panel

Abstract

To provide a panel which can inhibit deformation of face materials when a load is applied to an additional member provided on the panel.SOLUTION: According to the invention, a panel includes first and second face materials and an additional member. The first and second face materials are disposed spaced apart from each other. The additional member includes first and second members. The first member has a portion which contacts with an outer surface of the first face material. The second member has a portion disposed between the first and second face materials. The first and second members are connected through an opening provided at the first surface material. The second member is adhered to an inner surface of the second face material.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a panel that can be used as a luggage board or the like to be installed in the trunk of a vehicle. [Background technology]

[0002] Patent Document 1 discloses a panel constructed by attaching thin plate-shaped face materials to a core material. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2016-7900 A Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, additional members such as bases for attaching straps, handles, legs, hooks, etc., or fasteners (e.g., claws) for fixing the panel to a car, bed, etc., may be fixed to a panel such as that described in Patent Document 1. These additional members can be fixed to the panel by riveting. However, when the additional members are fixed in this way, if the surface material is thin, there is a risk that the surface material will deform when a high load is applied to the additional members.

[0005] The present invention has been made in consideration of the above circumstances, and provides a panel that can suppress deformation of the face material when a load is applied to an additional member provided on the panel. [Means for solving the problem]

[0006] According to the present invention, there is provided a panel comprising first and second facings and an additional member, the first and second facings being spaced apart from each other, the additional member comprising first and second members, the first member having a portion that abuts the outer surface of the first facing, the second member having a portion that is disposed between the first and second facings, the first and second members being connected through an opening in the first facing, and the second member being adhered to the inner surface of the second facing.

[0007] In the panel of the present invention, the first and second members constituting the additional member are connected through an opening in the first panel, and the second member is bonded to the inner surface of the second panel. This allows the first and second panels to bear the load applied to the first member, dispersing the load and suppressing deformation of the first and second panels.

[0008] Various embodiments of the present invention will be described below as examples, and the embodiments shown below can be combined with each other. Preferably, in the panel described above, the second member comprises a base and a column portion, the base is adhered to the second face material, and the column portion extends from the base toward the first member and is connected to the first member. Preferably, the panel is as described above, and further comprises a core material between first and second face materials, the first and second face materials being bonded to the core material. Preferably, in the panel described above, the base is arranged between the second face material and the core material and is housed in a recess provided in the core material, and the column portion is connected to the first member through a through hole provided in the core material. Preferably, in the panel described above, a protrusion that protrudes radially outward is provided on the outer peripheral surface of the column portion, and the protrusion is pressed into the through hole. [Brief explanation of the drawings]

[0009] [Figure 1] 1A and 1B are perspective views of a panel 1 according to a first embodiment of the present invention, viewed obliquely from above and below, respectively. [Figure 2] FIG. 1B is an exploded perspective view of FIG. 1A. [Figure 3] FIG. 1C is an exploded perspective view of FIG. 1B. [Figure 4] 4A is a plan view of FIG. 1A, and FIG. 4B is a cross-sectional view taken along line AA in FIG. 4A. [Figure 5] FIG. 4C is an enlarged view of region B in FIG. 4B. [Figure 6] FIG. 6 is an exploded view of FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0010] The following describes embodiments of the present invention. The various features shown in the following embodiments can be combined with each other. Furthermore, each feature can be an invention independently.

[0011] 1. First embodiment 1-1. Structure of Panel 1 As shown in Figures 1 to 6, a panel 1 according to a first embodiment of the present invention comprises first and second face materials 3a, 3b, and an additional member 4. The first and second face materials 3a, 3b are arranged spaced apart from each other. A core material 2 is preferably arranged between the first and second face materials 3a, 3b. The panel 1 preferably has a substantially rectangular parallelepiped shape. The panel 1 can be used as a luggage board or the like to be installed in the trunk of a vehicle.

