The first split mold and the second split mold each have a cavity portion and a pinch-off portion. The movable portion is attached to the first split mold and the second split mold in a manner capable of relative movement with respect to the first split mold and the second split mold, and the movable portion includes a suction portion and an engagement portion. The molded body comprises a molded body body, a cutting line and a burr portion, The molded body is molded in the cavity during the molding step. The cutting line is flattened by the pinching portion during the forming process. The burr portion is connected to the molded body via the cutting line and is provided on the movable portion. In the burr forming step, the burr is sucked toward the engaging portion by the suction portion, thereby forming the burr at the engaging portion. In the cutting step, the burr portion is cut from the molded body along the cutting line by moving the movable portion relative to the first and second split dies while the burr portion is formed on the engaging portion.

2. The method according to claim 1, wherein The first split mold has an end surface portion, The movable portion has an abutting surface portion, In the burr portion shaping step, the abutting surface portion abuts against the end surface portion.

3. The method according to claim 2, wherein: The mold also has a sealing member, The sealing member is mounted on the end surface portion or the abutting surface portion.

4. The method according to claim 2, wherein: The first split mold has a first outer side, The pinch-off portion of the first split mold is formed on the first outer side, and the end surface portion is formed on the first outer side, The second split mold has a second outer side, The pinch-off portion of the second split mold is formed on the second outer portion, and the second outer portion is arranged to face the first outer portion in the opening and closing direction of the first split mold and the second split mold.

5. The method according to claim 3, wherein The first split mold has a first outer side, The pinch-off portion of the first split mold is formed on the first outer side, and the end surface portion is formed on the first outer side, The second split mold has a second outer side, The pinch-off portion of the second split mold is formed on the second outer portion, and the second outer portion is arranged to face the first outer portion in the opening and closing direction of the first split mold and the second split mold.

6. The method according to any one of claims 1 to 5, wherein The molded body comprises a resin sheet and a skin material, The skin material is arranged on the outside of the resin sheet.

7. The method according to claim 6, wherein: The first split mold and the second split mold are respectively formed with pressure reducing and suction holes. The decompression and suction hole is formed in the cavity portion, and the decompression and suction hole is formed in such a manner that the resin sheet is shaped on the first split mold and the second split mold. In a state where the resin sheet is formed on the first split mold and the second split mold, the skin material arranged in the cavity is provided along the first split mold. The decompression and suction hole is not formed on the first outer side of the first split mold.

8. The method according to claim 7, wherein: A skin material margin space is formed between the first outer portion and the second outer portion. In the molding step, the end portion of the skin material is arranged in the skin material margin space.

9. A method for manufacturing a structure, wherein: It has forming process, snapping process and cutting process. In the molding process, a mold is used to mold the molded body. The mold has a movable portion and a first split mold and a second split mold that form a pair. The first split mold and the second split mold each have a cavity portion, an inner pinch-off portion, and an outer pinch-off portion. The inner pinch-off portion is connected to the cavity portion, The outer pinch-off portion is arranged at a position farther from the cavity portion than the inner pinch-off portion. The movable portion is attached to the first split mold and the second split mold in a manner capable of relative movement with respect to the first split mold and the second split mold, and the movable portion has an engaging portion. The molded body comprises a molded body main body, an outer line portion and an outer burr portion, The molded body has an inner line portion and an inner burr portion, The molded body is molded in the cavity during the molding step. The inner line portion is flattened by the inner pinch-off portion during the forming process. The inner burr portion is formed between the inner line portion and the outer line portion, The outer line portion is flattened by the outer pinching portion during the forming process. The outer burr portion is connected to the outer line portion, In the engagement step, the outer burr portion is engaged with the engagement portion of the movable portion. In the cutting step, the outer burr portion is cut from the inner burr portion along the outer line portion by moving the movable portion relative to the first split mold and the second split mold in a state where the outer burr portion is engaged with the engaging portion. The movable part further has an attraction part, In the engagement step, the outer burr portion is sucked toward the engagement portion by the suction portion, thereby shaping the outer burr portion at the engagement portion and engaging the outer burr portion with the engagement portion.

10. The method according to claim 9, wherein: The outer pinch-off portion is formed along the engaging portion in a plan view of the first split mold and the movable portion.

11. The method according to claim 9, wherein The top surface of the outer pinch-off portion is aligned with the top surface of the engaging portion.

12. The method according to claim 11, wherein The first split mold has an end surface portion, The movable portion has an abutting surface portion, In the engaging step, the outer burr portion is sucked to the engaging portion via the suction portion in a state in which the abutting surface portion is in contact with the end surface portion.

13. The method according to claim 12, wherein: The mold also has a sealing member, The sealing member is mounted on the end surface portion or the abutting surface portion.

14. The method according to claim 12, wherein: The first split mold has a first outer side, The inner pinch-off portion and the outer pinch-off portion of the first split mold are formed on the first outer side, and the end surface portion is formed on the first outer side. The second split mold has a second outer side, The inner pinch-off portion and the outer pinch-off portion of the second split mold are formed on the second outer portion, and the second outer portion is arranged to face the first outer portion in the opening and closing direction of the first split mold and the second split mold.

15. The method according to claim 13, wherein: The first split mold has a first outer side, The inner pinch-off portion and the outer pinch-off portion of the first split mold are formed on the first outer side, and the end surface portion is formed on the first outer side. The second split mold has a second outer side, The inner pinch-off portion and the outer pinch-off portion of the second split mold are formed on the second outer portion, and the second outer portion is arranged to face the first outer portion in the opening and closing direction of the first split mold and the second split mold.

16. The method according to any one of claims 9 to 15, wherein The molded body comprises a resin sheet and a skin material, The skin material is arranged on the outside of the resin sheet.

17. The method according to claim 16, wherein The first split mold and the second split mold are respectively formed with pressure reducing and suction holes. The decompression and suction hole is formed in the cavity portion, and the decompression and suction hole is formed in such a manner that the resin sheet is shaped on the first split mold and the second split mold. In a state where the resin sheet is formed on the first split mold and the second split mold, the skin material arranged in the cavity is provided along the first split mold. The decompression and suction hole is not formed on the first outer side of the first split mold.

18. The method according to claim 17, wherein A skin material margin space is formed between the first outer portion and the second outer portion. In the molding step, the end portion of the skin material is arranged in the skin material margin space.

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