Panel member, method for manufacturing panel member, and apparatus for manufacturing panel member

Abstract

The purpose of the present invention is to provide a panel member that is lightweight and has high strength with respect to an impact from the outside.　This panel member (100) comprises a first skin member (1) and a second skin member (2) that contain a thermoplastic resin, and an intermediate member (3) that contains a continuous fiber. The first skin member (1) has a first joining region (C11) joined to the intermediate member (3), and a first non-joining region (C12). The second skin member (2) has a second joining region (C21) joined to the intermediate member (3), and a second non-joining region (C22). The first joining region (C11) and first non-joining region (C12), and the second joining region (C21) and second non-joining region (C22), are arranged in an alternating manner in a first direction X. The dimension LU2 of the first non-joining region (C12) in the first direction X is different from the dimension (LD2) of the second non-joining region (C22) in the first direction X.

Description

Panel member, panel member manufacturing method, and panel member manufacturing device

[0001] The present invention relates to a panel member having a skin member containing a thermoplastic resin and an intermediate member containing continuous fibers, a method for manufacturing the same, and an apparatus for manufacturing the same.

[0002] Conventionally, panel members have been known in which a low-density intermediate member such as a honeycomb, polymer foam, or corrugated sheet is sandwiched between a sheet-like outer layer body (skin member). Such panel members have excellent strength and rigidity. Therefore, such panel members are used in various fields and applications, such as aircraft fuselage parts.

[0003] Furthermore, when the intermediate member has a corrugated shape, for example, it has superior bending strength compared to a honeycomb-shaped panel member. Furthermore, when such a panel member contains a thermoplastic resin, secondary molding is possible by applying heat, which is advantageous in terms of adopting a shape according to the application. In recent years, it has also become known to improve the mechanical strength according to the shape of the structure by devising the arrangement of continuous fibers (see, for example, Patent Document 1).

[0004] Japanese Patent Application Laid-Open No. 2019-130695

[0005] In order to expand the range of applications and improve versatility, panel members having intermediate members containing the above-mentioned thermoplastic resin and continuous fibers are expected to be further lighter in weight and have improved mechanical strength. Therefore, the inventors of the present invention have focused on a configuration that can achieve both of these goals simultaneously through extensive research.

[0006] For example, by reducing the area occupied by the intermediate member in the panel member, the weight of the panel member can be reduced. However, reducing the area occupied by the intermediate member is likely to result in a decrease in the strength of the panel member. In particular, if the joint area between the skin member and the intermediate member becomes smaller (in other words, if the non-joint area becomes larger), there is a risk that the strength against external impacts will decrease. Therefore, it has been difficult to achieve further weight reduction and strength improvement.

[0007] The present invention has been made in consideration of these points, and aims to provide a panel member that is lightweight and has high strength against external impacts, as well as a manufacturing method and manufacturing apparatus that can satisfactorily manufacture such a panel member.

[0008] The panel member disclosed herein includes first and second skin members each having a sheet shape and containing a thermoplastic resin, and an intermediate member containing continuous fibers and interposed between the first and second skin members. The first skin member has a first bonded region bonded to the intermediate member and a first non-bonded region not bonded to the intermediate member. The second skin member has a second bonded region bonded to the intermediate member and a second non-bonded region not bonded to the intermediate member. The first bonded region and the first non-bonded region are alternately arranged in a first direction. The second bonded region and the second non-bonded region are alternately arranged in the first direction. The dimension of the first non-bonded region in the first direction is different from the dimension of the second non-bonded region in the first direction.

[0009] According to the panel member described above, the first and second skin members have non-bonded regions where they are not bonded to the intermediate member, thereby forming gaps and reducing weight. Furthermore, weight reduction can be further promoted by, for example, increasing the proportion of the non-bonded regions compared to conventional panels. Furthermore, the first and second non-bonded regions have different dimensions, so the bonded region of the first skin member (first bonded region) and the bonded region of the second skin member (second bonded region) have different dimensions. By placing the skin member with the larger bonded region of the first or second skin member on the side more susceptible to impact, impact can be effectively dispersed or absorbed, resulting in high durability.

[0010] When the panel member is used as a floor surface of a structure, the first skin member may be an upper skin member disposed above the intermediate member, and the second skin member may be a lower skin member disposed below the intermediate member. In this case, the dimension of the first non-bonded region in the first direction may be smaller than the dimension of the second non-bonded region in the first direction. This increases the dimension of the bonded region of the first skin member (in other words, the proportion of the bonded region). The first skin member can exhibit high compressive strength against bending strength (compression of the upper skin member and tension of the lower skin member) that occurs when a person steps on the floor material.

[0011] The strength of the panel member can be further improved by devising an arrangement structure of the continuous fibers.

[0012] For example, the dimension of the first bonded region in a second direction perpendicular to the first direction may be larger than the dimension of the first bonded region in the first direction. The dimension of the first non-bonded region in the second direction may be larger than the dimension of the first non-bonded region in the first direction. The dimension of the second bonded region in the second direction may be larger than the dimension of the second bonded region in the first direction. The dimension of the second non-bonded region in the second direction may be larger than the dimension of the second non-bonded region in the first direction. The intermediate member may include first intermediate continuous fibers extending in the first direction as the continuous fibers. In this way, by alternately arranging the bonded regions and non-bonded regions of the first skin member and the second skin member in the first direction, defining the longitudinal direction of the bonded regions and non-bonded regions as the second direction, and defining the first direction as the longitudinal direction of the continuous fibers of the intermediate member, the strength of the panel member against out-of-plane compression (a pressing force that crushes the intermediate member) can be improved.

[0013] Furthermore, the intermediate member may include, as the continuous fibers, second intermediate continuous fibers extending in a direction intersecting the first direction. The first intermediate continuous fibers may be disposed between the first skin member and the second intermediate continuous fibers in a portion of the intermediate member facing the first skin member. This allows the intermediate member to have strength against the out-of-plane compression at its outer portion. The portion of the intermediate member that transitions from a portion bonded to the first skin member to a portion not bonded (non-bonded portion) (for example, a corner portion if the intermediate portion is corrugated) is reinforced, making it easier to maintain the shape of the intermediate member. This increases the strength of the panel member against out-of-plane compression.

[0014] The first skin member may include first skin continuous fibers extending in the first direction and second skin continuous fibers extending in a direction intersecting the first direction. The first skin continuous fibers may be disposed in a region of the first skin member opposite the intermediate member. The second skin continuous fibers may be disposed between the first skin continuous fibers and the intermediate member. This provides the first skin member with strength against the out-of-plane compression in the outer region. This provides a particularly significant effect against localized stress applied to the first skin member.

[0015] In the panel member described above, intermediate members of various shapes can be used. The cross-sectional shape of the intermediate member perpendicular to the second direction perpendicular to the first direction may be formed in a corrugated shape. By increasing the bonding area of ​​the skin member, the structure becomes strong against external stress on the skin member. Furthermore, by relatively increasing the bonding area, the corrugation period (number of pitches) can be reduced, thereby reducing the weight.

[0016] The intermediate member may include a plurality of element members arranged in the first direction and spaced apart from one another in the first direction. The cross-sectional shape of each element member perpendicular to a second direction perpendicular to the first direction may be hat-shaped. This shape can also achieve the same effect as the corrugated cross-sectional shape. Furthermore, since the non-bonded region in one of the skin members is wider than in the corrugated cross-sectional shape, further weight reduction is possible.

[0017] The disclosed method for manufacturing a panel member includes joining an intermediate member containing continuous fibers to first and second skin members each having a sheet shape including a thermoplastic resin. The intermediate member is disposed between the first and second skin members. The intermediate member has a plurality of recesses and protrusions aligned in a first direction and extending in a second direction perpendicular to the first direction, thereby forming a plurality of void regions. The manufacturing method includes a step of heating the recesses and protrusions of the intermediate member by heat treatment; a skin member disposing step of disposing a first skin member on one side of the intermediate member in a third direction perpendicular to the first and second directions and a second skin member on the other side of the third direction; and a skin member joining step of joining the first skin member to the protrusions and the second skin member to the recesses after the skin member disposing step.

[0018] The uneven portion heating step may include a contact placement substep of placing a contact member in the gap region and contacting the intermediate member, and a contact heating substep of heating the contact member. By employing this manufacturing method, the first skin member and the intermediate member, and the second skin member and the intermediate member can be joined while the contact member is in contact with the intermediate member. By skillfully controlling the heating of the contact member, the joining process can be performed while maintaining appropriate temperature conditions, leading to stable product quality.

[0019] The skin member positioning step may include a skin support substep of supporting the first skin member with a first support member and a skin tension substep of applying a tensile load to the first skin member in the first direction. The skin member positioning step may include a skin support substep of supporting the second skin member with a second support member and a skin tension substep of applying a tensile load to the second skin member in the first direction. This manufacturing method allows the skin member to be in a state with a predetermined tension, and each portion of the skin member can be accurately joined. Therefore, poor joining and the like can be avoided, and a high-quality panel member can be manufactured.

[0020] After the contact heating sub-step, heating of the contact member may be continued in the skin member joining step, thereby preventing an excessive temperature drop due to heat radiation and avoiding poor joining.

