Structure and method for manufacturing the structure

Abstract

To provide a structure with a configuration that can prevent assemblability from being damaged, and to provide a method for manufacturing the same.SOLUTION: A structure includes a reinforcement member, a core material, a separate member and a resin molding. The reinforcement member includes a core material fitting part. The core material fitting part is fitted with the core material. The separate member is disposed in one end part of the reinforcement member in a longitudinal direction. The resin molding is formed so as to cover the reinforcement member, the core material and the separate member.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a structure and a method for manufacturing the structure.

Background Art

[0002] Patent Document 1 discloses a method for manufacturing an assembly by attaching a core material, which is a foamed resin molded body, to a long reinforcing member made of metal or hard plastic. The core material described in Patent Document 1 has stoppers formed so as to protrude. The stoppers are provided at both ends of the portion of the core material to which the reinforcing member is attached. The stoppers of the core material described in Patent Document 1 have a function of suppressing the relative position between the reinforcing member and the core material from shifting.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the assembly of Patent Document 1, if there is too much margin in the clearance between the longitudinal end of the reinforcing member and the stopper portion of the core material, the reinforcing member may move, and the function of suppressing the relative position shift may not be properly exerted. Therefore, in order to properly exert this function, it is necessary to set a small clearance between the longitudinal end of the reinforcing member and the stopper portion of the core material. In addition, since the dimensions of the core material and the like vary during the manufacture of the core material and the like, this clearance may be smaller than expected. Therefore, the method of Patent Document 1 has a problem that it is difficult to assemble the reinforcing member and the core material.

[0005] This invention has been made in view of these circumstances, and aims to provide a structure having a configuration that can suppress impairment of assembly ease, and a method for manufacturing the same. [Means for solving the problem]

[0006] According to the present invention, a structure is provided comprising a reinforcing member, a core material, a separate member, and a resin molded body, wherein the reinforcing member has a core material mounting portion to which the core material is attached, the separate member is arranged at one end in the longitudinal direction of the reinforcing member, and the resin molded body is formed to cover the reinforcing member, the core material, and the separate member.

[0007] According to the present invention, by positioning a separate member at one end of the reinforcing member in the longitudinal direction, the relative positional displacement between the reinforcing member and the core material is suppressed. Here, since the separate member is separate from the core material, it can be positioned at one end of the reinforcing member in the longitudinal direction at a different timing than when the core material is attached to the core material mounting portion of the reinforcing member. Therefore, according to the present invention, it is possible to suppress any impairment of assembly ease.

[0008] The following are examples of various embodiments of the present invention. The embodiments shown below can be combined with each other. Preferably, the separate member has a connecting portion, and the separate member is configured such that the connecting portion connects to at least one of the reinforcing member and the core member, thereby restricting the positions of the core member and the reinforcing member. Preferably, the connecting portion is formed to protrude and is press-fitted into the reinforcing member, thereby providing a structure. Preferably, the structure is provided in which the separate member has a restricting portion, the restricting portion is formed to protrude, and its tip is positioned opposite the core material so as to restrict the positions of the core material and the reinforcing member. Preferably, the structure is provided in which the core material has a first core material and a second core material, the core material mounting portion has a first core material mounting portion and a second core material mounting portion, the first core material is attached to the first core material mounting portion and the second core material is attached to the second core material mounting portion and the separate member is attached between the first and second core materials. Preferably, the first core material has a first end face portion, and the second core material has a second end face portion, the reinforcing member is sandwiched between the first end face portion and the second end face portion, and the other member has a base portion, the base portion is provided so as to be surrounded by the one end portion in the longitudinal direction of the reinforcing member and the first and second end face portions, and the base portion extends from the first end face portion to the second end face portion, thereby providing a structure. Preferably, a structure is provided comprising a plurality of the separate members, wherein the separate members are arranged at the other end of the reinforcing member in addition to the one end in the longitudinal direction of the reinforcing member. According to another aspect of the embodiments of the present invention, a method for manufacturing a structure is provided, comprising an assembly step and a molding step, wherein the structure comprises a reinforcing member, a core material, a separate member, and a resin molded body, the reinforcing member having a core material mounting portion, the resin molded body being formed to cover the reinforcing member, the core material, and the separate member, the assembly step comprising a core material mounting step and a separate member mounting step, the core material mounting step comprising attaching the core material to the core material mounting portion, the separate member mounting step comprising placing the separate member at one end of the reinforcing member in the longitudinal direction to manufacture the assembly, and the molding step comprising molding a resin sheet and the assembly using a split mold to manufacture a molded product, the resin sheet constituting the resin molded body, and the molded product including the structure. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1A is a perspective view of a resin panel 1 (an example of a structure) according to the embodiment. In the dashed area A shown in Figure 1A, the resin molded body 2 corresponding to the dashed area A has been removed, and the internal structure (reinforcement member 4) is visible. Figure 1B is a perspective view of an assembly 1t according to the embodiment. [Figure 2]Figure 2 is an exploded perspective view of assembly 1t shown in Figure 1B. [Figure 3] Figure 3A is a perspective view of the reinforcing member 4 and the connecting member 5. In Figure 3A, one connecting member 5 is detached from the reinforcing member 4, and the other connecting member 5 is connected to the reinforcing member 4. Figure 3B is an enlarged view of area B shown in Figure 3A. [Figure 4] Figure 4 is a view of the enlarged view shown in Figure 3 from a different angle. [Figure 5] Figure 5 is a perspective view showing the state before the core material 3 is attached to the reinforcing member 4 during the core material attachment process of the assembly process. [Figure 6] Figure 6 is a perspective view showing the state before attaching the connecting member 5 to the reinforcing member 4 during the connecting member attachment process of the assembly process. [Figure 7] Figure 7 is a cross-sectional view corresponding to the perspective view shown in Figure 6. Figure 7 is a cross-sectional view taken in a plane that passes through the two points P shown in Figure 6 and is parallel to the flange portion 4a of the reinforcing member 4. [Figure 8] Figure 8 is a perspective view showing the state after the assembly process, specifically the attachment of connecting members, has been completed. [Figure 9] Figure 9 is a cross-sectional view corresponding to the perspective view shown in Figure 8. [Figure 10] Figure 10 is an explanatory diagram of the configuration of the molding machine 10 (the divided molds 21 and 22 and the assembly 1t are shown in cross-sectional views). Figure 10 shows the process of the hanging process. The assembly 1t shown in Figure 10 is a cross-sectional view taken in a plane that passes through the two points Q shown in Figure 8 and is parallel to the vertical direction. This cross-section passes through the opposing part 5c1 of the regulating part 5c (see Figure 4). [Figure 11] Figure 11 shows the state after the shaping process has been completed. [Figure 12] Figure 12 shows the state after the mold clamping process has been completed. [Figure 13] Figure 13 is an exploded perspective view of an assembly 1t having a core material 3 according to a modified example. [Figure 14] Figure 14A is an enlarged view of area A shown in Figure 13. Figure 14B shows the assembled state of the core material 3 and reinforcing member 4 shown in Figure 14A.

