Structural member and laminated structure

Abstract

To provide a structural member and a laminated structure that can exhibit high load resistance performance when a load is applied in a direction perpendicular to a surface since a panel material and a frame material are covered with a curable resin in a state where they overlap in the thickness direction.SOLUTION: A structural member 1 comprises a core layer 2 including a panel material 22 formed of an expandable material and a frame material 21 attached to at least one surface of the panel material 22. At least a portion of the core layer 2 where the frame material 21 is exposed on the surface is covered with a curable resin layer 3.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] This disclosure relates to structural members and laminated structures primarily used as building and vehicle materials. [Background technology]

[0002] 2. Description of the Related Art Conventionally, in structural members used mainly as materials for buildings and vehicles, a configuration has been proposed in which a resin member is attached to a frame member (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2018-177123 A Summary of the Invention [Problem to be solved by the invention]

[0004] According to the technology described in Patent Document 1, when a load is applied in a direction perpendicular to the surface of a structural member, it is difficult to exhibit sufficient load-bearing performance. Therefore, an object of the present disclosure is to solve the above-mentioned problems. [Means for solving the problem]

[0005] In order to solve the above-mentioned problems, the present invention provides the following structural member and laminated structure.

[0006] (1) A structural component comprising a core layer having a panel material formed of a foamable material and a frame material attached to at least one surface of the panel material, and at least a portion of the core layer where the frame material is exposed to the surface is covered with a curable resin layer.

[0007] According to the structural member described in (1), the panel material and the frame material are covered with a curable resin while overlapping in the thickness direction, so that the structural member can exhibit high load-bearing performance when a load is applied in a direction perpendicular to the surface.

[0008] In the structural member described in (1), the panel material may be polypropylene foam, polyethylene foam, PET foam, urethane foam, polystyrene foam, etc. The frame material may be metal material such as steel or aluminum, wood, or resin material such as FRP, etc. The curable resin layer may be polyurea and / or polyurethane.

[0009] (2) The structural member according to (1), wherein the entire surface of the core layer is covered with the curable resin layer.

[0010] According to the structural member described in (2), the rigidity can be increased.

[0011] (3) A structural member as described in (2), in which a groove is formed on the one surface of the panel material, and the frame material is assembled to the panel material by being inserted into the groove.

[0012] According to the structural member described in (3), the ease of assembling the frame material to the panel material can be improved.

[0013] (4) A structural member as described in (3), in which, when the frame material is assembled to the panel material, a portion of the frame material protrudes from the one surface of the panel material.

[0014] According to the structural member described in (4), the adhesion between the frame material and the curable resin layer can be improved.

[0015] (5) A structural member as described in (4), wherein the frame material is formed by combining a plurality of rod-shaped members.

[0016] According to the structural member described in (5), the rigidity of the structural member can be further increased.

[0017] (6) A laminated structure comprising a structural member according to any one of (1) to (5) and a reinforcing plate attached to any one surface of the structural member.

[0018] The laminated structure described in (6) can exhibit high load-bearing performance when a load is applied in a direction perpendicular to the reinforcing plate.

[0019] In the laminated structure described in (6), the reinforcing plate may be made of metal materials such as steel or aluminum, wood, or resin materials such as FRP. Effect of the Invention

[0020] The structural member and laminated structure according to the present invention can exhibit high load-bearing performance when a load is applied in a direction perpendicular to the surface. [Brief description of the drawings]

[0021] [Figure 1] FIG. 1 is a perspective view showing a structural member according to an embodiment and a container employing a laminated structure. [Diagram 2] FIG. 2 is a perspective view showing a structural member according to an embodiment and a frame of a container that employs a laminated structure. [Diagram 3] FIG. 2 is a cross-sectional view showing a structural member according to an embodiment and a container employing a laminated structure. [Figure 4] FIG. 2A is a schematic cross-sectional view showing a procedure for forming a structural member, FIG. 2B is a schematic cross-sectional view showing the structural member, and FIG. 2C is a schematic cross-sectional view showing a laminated structure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Next, a container employing one embodiment of a structural member 1 and a laminated structure 1A according to the present invention will be described with reference to Figures 1 to 3. As shown in Figures 1 to 3, the container is composed of a structural member 1 and a laminated structure 1A. The structural member 1 and the laminated structure 1A according to the present invention can also be used as materials for buildings or vehicles other than the container according to this embodiment.