[0012] The length of the panel 1 in the first direction is L1, and the length in the second direction perpendicular to the first direction is L2, where L1 ≥ L2. L1 is, for example, 600 to 1200 mm, specifically, for example, 600, 700, 800, 900, 1000, 1100, or 1200 mm, or may be within a range between any two of the values ​​exemplified herein. L1 is, for example, 300 to 1200 mm, specifically, for example, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, or 1200 mm, or may be within a range between any two of the values ​​exemplified herein. The value of L2 / L1 is, for example, 0.3 to 1, specifically, for example, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0, or may be within a range between any two of the values ​​exemplified herein.

[0013] The core material 2 is preferably a plate-shaped member. The thickness of the core material 2 is 10 to 25 mm, preferably 18 to 22 mm. If the core material 2 is too thin, the overall deflection of the panel 1 will be too large. On the other hand, if the core material 2 is too thick, the weight of the panel 1 will be too large. Specific examples of the thickness are 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, and 25 mm, and may be within a range between any two of the values ​​exemplified here. The thickness of the core material 2 refers to the distance between the surfaces to which the first and second face materials 3a and 3b are bonded. The core material 2 preferably has recesses, and the first and second face materials 3a and 3b are fixed within the recesses. This prevents the first and second face materials 3a and 3b from peeling off from the core material 2.

[0014] The core material 2 may be a foamed or non-foamed material. The core material 2 may also be hollow or solid. The core material 2 is preferably formed by molding using a mold. In this case, the core material 2 can be formed into a desired shape before manufacturing the panel 1, which provides excellent handleability. Furthermore, the core material 2 can be shaped to match the desired panel shape, which allows for a product with an optimized shape to be obtained.

[0015] Examples of the core material 2 include a bead foam molded body obtained by bead expansion molding, a foamed or non-foamed sheet molded body obtained by imparting a textured shape to a single foamed or non-foamed resin sheet, and a foamed or non-foamed hollow molded body obtained by molding a foamed or non-foamed cylindrical parison or two resin sheets.

[0016] The bead expansion molding can be made of, for example, expanded polystyrene, expanded acrylonitrile styrene, expanded polypropylene, etc., and its expansion ratio is, for example, 15 to 50 times, specifically, for example, 15, 20, 25, 30, 35, 40, 45, or 50 times, or may be within a range between any two of the numerical values ​​exemplified here.

[0017] The foamed parison or foamed resin sheet can be made of a polyolefin such as polyethylene or polypropylene, and the foaming ratio of a molded article using this is, for example, 1.1 to 8 times, specifically, for example, 1.1, 1.5, 2, 3, 4, 5, 6, 7, or 8, and may be within a range between any two of the numerical values ​​exemplified here.

[0018] The first and second face materials 3a, 3b are each plate-shaped members, and a preferred distance between the first and second face materials 3a, 3b is the same as the numerical value exemplified for the thickness of the core material 2. The first and second face materials 3a, 3b are preferably bonded to the first and second main surfaces 2a, 2b of the core material 2. The first and second face materials 3a, 3b can be made of a material having higher rigidity per unit thickness than the core material 2, such as metal (aluminum, iron, etc.) or fiber-reinforced resin. The thickness of each of the first and second face materials 3a, 3b is, for example, 0.05 to 1 mm, and preferably 0.08 to 0.5 mm. Specifically, the thickness is, for example, 0.05, 0.08, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.60, 0.70, 0.80, 0.90, or 1.00 mm, and may be within a range between any two of the values ​​exemplified here. In this specification, values ​​such as thickness and depth refer to average values ​​unless otherwise specified.

[0019] The first and second face materials 3a and 3b can each be bonded to the core material 2 with an adhesive. Examples of adhesives include urethane adhesives and olefin adhesives, with one-component reactive urethane adhesives being preferred.

[0020] The additional member 4 is a member additionally provided on the panel 1, such as a base for attaching a strap, handle, leg, hook, etc., or a fastener (e.g., a nail) for securing the panel to a car, bed, etc. Attaching the additional member 4 to the panel 1 can improve the usability of the panel 1. The additional member 4 includes first and second members 4a and 4b. The first member 4a has a portion that abuts against the outer surface 3a1 of the first face member 3a, and the second member 4b has a portion that is disposed between the first and second face members 3a and 3b. The outer surface 3a1 is the surface facing outward of the panel 1. The first and second members 4a and 4b are connected through an opening 3a2 provided in the first face member 3a. The method of connecting the first and second members 4a and 4b is not particularly limited, and examples include a method using a connector 5 such as a screw 5a, a method using an adhesive, or a method using a mechanical connection structure such as a snap fit or press fit. The second member 4b is bonded to the inner surface 3b1 of the second face member 3b. The inner surface 3b1 is the surface facing inward of the panel 1, in other words, the surface on the first face member 3a side. With this configuration, the load applied to the first member 4a can be borne by the first and second face members 3a, 3b, so the load is distributed and deformation of the first and second face members 3a, 3b is suppressed.