Mode for Carrying Out the Invention

[0010] Hereinafter, embodiments will be described based on the drawings. Various characteristic matters shown in the following embodiments can be combined with each other. Also, an invention can be established independently for each characteristic.

[0011] 1 Explanation of the configuration of the resin panel 1 As shown in FIG. 1A, the resin panel 1 (an example of a structure) according to the embodiment is a panel covered with a resin molded body 2 having a substantially rectangular shape in plan view. As shown in FIGS. 1A and 1B, the resin panel 1 includes a resin molded body 2 and an assembly 1t. The resin panel 1 is used, for example, as a deck board for a vehicle.

[0012] ​​​​​​​​​​​​​​​​

[0015] As shown in Figure 5, the core material 3 comprises a main body portion 3a, a protruding portion 3b, and an end face portion 3c.

[0016] <Main body part 3a> As shown in Figure 5, the main body portion 3a is a flat plate-shaped member, and both sides of the main body portion 3a are in close contact with the resin molded body 2 (see Figure 1A). The resin constituting the resin molded body 2 is welded to the main body portion 3a. The main body portion 3a is provided with an end face portion 3c.

[0017] <Protrusion 3b> As shown in Figure 5, the protrusion 3b is inserted into the reinforcing member 4 when the core material 3 is attached to the reinforcing member 4. The protrusion 3b is formed to protrude from the end face portion 3c, and the protrusion 3b extends parallel to the longitudinal direction D of the reinforcing member 4. In this embodiment, the width of the protrusion 3b in the longitudinal direction D is smaller than the width of the reinforcing member 4 in the longitudinal direction D.

[0018] The protruding portion 3b has a pair of engaging end faces 3b1 and a pair of restricting end faces 3b2. One of the pair of engaging end faces 3b1 is formed on one side of the protruding portion 3b (the upper side of the paper in Figure 5), and the other is formed on the other side of the protruding portion 3b (the lower side of the paper in Figure 5). The engaging end faces 3b1 extend parallel to the longitudinal direction D, and multiple engaging portions 3b3 are formed on the engaging end faces 3b1. The restricting end faces 3b2 are formed at both ends of the protruding portion 3b in the longitudinal direction D. The restricting end faces 3b2 shown in Figures 6 and 7 are abutted against the restricting portion 5c of the connecting member 5, which will be described later, and as a result, relative movement (positional displacement in the longitudinal direction D) of the core material 3 and the reinforcing member 4 is suppressed.

[0019] The engaging portion 3b3 shown in Figure 5 is in contact with the reinforcing member 4 when the protruding portion 3b is inserted into the reinforcing member 4 (the core material mounting portion 4a1, which will be described later). The engaging portion 3b3 is formed to protrude from the engaging end face 3b1 in a direction perpendicular to the engaging end face 3b1. In this embodiment, multiple engaging portions 3b3 are arranged on the engaging end face 3b1 so as to be aligned in the longitudinal direction D. A groove 3b4 is formed in the engaging portion 3b3. When the protruding portion 3b is inserted into the reinforcing member 4 (the core material mounting portion 4a1 described later), a part of the reinforcing member 4 (the claw portion 4a2 described later) fits into the groove 3b4, and the core material 3 and the reinforcing member 4 engage. Because the engaging portion 3b3 and the groove 3b4 are formed in the protruding portion 3b, displacement (relative movement) of the core material 3 and the reinforcing member 4 in the short direction d is suppressed.

[0020] <End part 3c> The end faces 3c shown in Figures 5 and 6 are provided so as to face the reinforcing member 4 (the end of the flange portion 4a and the claw portion 4a2, which will be described later) when the core material 3 is attached to the reinforcing member 4. The end faces 3c are also provided so as to face the connecting member 5 (the second surface portion 5a2 of the base portion 5a, which will be described later) when the connecting member 5 and the core material 3 are attached to the reinforcing member 4. One end face 3c of a pair of core materials 3 is an example of a first end face, and the other end face 3c of a pair of core materials 3 is an example of a second end face.

[0021] 1-2-2 Reinforcement member 4 The reinforcing member 4 is a long, rod-shaped member that increases the rigidity of the resin panel 1. The reinforcing member 4 may be made of a metal such as aluminum, or it may be made of reinforced plastic. The reinforcing member 4 is sandwiched between the end faces 3c of a pair of core materials 3.

[0022] As shown in Figures 3A to 4, the reinforcing member 4 has a pair of flange portions 4a, a pair of connecting portions 4b, a linking portion 4c, and an end face portion 4d.

[0023] <Flange section 4a> As shown in Figures 3A to 4, the reinforcing member 4 has a pair of flange portions 4a, which are arranged to face each other in the thickness direction Td of the resin panel 1. The flange portions 4a are elongated plate-like members formed to extend in the longitudinal direction D. Furthermore, when the core material 3 is attached to the reinforcing member 4, the flange portions 4a are provided from one end face 3c of the core material 3 to the other end face 3c of the core material 3.

[0024] A core material mounting portion 4a1 is formed between a pair of flange portions 4a. The core material mounting portion 4a1 is formed so that the protruding portion 3b of the core material 3 can be inserted into it. One of the pair of core material mounting portions 4a1 is an example of a first core material mounting portion, and the other is an example of a second core material mounting portion. The core material mounting portions 4a1 are provided on both sides of the reinforcing member 4 in the short direction d. Thus, in this embodiment, a configuration in which the reinforcing member 4 has two core material mounting portions 4a1 is described as an example, but it is not limited to this. The reinforcing member 4 may have one core material mounting portion 4a1 or three or more.

[0025] The flange portion 4a is connected to a pair of connecting portions 4b. The flange portion 4a has claw portions 4a2 formed at both ends in the short direction d. The claw portions 4a2 are formed to protrude in the thickness direction Td and can engage with the groove portion 3b4 of the core material 3. In addition, a connecting portion 4c is formed between the pair of flange portions 4a.

[0026] The flange portion 4a has surfaces 4a3 and 4a4 formed on it. Surface 4a3 contacts the inner surface of the resin molded body 2. Surface 4a4 is formed on the opposite side of surface 4a3. Surface 4a4 contacts the protrusion 5b2 of the connecting portion 5b of the connecting member 5, which will be described later, by pressing against it when the connecting member 5 is press-fitted into the reinforcing member 4. Surface 4a4 is formed between a pair of connecting portions 4b.

[0027] <Connection part 4b> As shown in Figures 3A to 4, the reinforcing member 4 has a pair of connecting portions 4b, which are arranged to face each other in the short direction d. The connecting portion 4b is an elongated plate-like member formed to extend in the longitudinal direction D. One end of the connecting portion 4b is connected to one flange portion 4a, and the other end of the connecting portion 4b is connected to the other flange portion 4a. In this embodiment, the connecting portion 4b and the flange portion 4a have the same width in the longitudinal direction D.

[0028] <Connection part 4c> As shown in Figure 3B, the connecting portion 4c is the part that connects to the connecting portion 5b of the connecting member 5, which will be described later. In this embodiment, the connecting portion 4c is made up of an insertion hole, and the connecting portion 5b of the connecting member 5 is press-fitted into the connecting portion 4c. The connecting portion 4c is formed so as to be surrounded by the surfaces 4a4 of the pair of flange portions 4a and the inner surface of the connecting portion 4b (the opposing surfaces of the pair of connecting portions 4b).

[0029] <End part 4d> As shown in Figure 3B, the end faces 4d are formed at both ends of the reinforcing member 4 in the longitudinal direction D. The end faces 4d are the parts against which the base 5a of the connecting member 5, which will be described later, abuts when the connecting member 5 is attached to the reinforcing member 4.

[0030] 1-2-3 Connecting member 5 As shown in Figures 2 and 3A, the connecting member 5 (an example of a separate member) is positioned at the longitudinal ends (one end and the other end) of the reinforcing member 4 when the core member 3, reinforcing member 4, and connecting member 5 are assembled. The connecting member 5 is an example of a separate member and is independent of the core member 3 and the reinforcing member 4. The connecting member 5 is also composed of cap members attached to the longitudinal ends (one end and the other end) of the reinforcing member 4. Furthermore, the connecting member 5 is a regulating member; that is, it is configured to restrict the positions of the core member 3 and the reinforcing member 4 by connecting to the reinforcing member 4.