[0021] The skin member joining step may include a contact restraint sub-step of applying a restraint load to the contact member to restrain expansion of the contact member in the first direction. This prevents deformation of the contact member due to the load applied during the joining process. This prevents unnecessary shape changes in the intermediate member, thereby maintaining the quality of the panel member. Note that the above "applying a restraint load" is sufficient as long as the restraint load is applied to the contact member as a result of the contact member attempting to expand. Therefore, it is sufficient that the contact member is in a state of being restrained as specified.

[0022] The manufacturing method may include an intermediate member forming step of forming the intermediate member, and the intermediate member forming step may include a processing and shaping substep of processing the intermediate member into a shape in which the dimension in the first direction of one of the recessed portion and the protruding portion gradually narrows along the second direction, and the dimension in the first direction of the other of the recessed portion and the protruding portion gradually expands along the second direction. The skin member joining step may include a press cooling substep of cooling the first skin member, the second skin member, and the intermediate member, and a contact detachment substep of removing the contact member from the gap region along the first direction.

[0023] The uneven portion heating step may include a contact placement substep of placing a contact member in the gap region and contacting the intermediate member. The skin member joining step may include a press-joining substep of pressing the first skin member against the convex portion and pressing the second skin member against the concave portion. The press-joining substep may be performed after the contact placement substep. According to this manufacturing method, the abutment member presses each skin member toward the intermediate member while positioned in the gap region, so that the non-joined region of each skin member can be pressed toward the abutment member in the same way as the joined region of each skin member with the intermediate member. Therefore, each skin member is pressed approximately evenly, resulting in a high-quality panel member.

[0024] The skin member joining step may include a press-joining substep of pressing the first skin member against the convex portion and / or pressing the second skin member against the concave portion with a pressing member, and a press-cooling substep of cooling the pressing member. According to this manufacturing method, the pressing process continues during the cooling process, taking into consideration the effect on the joining process. This allows for sufficient refined effects, including pressure feedback. In particular, when a rapid temperature rise or fall occurs, the unexpected effects of the temperature change can be significantly suppressed.

[0025] In addition to the above, the uneven portion heating step may include an abutment placement substep of placing an abutment member in the gap region and abutting it against the intermediate member, and an abutment heating substep of heating the abutment member.

[0026] The skin member joining step may include a heating member placement substep of placing a heating member between the first skin member and the intermediate member and heating the first skin member and the intermediate member with the heating member, and / or placing a heating member between the second skin member and the intermediate member and heating the second skin member and the intermediate member with the heating member.

[0027] The panel member manufacturing apparatus disclosed herein is a manufacturing apparatus for manufacturing a panel member by joining an intermediate member containing continuous fibers to first and second skin members each having a sheet shape including a thermoplastic resin. The intermediate member is disposed between the first and second skin members. The intermediate member has a plurality of void regions formed therein by a plurality of recesses and protrusions aligned in a first direction and extending in a second direction perpendicular to the first direction. The manufacturing apparatus includes: a first mold for positioning the first skin member relative to the intermediate member in one direction of a third direction perpendicular to the first and second directions and supporting the first skin member movably in the other direction of the third direction; a second mold for positioning the second skin member relative to the intermediate member in the other direction of the third direction and supporting the second skin member movably in the one direction of the third direction; a plurality of contact members disposed in the void regions of the intermediate member and contacting the recesses and protrusions; and a restraining member for restraining the movement of the contact members in the first direction.

[0028] According to the present invention, it is possible to provide a panel member that is lightweight and has high strength against external impacts, and also to provide a manufacturing method and manufacturing apparatus that can satisfactorily manufacture such a panel member.

[0029] FIG. 1( a) is a schematic perspective view showing a state in which a panel member according to the first embodiment is placed on a support rail. FIG. 1( b) is a schematic cross-sectional view showing the XZ plane in FIG. 1( a). FIG. 2( a) is a schematic perspective view showing the longitudinal direction of the continuous fibers in the outermost layer of the upper skin member of the panel member according to the first embodiment. FIG. 2( b) is a schematic perspective view showing the longitudinal direction of the continuous fibers in the outermost layer of the intermediate member of the same panel member. FIGS. 3( a) to 3( c) are schematic cross-sectional views showing the structure and effects of the panel member according to the first embodiment. FIGS. 4( a) to 4( d) are schematic cross-sectional views showing a state in which the panel member according to the first embodiment is fixed to a support rail by various means. FIG. 5( a) is a schematic cross-sectional view showing the structure of a panel member according to the second embodiment. FIG. 5( b) is a schematic cross-sectional view showing the structure of a panel member according to the third embodiment. FIG. 6 is a schematic cross-sectional view showing a state in which a panel member according to the fourth embodiment is placed on a support rail. FIG. 7 is a process explanatory diagram showing each step of a method for manufacturing a panel member. Fig. 8(a) is a schematic cross-sectional view showing a step of heating the uneven portion of the panel member. Fig. 8(b) is a schematic cross-sectional view showing a step of arranging a skin member on the panel member. Figs. 9(a) to 9(c) are schematic cross-sectional views showing a step of joining the skin member to the panel member. Fig. 10 is a schematic perspective view showing a panel member according to another embodiment and a method of manufacturing the same.

[0030]

[0016] Embodiments of a panel member, a method for manufacturing a panel member, and an apparatus for manufacturing a panel member will be described with reference to the drawings. In the following description, first, several embodiments of the panel member will be described, and then embodiments of the method for manufacturing a panel member and the apparatus for manufacturing the panel member will be described.

[0031] In the following description, unless otherwise specified, the X direction includes the X direction shown in the drawing and its opposite direction. Similarly, the Y direction includes the Y direction shown in the drawing and its opposite direction, and the Z direction includes the Z direction shown in the drawing and its opposite direction. "Matching" includes not only perfect matching but also approximate matching.

[0032] <First Embodiment of Panel Member> Fig. 1(a) is a schematic perspective view of a panel member 100 according to a first embodiment. The panel member 100 has a first skin member 1 and a second skin member 2 in sheet form containing a thermoplastic resin, and an intermediate member 3 containing continuous fibers and interposed between them. One and the other ends of the panel member 100 in the Y direction are supported by support rails R1 and R2 extending in the X direction, respectively. This allows the panel member 100 to be installed as a flooring material.

[0033] In this embodiment, the first skin member 1 is disposed above the intermediate member 3. The first skin member 1 is used as an upper skin member of the panel member 100. The first skin member 1 is a carbon fiber reinforced composite material made of a thermoplastic resin (e.g., polyphenylene sulfide or ketone-based resin) containing carbon fiber (e.g., PAN-based carbon fiber). The second skin member 2 is also a carbon fiber reinforced composite material made of a thermoplastic resin containing carbon fiber. The intermediate member 3 is formed of a corrugated material in which recesses and protrusions are alternately arranged in the X direction. The recesses and protrusions are continuous in the X direction and integrally formed. Each recess and protrusion extends in the Y direction. Like the skin members 1 and 2, the intermediate member 3 is a carbon fiber reinforced composite material made of a thermoplastic resin containing carbon fiber. Because the panel member 100 is formed from the above composite material, it is lightweight and has excellent strength and rigidity. Furthermore, because the panel member 100 contains carbon fiber, it has excellent flame retardancy.

[0034] The shape of the panel member 100 will be described with reference to Fig. 1(b). Fig. 1(b) is a schematic cross-sectional view of the panel member 100 taken along the XZ plane in Fig. 1(a). In other words, Fig. 1(b) is a schematic cross-sectional view of the panel member 100 perpendicular to the Y direction. For ease of explanation, support rails R1 and R2 are omitted.

[0035] The first skin member 1 has a bonded region C11 bonded to the intermediate member 3 and a non-bonded region C12 spaced apart from the intermediate member 3 and not bonded to the intermediate member 3. The bonded regions C11 and non-bonded regions C12 are alternately arranged in the X direction and are continuous with each other. The length of the bonded region C11 in the X direction is LU1, and the length of the non-bonded region C12 in the X direction is LU2. LU1 is greater than LU2. In the X direction, the bonded region C11 is greater than the non-bonded region C12. The thickness D1 of the first skin member 1 is substantially uniform. Here, the thickness D1 is 0.8 mm, but is not particularly limited. The thickness D1 can be changed as appropriate, for example, within a range of approximately 0.4 to 1.2 mm.

[0036] The second skin member 2 has a bonded region C21 bonded to the intermediate member 3 and a non-bonded region C22 spaced apart from the intermediate member 3 and not bonded to the intermediate member 3. The bonded regions C21 and non-bonded regions C22 are alternately arranged in the X direction and are continuous with each other. The X-direction length of the bonded region C21 is LD1, and the X-direction length of the non-bonded region C22 is LD2. LD2 is greater than LD1. In the X direction, the non-bonded region C22 is greater than the bonded region C21. The length LD2 of the non-bonded region C22 is different from the length LU2 of the non-bonded region C12 of the first skin member 1. In this embodiment, the length LD2 of the non-bonded region C22 of the second skin member 2 is greater than the length LU2 of the non-bonded region C12 of the first skin member 1. The thickness D2 of the second skin member 2 is substantially uniform. Here, the thickness D2 is 0.6 mm, but is not particularly limited. The thickness D2 can be changed appropriately within a range of, for example, about 0.4 to 1.2 mm.