[0021] The first member 4a is a member that forms the main body of the additional member 4. The first member 4a includes a base 4a1 and a pillar portion 4a2. The base 4a1 abuts against the outer surface 3a1. The pillar portion 4a2 extends from the base 4a1 toward the second member 4b. The first member 4a can be positioned relative to the first panel 3a by placing the pillar portion 4a2 in the opening 3a2. The pillar portion 4a2 can be omitted. Preferably, as shown in FIG. 6, the base 4a1 and the pillar portion 4a2 are provided with through holes 4a3, and a connector 5 can be inserted into the through holes 4a3 to connect the first and second members 4a and 4b. In this embodiment, there are three pillar portions 4a2, but any number of pillar portions 4a2 may be provided to obtain the required strength depending on the application of the additional member 4. The number of pillars 4a2 is, for example, 1 to 10, specifically, for example, 1, 2, 3, 4, 5, or 10, and may be within a range between any two of the numerical values ​​exemplified here. The plurality of pillars 4a2 are connected by a base 4a1. In this embodiment, the additional member 4 is a fastener used to fasten the panel 1, and is provided with a protruding tube 4a4 that protrudes from the base 4a1. The protruding tube 4a4 is used to fasten the panel 1.

[0022] The second member 4b is a member that reduces the load applied to the first member 4a and suppresses deformation of the first member 3a by transmitting a portion of the load applied to the first member 4a to the second face member 3b. The second member 4b has a base 4b1 and a pillar portion 4b2. The base 4b1 is bonded to the inner surface 3b1. The pillar portion 4b2 extends from the base 4b1 toward the first member 4a. The base 4b1 is flange-shaped and has a larger area than the pillar portion 4b2 when viewed from a direction perpendicular to the second face member 3b. The attachment strength of the additional member 4 is increased by bonding the base 4b1, which has a large area, to the second face member 3b. Furthermore, if particularly high attachment strength is required of the additional member 4, the areas of the base 4b1 and the pillar portion 4b2 can be increased accordingly.

[0023] The first and second members 4a, 4b are connected by connecting the pillar portions 4a2 and 4b2 to each other. The pillar portion 4b2 preferably has a recess 4b3 for inserting a connector 5 such as a screw 5a. The inner surface of the recess 4b3 may or may not be threaded. If the inner surface of the recess 4b3 is not threaded, the screw 5a can be inserted into the recess 4b3 while forming the thread with the screw 5a. The number of pillar portions 4b2 is the same as that of the pillar portion 4a2. Multiple pillar portions 4b2 are connected by the base 4b1.

[0024] The core material 2 has a recess 2c and a through hole 2d. The base 4b1 is disposed within the recess 2c. The recess 2c is preferably disposed so that the step between the surface 4b4 of the base 4b1 facing the second surface material 3b and the second main surface 2b of the core material 2 is 0.5 mm or less. This makes it easier to simultaneously bond the base 4b1 and the core material 2 to the second surface material 3b. When a recess for accommodating the second surface material 3b is disposed in the core material 2, the recess 2c is disposed within the recess for accommodating the second surface material 3b. The pillar portion 4a2 and the pillar portion 4b2 are connected to each other via the through hole 2d. The pillar portion 4b2 is disposed within the through hole 2d. In this embodiment, the pillar portion 4a2 does not reach the through hole 2d, but it may be long enough to reach the through hole 2d.