[0023] 1 to 3, the structural member 1 according to this embodiment is configured by covering a core layer 2 with a curable resin layer 3. In the structural member 1 according to this embodiment, the material of the curable resin layer 3 can be polyurea and / or polyurethane.

[0024] When polyurea is used for the curable resin layer 3, a compound having an isocyanate group and a curing agent having an amino group, each supplied from an independent raw material supply hose, are sprayed with an impingement mix spray gun onto the surface of the core layer 2. This forms a layer of room temperature curable polyurea as the curable resin layer 3 around the core layer 2.

[0025] A polyurea layer is formed by urea bonding between an isocyanate and a curing agent having an amino group. The reaction between the isocyanate and the curing agent is very fast, and the contact hardening occurs within a few seconds. Therefore, if the isocyanate and the curing agent are applied to the surface of the base with an impingement mix spray gun, a polyurea layer of a desired thickness is immediately formed.

[0026] Examples of the compound having an isocyanate group include aromatic isocyanates, alicyclic isocyanates, aliphatic isocyanates, and hydrogenated aromatic isocyanates. More specifically, examples of the compound include diisocyanates such as tolylene diisocyanate (TDI), diphenylmethane-4,4'-diisocyanate (MDI), and 1,5-naphthalene diisocyanate (NDI), adducts of polyhydric alcohols and diisocyanates, isophorone diisocyanate, and hexamethylene diisocyanate. The compound having an isocyanate group may be a blocked isocyanate in which the isocyanate group is first protected with a protecting group to make it inactive. The protecting group is removed by heat or the like, and the isocyanate group can be regenerated and used. Examples of the protecting agent that can become a protecting group include phenol, caprolactam, oxime, and alcohol. Examples of the curing agent having an amino group include polyamines. The polyamine may be any compound having two or more amino groups.

[0027] The core layer 2 is constructed by assembling a frame material 21 onto one surface of a panel material 22. In the structural member 1 according to this embodiment, the frame material 21 may be made of metal materials such as steel or aluminum, wood, or resin materials such as FRP. It is preferable to use aluminum as the material for the frame material 21 because it is lightweight and highly versatile.

[0028] 3 and 4, in this embodiment, the frame material 21 is a pipe having a circular cross section, but the cross section of the frame material 21 can be other shapes such as a rectangle, T-shape, H-shape, L-shape, etc. Also, a solid columnar member can be used as the frame material 21, but from the viewpoint of being lightweight and easy to achieve rigidity, it is preferable to use a hollow tubular member for the frame material 21.

[0029] Moreover, the material for the panel material 22 may be foamed polypropylene, foamed polyethylene, foamed PET, foamed urethane, or foamed polystyrene. The material for the panel material 22 may be any material other than foamed resin, as long as it is possible to form the core layer 2 by inserting the frame material 21 into the groove portion 22a of the panel material 22 as described below, and rubber material, wood, or the like may also be used. Of these, foamed resin is superior in terms of cost merit and light weight. Furthermore, from the viewpoints of cost merit and the ability to mold large sizes among foamed resins, it is preferable to use foamed polystyrene as the material for the panel material 22.

[0030] A method for forming a structural member 1 according to the present invention will be described with reference to Figures 4(a) and (b). As shown in Figure 4(a), a groove portion 22a is formed on one surface of a panel material 22. The groove width of the groove portion 22a is formed to be equal to or smaller than the width dimension of the frame material 21. The frame material 21 is then inserted into the groove portion 22a to be assembled to the panel material 22, thereby forming a core layer 2. The core layer 2 in which the frame material 21 is assembled to the panel material 22 is covered with a curable resin layer 3 as shown in Figure 4(b), thereby forming the structural member 1.

[0031] According to the structural member 1 configured as described above, the panel material 22 and the frame material 21 are covered with the curable resin layer 3 while overlapping in the thickness direction. Therefore, when a load is applied in a direction perpendicular to the surface of the structural member 1, the load can be supported by the panel material 22 in addition to the frame material 21, and therefore high load-bearing performance can be exhibited.

