Panel structure processing method, panel structure processing device, and panel structure

Abstract

To suppress strength reduction at a bending portion.SOLUTION: A method of processing a panel structure comprising a core member formed using a thermoplastic resin and provided with a plurality of protruded portions that extend in one direction on both surfaces, and faceplates formed into a plate shape using the thermoplastic resin and placed so as to sandwich the core member from both sides in a height direction of the protruded portions includes: an insertion step of inserting a rod-like member into a space formed between a faceplate and the core member of the panel structure along the one direction; and a bending step of heating and softening an object portion along the rod-like member of the panel structure in a state in which the rod-like member is inserted, and bending the panel structure along the rod-like member to form a bending portion at the object portion.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a method for processing a panel structure, a processing device for a panel structure, and a panel structure. [Background technology]

[0002] When folding a panel structure made of corrugated plastic cardboard, a processing method is known in which a heated blade is pressed against the surface of the panel structure to form a groove, and the panel structure is folded along the groove (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-262943 Summary of the Invention [Problem to be solved by the invention]

[0004] When a panel structure is bent by applying heat and pressure as in the processing method of Patent Document 1, peeling or the like may occur at the bent portion, or the panel structure at the bent portion may be crushed, which may reduce the strength of the panel structure at the bent portion.

[0005] The present disclosure has been made in consideration of the above, and aims to provide a processing method for a panel structure, a processing device for a panel structure, and a panel structure that can suppress a decrease in strength at the bending portion. [Means for solving the problem]

[0006] The processing method for a panel structure according to the present disclosure is a processing method for a panel structure comprising a core member formed using a thermoplastic resin and having a plurality of convex portions extending in one direction on both sides thereof, and a face plate formed using a thermoplastic resin in a plate shape and arranged to sandwich the core member from both sides in the height direction of the convex portions, and includes an insertion step of inserting a rod-shaped member along the one direction into a space formed between the face plate and the core member of the panel structure, and a bending step of heating and softening a target portion of the panel structure along the rod-shaped member with the rod-shaped member inserted, and bending the panel structure along the rod-shaped member to form a bent portion in the target portion.

[0007] The panel structure processing device of the present disclosure is a panel structure processing device comprising: a core member formed using thermoplastic resin and having a plurality of convex portions extending in one direction on both sides thereof; and a face plate formed using thermoplastic resin in a plate shape and arranged to sandwich the core member from both sides in the height direction of the convex portions, and is further equipped with a holding section that holds the panel structure with a rod-shaped member inserted along the one direction into the space formed between the face plate and the core member; a heating section that heats and softens a target portion of the panel structure along the rod-shaped member; and a bending auxiliary section that is arranged along the target portion on the inside of the bending direction of the target portion when bending the panel structure along the rod-shaped member.

[0008] The panel structure of the present disclosure comprises a core member formed using thermoplastic resin and having a plurality of convex portions extending in one direction on both sides thereof, and a face plate formed using thermoplastic resin in a plate shape and arranged to sandwich the core member from both sides in the height direction of the convex portions, and has a bending portion bent along the one direction, and at the bending portion, the face plate and the core member are formed to surround a columnar space along the one direction. [Effects of the Invention]

[0009] According to the present disclosure, it is possible to suppress a decrease in strength at the bent portion. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a diagram showing an example of a panel structure to be processed in this embodiment. [Figure 2] FIG. 2 is a flowchart showing an example of a method for processing a panel structure according to this embodiment. [Figure 3] FIG. 3 is a diagram showing an example of a rod-shaped member used in the insertion step. [Figure 4] FIG. 4 is a diagram showing an example of the insertion step. [Figure 5] FIG. 5 is a diagram showing an example of heating in the bending process. [Figure 6] FIG. 6 is a diagram showing an example of folding the panel structure in the folding step. [Figure 7] FIG. 7 is a diagram illustrating an example of the cooling step. [Figure 8] FIG. 8 is a diagram showing an example of the panel structure after the removal step. [Figure 9] FIG. 9 is a diagram showing another example of folding the panel structure in the folding step. [Figure 10] FIG. 10 is a diagram showing another example of a rod-shaped member used in the insertion step. [Figure 11] FIG. 11 is a diagram showing another example of the insertion step. [Figure 12] FIG. 12 is a diagram showing another example of folding the panel structure in the folding step. [Figure 13] FIG. 13 is a diagram showing another example of folding the panel structure in the folding step. [Figure 14] FIG. 14 is a diagram showing another example of the insertion step. [Figure 15] FIG. 15 is a diagram showing another example of folding the panel structure in the folding step. [Figure 16] FIG. 16 is a diagram showing another example of folding the panel structure in the folding step. [Figure 17] FIG. 17 is a diagram showing an example of a processing device according to this embodiment. [Figure 18] FIG. 18 is a diagram showing an example of a bending process performed using a processing device. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments of a method for processing a panel structure, a processing device for a panel structure, and a panel structure according to the present disclosure will be described with reference to the drawings. Note that the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by a person skilled in the art, or those that are substantially identical.

[0012] 1 is a diagram showing an example of a panel structure 10 to be processed in this embodiment. As shown in FIG. 1, the panel structure 10 includes a core member 12, a face plate 14, and a joint 16.