[0037] The intermediate member 3 has an upper surface portion C31 joined to the joining region C11 of the first skin member 1, a lower surface portion C32 joined to the joining region C21 of the second skin member 2, and a connecting portion C33 connecting the upper surface portion C31 and the lower surface portion C32. The upper surface portion C31 is heat-welded to the joining region C11 of the first skin member 1. The lower surface portion C32 is heat-welded to the joining region C21 of the second skin member 2. The upper surface portion C31, the connecting portion C33, and the lower surface portion C32 are integrally formed. The intermediate member 3 has a corrugated cross-sectional shape that is continuously and integrally formed along the X direction. The cross-sectional shape of the intermediate member 3 perpendicular to the Y direction is corrugated. Due to the corrugated cross-sectional shape of the intermediate member 3, multiple gap regions V1 and V2 are formed. The intermediate member 3 has a shape obtained by extending the above cross-sectional shape in the Y direction. As described above, the sizes of the joining areas C11 and C21 are different, so the upper surface portion C31 is larger than the lower surface portion C32. The inclination angle a of the connecting portion C33 relative to the first skin member 1 and the inclination angle b of the connecting portion C33 relative to the second skin member 2 are both set to 70 degrees. The inclination angles a and b may be in the range of 45 to 90 degrees, with a range of approximately 60 to 75 degrees being particularly preferable. In this embodiment, the thickness D of the panel member 100 is 10 mm.

[0038] Next, the orientation of the carbon fibers (continuous fibers) in the panel member 100 will be described with reference to Fig. 2. For convenience of explanation, Fig. 2 shows the carbon fibers in addition to the schematic perspective view of Fig. 1(a).

[0039] The first skin member 1 has four layers in the Z direction. Each layer contains multiple carbon fibers 11. The orientations of the carbon fibers 11 are 0 degrees, 90 degrees, 90 degrees, and 0 degrees from bottom to top. The orientation of the carbon fibers is expressed as an angle with respect to the X direction. In the first skin member 1, the carbon fibers 11 are biaxially oriented. As shown in FIG. 2( a), the top layer of the first skin member 1, which serves as the upper skin member, contains multiple carbon fibers 11 extending in the X direction. In the top layer of the first skin member 1, the X direction is the longitudinal direction of the carbon fibers 11. Here, the carbon fiber 11 content in the first skin member 1 is 60% by mass. However, the carbon fiber 11 content in the first skin member 1 can be changed as needed, for example, between 40 and 70% by mass, with 55 to 70% by mass being particularly preferred.

[0040] The second skin member 2, which serves as the lower skin member, has three layers in the Z direction. Each layer contains a plurality of carbon fibers 11. The carbon fibers are oriented at 90 degrees, 0 degrees, and 90 degrees from bottom to top. In the second skin member 2, the carbon fibers 11 are biaxially oriented. Although not shown, in the top layer (top portion) of the second skin member 2, unlike the top layer of the first skin member 1, the longitudinal direction of the carbon fibers 11 is the Y direction. Here, the carbon fiber 11 content in the second skin member 2 is 60% by mass. However, the carbon fiber 11 content in the second skin member 2 can be changed as needed, for example, between 40 and 70% by mass, with 55 to 70% by mass being particularly preferred.

[0041] The intermediate member 3 has four layers in the Z direction. Each layer contains carbon fibers 13. The carbon fibers are oriented at 0 degrees, 90 degrees, 90 degrees, and 0 degrees from bottom to top. In the intermediate member 3, the carbon fibers 13 are biaxially oriented. FIG. 2( b ) shows the intermediate member 3 with the first skin member 1 removed. As shown in FIG. 2( b ), in the top layer (topmost portion) of the intermediate member 3, the longitudinal direction of the carbon fibers 13 is the X direction. Note that the top layer of the intermediate member 3 is the outermost layer closest to the first skin member 1. As described above, the corrugated cross-sectional shape of the intermediate member 3 extends in the Y direction. The carbon fibers 13 with the X direction as their longitudinal direction are substantially perpendicular to the extension direction (Y direction) of the corrugated cross-sectional shape. By including such 0-degree oriented carbon fibers 13 across multiple corrugated portions (i.e., multiple recesses and protrusions), the panel member 100 can exhibit high rigidity against external compressive forces. The content of the carbon fibers 13 in the intermediate member 3 is also 60% by mass. However, the content of the carbon fibers 13 in the intermediate member 3 can be appropriately changed, for example, within a range of 40 to 70% by mass, and is particularly preferably 55 to 70% by mass.

[0042] As shown in FIG. 3A , within one pitch LC of the corrugated shape (i.e., the length of one set of recessed and protruding portions in the X direction), LU1 > LU2 for the first skin member 1, and LD1 < LD2 for the second skin member 2. For the bonded regions C11 and C21, LU1 > LD1, and for the non-bonded regions C12 and C22, LU2 < LD2. In other words, the corrugated shape is asymmetrical left-right and up-down in the XZ plane within one pitch LC. This shape within one pitch LC of the intermediate member 3 is continuously repeated in the X direction. The hollow portions formed by the protruding portions of the intermediate member 3 are referred to as mountain-shaped hollow portions S1, and the hollow portions formed by the recessed portions are referred to as valley-shaped hollow portions S2. Because the length LU1 of the bonded region C11 is greater than the length LU2 of the non-bonded region C12, the mountain-shaped hollow portions S1 are greater than the valley-shaped hollow portions S2. Because the length LU1 of the joining region C11 is relatively long, the number of pitches of the corrugated shape is small. This reduces the volume of the intermediate member 3 required, thereby reducing the weight of the panel member 100. In particular, the panel member 100 according to this embodiment is used as cabin flooring in aircraft. Therefore, considering the number and size of the panel members 100 used, the effect of the weight reduction is significant.

[0043] In the panel member 100 according to this embodiment, in which the first skin member 1 is an upper skin member, a localized load, such as a load P1 caused by high heels or a dropped object, may be applied to the non-bonded region C12 of the first skin member 1, as shown in FIG. 3( b). According to this embodiment, the non-bonded region C12 is smaller than the bonded region C11, thereby suppressing the amount of deflection (see the dashed-dotted line) of the first skin member 1 when a localized load is applied. Furthermore, the bonded region C11 occupies a larger proportion of the first skin member 1 than the non-bonded region C12. This reduces the likelihood of the load P1 being applied to the non-bonded region C12. Furthermore, in the first skin member 1, the carbon fibers in the top layer extend in the X direction. Therefore, the carbon fibers in the top layer suppress the amount of deflection and improve durability against impact loads. Furthermore, the first skin member 1 has a four-layer structure, which is thicker and has a stronger biaxial orientation than the three-layer second skin member 2. As described above, the first skin member 1 of this embodiment has performance as an upper skin member that exceeds a desired level in terms of impact strength from above.

[0044] The panel member 100 according to this embodiment also exhibits high durability against out-of-plane compression. When pressure P2 is applied from above to the first skin member 1, as shown in FIG. 3(c), the intermediate member 3 receives the pressure P2 through the first skin member 1. The intermediate member 3 changes shape as shown by the dashed line, and the panel member 100 is compressed in the Z direction. However, because the intermediate member 3 has a four-layer structure and biaxially oriented carbon fibers, the panel member 100 exhibits high durability even in the compressed state. Furthermore, in the top layer of the intermediate member 3 closest to the first skin member 1, the orientation of the carbon fibers 13 is 0 degrees (see FIG. 2(b)). This also allows the panel member 100 to exhibit high durability. The carbon fibers 13 in the top layer of the intermediate member 3 reinforce the corner portion C301 (specifically, the portion where the intermediate member 3 transitions from being joined to the first skin member 1 to being not joined (non-joined portion)). This makes it easier to maintain the shape of the first skin member 1, and therefore the overall shape of the panel member 100. According to this embodiment, the strength against the above-mentioned out-of-plane compression is increased.

[0045] Next, the support state of the panel member 100 by the metal support rails R1, R2 will be described with reference to Fig. 4. Fig. 4, like Fig. 3, is a schematic cross-sectional view taken along the XZ plane.

[0046] As shown in the figure, the panel member 100 is fixed to the support rail R1 with a bolt 41 and a nut 42. The panel member 100 is similarly fixed to the support rail R2. A spacer 43 is provided on the shaft of the bolt 41. Insertion holes TH for the bolt 41 and the spacer 43 are formed in the non-joint region C12 of the first skin member 1. Insertion holes TH for the bolt 41 and the spacer 43 are also formed in the second skin member 2, the intermediate member 3, and the support rail R1 at positions corresponding to the insertion holes TH (specifically, positions vertically below the insertion holes TH). The bolts 41 and nuts 42 inserted into these insertion holes function as fixing means for fixing the panel member 100 to the support rail R1. In this embodiment, the spacer 43 positions the top of the bolt 41 flush with the first skin member 1. The top of the bolt 41 does not protrude from the first skin member 1. Therefore, when the panel member 100 is used as a flooring material, a flat floor surface without any irregularities is formed.

