Laminate

Abstract

This invention provides a laminated board that can reduce weight and manufacturing costs by partially eliminating the core material. [Solution] The laminated board 10 comprises a main body portion 11 in which a pair of base materials 12 and 13 are arranged at intervals in the thickness direction, and the ends 12a and 13a of the pair of base materials 12 and 13 are welded together. The main body portion 11 is composed of a first board portion 20 in which a core material 15 is arranged between the pair of base materials 12 and 13, and a second board portion 30 in which a nonwoven fabric 16 is arranged between the pair of base materials 12 and 13.

Description

Technical Field

[0001] The present invention relates to a laminate.

Background Art

[0002] Conventionally, a laminate in which a core material is interposed between two synthetic resin base materials is known (see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above Patent Document 1, a foamed resin (bulking cross-linked material) as a core material is interposed between two synthetic resin base materials over almost the entire area of the laminate, and there is room for improvement in terms of the weight and manufacturing cost of the laminate.

[0005] The present invention has been made in view of such problems of the prior art. The object of the present invention is to provide a laminate capable of reducing weight and manufacturing cost by partially eliminating the core material.

Means for Solving the Problems

[0006] The laminate according to an aspect of the present invention includes a main body portion in which a pair of base materials are arranged at intervals in the thickness direction and the ends of the pair of base materials are welded together. The main body portion has a first board portion in which a core material is arranged between a pair of base materials, and a second board portion in which a non-woven fabric is arranged between a pair of base materials.

Effects of the Invention

[0007] According to the present invention, it is possible to provide a laminated board that can reduce weight and manufacturing costs by partially eliminating the core material. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic perspective view showing the rear of a vehicle equipped with the laminated plate according to this embodiment. [Figure 2] This is a plan view showing an example of a laminate according to this embodiment. [Figure 3] This is a cross-sectional view taken along line AA in Figure 2. [Figure 4] Figure 2 is a cross-sectional view taken along the line BB. [Figure 5A] This is a cross-sectional view showing an enlarged view of section C in Figure 4. [Figure 5B] This is a cross-sectional view showing an enlarged view of section C in Figure 4. [Figure 6] This is a plan view showing an example of a laminate according to another embodiment. [Figure 7] Figure 6 is a cross-sectional view taken along the DD line. [Modes for carrying out the invention]

[0009] The laminate according to this embodiment will be described in detail below with reference to the drawings. Note that the dimensional ratios in the drawings are exaggerated for illustrative purposes and may differ from the actual ratios.

[0010] In this embodiment, a vehicle deck board is used as an example of a laminated board.

[0011] [Overall configuration of the vehicle deck board] As shown in Figure 1, the laminated board (vehicle deck board 10) according to this embodiment is placed on the floor 3 of the luggage compartment 2 of the automobile 1 and covers the floor 3 of the luggage compartment 2. The luggage compartment 2 is partitioned by the rear seats 4, which serve as the front wall of the luggage compartment 2, a back door (rear wall) (not shown), and a roof panel (upper wall).

[0012] The vehicle deck board 10 allows for loading and unloading of luggage in the cargo compartment 5 below the floor 3 by rotating the rear portion (first board portion 20, described later) upward around a hinge portion 40 located in the middle of the vehicle in the front-rear direction. In this embodiment, the vehicle deck board 10 can be rotated by hooking a finger or the like into the notch 10a at the rear of the vehicle in the front-rear direction and lifting it up.

[0013] As shown in Figures 2 to 5A, the vehicle deck board 10 comprises a main body portion 11 formed in the shape of a plate. The main body portion 11 is composed of a first base material 12 made of synthetic resin, which is arranged on the surface side (upper side in the figure) of the main body portion 11, and a second base material 13 made of synthetic resin, which is arranged on the back side (lower side in the figure) of the main body portion 11 (see Figure 5A). That is, the main body portion 11 is composed of a pair of base materials 12 and 13 that are spaced apart in the thickness direction (vertical direction) of the vehicle deck board 10, and the ends 12a and 13a of this pair of base materials 12 and 13 are welded together (see Figures 3 and 4). The pair of base materials 12 and 13 are thermoplastic resin sheets made of thermoplastic resins such as polypropylene, engineering plastics, and olefin resins. Specifically, for example, it is preferable to add additives to polypropylene resin, and preferred additives include inorganic fillers such as mica, silica, talc, calcium carbonate, glass fibers, and carbon fibers, as well as colorants, stabilizers, plasticizers, antistatic agents, flame retardants, and foaming agents.

[0014] Furthermore, the vehicle deck board 10 has a surface layer 14 that covers at least the front side (first base material 12) of the main body 11 (see Figure 5A). In addition, the vehicle deck board 10 may have a surface layer (not shown) that covers the back side (second base material 13) of the main body 11.