[0013] The core member 12 and the face plate 14 are formed using a thermoplastic resin. Examples of the thermoplastic resin include composite materials, polypropylene, and the like. Examples of the composite material include thermoplastic fiber reinforced plastics (FRP: Fiber Reinforced Plastics) that contain reinforcing fibers. Examples of the fiber reinforced plastics include glass fiber reinforced plastics (GFRP: Glass Fiber Reinforced Plastics) and carbon fiber reinforced plastics (CFRP: Carbon Fiber Reinforced Plastics). Note that the fiber reinforced plastics are not limited to the above. The core member 12 and the face plate 14 may be formed of the same material or different materials.

[0014] The core member 12 is formed, for example, in a wave shape. The core member 12 has a plurality of protrusions 18 on both surfaces. Each protrusion 18 extends in a linear extension direction (one direction) D1. The core member 12 has recesses at positions corresponding to the protrusions 18 on the surface opposite to the protruding direction of the protrusions 18. Such a core member 12 may also be called a corrugated shape. Note that the core member 12 may have any configuration as long as the protrusions 18 are repeatedly provided in the same shape along each surface of the core member 12 in a direction intersecting the extension direction D1. Therefore, the core member 12 is not limited to a wave shape or a corrugated shape and may have other shapes. Examples of other shapes include a so-called harmonica shape (or harmonica structure) used in the cross-sectional shape of plastic corrugated cardboard, for example.

[0015] The face plate 14 is disposed so as to sandwich the core member 12 from both sides of the protrusion 18 in the height direction. The face plate 14 is disposed on the protrusion 18 of the core member 12. In this embodiment, the face plate 14 is, for example, rectangular. The shape of the face plate 14 may be a shape other than rectangular. By disposing the face plate 14, a space K1 is formed between the face plate 14 and the protrusion 18 in one direction.

[0016] The joints 16 connect the core member 12 and the face plate 14. The joints 16 are formed between the tops of the protrusions 18 and the face plate 14. The joints 16 are selectively formed, for example, between the tops of multiple protrusions 18 and the face plate 14. The joints 16 are formed, for example, according to the rigidity and impact resistance characteristics required of the panel structure 10. The joints 16 can be formed by heating and melting the joints between the tops of the protrusions 18 and the face plate 14, and then placing the face plate 14 and cooling it. Heating can be performed using, for example, a heat source such as a heater or heating wire, ultrasonic vibration, electromagnetic induction using a magnetic field, or a laser, but is not limited to these methods. The joints 16 may also be configured such that the protrusions 18 and the face plate 14 are bonded together using an adhesive (not shown).

[0017] Fig. 2 is a flowchart showing an example of a processing method for the panel structure 10 according to this embodiment. As shown in Fig. 2, the processing method for the panel structure 10 according to this embodiment includes an insertion step S10, a folding step S20, a cooling step S30, and a removal step S40.

[0018] In the insertion step S10, the rod-shaped member 30 is inserted into the space K1 formed between the face plate 14 and the protrusion 18 of the panel structure 10 along the extending direction D1.

[0019] 3 is a diagram showing an example of a rod-shaped member 30 used in the insertion step S10. As shown in FIG. 3, the rod-shaped member 30 has a heating member 32, a protective layer 34, and a commingle material 36.

[0020] The heating member 32 is formed in a cylindrical shape using a conductive material such as metal. The heating member 32 generates heat, for example, by passing an electric current through it. The heating member 32 is formed to a length such that both ends protrude from the space K1 when inserted into the space K1 of the panel structure 10. Electrodes, for example, can be connected to both ends protruding from the heating member 32.

[0021] The protective layer 34 is formed using, for example, a polyimide resin material. The protective layer 34 is arranged so as to cover the portion of the heating member 32 that is housed in the space K1 of the panel structure 10. The protective layer 34 is provided so as to be separable from the heating member 32. In this embodiment, for example, a film member is used as the protective layer 34. The protective layer 34 is not limited to a film member and may also be a tape member.

[0022] The commingle material 36 is formed, for example, in a linear shape using a mixture of reinforcing fibers and thermoplastic resin fibers. The shape of the commingle material is not limited to a washcoat, and may be other shapes such as a tape (strip) or a sheet. The commingle material 36 is arranged in a wound state around the portion of the heating member 32 that is covered by the protective layer 34. When heat is applied to the commingle material 36, the thermoplastic resin fibers melt.

[0023] The rod-shaped member 30 is, for example, cylindrical in shape when the heating member 32, the protective layer 34, and the commingling material 36 are provided. The shape of the rod-shaped member 30 may be other types of columnar, such as a rectangular column. When inserted into the space K1, the diameter of the rod-shaped member 30 can be set so as to contact the face plate 14 that surrounds the space K1 and the portions of the protrusions 18 that extend on both sides in the extension direction D1.

[0024] Fig. 4 is a diagram showing an example of the insertion step S10. As shown in Fig. 4, in the insertion step S10, a rod-shaped member 30 having a heating member 32, a protective layer 34, and a commingle material 36 is inserted along the extension direction D1 into the space K1 between the face plate 14 and the protrusion 18 of the panel structure 10. The rod-shaped member 30 is inserted so that both longitudinal ends of the heating member 32 protrude from the space K1 in the extension direction D1. The rod-shaped member 30 is also inserted so that the entire portion of the heating member 32 around which the commingle material 36 is wrapped is accommodated in the space K1.

[0025] After the rod-shaped member 30 is inserted into the space K1, a bending step S20 is performed. In the bending step S20, a target portion of the panel structure 10 along the rod-shaped member 30 with the rod-shaped member 30 inserted therein is heated and softened, and the panel structure 10 is bent along the rod-shaped member 30 to form a bent portion in the target portion.