[0047] The portion of the panel member 100 below the non-bonded region C12 has a two-layer structure consisting of the bonded region C21 of the second skin member 2 and a region of the intermediate member 3 bonded to the bonded region C21. The bolt 41 is fastened to the non-bonded region C12 of the first skin member 1. As a result, the fastening force of the bolt 41 and nut 42 acts on the support rail R1 and the two-layer structure of the second skin member 2 and the intermediate member 3. Note that the fastening force of the bolt 41 acting on the two-layer structure also includes forces that transmit stresses generated in each of the two-layer structure portions in the planar direction via the bolt 41. This fastening force secures the panel member 100 to the support rail R1. If the bolt 41 were fastened to the bonded region C11 of the first skin member 1, the fastening force of the bolt 41 and nut 42 would act on the single-layer structure of the non-bonded region C22 of the second skin member 2. In contrast, in this embodiment, the fastening force of the bolts 41 and nuts 42 acts on the two-layer structure, resulting in a greater fastening force. The bolts 41, nuts 42, spacers 43, and insertion holes TH are provided at multiple locations as shown in the figure. They are provided at predetermined intervals not only in the left-right direction (X direction) but also in the depth direction (Y direction) in the figure. This allows for high fastening force to be obtained at each location, thereby reducing the number of bolts 41 and nuts 42 used throughout the panel member 100. However, the locations of the bolts 41 and nuts 42 are not limited to those shown in the figure. The bolt 41 may be fastened to the joining region C11 of the first skin member 1 (see the two-dot chain line in FIG. 4( b)). The bolt 41 may be fastened to both the joining region C11 and the non-joining region C12. Furthermore, the bolt 41 does not have to be provided in the approximate center of the non-joining region C12 (as well as the joining region C11) as shown in the figure. The bolt 41 may be provided at the connection portion C33.

[0048] Other fixing means may be used to fix the panel member 100 to the support rails R1, R2, such as the means shown in Figure 4(b), Figure 4(c) or Figure 4(d).

[0049] FIG. 4( b ) shows a configuration in which an insert member 431 is used instead of the spacer 43. The bolts 411 and nuts 421 used in this configuration, together with the insert member 431, serve as fastening means for fixing the panel member 100 to the support rail R1. The bolts 411 engage with the insert member 431. As shown, the insert member 431 engages with all of the first skin member 1, the second skin member 2, and the intermediate member 3. The insert member 431 is provided in the non-bonding region C12 of the first skin member 1. In this configuration using the insert member 431, the fastening force of the panel member 100 to the support rail R1 is generated by stress generated in the two-layer structure between the intermediate member 3 and the bonding region C21 of the second skin member 2, and stress generated in the non-bonding region C12 of the first skin member 1. Note that the insert member 431 may be provided in, for example, the bonding region C11 of the first skin member 1, rather than the non-bonding region C12. In this case, the fastening force is generated by stress generated in the two-layer structure between the intermediate member 3 and the bonded region C11 of the first skin member 1, and pressure generated in the non-bonded region C22 of the second skin member 2. Therefore, the fastening force is equivalent to the fastening force when the insert member 431 is provided in the non-bonded region C12 of the first skin member 1. The same effect can be obtained whether the bolt 411, nut 421, and insert member 431 are provided in the non-bonded region C12 or the bonded region C11 of the first skin member 1. Note that a configuration in which they are provided in both regions C11 and C12 may also be used.

[0050] 4(c), an insert member 432 having a unit structure in which multiple members are assembled in the vertical direction (Z direction) may be used instead of the insert member 431. Compared to the insert member 431 shown in FIG. 4(b), when a unit structure is preferred depending on the application, it is also possible to apply such an assembled insert member 432. Even with this configuration, it is possible to prevent the insert member 432 and the top of the bolt 411 from protruding from the first skin member 1.

[0051] As a means for fastening the bolt 411 and nut 421 described above, in addition to the structure using insert members 431 and 432, a structure using a core 433 as shown in FIG. 4( d ) can also be used. In this case, as in FIG. 4( a ), the top of the bolt 411 can be made substantially flush with the first skin member 1. Furthermore, in a structure using the core 433, a bolt with its top positioned downward can be inserted from the second skin member 2 side (vertically downward) without providing an insertion hole in the first skin member 1. In this case, by using a bolt that can be fastened at a position that does not reach the first skin member 1, the surface (upper surface) of the first skin member 1 can be made substantially flush. Since the core 433 is fastened to the bolt 411, in the above example, the core 433 is positioned in the space between the non-bonding region C12 of the first skin member 1 and the intermediate member 3. However, when the bolt 411 is provided in the joining area C11 (for example, at the position of the dotted line in Figure 4 (b)), the core 433 may be positioned in the space between the non-joining area C22 of the second skin member 2 and the intermediate member 3.

[0052] The panel member 100 according to this embodiment has the above-described structure including thermoplastic resin and carbon fiber, and therefore is impact-resistant. Furthermore, the pitch number of the intermediate member 3 can be reduced, thereby reducing weight. Furthermore, to improve durability against compressive loads, the corrugated intermediate member 3 has multiple layers containing continuous carbon fiber. The multiple layers have at least a biaxial orientation in which the carbon fibers are oriented approximately perpendicular to the longitudinal direction of the corrugated shape. Furthermore, since the layer with the approximately perpendicularly oriented carbon fibers is the uppermost layer, the durability against the compressive load (out-of-plane compression) is significantly enhanced. Additionally, as described above, by skillfully combining the orientation of the carbon fibers in each layer, the bending strength of the panel member 100 can be increased. Similarly, the first skin member 1 and the second skin member 2 also have multiple layers in which the carbon fibers are oriented at least biaxially, thereby improving bending strength. Furthermore, by orienting the longitudinal direction of the carbon fiber in the uppermost layer of the first skin member 1, which is prone to impacts (particularly localized impacts), to a direction that intersects the longitudinal direction of the corrugated shape at a right angle, high durability against impacts can be achieved. Note that, when the panel member 100 is used for an application in which the second skin member 2 is prone to be subjected to impacts as described above, the corrugated shape of the intermediate member 3 and the configuration of the multiple layers containing carbon fiber in the first skin member 1, second skin member 2, and intermediate member 3 can be appropriately modified to suit the application, for example, by turning them upside down.

[0053] Second Embodiment of Panel Member FIG. 5A shows a schematic cross-sectional shape of a panel member 100A according to a second embodiment. In the panel member 100A according to this embodiment, the intermediate member 3A is formed in a hat shape. The intermediate member 3A includes multiple element members aligned in the X direction, and the element members are spaced apart in the X direction. The cross-sectional shape of the element members perpendicular to the Y direction is formed in a hat shape. The first skin member 1A has a non-bonded region C12A between two bonded regions C11A. The two bonded regions C11A and the non-bonded region C12A face the non-bonded region C22 of the second skin member 2. In the first skin member 1A, the two bonded regions C11A and the non-bonded region C12A are alternately arranged in the X direction. In the second skin member 2A, the bonded region C21 joined to the intermediate member 3A and the non-bonded region C22 are alternately arranged in the X direction. The length LU2 and the length LU2A of the first skin member 1A are different from the length LD2 of the second skin member 2A.

[0054] In this embodiment, two types of non-bonding regions C12, C12A are provided in the first skin member 1A. The non-bonding region C12 faces the bonding region C21 in the second skin member 2A. The length LU2 of the non-bonding region C12 is substantially the same as the length LU2 of the non-bonding region C12 in the first embodiment (see FIG. 1B). Meanwhile, the length LU2A of the non-bonding region C12A is shorter than the length LU2 of the non-bonding region C12. Here, the lengths LU11A, LU12A of the bonding regions C11A on the left and right sides adjacent to the non-bonding region C12A are equal to each other, but may be different from each other.

[0055] The length LD1 of the bonded region C21 of the second skin member 2A and the length LD2 of the non-bonded region C22 are both approximately the same as the lengths LD1 and LD2 in the first embodiment. In the intermediate member 3A, the inclination angles a and b of the connecting portion C33A relative to the first skin member 1A and the second skin member 2A are also approximately the same as the inclination angles a and b in the first embodiment.

[0056] In the above-described panel member 100A, LU2<LD2. Furthermore, if the sum of the lengths of the non-bonded region C12A of the first skin member 1A and the bonded regions C11A on both sides of it is LUA (=LU11A+LU2A+LU12A), then LUA>LD1. The panel member 100A according to this embodiment can also be made lighter and maintain high bending strength. Furthermore, because it has a structure containing carbon fiber similar to that of the first embodiment, it can maintain a high level of bending strength while exhibiting high durability against external impacts.

[0057] <Third embodiment of panel member> In a panel member 100A according to the second embodiment, a first skin member 1A has two types of non-bonded regions C12, C12A. Meanwhile, in a panel member 100B according to a third embodiment shown in Fig. 5(b), a second skin member 2B has two types of non-bonded regions C22, C22B. In the third embodiment, an intermediate member 3B has a hat-shaped cross section that is upside down from that of the second embodiment.

[0058] In this embodiment, LU2<LD2. Furthermore, if the sum of the lengths of the non-bonded region C22B of the second skin member 2B and the bonded regions C21B on both sides of it is LDB (=LD11B+LD2B+LD12B), then LDB<LU1. The panel member 100B according to this embodiment can also be made lighter and maintain high bending strength. Furthermore, because it has a structure containing carbon fiber similar to that of the first embodiment, it can maintain a high level of bending strength while exhibiting high durability against external impacts.

[0059] When the first skin member 1B is used as an upper skin member, it is preferable that the proportion of the bonded region C11 in the first skin member 1B be large. In the panel member 100B according to the third embodiment, the proportion of the bonded region C11 can be increased compared to the panel member 100A according to the second embodiment, which is preferable. In this embodiment, the durability of the first skin member 1B against impacts can be increased, so the length LU1 of the bonded region C11 in the first skin member 1B can be increased. Furthermore, a non-bonded region may be provided in the middle of the bonded region C11 (for example, as shown in FIG. 5A , the bonded region C11A, non-bonded region C12A, and bonded region C11A are arranged in this order) while maintaining the various effects described above.