[0031] The connecting member 5 can be made of resin. Preferably, the resin used to make up the connecting member 5 is the same resin as the resin molded body 2 (the resin sheet 19 that makes up the resin molded body 2, as described later). For example, if the resin that makes up the resin molded body 2 is a polypropylene resin, then it is preferable that the resin used to make up the connecting member 5 is polypropylene. This allows the connecting member 5 and the resin (molten resin) that makes up the resin molded body 2 to be welded together, improving the strength of the resin panel 1. The connecting member 5 can be made of a solid resin material. Therefore, the connecting member 5 is harder than the core material 3, which is a foamed molded body. On the other hand, the reinforcing member 4 is made of metal or reinforced plastic and is harder than the connecting member 5.

[0032] The connecting member 5 has a base portion 5a, a connecting portion 5b, and a restricting portion 5c.

[0033] <Base 5a> As shown in Figures 3B and 4, the base portion 5a is the part that is gripped, for example, by a worker or a robot arm when attaching the connecting member 5 to the reinforcing member 4. The base portion 5a is provided so as to be surrounded by the end of the reinforcing member 4 in the longitudinal direction D and the end faces 3c of the pair of core materials 3. Also, as shown in Figure 8, the base portion 5a extends from one end face 3c of the pair of core materials 3 to the other end face 3c of the pair of core materials 3. The base portion 5a has a first surface portion 5a1 and a pair of second surface portions 5a2.

[0034] As shown in Figure 3B, the first surface portion 5a1 is formed so that its end surface in the thickness direction Td is curved. The second surface portion 5a2 is connected to both ends of the first surface portion 5a1 in the short direction. The second surface portion 5a2 faces the end surface portion 3c of the core material 3 when the connecting member 5 is attached to the reinforcing member 4. A connecting portion 5b and a pair of restricting portions 5c are arranged between the pair of second surface portions 5a2. Here, as shown in Figure 3B, the first surface portion 5a1 has an edge portion 5a3, which abuts against the end surface portion 4d of the reinforcing member 4 when the connecting member 5 is attached to the reinforcing member 4. The second surface portion 5a2 has an edge portion 5a4, which abuts against the end surface portion 4d of the reinforcing member 4 when the connecting member 5 is attached to the reinforcing member 4. In other words, the connecting member 5 can be press-fitted into the reinforcing member 4 until the edges 5a3 and 5a4 abut against the end surface portion 4d.

[0035] <Connection part 5b> As shown in Figures 3B and 4, the connecting portion 5b is formed such that its base end is connected to the base portion 5a and it protrudes from the base portion 5a. The connecting portion 5b is also configured to be connectable to the connecting portion 4c. In this embodiment, the connecting portion 5b is connected to the connecting portion 4c by press-fitting the convex structure of the connecting portion 5b into the concave structure of the connecting portion 4c. The connecting portion 5b has a columnar portion 5b1 and a pair of protrusions 5b2.

[0036] The columnar portion 5b1 is in contact with the connecting portion 4b in a pressing manner when the connecting portion 5b is press-fitted into the connecting portion 4c. In this embodiment, the columnar portion 5b1 is formed in a substantially cylindrical shape. Furthermore, the columnar portion 5b1 is tapered. That is, the tip portion of the columnar portion 5b1 is smaller than the distance between the opposing pairs of connecting portions 4b, and the base portion is larger than the distance between the opposing portions. In addition, the tip portion 5b11 of the columnar portion 5b1 is tapered. Because the columnar portion 5b1 is tapered and the tip portion 5b11 at the end of the columnar portion 5b1 is tapered, the columnar portion 5b1 is easily press-fitted into the connecting portion 4c.

[0037] The projection 5b2 is formed to extend in the longitudinal direction D and is connected to the columnar portion 5b1. The projection 5b2 has a tip surface 5b21 and a press-fit end surface 5b22. The tip surface 5b21 is tapered. This makes it easier to insert the connecting portion 5b into the connecting portion 4c. The press-fit end face 5b22 is in contact with the surface 4a4 of the flange portion 4a of the reinforcing member 4 when the connecting portion 5b is press-fitted into the connecting portion 4c. The press-fit end face 5b22 is formed to slope from the base end side (base portion 5a side) to the tip end side (tip surface 5b21 side). As a result, the pressing force gradually increases when the connecting portion 5b is being press-fitted into the connecting portion 4c, making it easier to press-fit the connecting portion 5b into the connecting portion 4c.

[0038] <Regulatory Section 5c> As shown in Figures 3B and 4, the connecting member 5 has a pair of restricting portions 5c, and a connecting portion 5b is positioned between the pair of restricting portions 5c. The restricting portions 5c are configured to be insertable into the core material mounting portion 4a1. The base end of the restricting portion 5c is connected to the base portion 5a and is formed to protrude from the base portion 5a. The restricting portion 5c is configured to restrict the positions of the core material 3 and the reinforcing member 4. Specifically, when the connecting member 5 is attached to the reinforcing member 4, the restricting portion 5c abuts against and contacts the restricting end face 3b2 of the core material 3. The restricting portion 5c has an opposing portion 5c1 and a reinforcing portion 5c2.

[0039] As shown in Figure 9, the opposing portion 5c1 is the part that faces the restrictive end face 3b2 of the core material 3 when the connecting member 5 is attached to the reinforcing member 4. At this time, the opposing portion 5c1 abuts against and contacts the restrictive end face 3b2 of the core material 3. The opposing portion 5c1 is plate-shaped and is located on the end side of the connecting member 5 in the short direction d.

[0040] As shown in Figure 4, the reinforcing portion 5c2 is plate-shaped and has the function of increasing the rigidity of the restricting portion 5c. In this embodiment, the reinforcing portion 5c2 is not in contact with the restricting end face 3b2 of the core material 3, but it may be configured to be in contact. The reinforcing portion 5c2 is connected to both ends of the opposing portion 5c1 in the thickness direction Td. The reinforcing portion 5c2 has a tip surface 5c21, which is tapered. This makes it easier to insert the restricting portion 5c into the core material mounting portion 4a1. When the reinforcing portion 5c2 is inserted into the core material mounting portion 4a1, the reinforcing portion 5c2 is in contact with the flange portion 4a.

[0041] Since the protruding portion 3b of the core material 3 is sandwiched between the restricting portions 5c of the pair of connecting members 5, the movement of the core material 3 in the longitudinal direction D is prevented by the restricting portions 5c. Furthermore, since the reinforcing member 4 is connected to the connecting member 5 and becomes one unit, if the reinforcing member 4 attempts to move parallel to the longitudinal direction D, the movement of the reinforcing member 4 is prevented by the restricting end face 3b2.

[0042] In this embodiment, the pair of restricting portions 5c (the tips of the pair of restricting portions 5c) are described as being in contact with the protruding portion 3b, but the invention is not limited to this. One or both of the pair of restricting portions 5c (the tips of the pair of restricting portions 5c) do not need to be in contact with the protruding portion 3b. In this case, a gap will be formed between the restricting portion 5c and the restricting end face 3b2, but the range of relative movement between the core material 3 and the reinforcing member 4 can be restricted to within the width of this gap. In other words, the restricting portion 5c restricting the positions of the core material 3 and the reinforcing member 4 includes restricting the range of relative movement between the core material 3 and the reinforcing member 4. Specifically, this gap (mm) is, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, and may be within the range between any two of the values ​​exemplified here.

[0043] 2. Manufacturing method of resin panel 1 Next, a method for manufacturing the resin panel 1 will be described. The method for manufacturing the resin panel 1 in this embodiment comprises an assembly step and a molding step.

[0044] 2-1 Assembly Process The assembly process includes a core material installation process and a connecting member installation process (an example of a separate member installation process). The assembly process may be performed by a worker or by a device such as a robotic arm or manipulator.

[0045] 2-1-1 Core material installation process As shown in Figures 5 and 6, in the core material mounting process, the protruding portion 3b of the core material 3 is inserted into the core material mounting portion 4a1 and mounted. When the protruding portion 3b is inserted into the core material mounting portion 4a1, the claw portion 4a2 engages with the groove portion 3b4. In this state, relative movement (misalignment) of the core material 3 and the reinforcing member 4 in the short direction d is suppressed, but relative movement of the core material 3 and the reinforcing member 4 is possible in the long direction.

[0046] 2-1-2 Connecting Member Installation Process As shown in Figures 6 to 9, in the connecting member installation process, the connecting member 5 is placed at one end of the reinforcing member 4 in the longitudinal direction to manufacture the assembly 1t. The connecting portion 5b of the connecting member 5 is press-fitted into the connecting portion 4c, connecting the connecting member 5 to the reinforcing member 4. During press-fitting, the columnar portion 5b1 presses against the connecting portion 4b, and the press-fitted end face 5b22 presses against the surface 4a4 of the flange portion 4a. Press-fitting is completed when the edges 5a3 and 5a4 abut against the end face portion 4d of the reinforcing member 4. Here, in the connecting member installation process, a pair of restricting portions 5c (the tips of the pair of restricting portions 5c) abut against and make contact with the protruding portion 3b. Therefore, centering of the reinforcing member 4 with respect to the core material 3 is also performed at this time. In this embodiment, the two connecting members 5 are attached to both ends of the reinforcing member 4 in the longitudinal direction.

[0047] 2-2 Molding process In the molding process, the assembly 1t and resin sheet 19 manufactured in the assembly process are molded using divided molds 21 and 22. The molding process comprises a hanging process, a shaping process, an assembly placement process, and a mold clamping process.

[0048] The configuration of the molding machine 10 used in the molding process will be briefly explained. As shown in Figure 10, the molding machine 10 comprises a resin sheet forming device 14 and dividing molds 21 and 22. The molding machine 10 also includes a manipulator (not shown) for transporting the assembled body 1t between the dividing molds 21 and 22. The resin sheet forming device 14 comprises a hopper 12, an extruder 13, an accumulator 17, and a T-die 18.

[0049] The raw material resin 11 (for example, a thermoplastic resin such as polyolefin) is fed from the hopper 12 into the cylinder 13a, where it is heated and melted into molten resin. The molten resin is transported toward the tip of the cylinder 13a by the rotation of a screw located inside the cylinder 13a of the extruder 13. The molten resin is supplied to the cylinder 17a of the accumulator 17 through the connecting pipe 15, and after a predetermined amount of molten resin 11a is stored in the cylinder 17a, the piston 17b is moved. As a result, the molten resin 11a is pushed out through the connecting pipe 16 from a slit provided in the T-die 18. The split molds 21 and 22 have a cavity portion cv, and a pinch-off portion pt is provided so as to surround the cavity portion cv. A vacuum suction hole (not shown) is provided inside the cavity portion cv, and it is possible to shape the resin sheet 19 into a shape that conforms to the inner surface of the cavity portion cv by vacuum suction through the vacuum suction hole.