[0026] Fig. 5 is a diagram showing an example of heating in the bending step S20. As shown in Fig. 5, in the bending step S20, the target portion 20 is heated from inside the panel structure 10 by a heating member 32 inserted into the space K1 of the panel structure 10. The target portion 20 is a portion including the face plate 14 and the protrusion 18 that surround the space K1 into which the rod-shaped member 30 is inserted.

[0027] When an electric current is passed through the heating element 32, the heating element 32 generates heat. The heat generated by the heating element 32 heats and softens the target portion 20. The heat generated by the heating element 32 also melts the thermoplastic resin fibers 36a of the commingle material 36, causing them to adhere to the face plate 14 and the protrusions 18 of the panel structure 10. The melted thermoplastic resin fibers 36a also adhere to the protective layer 34.

[0028] After softening the target portion 20, the panel structure 10 is bent along the rod-shaped member 30 to form a bent portion in the target portion 20. Figure 6 is a diagram showing an example of bending the panel structure 10 in the bending process. Figure 6 shows an example of bending the panel structure 10 so that the protrusion 18 is positioned inside the rod-shaped member 30 in the bending direction D2.

[0029] As shown in FIG. 6, when the panel structure 10 is bent so that the protrusions 18 are positioned inside the bending direction D2 relative to the rod-shaped members 30, a compressive force is generated in the protrusions 18 and face plate 14B, which are positioned inside the bending direction D2. The compressive force generated in the protrusions 18 and face plate 14B presses the rod-shaped members 30 against the face plate 14A, which is positioned outside the bending direction D2. Because the rod-shaped members 30 are positioned in the space K1, the compressive force prevents the protrusions 18 and face plate 14B from deforming inward of the space K1. This prevents the space K1 from collapsing and the joint 16 from peeling off due to bending. This compressive force also causes the tip ends of the protrusions 18 in the protruding direction to deform so as to expand laterally relative to the extension direction D1.

[0030] Furthermore, when the panel structure 10 is bent, a tensile force is generated in the face plate 14A disposed on the outer side of the bending direction D2. The face plate 14A on the outer side of the bending direction D2 is efficiently heated and softened by the rod-shaped member 30, and is deformed so as to extend laterally in the extension direction D1 without breaking due to the tensile force.

[0031] Furthermore, the thermoplastic resin fibers 36a of the commingle material 36 provided on the rod-shaped member 30 melt when heated and adhere to the face plate 14A and the protrusions 18.

[0032] After forming the bent portions 22 in the panel structure 10, a cooling step S30 is performed. In the cooling step S30, the bent portions 22 are cooled. Fig. 7 is a diagram showing an example of the cooling step S30. In the cooling step S30, for example, heating by the heating member 32 is stopped, and the panel structure 10 including the bent portions 22 is cooled by natural cooling. The panel structure 10 may also be cooled using a cooling device or the like.

[0033] The cooling step S30 hardens the softened or melted thermoplastic resin. For example, the face plate 14 and the protrusions 18 that have been heated and softened by the heating element 32 are hardened. As a result, the panel structure 10 maintains the shape in which the bent portions 22 have been formed. Furthermore, the thermoplastic resin fibers 36a of the commingle material 36 that have been heated and melted by the heating element 32 and that have adhered to the face plate 14 and the protrusions 18 are hardened. The hardening of the thermoplastic resin fibers 36a reinforces the face plate 14 and the protrusions 18. For example, the face plate 14A on the outer side in the bending direction D2 may be elongated by being bent in the bending step S20, resulting in a reduction in plate thickness. In this embodiment, the thermoplastic resin fibers 36a harden while adhering to the face plate 14A, thereby reinforcing the face plate 14A.

[0034] After cooling the bent portions 22, the removal step S40 is performed. In the removal step S40, at least a part of the rod-shaped members 30 is removed from the panel structure 10 in a state in which the bent portions 22 have been cooled.

[0035] In this embodiment, the thermoplastic resin fibers 36a of the commingle material 36 harden while adhering to the protective layer 34. That is, the protective layer 34 is bonded to the face plate 14 and the protrusions 18 via the thermoplastic resin fibers 36a. Therefore, in the removal step S40, by separating and removing the heating element 32 from the protective layer 34, a portion of the rod-shaped element 30 can be easily removed. Depending on the state of adhesion between the thermoplastic resin fibers 36a and the protective layer 34, the protective layer 34 may be detachable from the thermoplastic resin fibers 36a without destroying the shape of the bent portion 22. In this case, the protective layer 34 may be detached from the thermoplastic resin fibers 36a, and the heating element 32 may be removed together with the protective layer 34.

[0036] Fig. 8 is a diagram showing an example of the panel structure 10 after the removal step S40 has been performed. As shown in Fig. 9, by performing the removal step S40, the panel structure 10 has a bent portion 22 that is bent in a bending direction D2 along the extension direction D1. Furthermore, the panel structure 10 is formed such that the face plate 14 and the protrusion 18 surround a columnar space K2 along the extension direction D1 at the bent portion 22.

[0037] The space K2 has a shape corresponding to the shape of the rod-shaped member 30 removed in the removal step S40. The shape of the space K2 is different from the shape of the space K1 in the portion of the panel structure 10 other than the bent portion 22. For example, when viewed in cross section along a plane perpendicular to the extension direction D1, the space K2 has substantially the same shape in any portion in the extension direction D1. When viewed in cross section along a plane perpendicular to the extension direction D1, the dimensions of the space K2 correspond to the dimensions of the rod-shaped member 30 removed in the removal step S40. The space forming portion 24 is formed when the face plate 14 and the protrusion 18 are softened by heat and hardened into a shape that conforms to the rod-shaped member 30.