[0015] The main body 11 of the vehicle deck board 10 according to this embodiment has a first board part 20 and a second board part 30. These first board part 20 and second board part 30 are connected via a hinge part 40. Between the first board part 20 and the second board part 30, a first base material 12 and a second base material 13 are welded to form a welded part, and this welded part constitutes the hinge part 40 (see FIG. 5A). Note that the welded part of the first base material 12 and the second base material 13 between the first board part 20 and the second board part 30 may not be used as a hinge. Also, a hinge part 40 may not be provided between the first board part 20 and the second board part 30.

[0016] In this embodiment, the thickness of the first board part 20 is thicker than the thickness of the second board part 30. However, it is not limited to this, and the thickness of the first board part 20 may be thinner than the thickness of the second board part 30, or the thickness of the first board part 20 and the thickness of the second board part 30 may be substantially the same.

[0017] As shown in FIG. 5A, the first board part 20 is configured such that a core material 15 is disposed between a pair of base materials 12, 13. This first board part 20 constitutes a part with a core material (or a region with a core material) where the core material 15 as a core material is disposed. The core material 15 is made of a foamed resin material such as polypropylene (PP), polyethylene (PE), polystyrene (PS), etc.

[0018] In the second board part 30, a non-woven fabric 16 is disposed between a pair of base materials 12, 13. The non-woven fabric 16 is configured using, for example, a spunbond non-woven fabric. Specifically, the non-woven fabric 16 is made of polyester and has a basis weight of 18 g / m 2 ~30 g / m 2 . The back surface of the melted first base material 12 and the reinforcing recess 31 of the second base material 13 are intertwined with the fibers of the non-woven fabric 16 and bond more firmly. This second board part 30 constitutes a part without a core material (or a region without a core material) where the core material 15 as a core material is not disposed.

[0019] Furthermore, the second board portion 30 has a plurality of reinforcing recesses 31 formed by recessing at least one of the pair of base materials 12 and 13. In this embodiment, the reinforcing recesses 31 are formed by recessing upward the second base material 13, which is formed on the back side of the main body portion 11, of the pair of base materials 12 and 13. In addition, the second board portion 30 may be formed by dividing it into a plurality of parts via slits 32 that extend in the longitudinal direction of the vehicle (see Figure 2).

[0020] On the other hand, as shown in Figure 5A, the nonwoven fabric 16 is not sandwiched between the base materials 12, 13 and the core material 15 in the first board portion 20. It is preferable that the nonwoven fabric 16 is not sandwiched between the base materials 12, 13 and the core material 15 in the first board portion 20, but as shown in Figure 5B, a part of the nonwoven fabric 16 may be sandwiched between the base material 12 or base material 13 and the core material 15.

[0021] [Method for molding vehicle deck boards] Next, an example of a method for molding the vehicle deck board 10 will be described.

[0022] (1) First, the outer layer 14 is placed in the lower mold of the mold which is divided into upper and lower parts.

[0023] (2) Next, the surface thermoplastic resin sheet (first base material 12) is placed on top of the surface layer 14.

[0024] (3) Next, while vacuum suction is applied to the lower mold, the core material (core material 15) is placed on the first base material 12 corresponding to the core material portion, and the spunbond nonwoven fabric (nonwoven fabric 16) is placed above the first base material 12 corresponding to the core material portion.

[0025] (4) Next, the surface thermoplastic resin sheet (second base material 13) is placed on top of the core material 15 and the nonwoven fabric 16.

[0026] (5) Next, the upper mold is lowered toward the lower mold, and a blow nozzle is inserted into the clamped upper and lower molds (molding molds) to inject compressed air into the space between the surface thermoplastic resin sheet (first base material 12) and the back thermoplastic resin sheet (second base material 13) to perform blow molding. In the area corresponding to the second board section 30, which is the core material-free section, compressed air is injected into the space between the back thermoplastic resin sheet (second base material 13) and the spunbond nonwoven fabric (nonwoven fabric 16).

[0027] (6) Then, the product (vehicle deck board 10) is removed from the mold.

[0028] In this way, a laminated board (vehicle deck board 10) is formed.

[0029] The effects and advantages of this embodiment will be explained below.

[0030] [Effects and Effects] (1) The laminated board 10 comprises a main body portion 11 in which a pair of base materials 12 and 13 are arranged at intervals in the thickness direction, and the ends 12a and 13a of the pair of base materials 12 and 13 are welded together. The main body portion 11 has a first board portion 20 in which a core material 15 is arranged between the pair of base materials 12 and 13, and a second board portion 30 in which a nonwoven fabric 16 is arranged between the pair of base materials 12 and 13.

[0031] By combining a first board section 20 having a core material (core material 15) with a second board section 30 having a hollow structure, the weight and cost of the laminated board (vehicle deck board 10) can be reduced. Furthermore, by partially arranging spunbond nonwoven fabric (nonwoven fabric 16) on the laminated board (vehicle deck board 10), the second board section 30, which is the core material-free portion, can be easily molded. In other words, by arranging spunbond nonwoven fabric (nonwoven fabric 16) on the second board section 30, which is the core material-free portion, the weight of the laminated board (vehicle deck board 10) can be reduced, and the adhesion between the pair of base materials 12 and 13 before blow molding can be suppressed.

[0032] As described above, according to this embodiment, by partially eliminating the core material 15, it is possible to provide a laminated board (vehicle deck board 10) that can reduce weight and manufacturing costs.

[0033] (2) In the laminated board 10, the nonwoven fabric 16 is a spunbond nonwoven fabric.

[0034] In this laminate (vehicle deck board 10), spunbond nonwoven fabric is used as the nonwoven fabric 16 placed between a pair of base materials 12 and 13. Because spunbond nonwoven fabric has continuous long fibers, it has higher strength, better productivity, and lower cost compared to general short-fiber nonwoven fabrics.

[0035] (3) In the laminated board 10, the nonwoven fabric 16 is not sandwiched between the base material 12, 13 and the core material 15.

[0036] If a spunbond nonwoven fabric (nonwoven fabric 16) is interposed between the base materials 12, 13 and the core material (core material 15) in the first board section 20, a problem may arise in which the core material (core material 15) does not adhere well to the base materials 12, 13. On the other hand, by not placing a spunbond nonwoven fabric (nonwoven fabric 16) between the base materials 12, 13 and the core material (core material 15) in the first board section 20, it becomes possible to avoid deterioration in the adhesion between the base materials 12, 13 and the core material 15.

[0037] (4) In the laminated board 10, at least a portion of the nonwoven fabric 16 may be sandwiched between the base material 12, 13 and the core material 15.

[0038] While vacuum suction is applied to the lower mold, the core material (core material 15) is placed on the first base material 12 corresponding to the core material portion, and the spunbond nonwoven fabric (nonwoven fabric 16) is placed above the first base material 12 corresponding to the core material portion. Because the nonwoven fabric 16 is breathable and lightweight, it may fall outside the core material portion when placed on the lower mold of the molding die, so the size (dimensions) of the nonwoven fabric 16 is made larger than the core material portion. As a result, a portion of the nonwoven fabric 16 is sandwiched between the base material 12 or base material 13 and the core material 15.

[0039] (5) In the laminated board 10, the second board portion 30 has a reinforcing recess 31 formed by recessing at least one of the pair of base materials 12, 13.

[0040] By forming a reinforcing recess 31 in the second board portion 30, which is the part without a core material, the strength of the second board portion 30 can be ensured.

[0041] (6) In the laminated board 10, the first board portion 20 and the second board portion 30 are connected via a hinge portion 40.

[0042] When opening the laminated board (vehicle deck board 10) to take out items stored in the cargo compartment, the opening and closing area of ​​the laminated board (vehicle deck board 10) can be opened by rotating it around the hinge portion 40 as an axis.

[0043] Although this embodiment has been described above, this embodiment is not limited to these, and various modifications are possible within the scope of the gist of this embodiment.

[0044] For example, as shown in Figures 6 and 7, the laminated board (vehicle deck board 10A) may have multiple hinge portions 40 (two in the illustrated example). In the vehicle deck board 10A, one of the two hinge portions 40 is formed between the first board portion 20 and the second board portion 30, and the other hinge portion 40 is formed in the middle of the first board portion 20. A core material (core material 15) may or may not be placed in the portion between the two hinge portions 40. [Explanation of Symbols]

[0045] 10 Vehicle deck boards (laminated boards) 11 Main body 12. Thermoplastic resin sheet on the surface side (first substrate) 12a end 13. Thermoplastic resin sheet on the reverse side (second base material) 13a End 14 Epidermis 15. Core material 16. Spunbond nonwoven fabric (nonwoven fabric) 20 1st Board Section 30. Second Board Section 31 Reinforcement recess 40 Hinge section

Claims

1. The main body comprises a pair of base materials arranged at intervals in the thickness direction, with the ends of the pair of base materials welded together. The main body is, A first board portion is formed by placing a core material between a pair of base materials, A second board portion having a nonwoven fabric disposed between a pair of the base materials, Laminated board.

2. The laminate according to claim 1, wherein the nonwoven fabric is a spunbond nonwoven fabric.

3. The laminate according to claim 1 or 2, wherein the nonwoven fabric is not sandwiched between the base material and the core material.

4. The laminate according to claim 1 or 2, wherein at least a portion of the nonwoven fabric is sandwiched between the base material and the core material.

5. The laminate according to claim 1 or 2, wherein the second board portion has a reinforcing recess formed by recessing at least one of the pair of base materials.

6. The laminate according to claim 1 or 2, wherein the first board portion and the second board portion are connected via a hinge portion.

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