[0032] In the structural member 1 of this embodiment, by pushing the frame material 21 into the groove portion 22a of the panel material 22 to form the core layer 2, it becomes possible to easily fix the panel material 22 to the frame material 21, improving the assembling ability of the frame material 21 to the panel material 22 and enabling the formation of the core layer 2 with simple operations.

[0033] It is also possible to use other methods for assembling the frame material 21 to the panel material 22. For example, it is also possible to employ a method of fixing using fixing members such as bolts and nuts, a method of assembling via a bracket, a method of fixing using an adhesive, or the like.

[0034] 4(a), the structural member 1 according to this embodiment is configured so that when the frame material 21 is assembled to the panel material 22, a part of the frame material 21 protrudes from one surface of the panel material 22. This makes it possible to increase the contact area between the frame material 21 and the curable resin layer 3 when the core layer 2 is covered with the curable resin layer 3, thereby improving the adhesion between the frame material 21 and the curable resin layer 3.

[0035] In addition, in the structural member 1 according to this embodiment, it is preferable that a plurality of rod-shaped members are combined to form the frame member 21, as shown in Fig. 2. By forming the frame member 21 from a plurality of rod-shaped members in this manner, it is possible to improve the load-bearing performance against surface pressure, and to further increase the rigidity of the structural member 1 when covered with the curable resin layer 3.

[0036] In the structural member 1 according to this embodiment, the entire surface of the core layer 2 is coated with the curable resin layer 3, as shown in Fig. 4(b). This allows the curable resin layer 3 to be exposed on the entire surface of the structural member 1, thereby increasing the rigidity of the structural member 1. Note that in the structural member 1, it is sufficient that at least the portion of the core layer 2 where the frame material 21 is exposed on the surface (the upper surface in Fig. 4(a)) is coated with the curable resin layer 3, and it is not necessary that the entire surface of the core layer 2 is coated with the curable resin layer 3. In other words, the structural member 1 may have a configuration in which a portion of the panel material 22 constituting the core layer 2 is exposed.

[0037] Next, a laminated structure 1A according to the present invention will be described with reference to Figures 3 and 4(c). The laminated structure 1A according to this embodiment is configured by assembling a reinforcing plate 4 onto one surface of a structural member 1. In this embodiment, the reinforcing plate 4 can be made of metal materials such as steel or aluminum, wood, or resin materials such as FRP.

[0038] According to the laminated structure 1A of this embodiment, high load-bearing performance can be exhibited when a load is applied in a direction perpendicular to the reinforcing plate 4. The laminated structure 1A of this embodiment is provided with the reinforcing plate 4 on the side of the core layer 2 where the frame material 21 is arranged (upper side in Figs. 3 and 4(c)), but it is also possible to provide a reinforcing plate 4 that is less likely to bend and deform than the curable resin layer on the side of the core layer 2 where the frame material 21 is not arranged (lower side in Figs. 3 and 4(c)). It is preferable to use a metal plate that is less likely to deform, such as an aluminum plate, as the reinforcing plate 4. As a result, when a large load is applied, such as on the bottom surface of the container of this embodiment, the reinforcing plate 4 is less likely to bend and deform than the curable resin layer, so that the load can be distributed over the entire bottom surface, and the laminated structure 1A can be prevented from being significantly deformed. [Explanation of symbols]

[0039] 1 Structural member 1A Laminated structure 2 Core layer 3 Hardening resin layer 4 Reinforcement plate 21 Frame material 22 Panel material 22a Groove

Claims

1. A core layer including a panel material formed of a foam material and a frame material attached to at least one surface of the panel material, A structural member, wherein at least a portion of the core layer where the frame material is exposed on the surface is covered with a curable resin layer.

2. The structural member according to claim 1 , wherein the entire surface of the core layer is covered with the curable resin layer.

3. A groove is formed on the one surface of the panel material, 3. The structural member according to claim 2, wherein said frame material is assembled to said panel material by being inserted into said groove.

4. The structural member according to claim 3 , wherein when the frame material is assembled to the panel material, a portion of the frame material protrudes from the one surface of the panel material.

5. The structural member according to claim 4 , wherein the frame material is formed by combining a plurality of rod-shaped members.

6. A laminated structure comprising: a structural member according to claim 1; and a reinforcing plate attached to one surface of the structural member.

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