[0038] In this embodiment, the thermoplastic resin fibers 36a of the commingle material 36 are provided in a hardened state at the bent portions 22 of the panel structure 10. In this case, the thermoplastic resin fibers 36a form a part of the space forming portion 24 that surrounds the space K2. In addition, when the heating member 32 is separated from the protective layer 34 and removed in the removal step S40, the protective layer 34 remains at the bent portions 22 of the panel structure 10. In this case, the protective layer 34 forms a part of the space forming portion 24 that surrounds the space K2.

[0039] As described above, according to the above-described processing method for the panel structure 10, the panel structure 10 is bent with the rod-shaped members 30 disposed in the space K1, thereby suppressing deformation of the protrusions 18 and the face plate 14B toward the inside of the space K1. This suppresses crushing of the space K1 and peeling of the joints 16 due to bending. This makes it possible to suppress a decrease in strength at the bent portions.

[0040] Furthermore, the above-described panel structure 10 has a bent portion 22 that is bent in one direction, and at the bent portion 22, the face plate 14 and the protruding portion 18 are formed so as to surround a columnar space K1 that is aligned in one direction. Therefore, it is possible to provide a panel structure 10 in which a decrease in strength at the bent portion 22 is suppressed.

[0041] FIG. 9 illustrates another example of bending the panel structure 10 in the bending step S20. FIG. 9 illustrates a case where the panel structure 10 is bent so that the protrusions 18 are positioned outward in the bending direction D2 relative to the rod-shaped members 30. When the panel structure 10 is bent so that the protrusions 18 are positioned outward in the bending direction D2 relative to the rod-shaped members 30 as shown in FIG. 9, a compressive force is generated in the face plate 14B, which is positioned inward in the bending direction D2. The compressive force generated in the face plate 14B presses the rod-shaped members 30 against the protrusions 18 and the face plate 14A, which are positioned outward in the bending direction D2. This pressing force deforms the tip end of the protrusion 18 in the protruding direction so as to expand laterally relative to the extension direction D1. Furthermore, because the rod-shaped members 30 are positioned in the space K1, the compressive force suppresses deformation of the face plate 14B toward the space K1. This suppresses collapse of the space K1 and peeling of the joint 16 due to the bending. In the example shown in FIG. 9, the rod-shaped member 30 is pressed against the joint 16, so that separation of the joint 16 is more reliably prevented.

[0042] Furthermore, when the panel structure 10 is bent, a tensile force is generated in the face plate 14A and the protrusions 18 that are disposed on the outside of the bending direction D2. The face plate 14A and the protrusions 18 on the outside of the bending direction D2 are efficiently heated by the rod-shaped members 30 and softened, and are deformed so as to extend laterally in the extension direction D1 without being broken by the tensile force.

[0043] Furthermore, the thermoplastic resin fibers 36a of the commingle material 36 provided on the rod-shaped member 30 melt when heated and adhere to the face plate 14A and the protrusions 18.

[0044] 10 is a diagram showing another example of a rod-shaped member used in the insertion step S10. As shown in FIG.

[0045] The heating member 42 has, for example, a rod-shaped core member 42a and a sheet heating element 42b wound around the core member 42a. The core member 42a is formed using a material that can maintain its rigidity even when subjected to heat. The sheet heating element 42b is configured with a wiring layer 42d made of metal or the like formed on a film member 42c made of, for example, resin. Heat is generated by passing a current through the wiring layer 42d. The protective layer 44 and the commingle material 46 can be configured similarly to the protective layer 34 and the commingle material 36 described above. Note that the film member 42c may be configured to have the same function as the protective layer 34. In this case, the protective layer 44 may not be provided.

[0046] Fig. 11 is a diagram showing another example of the insertion step S10. Fig. 11 shows an example in which a plurality of rod-shaped members 30 are used in the insertion step S10. As shown in Fig. 11, in the insertion step S10, the rod-shaped members 30 can be inserted into three adjacent spaces K1 in the panel structure 10 that are separated by protrusions 18. The rod-shaped members 30 inserted into the spaces K1 may have the same configuration, or at least one of them may have a different configuration.

[0047] FIG. 12 shows another example of bending the panel structure 10 in the bending step S20. FIG. 12 illustrates an example of bending the panel structure 10 into which a plurality of rod-shaped members 30 are inserted. As shown in FIG. 12, in the bending step S20, bending is performed at the convex portion 18 of the central space K1 in the adjacent direction among the three spaces K1. FIG. 13 illustrates an example of bending the panel structure 10 so that the convex portion 18 is positioned inside the rod-shaped member 30 in the bending direction D2. As shown in FIG. 12, because a rod-shaped member 30 is disposed in each of the three spaces K1, deformation of the face plate 14 and the convex portion 18 toward the inside of the space K1 due to compression force can be suppressed. This more reliably suppresses crushing of the space K1 and peeling of the joint 16 due to bending.

[0048] 13 is a diagram showing another example of bending the panel structure 10 in the bending step S20. FIG. 13 shows another example of bending the panel structure 10 into which a plurality of rod-shaped members 30 are inserted, in which the protrusions 18 are positioned outward in the bending direction D2 relative to the rod-shaped members 30. As shown in FIG. 13, since the rod-shaped members 30 are respectively disposed in the three spaces K1, deformation of the face plate 14 and the protrusions 18 toward the inside of the spaces K1 due to compressive force can be suppressed. This makes it possible to more reliably suppress collapse of the spaces K1 and peeling of the joints 16 due to bending.