[0060] <Fourth embodiment of panel member> In the first to third embodiments, the longitudinal direction of the bonded regions and non-bonded regions of the intermediate members 3, 3A, 3B is the Y direction (see FIG. 1(a)), and the intermediate members 3, 3A, 3B have multiple layers containing carbon fiber. Figure 6 shows a panel member 100C according to the fourth embodiment.

[0061] In the panel member 100C according to this embodiment, the longitudinal direction of the bonded and non-bonded regions of the intermediate member 3C is the X direction. In each of the first skin member 1C and the second skin member 2C, the bonded and non-bonded regions are alternately arranged in the Y direction. The Y-direction length of the non-bonded regions of the first skin member 1C is different from the Y-direction length of the non-bonded regions of the second skin member 2C. Therefore, as with the other embodiments, this embodiment can also achieve a lightweight structure while exhibiting high bending strength in a certain direction and high durability against external impacts.

[0062] In the panel member 100C, as shown in the figure, carbon fibers 11C extending in the Y direction are oriented in the top layer of the first skin member 1C. As described above, the first skin member 1C is formed of multiple biaxially oriented layers, providing a predetermined level of durability against external impacts. The same applies to the second skin member 2C and the intermediate member 3C. The carbon fiber orientation can be changed depending on the desired bending strength and impact durability. Furthermore, when using the various fastening means (see FIG. 4 ) described in the first embodiment, the fastening means may be arranged side by side in the X direction. In cases where the spacing between the fastening means is not constant but variable, or where the spacing is determined appropriately based on design or assembly constraints, the present embodiment, in which the longitudinal direction of the bonded and non-bonded regions of the intermediate member 3C is in the X direction, is preferable because it provides greater flexibility in determining the positioning of the fastening means.

[0063] <Other Embodiments of Panel Member> The panel members 100, 100A, 100B, and 100C according to the respective embodiments have been described above, but the type of thermoplastic resin contained in the first skin member and the second skin member is not particularly limited. Polyphenylene sulfide, ketone resin, or other resins can be used. By using a material with a high melting point, a resin with high strength can be formed. However, the present invention is not limited to these materials, and other materials may also be used. The same type of thermoplastic resin may also be used for the intermediate member.

[0064] Examples of the carbon fibers that can be used include PAN-based carbon fibers and pitch-based carbon fibers. However, the continuous fibers are not limited to carbon fibers, and glass fibers (e.g., E-glass fibers) can also be used. Regarding the longitudinal directions of these continuous fibers, "coinciding" with the X and Y directions includes cases where the longitudinal directions are completely aligned with the X and Y directions, respectively, as well as cases where the longitudinal directions are slightly offset from the X and Y directions. This is because the same effects as described above can be obtained even when the longitudinal directions of the continuous fibers are slightly offset from the X and Y directions.

[0065] In the above-described embodiment, each of the skin members 1, 2 and the intermediate member 3 has a laminated structure in which layers containing carbon fibers 11, 13 are stacked, but the number of stacked layers can be changed as appropriate. In addition, the orientation of the carbon fibers is not limited to biaxial orientation.

[0066] The thermoplastic resins and continuous fibers used in the first skin member, second skin member, and intermediate member that make up the panel member may be different for each member, or may be appropriately combined. In the above-described embodiment, in the panel member made of thermoplastic resin, the first skin member and the intermediate member, and the second skin member and the intermediate member are welded together. This allows the panel member to be formed from the same material. This increases recyclability and shortens manufacturing lead times. Thus, the more the same material is used, the greater the above-described effects.

[0067] Furthermore, the panel members 100, 100A, 100B, and 100C of the above-described embodiments can be applied to various portions (such as the center and end portions) of cabin flooring within an aircraft. Naturally, the panel member according to the present invention is not limited to flooring or components installed in the cabin, but can also be applied to other portions, such as the fuselage portion of a cargo hold. Furthermore, since the panel member according to the present invention can achieve the various effects described above, it can be applied not only to aircraft, but also to various forms such as other transport machinery, buildings and structures that require a certain level of strength, or transported goods for which lightweight construction is preferred.

[0068] When manufacturing panel components containing the above-mentioned thermoplastic resins, the quality of the panel components is significantly affected by the skillful combination of the heating process and the joining process of the skin and intermediate components. The heating process is performed based on the melting points of the skin and intermediate components. After the heating process is completed, the skin and intermediate components dissipate heat. If the transition from the heating process to the joining process is not timely or is not rapid, the temperatures may fall far below the melting points, resulting in poor joining. Furthermore, it is desirable not only to ensure high joining strength, but also to ensure that the strength is even. In particular, in panel components formed with multiple void regions, if pressure is concentrated only in the joining region, it becomes difficult to achieve the desired bending strength.

[0069] Furthermore, a cooling process is required after the heating process. Given the need for rapid manufacturing, if the temperature does not drop sufficiently or if heat remains locally, this can lead to a deterioration in product quality. In particular, improved mechanical strength and weight reduction are expected for panel components in which an intermediate component is joined to a skin component to form multiple void regions. To achieve these goals, it is necessary to consider not only sufficient joint strength but also the detailed shapes and properties of the skin components and intermediate components that form the void regions. These points must be taken into consideration until the cooling process is complete. For panel components containing thermoplastic resins, which are easily molded, sudden temperature changes can have a negative impact on the final quality.

[0070] This manufacturing process is highly versatile and can be used to manufacture panel components for a variety of purposes and types. It is important to use different methods to precisely control environmental conditions such as temperature and humidity, as well as processing time, depending on the purpose and type of panel component. Therefore, there is a need for manufacturing methods and equipment that can effectively manufacture panel components by skillfully combining each processing step.

[0071] <First embodiment of manufacturing method and manufacturing apparatus for panel member> Next, an embodiment of a manufacturing method and manufacturing apparatus for the panel member 100 will be described. In this embodiment, an apparatus that combines processing devices used in each step of the manufacturing method described below is used as the manufacturing apparatus for the panel member 100. Figure 7 shows the flow of each step of the manufacturing method. Figures 8 and 9 are schematic cross-sectional views showing the contents of some steps.

[0072] The manufacturing method of this embodiment includes a skin member forming step S1, in which the first skin member 1 and the second skin member 2 are formed before being joined to the intermediate member 3; an intermediate member forming step S2, in which the intermediate member 3 is formed before being joined to the first skin member 1 and the second skin member 2; a skin member positioning step S3, which is a preparatory step for joining the first skin member 1 and the second skin member 2 to the intermediate member 3; an uneven portion heating step S4, in which the uneven portions of the corrugated intermediate member 3 are heated; and a skin member joining step S5, in which the intermediate member 3 is joined to the first skin member 1 and the second skin member 2 after the skin member positioning step S3 and the uneven portion heating step S4.

[0073] In the skin member formation step S1, the sheet-like first skin member 1 and the sheet-like second skin member 2 described above are formed. In this step S1, first, a first skin substrate is prepared by forming four layers of carbon fiber 11 (S101). Next, the spaces formed between the carbon fibers 11 of the first skin substrate are impregnated with a thermoplastic resin (S102). This results in the formation of a sheet as the first skin member 1 and allows the carbon fibers 11 to be stably fixed. Similarly, for the second skin member 2, a second skin substrate is prepared by forming three layers of carbon fiber 11 (S101), and the second skin substrate is impregnated with a thermoplastic resin (S102). This results in the formation of a sheet as the second skin member 2 and allows the carbon fibers 11 to be stably fixed.

[0074] In the intermediate member forming step S2, an intermediate substrate is prepared by forming four layers of carbon fibers 13 (S201), and then the spaces formed between the carbon fibers 13 of the intermediate substrate are impregnated with a thermoplastic resin (S202). This forms a sheet containing the carbon fibers 13 and enables the carbon fibers 13 to be stably fixed. Next, the sheet is formed into a corrugated shape using a press (S203), thereby forming the intermediate member 3 (processing and forming substep S21).

[0075] As described above, after the skin substrates and intermediate substrates are impregnated with thermoplastic resin, the first skin member 1, the second skin member 2, and the intermediate member 3 can be joined together. As shown in FIG. 8( a), an upper mold MU and a lower mold MD are arranged one above the other to secure the first skin member 1 and the second skin member 2. Then, a heat treatment is initiated for each of the upper mold MU and the lower mold MD (S200). After the heat treatment is initiated, the process proceeds to a skin member placement step S3. The skin member placement step S3 includes a skin support substep S31 in which each of the skin members 1 and 2 is supported by the molds MU and MD, and a skin tension substep S32 in which a tensile load is applied to each of the skin members 1 and 2 in a first direction (the X direction in this embodiment). In the skin support substep S31, the first skin member 1 is supported by the upper mold MU, and the second skin member 2 is supported by the lower mold MD (S301). In this embodiment, the temperatures of the molds MU and MD are prevented from becoming excessively high at the time of this sub-step S31. In the skin tension sub-step S32, a tensile load in the X direction is applied to the first skin member 1, and a tensile load in the X direction is applied to the second skin member 2 (S302).