[0025] As shown in FIGS. 2 and 3, protrusions 4b5 protruding radially outward are preferably provided on the outer peripheral surface of the pillar portion 4b2. By forcing the protrusions 4b5 into the through-holes 2d, it becomes possible to hold the second member 4b on the core material 2 before bonding the second face member 3b to the core material 2. The protrusions 4b5 preferably protrude less toward the tip of the pillar portion 4b2. In this case, it becomes easier to press the protrusions 4b5 into the core material 2. A plurality of protrusions 4b5 are preferably provided spaced apart in the circumferential direction of the pillar portion 4b2. The plurality of protrusions 4b5 are preferably provided at equal intervals. The number of protrusions 4b5 arranged in the circumferential direction is preferably three or more, and more preferably four or more. The number of protrusions is, for example, 3 to 16, specifically, for example, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, or 16, and may be within a range between any two of the numerical values ​​exemplified here.

[0026] 1-2. Manufacturing method of panel 1 In one example, the panel 1 can be manufactured by the following method. The order of the steps may be changed as appropriate.

[0027] First, the second member 4b is held by the core material 2 so that the base 4b1 is disposed in the recess 2c of the core material 2. Next, the second main surface 2b of the core material 2 and the surface 4b4 of the second member 4b are bonded to the second surface material 3b. Next, the first main surface 2a of the core material 2 and the first face material 3a are bonded together. Next, the first member 4a and the second member 4b are connected through the opening 3a2 of the first surface member 3a.

[0028] The above steps result in a panel 1 having the additional member 4 attached. If the panel 1 is to be covered with a skin material such as nonwoven fabric, a step of adhering the skin material to cover the first and second face members 3a, 3b and the exposed portions of the core member 2 can be provided before or after connecting the first member 4a and the second member 4b.

[0029] 2. Other embodiments The present invention may be implemented in the following forms. The core material 2 is not essential and can be omitted. When the core material 2 is omitted, the first and second surface materials 3a, 3b can be spaced apart by the pillar portions 4a2 and 4b2. Instead of providing the recess 2c in the core material 2, a through hole may be provided by hollowing out the entire portion facing the base 4b1. Even in this case, interference between the core material 2 and the base 4b1 can be avoided. Instead of providing the protrusions 4b5, the diameter of the through hole 2d may be made slightly smaller than the diameter of the pillar portion 4b2, and the pillar portion 4b2 without the protrusions 4b5 may be press-fitted into the through hole 2d. Also, the base 4b1 may be press-fitted into the recess 2c. The second member 4b may be held in the core material 2 by a means other than press-fitting. For example, the base 4b1 may be bonded to the bottom surface of the recess 2c. [Explanation of symbols]

[0030] 1: Panel 2: Core material 2a: 1st principal surface 2b: 2nd principal surface 2c: Recess 2d: Through hole 3a: First surface material 3a1 :Outer surface 3a2 :Aperture 3b: 2nd surface material 3b1 :Inner surface 4: Additional parts 4a: First member 4a1: Bass 4a2:Column part 4a3 :Through hole 4a4:Protruding tube 4b: Second member 4b1: Bass 4b2:Column part 4b3: Recess 4b4 :plane 4b5 :Protrusion 5: Connector 5a: Screw

Claims

1. A panel comprising first and second face materials and an additional member, The first and second face materials are arranged spaced apart from each other so that the faces of the first and second face materials face each other; the additional member comprises a first member and a second member; the first member has a portion that abuts against the outer surface of the first face material; the second member has a portion disposed between the first and second faces; The first and second members are connected through an opening provided in the first face member, The second member is adhered to the inner surface of the second facing.

2. 2. The panel of claim 1, The second member includes a base and a post portion. The base is bonded to the second surface material, The column portion extends from the base toward the first member and is connected to the first member.

3. 3. The panel according to claim 1 or claim 2, a core material between the first and second face materials; A panel having first and second facings bonded to the core.

4. A panel according to claim 3 which relies on claim 2, the base is disposed between the second surface material and the core material and is housed in a recess provided in the core material; The column portion is connected to the first member through a through hole provided in the core material.

5. 5. The panel of claim 4, A protrusion protruding radially outward is provided on the outer circumferential surface of the pillar portion, The panel, wherein the protrusion is pressed into the through hole.

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