[0049] FIG. 14 is a diagram showing another example of the insertion step S10. FIG. 14 is a diagram showing another example in which a plurality of rod-shaped members 30 are used in the insertion step S10. As shown in FIG. 14, in the insertion step S10, the rod-shaped members 30 can be inserted into three adjacent spaces K1 in the panel structure 10 that are separated by protrusions 18. In this case, the rod-shaped members 30 inserted into each of the three spaces K1 are provided with the commingle material 36 wrapped around them so that the commingle material 36 overlaps in the radial direction. In addition, the rod-shaped members 30 inserted into the spaces K1 on both sides in the adjacent direction have a larger amount of the commingle material 36 wrapped around them than the rod-shaped member 30 inserted into the central space K1 in the adjacent direction among the three spaces K1.

[0050] FIG. 15 is a diagram showing another example of bending the panel structure 10 in the bending step S20. FIG. 15 shows another example of bending the panel structure 10 into which a plurality of rod-shaped members 30 are inserted. Specifically, this example shows bending the panel structure 10 so that the protruding portions 18 of the central spaces K1 in the adjacent directions among the three spaces K1 are positioned inside the rod-shaped members 30 in the bending direction D2. As shown in FIG. 15, because a rod-shaped member 30 is disposed in each of the three spaces K1, deformation of the face plate 14 and the protruding portions 18 toward the inside of the spaces K1 due to compressive force can be suppressed. This makes it possible to more reliably suppress crushing of the spaces K1 and peeling of the joints 16 due to bending.

[0051] Furthermore, by wrapping the commingle material 36 around the rod-shaped members 30 inserted into each space K1 so that they overlap in the radial direction, the surface layer of the rod-shaped members 30 becomes soft and easier to deform. Therefore, when the panel structure 10 is bent, the surface layer can more easily accommodate deformation of the face plate 14 and the protrusions 18, improving the conformability of the face plate 14 and the protrusions 18.

[0052] Furthermore, the commingle materials 36 of the rod-shaped members 30 inserted into the spaces K1 on both sides can reinforce the joint 16 between the protrusion 18 and the face plate 14 and its surrounding area. This makes it possible to prevent the space K1 from being crushed due to bending and the joint 16 from peeling off. Furthermore, compared to when the rod-shaped members 30 are inserted only into the central space K1, the weight of the reinforced portion by the commingle materials 36 is greater, improving the reinforcing strength.

[0053] Furthermore, by making the winding amount of the commingle material 36 on the rod-shaped members 30 inserted into the spaces K1 on both sides greater than the winding amount of the commingle material 36 on the rod-shaped member 30 inserted into the central space K1, the joints 16 between the protrusions 18 and the faceplate 14 and their surroundings can be sufficiently reinforced in the spaces K1 on both sides, thereby preventing the spaces K1 from being crushed and the joints 16 from peeling off due to bending. Furthermore, the rod-shaped member 30 inserted into the central space K1 is pressed outward in the bending direction D2 in the bending step S20. Therefore, the reinforcement of the inner portion (the joints 16 between the faceplate 14 and the protrusions 18 and their surroundings) is less than the reinforcement of the outer portion in the bending direction D2. In contrast, by making the amount of winding of the commingle material 36 of the rod-shaped members 30 inserted into the spaces K1 on both sides greater than the amount of winding of the commingle material 36 of the rod-shaped member 30 inserted into the central space K1, the inner portion of the central space K1 in the bending direction D2, i.e., the joint 16 and its surrounding area, can be reinforced from both sides.

[0054] FIG. 16 is a diagram showing another example of bending the panel structure 10 in the bending step S20. FIG. 16 shows another example of bending the panel structure 10 into which a plurality of rod-shaped members 30 are inserted. Specifically, this example shows bending the convex portions 18 of the central spaces K1 in adjacent directions among the three spaces K1 so that the convex portions 18 are positioned outward in the bending direction D2 relative to the rod-shaped members 30. As shown in FIG. 16, because a rod-shaped member 30 is disposed in each of the three spaces K1, deformation of the face plate 14 and the convex portions 18 toward the inside of the spaces K1 due to compressive force can be suppressed. This makes it possible to more reliably suppress crushing of the spaces K1 and peeling of the joints 16 due to bending.

[0055] Furthermore, similar to the case where the rod-shaped member 30 is bent so that the protrusions 18 are positioned inside the bending direction D2, the commingle material 36 is wrapped around the rod-shaped member 30 inserted into each space K1 so as to overlap in the radial direction, thereby softening the surface layer of the rod-shaped member 30 and making it easier to deform. Therefore, when the panel structure 10 is bent, it becomes easier to accommodate the deformation of the face plate 14 and the protrusions 18, improving the followability of the face plate 14 and the protrusions 18.

[0056] Furthermore, the commingle materials 36 of the rod-shaped members 30 inserted into the spaces K1 on both sides can reinforce the joint 16 between the protrusion 18 and the face plate 14 and its surrounding area. This makes it possible to prevent the space K1 from being crushed due to bending and the joint 16 from peeling off. Furthermore, compared to when the rod-shaped members 30 are inserted only into the central space K1, the weight of the reinforced portion by the commingle materials 36 is greater, improving the reinforcing strength.