[0076] The upper mold MU is provided with a locking portion MU1 to which the first skin member 1 is locked. The lower mold MD is provided with a locking portion MD1 to which the second skin member 2 is locked. The locking portion MU1 has a mechanism that allows the support portion MU11 of the first skin member 1 to move vertically and horizontally relative to the upper mold MU. The locking portion MD1 has a mechanism that allows the support portion MD11 of the second skin member 2 to move vertically and horizontally relative to the lower mold MD. Therefore, in the skin member placement step S3, the first skin member 1 supported by the locking portion MU1 can approach the heated upper mold MU until it comes into contact with it, and the second skin member 2 supported by the locking portion MD1 can approach the heated lower mold MD until it comes into contact with it (S301). As a result, the first skin member 1 is heated by the upper mold MU, and the second skin member 2 is heated by the lower mold MD, which starts melting the thermoplastic resin of the first skin member 1 and the second skin member 2. Note that this contact does not have to be complete contact, and they can be close to each other with a slight distance to allow them to receive sufficient heat.

[0077] Furthermore, when the skin members 1 and 2 are brought closer together, a tensile load in the X direction is applied to the first skin member 1 and the second skin member 2 by the locking portions MU1 and MD1 (S302). This applies a predetermined tension to the thermoplastic resin as it begins to melt, thereby maintaining the shape of each skin member 1 and 2. The stiffness of each skin member 1 and 2 may decrease as it melts, especially in areas farther from the support portions MU11 and MD11. However, applying the tensile load as described above can suppress this loss of stiffness. Maintaining a constant stiffness improves the bond strength of the bonded regions C11 and C21 to the intermediate member 3. Furthermore, the desired shape can be achieved even in the non-bonded regions C12 and C22, which are not bonded to the intermediate member 3. Therefore, deformation of each skin member 1, 2 (such as folding, overlapping, or swelling of the membrane material) can be prevented within the gap regions V1, V2 (the range of lengths LU2, LD2 of the non-bonded regions C12, C22). The predetermined length of each region of each skin member 1, 2 can be maintained, ensuring the desired shape. Thus, applying the tensile load described above is preferable because it contributes to improving the quality of the panel member 100.

[0078] The intermediate member 3 is also subjected to a process to prepare it for bonding to the skin members 1 and 2. In the uneven portion heating step S4, a contact placement substep S41 and a contact heating substep S42 are performed. In the contact placement substep S41, contact members (cores) SP1 and SP2 are placed in the regions corresponding to the gap regions V1 and V2, respectively (S401). In this manner, the contact members (cores) SP1 and SP2 fill the recesses and protrusions of the intermediate member 3. The contact member SP1 has a shape that allows it to contact the non-bonding region C12 of the skin member 1, the lower surface C32 of the intermediate member 3, and the connecting portion C33 (see FIG. 1(b)). The contact member SP2 has a shape that allows it to contact the non-bonding region C22 of the skin member 2, the upper surface C31 of the intermediate member 3, and the connecting portion C33 (see FIG. 1(b)). The contact members SP1 and SP2 are metallic members elongated in the Y direction (see FIG. 1A). Cartridge heaters (not shown) extending in the Y direction are provided inside the contact members SP1 and SP2. The contact members SP1 and SP2 are configured to be heatable approximately uniformly along their entire lengths. In the contact heating substep S42, the contact members SP1 and SP2 are heated (S402), and melting of the thermoplastic resin in the intermediate member 3 begins. The intermediate member 3 according to this embodiment contains carbon fibers (continuous fibers) with high thermal conductivity, and the carbon fibers are biaxially oriented. Even if the intermediate member 3 is heated locally, heat can be transferred to each portion of the intermediate member 3. However, in this embodiment, in order to achieve quality improvement over the entire surface of the intermediate member 3, such as maintaining stable rigidity, the contact members SP1 and SP2 have the above-described shape and are configured to be heatable approximately uniformly.

[0079] Following the skin member arrangement step S3 and the uneven portion heating step S4, the process proceeds to the skin member joining step S5. This step S5 includes a heating member arrangement substep S51 for heating each of the skin members 1, 2 and the intermediate member 3 from between the skin members 1, 2 and the intermediate member 3, a contact restraint substep S52 for preventing movement and deformation of the contact members SP1, SP2, a pressure joining substep S53 for applying pressure to each of the skin members 1, 2 to bring them into contact with the intermediate member 3, a pressure cooling substep S54 for cooling the skin members 1, 2 while applying the pressure, and a contact release substep S55 for removing the contact members SP1, SP2, etc., to release the pressure on the intermediate member 3, etc.

[0080] In the heating member placement substep S51, the infrared heater IH is positioned as shown in FIG. 8B (S511). Specifically, the infrared heater IH is positioned between the first skin member 1 and the intermediate member 3, above the upper surface C31 of the intermediate member 3. The infrared heater IH is also positioned between the second skin member 2 and the intermediate member 3, below the lower surface C32 of the intermediate member 3. Next, heating by the infrared heater IH begins (S512). This heating results in all portions of the skin members 1 and 2 and the intermediate member 3 being heated from both above and below (both positive and negative directions in the Z direction), resulting in substantially uniform heating. Furthermore, as described above, the skin members 1 and 2 and the intermediate member 3 are preheated by the upper mold MU, the lower mold MD, and the abutment members SP1 and SP2. This shortens the heating time using the infrared heater IH. At this time, the above-described support portions MU11 and MD11 apply tensile loads to the skin members 1 and 2. When a predetermined temperature or time is reached, the heating by the infrared heater IH is stopped, and the infrared heater IH is moved to a position where it is removed from between each of the skin members 1 and 2 and the intermediate member 3 (S513).

[0081] Next, the process proceeds to the contact and restraint sub-step S52. In the contact and restraint sub-step S52, a restraint member F1 is arranged as shown in FIG. 9A to restrict movement in the X direction of the contact members SP1 and SP2 aligned in the X direction (S521). The longitudinal direction of the restraint member F1 is the same as the longitudinal direction of the contact members SP1 and SP2, which is the Y direction. The restraint member F1 is arranged so as to continuously contact the contact members SP1 and SP2 along the Y direction. Therefore, the contact members SP1 and SP2 cannot move in the X direction. The restraint member F1 may be in close contact with the contact members SP1 and SP2 and fixed so as not to move in the X direction. Alternatively, the restraint member F1 may be configured to be movable along the X direction and to apply a predetermined stress to the contact members SP1 and SP2 in the X direction.

[0082] After the contact and restraint sub-step S52, the process proceeds to the pressure joining sub-step S53. First, the upper mold MU and the lower mold MD are moved toward the intermediate member 3, and the skin members 1 and 2 are brought into contact with the intermediate member 3 as shown in FIG. 9B (S531). At this time, the restraint members SP1 and SP2 are maintained by the restraint member F1, and the support members MU1 and MD1 continue to apply a tensile load to the skin members 1 and 2. While continuing this restraint and application of the tensile load, the upper mold MU and the lower mold MD begin pressing the skin members 1 and 2 against the intermediate member 3. This joins the uneven portions of the skin members 1 and 2 to the intermediate member 3. Specifically, the upper surface portion C31 is thermally welded to the first skin member 1, and the lower surface portion C32 is thermally welded to the second skin member 2 (S532). At this time, the timing of joining the first skin member 1 and the intermediate member 3 (the timing of starting the process S532 for applying pressure to join (thermal welding)) and the timing of joining the second skin member 2 and the intermediate member 3 are controlled to be simultaneous. In this embodiment, when the press-joining substep S53 is started, management is performed to prevent temperature variations between the intermediate member 3 and each of the skin members 1, 2, and 3 based on the thermal capacity and shape of these members. To maintain this uniform state, the joining timing is controlled to be simultaneous as described above. This improves the uniformity of the temperature conditions among the members 1, 2, and 3, further improving the quality of the panel member 100. Furthermore, in the press-joining substep S53, the infrared heater IH is moved (S513) as described above. Because the temperature of the thermoplastic resin in the skin members 1, 2, and the intermediate member 3 gradually decreases, it is desirable to complete the process within a short period of time. In this embodiment, heating of the contact members SP1 and SP2 and the molds MU and MD is continued in the press-joining substep S53. Therefore, the temperature drop can be suppressed, and a decrease in the joining (thermal welding) strength can be prevented. Furthermore, since the restraining member F1 restrains the movement of the contact members SP1 and SP2, deformation of the contact members SP1 and SP2 due to thermal expansion can be prevented. The contact members SP1 and SP2 are subjected to pressure in the Z direction from the upper mold MU and the lower mold MD, which may cause stress in the horizontal direction (X direction). However, deformation and movement of the contact members SP1 and SP2 due to this stress can also be prevented.Deformation of the intermediate member 3 can also be prevented. Therefore, a panel member 100 with excellent joining strength can be manufactured. Furthermore, according to this embodiment, the press-joining sub-step S53 is performed after the abutment members SP1, SP2 are arranged, particularly after the abutment members SP1, SP2 are arranged to match the size and shape of the gap regions V1, V2. Therefore, the first skin member 1 can be pressed approximately evenly against the convex portion of the intermediate member 3 and the abutment member SP1, and the second skin member 2 can be pressed approximately evenly against the concave portion of the intermediate member 3 and the abutment member SP2 (see FIG. 8( a)).