[0050] 2-2-1 Drooping process In the hanging process, as shown in Figure 10, the resin sheet 19 extruded from the T-die 18 is hung down on the front side of the divided molds 21 and 22.

[0051] 2-2-2 Shaping process In the shaping process, as shown in Figure 11, the resin sheet 19 is subjected to reduced pressure suction through the reduced pressure suction holes in the cavity portions cv of the divided molds 21 and 22, thereby shaping the resin sheet 19 to conform to the inner surface of the cavity portions cv. The shaping process may be carried out by moving the divided molds 21 and 22, or by adding an outer frame attached to each of the divided molds 21 and 22 to the molding machine 10. The outer frame is configured to move forward and backward, and has holes formed on its front end surface for reduced pressure suction of the resin sheet 19. The holes in the outer frame adsorb the resin sheet 19, making it easier to form a sealed space between the resin sheet 19, the outer frame, and the divided mold 21 (or divided mold 22). After that, it is preferable to perform reduced pressure suction of the resin sheet 19 through the reduced pressure suction holes in the cavity portions cv.

[0052] 2-2-3 Assembly arrangement process In the core material placement process, the assembly 1t is placed between the divided molds 21 and 22 using a manipulator (not shown) and welded to one of the resin sheets 19. In this embodiment, as shown in Figure 11, the assembly 1t is placed between the divided molds 21 and 22 in a position such that the longitudinal direction of the reinforcing member 4 is parallel to the vertical direction.

[0053] 2-2-4 Clamping Process In the mold clamping process, as shown in Figure 12, the pair of split molds 21 and 22 are clamped. This makes it possible to manufacture a molded product 1T with a shape that conforms to the inner surface of the cavity portion cv formed by the pair of split molds 21 and 22.

[0054] The molded product 1T includes a resin panel 1 and a burr 1br. Therefore, the desired resin panel 1 can be obtained by opening the split molds 21 and 22, removing the molded product 1T, and removing the burr 1br.

[0055] 3. Operation and Effects of the Embodiments In the resin panel 1 according to this embodiment, the connecting member 5 is positioned at one end of the reinforcing member 4 in the longitudinal direction D, thereby suppressing misalignment of the relative position between the reinforcing member 4 and the core material 3. Here, since the connecting member 5 is separate from the core material 3, the connecting member 5 can be positioned on the reinforcing member 4 at a different timing than when the core material 3 is attached to the core material mounting portion 4a1 of the reinforcing member 4. As a result, the resin panel 1 according to this embodiment has a configuration that can suppress impairment of assembly ease, and the manufacturing method of the resin panel 1 according to this embodiment can suppress impairment of assembly ease of components such as the core material 3 when manufacturing the assembly 1t.

[0056] In this embodiment, the relative positional displacement between the reinforcing member 4 and the core material 3 is suppressed in the assembly 1t. Therefore, when a worker or manipulator is transporting the assembly 1t, even if the reinforcing member 4 is in a position parallel to the vertical, the action of the connecting member 5 can suppress positional displacement between the core material 3 and the reinforcing member 4. Specifically, in this position, even if the reinforcing member 4 tries to move downward, the upper connecting member 5 (restricting portion 5c), which is integrated with the reinforcing member 4, interferes with the restricting end face 3b2 above the protruding portion 3b of the core material 3, thereby restricting the movement of the reinforcing member 4. Conversely, even if the reinforcing member 4 attempts to move upward, the lower connecting member 5 (restricting portion 5c), which is integrated with the reinforcing member 4, interferes with the restricting end face 3b2 below the protruding portion 3b of the core material 3, thereby restricting the movement of the reinforcing member 4. Furthermore, in this position, even if the core material 3 attempts to move upward or downward, it will interfere with the connecting member 5, as described above, and its movement will be restricted.

[0057] In the embodiment, the resin panel 1 has a pair of restricting portions 5c (the tips of the pair of restricting portions 5c) that abut against and contact the protruding portion 3b. This makes it easy to center the reinforcing member 4 relative to the core material 3. In other words, it is easy to adjust the relative positions of the core material 3 and the reinforcing member 4 to the desired position. When the resin panel 1 is a deck board for a vehicle, proper centering as described above makes it easier to equalize the load applied to the resin panel 1, thereby suppressing damage or detachment of the resin panel 1.

[0058] Let's assume that the width of the reinforcing member 4 in the longitudinal direction D is equal to the width of the core material 3 in the longitudinal direction D. In this case, the end (corner of the end) of the reinforcing member 4 in the longitudinal direction D is likely to come into contact with the resin molded body 2. Here, the reinforcing member 4 is made of, for example, metal and is harder than the resin molded body 2. Therefore, when a load is applied to the resin panel 1, for example, the resin molded body 2 is strongly pressed against the end (corner of the end) of the reinforcing member 4 in the longitudinal direction D, which can cause the resin molded body 2 to crack. Therefore, one possible solution is to make the longitudinal width of the reinforcing member 4 slightly shorter than the width of the core material 3 to ensure sufficient clearance. However, this method would create an internal space at the end of the reinforcing member 4 in the longitudinal direction D. As a result, even with this method, there is a possibility that the resin molded body 2 may buckle or crack when, for example, a load is applied to the resin panel 1. In contrast, in the resin panel 1 according to this embodiment, a connecting member 5 made of resin is arranged in the internal space described above. Therefore, even if a load is applied to the resin panel 1, for example, the resin molded body 2 is supported from the inside by the connecting member 5, thus suppressing buckling and cracking. The load applied to the connecting member 5 is transmitted to the harder (higher strength) reinforcing member 4, so the load can be relieved by the reinforcing member 4. Furthermore, since the connecting member 5 is made of a softer material than the reinforcing member 4, even if the resin molded body 2 is pressed strongly against the connecting member 5, cracking of the resin molded body 2 is suppressed. In addition, since the first surface portion 5a1 of the connecting member 5 is formed so that the end side in the thickness direction Td is curved, cracking of the resin molded body 2 is effectively suppressed.

[0059] 4. Variations 4-1 Modified example 1: One connecting member 5 of the resin panel 1 In the embodiment, the resin panel 1 had two connecting members 5, but in the modified example 1, there is only one. Furthermore, as shown in Figures 13 to 14B, the core material 3 further has a stopper portion 3d. The stopper portion 3d is formed to protrude from the main body portion 3a. The stopper portion 3d has a function corresponding to the connecting member 5, and the stopper portion 3d is positioned at the end of the reinforcing member 4 in the longitudinal direction D. This suppresses misalignment of the relative position between the reinforcing member 4 and the core material 3. Also, as shown in Figure 14B, the stopper portions 3d of the pair of core materials 3 are abutted together, preventing gaps from forming between the stopper portions 3d. Therefore, it is possible to prevent the resin molded body 2 from buckling or cracking when, for example, a load is applied to the resin panel 1.

[0060] 4-2 Modified example 2: Connecting member 5 is connected to core material 3 In the embodiment, the resin panel 1 was configured such that the connecting member 5 was connected to the reinforcing member 4, but it is not limited to this configuration. The connecting portion 5b may be configured to be connected to a pair of core materials 3 instead of to the reinforcing member 4. Even with this configuration, the same effects as in the embodiment can be obtained.

[0061] 4-3 Modification 3: One core material 3 of resin panel 1 The resin panel 1 according to this embodiment has a configuration that includes a plurality of core materials 3, but is not limited to this. For example, the reinforcing member 4 may have a C-shaped cross-section and be provided with one core material mounting portion 4a1 into which the core material 3 is inserted.

[0062] 4-4 Modification Example 4: Other Configuration Examples of Separate Components In the embodiment, the connecting portion 5b has a convex structure and the connecting portion 4c has a concave structure, but the embodiment is not limited to this. The connecting portion 5b may have a concave structure and the connecting portion 4c may have a convex structure, and the connecting portions 4c and 5b may be connected. In the embodiment, the connecting portion 5b is described as being press-fitted into the connecting portion 4c, but the invention is not limited to this, and for example, the connecting portions 4c and 5b may be connected to each other by their claw portions. In this embodiment, the connecting member 5 was in the form of a cap member. In other words, the connecting member 5 was configured such that, when the connecting member 5 was attached to the reinforcing member 4, the core material mounting portion 4a1 and the connecting portion 4c at the longitudinal end D of the reinforcing member 4 were closed. However, the form of the connecting member 5 is not limited to a cap member. The connecting member 5 may also have its core material mounting portion 4a1 and the connecting portion 4c open when the connecting member 5 is attached to the reinforcing member 4. In this embodiment, the connecting member 5 and the reinforcing member 4 are connected by an uneven structure, but the invention is not limited to this. For example, the resin panel 1 may use an adhesive member instead of the connecting member 5 as a restricting member to restrict the relative movement of the reinforcing member 4 and the core material 3. The adhesive member is bonded to the reinforcing member 4 by, for example, applying adhesive to the edges 5a3 and 5a4 of the base 5a and bonding it to the end face 4d. The adhesive member can have the same configuration as the connecting member 5, except that it does not have a connecting portion 5b and adhesive is applied to the edges 5a3 and 5a4. Alternatively, for example, adhesive may be applied to the second surface 5a2 and the adhesive member may be bonded to the core material 3.

[0063] 4-5 Modification 5: Other configurations of the manufacturing method In the manufacturing method according to this embodiment, as shown in Figure 11, the assembly 1t is positioned between the divided molds 21 and 22 in a manner such that the longitudinal direction of the reinforcing member 4 is parallel to the vertical direction, but it is not limited to this. For example, the assembly 1t may be positioned between the divided molds 21 and 22 in a manner such that the longitudinal direction of the reinforcing member 4 is horizontal. The manufacturing method according to the embodiment has been described as having the split molds 21 and 22 opening and closing in the left-right direction and the resin sheet 19 hanging down, but it is not limited to this. The split mold 21 may be positioned at the bottom and the split mold 22 at the top, and the split molds 21 and 22 may open and close in the up-down direction. In this case, the assembly 19t is placed on the resin sheet 19 formed in the split mold 21 using a manipulator or the like. Then, the molded product 1T can be manufactured by clamping the split mold 21 and the split mold 22 on which the resin sheet 19 is formed. [Explanation of Symbols]

[0064] 1: Resin panel 1T: Molded product 1br: Bali 1t: assembly 2: Resin molded body 3: Core material 3a: Main body 3b:Protrusion 3b1: Engagement end surface 3b2: Regulatory end face 3b3: Engagement part 3b4:Groove 3c: End face part 3D: Stopper part 4: Reinforcement member 4a: Flange section 4a1: Core material mounting section 4a2: Claw part 4a3: Face 4a4: Face 4b: Connection part 4c:Connection part 4d: End face part 5: Connecting member 5a: Base 5a1: First surface part 5a2: Second surface part 5a3 :Edge 5a4: Edge 5b:Connection part 5b1: Columnar part 5b11:Tip 5b2:Protrusion 5b21:Tip surface 5b22: Press-fit end face 5c: Regulatory Department 5c1: Opposite part 5c2: Reinforcement section 5c21:Tip surface 10: Molding machine 11: Raw resin 11a: Molten resin 12: Hopper 13: Extruder 13a: Cylinder 14: Resin sheet forming apparatus 15: Connecting pipe 16: Connecting pipe 17: Accumulator 17a: Cylinder 17b: Piston 18: T-Die 19: Resin sheet 21: Split mold 22: Split mold cv: Cavity section pt: Pinch-off section

Claims

1. It comprises a reinforcing member, a core material, a separate member, and a resin molded body. The reinforcing member has a core material mounting portion, The core material mounting portion is attached by the core material being engaged with the reinforcing member. The aforementioned separate member is positioned at one end of the reinforcing member in the longitudinal direction so as to restrict the positions of the core material and the reinforcing member. The resin molded body is a structure formed to cover the reinforcing member, the core material, and the other member.

2. The structure according to claim 1, The structure wherein the separate member has a connecting portion, and the separate member is configured such that the connecting portion connects to at least one of the reinforcing member and the core member, thereby restricting the positions of the core member and the reinforcing member.

3. The structure according to claim 2, The connecting portion is formed to protrude and is press-fitted into the reinforcing member, forming a structure.

4. A structure according to any one of claims 1 to 3, The aforementioned separate component has a restricting portion, The regulating portion is formed to protrude, and its tip is positioned opposite the core material so as to regulate the positions of the core material and the reinforcing member.

5. A structure according to any one of claims 1 to 4, The core material comprises a first core material and a second core material. The core material mounting portion has a first core material mounting portion and a second core material mounting portion. The first core material is attached to the first core material mounting section. The second core material is attached to the second core material mounting section. The aforementioned separate component is a structure installed between the first and second core materials.

6. The structure according to claim 5, The first core material has a first end face portion, and the second core material has a second end face portion. The reinforcing member is sandwiched between the first end face portion and the second end face portion. The aforementioned separate member has a base, The base portion is provided so as to be surrounded by the one end portion in the longitudinal direction of the reinforcing member and the first and second end faces, and the base portion extends from the first end face to the second end face.

7. A structure according to any one of claims 1 to 6, The system comprises multiple of the aforementioned separate members, A structure in which the aforementioned separate member is positioned at the other end of the reinforcing member in addition to the one end in the longitudinal direction of the reinforcing member.

8. A method for manufacturing a structure, It includes an assembly process and a molding process, The aforementioned structure comprises a reinforcing member, a core material, a separate member, and a resin molded body. The reinforcing member has a core material mounting portion, The resin molded body is formed to cover the reinforcing member, the core material, and the other member. The assembly process includes a core material mounting process and a separate component mounting process. In the core material mounting step, the core material is attached to the core material mounting portion by engaging it with the reinforcing member. In the process of attaching the separate component, the separate component is positioned at one end in the longitudinal direction of the reinforcing member so as to restrict the positions of the core material and the reinforcing member, thereby manufacturing the assembly. In the molding process described above, a molded product is manufactured by molding a resin sheet and the assembly using a segmented mold. The aforementioned resin sheet constitutes the resin molded body, The molded article includes the structure, and the method is also described.

9. comprising a reinforcing member, a core material, a separate member, and a resin molded body, The reinforcing member has a core material mounting portion, The core material is attached to the core material mounting portion. The aforementioned separate member is positioned at one end of the reinforcing member in the longitudinal direction so as to restrict the positions of the core material and the reinforcing member. The resin molded body is formed to cover the reinforcing member, the core material, and the other member. The core material comprises a first core material and a second core material. The core material mounting portion has a first core material mounting portion and a second core material mounting portion. The first core material is attached to the first core material mounting section. The second core material is attached to the second core material mounting section. The aforementioned separate component is installed between the first and second core materials. The first core material has a first end face portion, and the second core material has a second end face portion. The reinforcing member is sandwiched between the first end face portion and the second end face portion. The aforementioned separate member has a base, The base portion is provided so as to be surrounded by the one end portion in the longitudinal direction of the reinforcing member and the first and second end faces, and the base portion extends from the first end face to the second end face.

Images