[0057] Furthermore, by making the amount of winding of the commingle material 36 of the rod-shaped members 30 inserted into the spaces K1 on both sides greater than the amount of winding of the commingle material 36 of the rod-shaped members 30 inserted into the central space K1, the joint 16 between the convex portion 18 and the face plate 14 and its surrounding area can be sufficiently reinforced in the spaces K1 on both sides, thereby suppressing crushing of the space K1 due to bending and peeling of the joint 16.

[0058] Furthermore, the rod-shaped member 30 inserted into the central space K1 is pressed outward in the bending direction D2 in the bending step S20. This allows the joint 16 between the protrusion 18 and the face plate 14 to be reinforced. On the other hand, when the rod-shaped member 30 is bent so that the protrusion 18 is positioned outward in the bending direction D2 relative to the rod-shaped member 30, a tensile force generated outward in the bending direction D2 may cause the face plate 14 on both sides of the joint 16 to stretch, reducing the plate thickness. In contrast, by making the winding amount of the commingle material 36 of the rod-shaped member 30 inserted into the spaces K1 on both sides greater than the winding amount of the commingle material 36 of the rod-shaped member 30 inserted into the central space K1, the face plates 14 on both sides of the joint 16 can be sufficiently reinforced by the commingle material 36 of the rod-shaped member 30 disposed in the spaces K1 on both sides.

[0059] 17 is a diagram showing an example of a processing apparatus 50 according to this embodiment. The processing apparatus 50 is used when performing the above-mentioned bending step S20. As shown in FIG. 17, the processing apparatus 50 includes a holding unit 52, a heating unit 54, and a bending assist unit 56.

[0060] The holding portion 52 holds the panel structure 10 with the rod-shaped member 30 inserted along the extension direction D1 into the space K1 formed between the face plate 14 and the protrusion 18 of the panel structure 10. A base end portion 52a of the holding portion 52 is fixed. The holding portion 52 holds the panel structure 10 in a cantilevered state, for example.

[0061] The heating unit 54 heats and softens the target portion 20 along the rod-shaped member 30 of the panel structure 10. The heating unit 54 is, for example, a power source or the like for passing an electric current through the rod-shaped member 30. By passing an electric current through the rod-shaped member 30 by the heating unit 54, the rod-shaped member 30 generates heat, and the target portion 20 can be heated. Note that the heating unit 54 may also be a heater or the like provided outside the panel structure 10. In this case, the target portion 20 can be heated from outside the panel structure 10 by the heater.

[0062] The bending assist part 56 is arranged along the target part 20 on the inside of the bending direction D2 of the target part 20 when the panel structure 10, whose target part 20 has been softened, is bent along the rod-shaped member 30. The bending assist part 56 can be a columnar member having various shapes, such as a cylinder, a rectangular prism, or a triangular prism. An appropriate shape for the bending assist part 56 can be selected depending on the bending angle of the panel structure 10, the shape of the bent part, etc. At least one longitudinal end of the bending assist part 56 is fixed.

[0063] Fig. 18 is a diagram showing an example of performing the folding step S20 using processing device 50. As shown in Fig. 18, first, with the surface of panel structure 10 that is on the inside in folding direction D2 facing downward, one end of panel structure 10 in the direction in which protrusions 18 are arranged is held by holding unit 52. Then, target portion 20 is heated by heating unit 54 to soften it.

[0064] After the target portion 20 has softened, the bending assisting portion 56 is placed on the target portion 20 along the extension direction D1 and fixed so as not to move in the vertical direction. From this state, the other end of the panel structure 10 in the direction in which the protrusions 18 are aligned, i.e., the end not held by the holding portion 52, is grasped and lifted upward. This allows the panel structure 10 to be bent appropriately.

[0065] As described above, the processing method for a panel structure according to the first aspect of the present disclosure is a processing method for a panel structure 10 comprising a core member 12 formed using a thermoplastic resin and having a plurality of convex portions 18 extending in one direction on both sides thereof, and a face plate 14 formed in a plate shape using a thermoplastic resin and arranged to sandwich the core member 12 from both sides in the height direction of the convex portions 18, and includes an insertion process S10 in which a rod-shaped member 30 is inserted in one direction into a space K1 formed between the face plate 14 and the core member 12 of the panel structure 10, and a bending process S20 in which a target portion 20 along the rod-shaped member 30 of the panel structure 10 with the rod-shaped member 30 inserted is heated and softened, and a bending portion 22 is formed in the target portion 20 by bending the panel structure 10 along the rod-shaped member 30.

[0066] According to this configuration, the panel structure 10 is bent with the rod-shaped member 30 disposed in the space K1, which prevents the protrusion 18 and the face plate 14B from deforming inwardly of the space K1. This prevents the space K1 from collapsing and the joint 16 from peeling off due to bending. This prevents a decrease in strength at the bent portion.

[0067] A method for processing a panel structure according to a second aspect of the present disclosure is the same as the method for processing a panel structure according to the first aspect, except that a thermoplastic composite material is used as the thermoplastic resin in the panel structure 10. Therefore, in the panel structure 10 using the composite material, it is possible to suppress a decrease in strength at the bent portion.

[0068] A processing method for a panel structure according to a third aspect of the present disclosure is the processing method for a panel structure according to the first or second aspect, in which a rod-shaped heating member 32 is used as the rod-shaped member 30, and in the bending step S20, the heating member 32 heats the target portion 20 from inside the panel structure 10. Therefore, the target portion 20 of the panel structure 10 can be heated efficiently.

[0069] A fourth aspect of the present disclosure relates to a method for processing a panel structure, and is the same as the third aspect, except that the heating member 42 has a rod-shaped core member 42a and a sheet heating element 42b wound around the core member 42a. This allows the target portion 20 of the panel structure 10 to be heated efficiently.

[0070] A processing method for a panel structure according to a fifth aspect of the present disclosure is the processing method for a panel structure according to the third or fourth aspect, in which the rod-shaped member 30 has a commingle material 36 wrapped around a heating member 32, and in the bending step S20, a portion of the commingle material 36 is melted by the heating member 32 and adhered to the panel structure 10. Therefore, the panel structure 10 can be reinforced by the portion of the melted commingle material 36.

[0071] A processing method for a panel structure according to a sixth aspect of the present disclosure is the processing method for a panel structure according to the fifth aspect, further including a cooling step S30 for cooling the bent portion 22 and a removal step S40 for removing at least a portion of the rod-shaped member 30 after cooling the bent portion 22. A protective layer 34 is separably provided on the heating member 32 so as to cover the portion around which the commingle material 36 is wrapped. The commingle material 36 is wound on the protective layer 34. In the bending step S20, the protective layer 34 is attached to a portion of the melted commingle material 36. In the removal step S40, the heating member 32 is separated from the protective layer 34 and removed. Therefore, when a portion of the commingle material 36 is melted, it adheres to the protective layer 34 and does not directly adhere to the heating member 32, allowing the heating member 32 to be easily removed in the removal step S40. The protective layer 34 also reinforces the panel structure 10.

[0072] A processing method for a panel structure according to a seventh aspect of the present disclosure is the processing method for a panel structure according to any one of the first to sixth aspects, in which in the bending step S20, the protrusions 18 are bent so as to be positioned inside the bending direction D2 relative to the rod-shaped members 30. Therefore, the panel structure 10 can be folded efficiently while suppressing the collapse of the space K1 and the peeling of the joints 16, etc.

[0073] A processing method for a panel structure according to an eighth aspect of the present disclosure is the processing method for a panel structure according to any one of the first to sixth aspects, in which in the bending step S20, the protrusions 18 are bent so as to be positioned outside the bending direction D2 relative to the rod-shaped members 30. Therefore, the panel structure 10 can be folded efficiently while suppressing the collapse of the space K1 and the peeling of the joints 16, etc.

[0074] A processing method for a panel structure according to a ninth aspect of the present disclosure is the processing method for a panel structure according to the seventh or eighth aspect, in which, in the insertion step S10, rod-shaped members 30 are inserted into three adjacent spaces K1 separated by protrusions 18, and in the folding step S20, the panel structure 10 is folded along the rod-shaped member 30 inserted into the central space K1 of the three spaces K1. Therefore, in the central space K1 and the spaces K1 on both sides, crushing of the space K1 due to folding and peeling of the joints 16 are suppressed. This makes it possible to more reliably suppress a decrease in strength at the folded portions.

[0075] A processing method for a panel structure according to a tenth aspect of the present disclosure is the processing method for a panel structure according to the ninth aspect, wherein the rod-shaped members 30 have rod-shaped heating members 32 and linear commingle material 36 wound around the heating members 32, and the rod-shaped members 30 inserted into the other two spaces K1 are wound with a greater amount of commingle material 36 than the rod-shaped members 30 inserted into the central space K1 of the three spaces K1. In the bending step S20, the heating members 32 soften a portion of the commingle material 36 and cause it to adhere to the panel structure 10. Therefore, the panel structure 10 can be reinforced by a portion of the commingle material 36 in the central space K1 and the spaces K1 on both sides. Furthermore, since the reinforcing strength can be higher in the spaces K1 on both sides than in the central space K1, a decrease in strength at the bent portion can be more reliably suppressed.

[0076] A processing method for a panel structure according to an eleventh aspect of the present disclosure is the processing method for a panel structure according to any one of the first to tenth aspects, wherein in the bending step S20, the rod-shaped members 30 are bent so as to be pressed outward in the bending direction D2 of the panel structure 10. Therefore, the members on the outer side of the bending direction D2 of the panel structure 10 can be efficiently heated and can be reliably softened and deformed.

[0077] A processing apparatus 50 for a panel structure 10 relating to a twelfth aspect of the present disclosure is a processing apparatus 50 for a panel structure 10 comprising a core member 12 formed using thermoplastic resin and having a plurality of convex portions 18 extending in one direction on both sides thereof, and a face plate 14 formed in a plate shape using thermoplastic resin and arranged to sandwich the core member 12 from both sides in the height direction of the convex portions 18, and is also equipped with a holding section 52 that holds the panel structure 10 with a rod-shaped member 30 inserted in one direction into a space K1 formed between the face plate 14 and the core member 12, a heating section 54 that heats and softens a target portion 20 of the panel structure 10 along the rod-shaped member 30, and a bending auxiliary section 56 that is arranged along the target portion 20 on the inside of the bending direction D2 of the target portion 20 when bending the softened target portion 20 of the panel structure 10 along the rod-shaped member 30.

[0078] Therefore, the panel structure 10 can be folded efficiently so as to prevent a decrease in strength at the folded portion.

[0079] The panel structure according to the thirteenth aspect of the present disclosure comprises a core member 12 formed using a thermoplastic resin and having a plurality of convex portions 18 extending in one direction on both sides thereof, and a face plate 14 formed in a plate shape using a thermoplastic resin and arranged to sandwich the core member 12 on both sides in the height direction of the convex portions 18, and has a bending portion 22 bent along one direction, and at the bending portion 22, the face plate 14 and the core member 12 are formed so as to surround a columnar space K1 extending along one direction.

[0080] Therefore, it is possible to provide a panel structure 10 in which the reduction in strength at the bent portion 22 is suppressed.

[0081] The technical scope of the present invention is not limited to the above-described embodiments. The above-described components include those that can be easily imagined by a person skilled in the art, those that are substantially the same, and those that are within the scope of so-called equivalents. Furthermore, the above-described components can be combined as appropriate. Furthermore, various omissions, substitutions, or modifications of the components can be made without departing from the spirit of the above-described embodiments.

[0082] For example, in the above embodiment, the rod-shaped members 30, 40 have the heating members 32, 42, the protective layers 34, 44, and the commingle materials 36, 46. However, the present invention is not limited to this configuration. For example, the rod-shaped members 30, 40 may not have the protective layers 34, 44. Furthermore, the rod-shaped members 30, 40 may not have both the protective layers 34, 44 and the commingle materials 36, 46. [Explanation of symbols]

[0083] 10 Panel structure 12 Core member 14, 14A, 14B faceplates 16 Joint 18 Convex part 20 Target Part 22 Bending section 24 Space forming part 30,40 Rod-shaped member 32,42 Heating element 34,44 Protective layer 36,46 Comingle wood 36a Thermoplastic resin fiber 42a Core member 42b Planar heating element 42c Film material 42d wiring layer 50 Processing equipment 52 Holding part 52a Proximal end 54 Heating section 56 Bending auxiliary part D1 Extending direction D2 bending direction K1,K2 space S10 Insertion process S20 Bending process S30 Cooling process S40 Removal process

Claims

1. A method for processing a panel structure including a core member formed of a thermoplastic resin and having a plurality of convex portions extending in one direction on both sides thereof, and a face plate formed of a thermoplastic resin in a plate shape and disposed so as to sandwich the core member from both sides in a height direction of the convex portions, the method comprising: an inserting step of inserting a rod-shaped member along the one direction into a space formed between the face plate and the core member of the panel structure; a bending process in which a target portion of the panel structure along the rod-shaped member in a state in which the rod-shaped member is inserted is heated and softened, and a bent portion is formed in the target portion by bending the panel structure along the rod-shaped member; A method for processing a panel structure, comprising:

2. The panel structure uses a thermoplastic composite material as the thermoplastic resin. A method for processing a panel structure according to claim 1.

3. A rod-shaped heating member is used as the rod-shaped member, In the bending step, the target portion is heated from inside the panel structure by the heating member. A method for processing a panel structure according to claim 1.

4. The heating member has a rod-shaped core member and a sheet heating element wound around the core member. The method for processing a panel structure according to claim 3.

5. the rod-shaped member has a commingle material wound around the heating member, In the folding process, a part of the commingle material is melted by the heating member and adhered to the panel structure. A method for processing a panel structure according to claim 3 or 4.

6. a cooling step of cooling the bent portion formed in the bending step; a removing step of removing at least a part of the rod-shaped member after cooling the bent portion; Further comprising: a protective layer is provided on the heating member so as to be separable and cover the portion around which the commingle material is wound; the commingle material is provided in a wound state on the protective layer, In the bending step, the protective layer is attached to a part of the melted commingle material, In the removing step, the heating element is separated from the protective layer and removed. A method for processing a panel structure according to claim 5.

7. In the bending step, the rod-shaped member is bent so that the protrusion is positioned inside the rod-shaped member in the bending direction. A method for processing a panel structure according to claim 1.

8. In the bending step, the rod-shaped member is bent so that the protrusion is positioned outside in the bending direction. A method for processing a panel structure according to claim 1.

9. In the inserting step, the rod-shaped members are inserted into three adjacent spaces separated by the protrusions, In the bending step, the panel structure is bent along the rod-shaped member inserted into the central space among the three spaces. A method for processing a panel structure according to claim 7 or 8.

10. The rod-shaped member has a rod-shaped heating element and a linear commingle material wound around the heating element, The amount of winding of the commingle material is made larger for the rod-shaped members inserted into the other two spaces than for the rod-shaped member inserted into the central space among the three spaces, In the bending step, a part of the commingle material is softened by the heating member and attached to the panel structure. The method for processing a panel structure according to claim 9.

11. In the bending step, the rod-shaped member is bent so as to be pressed outward in the bending direction of the panel structure. A method for processing a panel structure according to claim 1.

12. A processing device for a panel structure, comprising: a core member formed of a thermoplastic resin and having a plurality of convex portions extending in one direction on both sides thereof; and a face plate formed of a thermoplastic resin in a plate shape and disposed so as to sandwich the core member from both sides in a height direction of the convex portions, a holding portion for holding the panel structure in which a rod-shaped member is inserted along the one direction into a space formed between the face plate and the core member; a heating unit that heats and softens a target portion of the panel structure along the rod-shaped member; a bending assisting portion that is arranged along the target portion on the inside of the bending direction of the target portion when the softened target portion of the panel structure is bent along the rod-shaped member; A processing device for a panel structure comprising:

13. a core member formed of a thermoplastic resin and having a plurality of protrusions extending in one direction on both sides thereof; a face plate formed in a plate shape using a thermoplastic resin and disposed so as to sandwich the core member from both sides in the height direction of the protrusion; Equipped with a bent portion bent along the one direction, At the bent portion, the face plate and the core member are formed to surround a columnar space extending in the one direction. Panel structure.

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