[0083] Next, the process proceeds to the pressure cooling substep S54. Although not shown, cooling water passages for flowing cooling water are formed inside the upper mold MU and the lower mold MD. In the pressure cooling substep S54, cooling water is circulated through the upper mold MU and the lower mold MD to cool them (S541). This cooling also cools the skin members 1 and 2 and the intermediate member 3, lowering their temperatures. However, even in this substep S54, the restraint member F1 of the contact members SP1 and SP2, the application of tensile loads to the skin members 1 and 2 by the support members MU1 and MD1, and the pressing in the Z direction by the upper mold MU and the lower mold MD continue. The cooling described above may cause the upper mold MU, the lower mold MD, the skin members 1 and 2, or the intermediate member 3 to shrink. However, by continuing the above-mentioned restraint, application of tensile load, and pressure, a pressure feedback function that continues to apply a predetermined pressure even if shrinkage occurs will act, so that the desired shape and quality can be stably obtained. However, in this sub-step S54, if the influence of shape changes due to temperature changes in the skin members 1, 2 or intermediate member 3 can be avoided, the application of the above-mentioned tensile load may be canceled in advance.

[0084] In the pressure cooling substep S54, once the temperatures of the upper mold MU and the lower mold MD have fallen to the predetermined crystallization temperature of the thermoplastic resin, the process proceeds to the contact release substep S55. In this substep S55, the pressure (including the application of a tensile load) applied to the skin members 1 and 2 by the upper mold MU and the lower mold MD is released (S551), and the restraint state by the restraint member F1 is released (S552). The panel member 100, in which the skin members 1 and 2 are joined to the intermediate member 3, is then removed. Since the contact members SP1 and SP2 are inserted through the panel member 100, the contact members SP1 and SP2 are removed by pushing the push rod in the Y direction (see FIG. 1A) (S553). As a result, multiple gap regions V1 and V2 are well formed, as shown in FIG. 9C, and good bonding strength is achieved in the bonding regions C11 and C21. In particular, in this embodiment, as described above, the pressure bonding is performed with the abutment members SP1 and SP2 positioned. This ensures sufficient bonding strength in the bonding regions C11 and C21, while also allowing for uniform pressing of areas other than the bonding regions C11 and C21. This results in a panel member 100 with excellent strength distribution. Furthermore, in the pressure cooling substep S54, processing is performed to enable the aforementioned pressure feedback. In this process, the abutment members SP1 and SP2 have shapes that match the desired gap regions V1 and V2, contributing to the realization of the above-described excellent strength distribution. This allows for the skin members 1 and 2 and the intermediate member 3 to be precisely shaped with excellent precision. Therefore, the bonding regions C11 and C21 of the skin members 1 and 2 are tightly bonded to the intermediate member 3, while the remaining areas of the skin members 1 and 2 achieve a smooth surface shape. Furthermore, the corners of the uneven portions of the intermediate member 3 can also be accurately shaped.

[0085] The panel member 100 manufactured as described above has a uniform layer structure in terms of thickness and shape not only in the bonded regions C11, C21 and non-bonded regions C12, C22 of the skin members 1, 2, but also in each region, such as the upper surface C31, lower surface C32, and connecting portion C33 of the intermediate member 3. Therefore, the panel member 100 has stable bending strength and durability. A structure with a large proportion of the non-bonded region C12, such as the panel member 100 of this embodiment, offers the above-mentioned advantages as well as weight reduction. The corrugated cross-sectional shape of the intermediate member 3 extends in the Y direction, and in the first skin member 1, the carbon fibers of the top layer are oriented in the X direction, perpendicular to the Y direction. This reduces deflection and provides high performance in terms of impact load durability. Furthermore, the first skin member 1 has a four-layer structure, which is thicker and has stronger biaxial orientation than the three-layer second skin member 2. As an upper skin member, the first skin member 1 has a desired level or more of functionality in terms of impact strength from above.

[0086] In this embodiment, the tensile load applied in the skin member placement step S3 is continued until the pressure cooling substep S54. This ensures stable bonding strength between each skin member 1, 2 and the intermediate member 3. Furthermore, stable shape and quality can be achieved not only at the bonded portions but also in the non-bonded regions C12, C22. Therefore, the panel member 100 has high durability against out-of-plane compression. When pressure is applied from above to the first skin member 1, which is the upper skin member, the intermediate member 3 undergoes a substantially uniform shape change at each pitch LC, resulting in the panel member 100 being well compressed in the Z direction. Because the intermediate member 3 has a four-layer structure and the continuous carbon fibers are biaxially oriented as described above, the panel member 100 exhibits high durability even in the compressed state. Furthermore, the orientation of the carbon fibers 13 in the top layer closest to the first skin member 1 is 0 degrees (see FIG. 2(b)), which significantly improves durability. The panel member 100 has this top layer of carbon fiber 13, which reinforces the corner portions of the intermediate member 3 (specifically, the portions that change from being joined to the first skin member 1 to not being joined (non-joined portions)), thereby maintaining the shape of the first skin member 1. The overall shape of the panel member 100 is well maintained, thereby improving the strength against out-of-plane compression as described above.

[0087] The manufacturing apparatus according to this embodiment is a manufacturing apparatus that implements the above-described manufacturing method. The manufacturing apparatus according to this embodiment includes an upper mold MU, a lower mold MD, contact members SP1 and SP2, and a restraining member F1. By including these components, it is possible to accurately control the sequence and management of each of the above-described manufacturing processes. In this embodiment, a heating process and a bonding process are performed. The manufacturing apparatus according to this embodiment takes into account the effects of heat dissipation, ensuring rapid operation. The manufacturing apparatus according to this embodiment is capable of applying appropriate loads not only during each process but also before and after each process. The manufacturing apparatus according to this embodiment is preferable in that it can achieve stable product quality. Note that the manufacturing apparatus is not limited to being integrated, and may be configured as separate units arranged in a predetermined space, as long as it can achieve the above-described manufacturing method and its effects.

[0088] <Second embodiment of manufacturing method and manufacturing apparatus for panel member> In the above-described embodiment, in the processing and forming sub-step S21, the intermediate members 3 having the same corrugated cross-sectional shape extending in the Y direction are formed, but it is also possible to form intermediate members 3 having different shapes. For example, an intermediate member 30 having the shape shown in FIG. 10 may be formed.

[0089] In this intermediate member 30, multiple recesses and protrusions are also arranged alternately in the X direction. In this embodiment, each of the recesses and protrusions has a shape in which the width (length in the X direction) gradually increases or decreases along the Y direction. The intermediate member 30 in this embodiment has first protrusions 301 whose width gradually increases in the positive Y direction, second protrusions 302 whose width gradually decreases in the positive Y direction, first recesses 311 whose width gradually decreases in the positive Y direction, and second recesses 312 whose width gradually increases in the positive Y direction. In this embodiment, a press is used in the processing and forming substep S21 to process the intermediate member 30 into the illustrated shape.

[0090] With respect to the upper surface of the first convex portion 301, the width WU301b of the end on the positive Y-direction side is greater than the width WU301a of the end on the negative Y-direction side. With respect to the opening of the first convex portion 301 when viewed from the negative Z-direction side (in other words, when viewed from below), the width of the end on the positive Y-direction side is greater than the width WD301a of the end on the negative Y-direction side. With respect to the upper surface of the second convex portion 302, the width WU302b of the end on the positive Y-direction side is smaller than the width WU302a of the end on the negative Y-direction side. With respect to the opening of the second convex portion 302 when viewed from the negative Z-direction side, the width of the end on the positive Y-direction side is smaller than the width WD302a of the end on the negative Y-direction side. When viewed from the positive Z direction (in other words, when viewed from above), the opening of the first recess 311 has a width WU311b at its end on the positive Y direction side that is smaller than a width WU311a at its end on the negative Y direction side. When viewed from the bottom of the first recess 311, the width at its end on the positive Y direction side is smaller than a width WD311a at its end on the negative Y direction side. When viewed from the positive Z direction (in other words, when viewed from above), the width WU312b at its end on the positive Y direction side is larger than a width WU312a at its end on the negative Y direction side. When viewed from the bottom of the second recess 312, the width at its end on the positive Y direction side is larger than a width WD312a at its end on the negative Y direction side.

[0091] 10 shows the process of the contact removal sub-step S55 according to this embodiment, in which the contact members SP11, SP12, SP21, and SP22 remain on some of the recessed and protruding portions. In FIG. 10, the process of removing the contact members SP11, SP12, SP21, and SP22 sequentially in this sub-step S55 is shown.

[0092] For the second convex portion 302, whose width gradually narrows in the positive Y direction, the abutting member SP22 is extruded in the negative Y direction as indicated by the white arrow. On the other hand, for the first convex portion 301, whose width gradually expands in the positive Y direction, the abutting member SP21 is extruded in the positive Y direction. For the second recessed portion 312, the abutting member SP12 is extruded in the positive Y direction. For the first recessed portion 311, the abutting member SP11 is extruded in the negative Y direction. As described above, when a thermoplastic resin is subjected to a heating treatment or a bonding treatment (such as a pressing treatment), minute deformations or damage may occur on the surfaces of each portion. However, by forming the shape shown in FIG. 6, in which the width gradually expands or narrows as in this embodiment, it becomes easier to extrude the abutting members SP11, SP12, SP21, and SP22.

[0093] <Other Embodiments of Panel Member Manufacturing Method and Manufacturing Apparatus> In each of the above-described embodiments, if satisfactory heating treatments can be performed in the heating treatment (S200) of the upper mold MU and the lower mold MD and the uneven portion heating step S4, the heating member placement substep S51 can be omitted. Omitting the heating member placement substep S51 is preferable in terms of shortening manufacturing time and simplifying the configuration of the manufacturing apparatus. Even if the heating member placement substep S51 is omitted, the contact members SP1, SP2, SP11, SP12, SP21, and SP22 are maintained in a heated state in the skin member joining step S5. This prevents a temperature drop before the joining process begins, thereby preventing poor joining. In each of the embodiments, the intermediate members 3 and 30 have a corrugated shape. However, as long as the intermediate members 3 and 30 have recesses and protrusions, thereby forming multiple void regions in the panel member, the intermediate members 3 and 30 may have shapes other than a corrugated shape. Furthermore, the corrugated shape of the intermediate member may be such that LU1<LU2 or LU1=LU2 within one pitch LC, or may be such that LD1>LD2 or LD1=LD2.

[0094] Furthermore, with regard to the manufacturing apparatus according to this embodiment, the components used are not limited to the shapes and materials described above. For example, while the contact members SP1, SP2, SP11, SP12, SP21, and SP22 are metallic components that provide the above-described effects in the above-described embodiment, other materials may be used as long as they are thermally conductive. For example, using materials with a low thermal expansion coefficient and stable shape and dimensions even in a heated state is also applicable because it can achieve the same effects. Furthermore, if a separate heating means is used in the contact heating substep S42, the contact members SP1, SP2, SP11, SP12, SP21, and SP22 themselves do not need to have thermal conductivity. In the above-described embodiment, a means for bringing the first skin member 1 and the second skin member 2 closer to the intermediate member 3 is used in the pressure joining substep S53, but this is not limiting. Alternatively, a means for bringing the intermediate member 3 closer to the first skin member 1 or the second skin member 2 may be used. Alternatively, a method may be employed in which the first skin member 1 and the intermediate member 3 are brought close to each other and then the first skin member 1 and the intermediate member 3 are brought close to each other. In the above-described embodiment, in the press-bonding substep S53, the first skin member 1 and the intermediate member 3 are bonded simultaneously (i.e., the timing at which the press-bonding process S532 is started) and the second skin member 2 and the intermediate member 3 are bonded simultaneously. However, these timings may be changed as appropriate depending on the heat capacity of the intermediate member 3 and the shapes of the intermediate member 3 and the skin members 1 and 2. For example, when the press-bonding substep S53 is started, the bonding timing may be controlled to provide a time difference to suppress temperature variations among the members 1, 2, and 3. This can improve the uniformity of the temperature conditions among the members 1, 2, and 3 during the manufacturing process, thereby enabling the production of a high-quality panel member 100. Note that timing control for improving the quality of the panel member 100 is not limited to controlling the timing at which bonding begins (the bonding timing). The same applies to the control of the timing of starting or ending the contact and release sub-step S55 for ending the joining process and the pressure cooling sub-step S54 for cooling.

[0095] REFERENCE SIGNS LIST 1 First skin member 2 Second skin member 3 Intermediate member C11 Bonded region (first skin member) C12 Non-bonded region (first skin member) C21 Bonded region (second skin member) C22 Non-bonded region (second skin member) 11 Carbon fiber (first skin member) 13 Carbon fiber (intermediate member) 100 Panel member R1, R2 Support rail

Claims

1. a first skin member and a second skin member each having a sheet shape including a thermoplastic resin; an intermediate member including continuous fibers and interposed between the first skin member and the second skin member; the first skin member has a first bonding region bonded to the intermediate member and a first non-bonding region not bonded to the intermediate member, the second skin member has a second bonded region bonded to the intermediate member and a second non-bonded region not bonded to the intermediate member, The first bonded regions and the first non-bonded regions are alternately arranged in a first direction, The second bonded regions and the second non-bonded regions are alternately arranged in the first direction, a dimension of the first non-bonded region in the first direction is smaller than a dimension of the second non-bonded region in the first direction; The first skin member has a plurality of layers, A panel member, wherein an outermost layer of the plurality of layers of the first skin member, which is the layer furthest from the intermediate member, includes first skin continuous fibers extending in the first direction.

2. the first skin member is an upper skin member disposed above the intermediate member, The panel member according to claim 1 , wherein the second skin member is a lower skin member disposed below the intermediate member.

3. A dimension of the first bonding region in a second direction perpendicular to the first direction is larger than a dimension of the first bonding region in the first direction, a dimension of the first non-bonded region in the second direction is larger than a dimension of the first non-bonded region in the first direction; A dimension of the second bonding region in the second direction is larger than a dimension of the second bonding region in the first direction, A dimension of the second non-bonded region in the second direction is larger than a dimension of the second non-bonded region in the first direction, The panel member according to claim 1 , wherein the intermediate member includes, as the continuous fibers, first intermediate continuous fibers extending in the first direction.

4. The intermediate member further includes, as the continuous fibers, second intermediate continuous fibers extending in a direction intersecting the first direction, The panel member according to claim 3 , wherein the first intermediate continuous fibers are disposed between the first skin member and the second intermediate continuous fibers at a portion of the intermediate member facing the first skin member.

5. The first skin member includes second skin continuous fibers extending in a direction intersecting the first direction, The first skin continuous fibers are disposed in a portion of the first skin member opposite to the intermediate member side, 2. The panel member of claim 1, wherein the second skin continuous fibers are disposed between the first skin continuous fibers and the intermediate member.

6. The panel member according to claim 1 , wherein a cross-sectional shape of the intermediate member perpendicular to a second direction perpendicular to the first direction is formed in a corrugated shape.

7. the intermediate member includes a plurality of element members arranged in the first direction and spaced apart from each other in the first direction, The panel member according to claim 1 , wherein a cross-sectional shape of the element member perpendicular to a second direction perpendicular to the first direction is formed in a hat shape.

8. A method for manufacturing a panel member according to claim 1, comprising the steps of: a plurality of void regions are formed in the intermediate member by a plurality of recesses and protrusions aligned in a first direction and extending in a second direction perpendicular to the first direction; a heating step of heating the recessed and protruding portions of the intermediate member; a skin member disposing step of disposing a first skin member on one side of the intermediate member in a third direction perpendicular to the first direction and the second direction, and disposing a second skin member on the other side of the third direction; a skin member joining step of joining the first skin member to the protrusion and joining the second skin member to the recess after the skin member arranging step; A method for manufacturing a panel member, comprising:

9. The uneven portion heating step includes: a contact placement sub-step of placing a contact member in the gap region and contacting the intermediate member; The method for manufacturing a panel member according to claim 8 , further comprising a contact heating sub-step of heating the contact member.

10. The skin member disposing step includes: a skin supporting sub-step of supporting the first skin member by a first support member; and a skin tensioning sub-step of applying a tensile load to the first skin member in the first direction, and / or The method for manufacturing a panel member according to claim 8 , further comprising: a skin supporting sub-step of supporting the second skin member by a second support member; and a skin tensioning sub-step of applying a tensile load to the second skin member in the first direction.

11. The method for manufacturing a panel member according to claim 9, wherein after the contact heating sub-step, heating of the contact members is continued in the skin member joining step.

12. The method for manufacturing a panel member according to claim 9 , wherein the skin member joining step includes a contact and restrain sub-step of applying a restraining load to the contact member to restrain expansion of the contact member in the first direction.

13. forming the intermediate member; the intermediate member forming step includes a processing and forming sub-step of processing the intermediate member into a shape in which one of the recess and the protrusion has a dimension in the first direction that gradually narrows along the second direction, and the other of the recess and the protrusion has a dimension in the first direction that gradually expands along the second direction, The method for manufacturing a panel member according to claim 8, wherein the skin member joining step includes a press cooling sub-step of cooling the first skin member, the second skin member, and the intermediate member, and a contact removal sub-step of removing the contact member from the gap region along the second direction.

14. The uneven portion heating step includes a contact placement sub-step of placing a contact member in the gap region and contacting the intermediate member, The skin member joining step includes a press-joining sub-step of joining the first skin member to the protruding portion while pressing it thereon and joining the second skin member to the recessed portion while pressing it thereon, The method for manufacturing a panel member according to claim 8 , wherein the press-joining sub-step is performed after the abutting and arranging sub-step.

15. The skin member joining step includes: a pressing and joining sub-step of pressing and joining the first skin member to the convex portion and / or pressing and joining the second skin member to the concave portion by a pressing member; The method for manufacturing a panel member according to claim 8 , further comprising a press cooling sub-step of cooling the pressing member.

16. The uneven portion heating step includes: a contact placement sub-step of placing a contact member in the gap region and contacting the intermediate member; The method for manufacturing a panel member according to claim 15, further comprising a contact heating sub-step of heating the contact member.

17. The method for manufacturing a panel member described in claim 16, wherein the skin member joining step includes a heating member placement substep of placing a heating member between the first skin member and the intermediate member and heating the first skin member and the intermediate member with the heating member, and / or placing a heating member between the second skin member and the intermediate member and heating the second skin member and the intermediate member with the heating member.

18. A manufacturing apparatus for manufacturing the panel member according to claim 1, a plurality of void regions are formed in the intermediate member by a plurality of recesses and protrusions aligned in a first direction and extending in a second direction perpendicular to the first direction; a first die that disposes the first skin member in one direction of a third direction perpendicular to the first direction and the second direction with respect to the intermediate member and supports the first skin member movably in the other direction of the third direction; a second mold that disposes the second skin member on the other side of the third direction relative to the intermediate member and supports the second skin member movably in one side of the third direction; a plurality of abutment members disposed in the gap region of the intermediate member and abutting the recessed portion and the protruding portion; a restraining member that restrains the movement of the contact member in the first direction; An apparatus for manufacturing a panel member comprising: