JP5772300B2 - Resin laminate - Google Patents

Description

  The present invention relates to a resin laminate, and more particularly, to a resin laminate that can realize further improvement in rigidity while ensuring weight reduction and thinning.

  Conventionally, so-called resin laminates have been used as interior materials, building materials, logistics and packaging materials for automobiles. The resin laminate has a resin surface material and a resin back material, and the back material is provided with a recess whose tip is abutted against the inner surface of the surface material. In particular, in the case of automobile interior materials and building materials where the appearance is important, a nonwoven fabric is stuck on the front side of the surface material. Conventionally, various methods have been adopted as a method for producing the resin laminate. First, a technique of manufacturing by integral extrusion hollow molding using a molten resin is employed. According to the resin laminate produced by such a method, compared to a double-walled hollow structure that simply has a hollow portion inside, a concave portion that connects the front surface material and the back surface material provides rigidity, particularly a surface material. On the other hand, it is possible to ensure the compressive rigidity against the load in the vertical direction.

  Secondly, as disclosed in Patent Document 1, two melts extruded individually between a pair of rolls, one of which is a roll having a large number of protrusions arranged on the surface in a staggered pattern. The sheet in the state is passed under a predetermined pressing force to form a recess in one sheet, and the two sheets are welded in such a form that the bottom surface of the recess is abutted against the inner surface of the other sheet. This is a technique in which another sheet is welded to the surface on the side where the opening of the recess is formed, and has a three-layer structure in which the sheet is welded to each of the front side and the back side of the sheet in which the recess is formed.

  Thirdly, as disclosed in Patent Document 2, unlike the second method, the extrusion is individually performed between a pair of rolls each having a plurality of protrusions arranged on the surface in a zigzag pattern. The two melted sheets are passed under a predetermined pressing force to form recesses in the respective sheets, and the two sheets in a form in which the bottom surfaces of the corresponding recesses of the respective sheets are welded to each other. It is a technique of welding and further welding another sheet to the opposite surface of each sheet, and has a four-layer structure in which the sheet is welded to the surface of the sheet on which the recess opening is formed. The following technical problems exist in the technology for producing a resin laminate by extruding a molten sheet as described above.

  That is, it is difficult to obtain a resin laminate having sufficient strength without directionality while ensuring manufacturing efficiency. More specifically, as a problem peculiar to extrusion molding common to the first method to the third method, the end portion in the extrusion direction of the sheet is in an open state, so that end surface treatment such as heat sealing treatment is essential. For this reason, an extra step is required, and the overall manufacturing efficiency is lowered. Further, the welding between the sheet having the concave portions formed in a zigzag pattern and another sheet, or the welding between the sheets having the concave portions formed in a zigzag pattern, respectively, passes while being fed by a roller between the pair of rollers. However, it is difficult to ensure a sufficient welding time, and it is difficult to ensure sufficient strength as a resin laminate due to insufficient welding, resulting in quality deterioration. In this respect, according to blow molding instead of continuous extrusion molding, it is possible to avoid a decrease in manufacturing efficiency due to the end face treatment as described above and a lack of strength due to insufficient welding. Patent Document 3 discloses a method by such blow molding. According to Patent Document 3, using a molten cylindrical parison, the back wall is provided with a recess whose front end is butt welded to the inner surface of the front wall, and the outer surface of the front wall is provided with a covering material. The point to stick is disclosed. However, blow molding using a cylindrical parison and applying blow pressure causes another technical problem. That is, it is difficult to sufficiently reduce the thickness and thickness of the resin laminate due to molding by applying blowing pressure using a cylindrical parison having a uniform thickness in the circumferential direction.

  More specifically, since the cylindrical parison is usually extruded from the annular slit between the die cores, its thickness is substantially uniform in the circumferential direction. On the other hand, when a pair of split molds are clamped Since the pressure applied to the mold of the parison is uniform over the entire surface of the parison because the blowing pressure is applied from the sealed space in the mold, the parison pressed against one mold forming the recess The parison is stretched in relation to the blow ratio according to the depth and the opening diameter, and a locally thin portion is generated. On the other hand, no concave portion is formed in the other mold, so that such a thin portion does not occur. . From this point, it is necessary to set the thickness of the cylindrical parison according to the thin part on the side of one mold, thereby forming a sheet with an extra thickness on the side of the other mold. become. As described above, when a cylindrical parison having a substantially uniform thickness in the circumferential direction is used, a difference in thickness inevitably occurs between a wall surface having a plurality of recesses and a wall surface where no recesses are formed after blow molding. As a result, it is impossible to achieve sufficient weight reduction and thinning of the resin laminate. In this regard, according to Patent Document 4, two melted sheets based on a cylindrical parison are used to have a hollow portion inside, and a plurality of concave portions on the two surfaces facing each other, the bottom surface portion of which is A method of manufacturing a plate of thermoplastic resin formed so as to face each other is disclosed. However, in particular, in the case of automobile laminates and building laminates for building materials where the appearance of the surface is important, it is necessary to attach a decorative material such as a nonwoven fabric to one sheet forming the surface. Therefore, it is preferable to avoid forming a plurality of recess openings on the surface by providing a recess for forming a recess in one sheet.

Japanese Patent No. 4327275 Japanese Patent No. 4192138 JP-A-11-105113 Japanese Patent Laid-Open No. 7-171877

In order to solve the above problems, the following manufacturing technique is effective.
That is, a split mold having a plurality of projecting portions projecting toward the other split mold is used for one split mold cavity, and two sheets of thermoplastic resin sheet material in a molten state are paired. Position between the split molds. Then, after forming a sealed space between the one sheet material and the cavity of the one split mold, the sealed space is sucked from the side of the one split mold. By this suction action, a plurality of recesses are formed into a sheet material with a plurality of protrusions, and a pair of split molds are clamped to weld the bottom of the recess to the other sheet material and reinforced with a plurality of ribs. A hollow resin laminate is obtained.

  If such a manufacturing technique is used, the thickness of each of the two sheet materials can be reduced to the maximum, thereby reducing the weight and the thickness while ensuring the manufacturing efficiency and the product quality.

  By the way, while the quality improvement of the resin laminated board represented by the vehicle interior goods is calculated | required, the further rigidity improvement of a laminated board is anticipated. Even in the manufacturing technique using the above-described divided mold, there is room for improvement in order to further improve the rigidity.

  Then, this invention is providing the resin laminated board which can implement | achieve further rigidity improvement, ensuring weight reduction and thickness reduction.

The resin laminate according to the present invention is
  The two sheets are provided with two sheets stacked with a hollow part therebetween, and one sheet is recessed in the hollow part to provide a plurality of concave parts, and the bottoms of the plurality of concave parts are welded to the other sheet. A resin laminate formed by connecting the sheets with the plurality of recesses,
  The plurality of recesses include a plurality of first recesses and a plurality of second recesses having a relatively large depth relative to the first recess.
  The resin laminated plate includes a thin plate portion having the plurality of first recesses and a thick plate portion having the plurality of second recesses, and the plurality of first recesses and the plurality of second recesses are substantially omitted. Arranged at the same pitch,
  The plurality of first recesses and the plurality of second recesses increase in diameter from the bottom toward the opening, and the slope angle of the slope of the first recess is relative to the slope angle of the slope of the second recess. The opening diameter of the first recess and the opening diameter of the second recess are made the same size.
  The resin laminate according to the present invention is
  The two sheets are provided with two sheets stacked with a hollow part therebetween, and one sheet is recessed in the hollow part to provide a plurality of concave parts, and the bottoms of the plurality of concave parts are welded to the other sheet. A resin laminate formed by connecting the sheets with the plurality of recesses,
  The plurality of recesses include a plurality of first recesses and a plurality of second recesses having a relatively large depth relative to the first recess.
  The resin laminated plate includes a thin plate portion having the plurality of first recesses and a thick plate portion having the plurality of second recesses, and the plurality of first recesses and the plurality of second recesses are substantially omitted. Arranged at the same pitch,
  The plurality of first recesses and the plurality of second recesses are enlarged in diameter from the bottom toward the opening, and the bottom diameter dimension of the first recess is relatively larger than the bottom diameter dimension of the second recess. The opening diameter of the first recess and the opening diameter of the second recess are the same size.

In the present invention, a resin laminated plate is constituted by a thin plate portion having a plurality of first recesses and a thick plate portion thicker than a thin plate portion having a plurality of second recesses having relatively large depths. One recess and the plurality of second recesses were arranged at substantially the same pitch.

Consider a case where the laminated plate has a uniform thickness.
When a bending load is applied to the supported laminated plate, the laminated plate is deformed with a deflection amount corresponding to the load. In general, in order to suppress the amount of bending without changing the material and shape, a measure for increasing the thickness of the resin laminate is taken. However, when the thickness of the laminate is uniform, the mass of the resin laminate inevitably increases as the thickness is increased.

  In this regard, in the present invention, the resin laminated plate is configured by the thin plate portion and the thick plate portion thicker than the thin plate portion. Thereby, in a resin laminated board, the area | region where thickness is required for a deformation | transformation suppression can be made into a thick board part, and the other area | region can be made into a thin board part. In other words, the rigidity of the resin laminate can be increased without increasing the mass by rationally combining the thin plate portion and the thick plate portion and adjusting the thickness of the sheet.

  In addition, since the plurality of first recesses and the plurality of second recesses are arranged at substantially the same pitch, the rigidity of the resin laminate can be made uniform. At the same time, the processability and moldability of the mold are improved and the appearance is improved.

  The thickness of each of the two resin sheets can be individually reduced to the maximum as long as the required strength is ensured, and weight reduction and thickness reduction can be achieved.

  Therefore, according to the present invention, there is provided a technique for manufacturing a resin laminate that can realize further improvement in rigidity while ensuring weight reduction and thinning.

In the present invention, the plurality of first recesses and the plurality of second recesses are formed in a truncated cone shape, the opening diameters of the plurality of first recesses and the opening diameters of the plurality of second recesses are the same size, and the plurality of first recesses The bottom diameter of the recess and the bottom diameter of the plurality of second recesses were the same size.

  When two types of recesses having different depths are formed into a truncated cone shape, the inclination angles of the recesses can be the same. In this case, in the two types of recesses, if the opening diameter is the same, the bottom diameter is different, and if the bottom diameter is the same, the opening diameter is different. Mixing two types of recesses having different opening diameters and bottom diameters in the molded product makes the molded product non-uniform in rigidity and is not preferable in the processing of the mold or the molding of the thick plate portion.

  In this regard, in the present invention, by adjusting the respective inclination angles of the first recess and the second recess, the opening diameter and the bottom diameter of the first recess and the second recess having different depths are made the same size. It is possible to make the rigidity of the laminated plate uniform and improve the workability of the mold and the moldability of the thick plate portion.

In the present invention, when a resin laminate is used as a structure in which both end portions of one sheet are supported and the center portion of the other sheet receives a bending load, a part of the center side from both supported end portions is used. The region or the entire region was used as the thick plate portion.

  The inventors of the present invention perform analysis by CAE (Computer Aided Engineering), and in the resin laminate, if a partial area or the entire area on the center side is a thick plate portion, the rigidity is increased without increasing the mass. I found out. As a result, the rigidity can be further increased reasonably.

In the present invention, a plurality of rows of belt-like regions connecting both supported end portions are provided, and the plurality of rows of belt-like regions are used as the thick plate portion.
In the analysis of CAE by the inventors, it was effective to use such a plurality of strip-like regions as thick plate portions. Therefore, the rigidity can be increased reasonably without increasing the mass of the resin laminate.

In the present invention, a region including both supported end portions and having a predetermined width along the outer periphery is defined as a thick plate portion.
In the analysis of CAE by the inventors, it was effective to use such a region along the outer periphery as a thick plate portion. Therefore, the rigidity can be increased reasonably without increasing the mass of the resin laminate.

In the present invention, the resin laminate is a vehicle interior material having a rectangular outer shape in plan view, and both supported end portions are opposite sides of one sheet.
ADVANTAGE OF THE INVENTION According to this invention, the vehicle interior material which can implement | achieve further rigidity improvement is ensured, ensuring lightweighting and thickness reduction.

It is a perspective view of the resin laminated board which concerns on 1st Embodiment. FIG. 2 is a perspective view of the resin laminated board, taken along the arrow 2 in FIG. 1. It is a bottom view of a resin laminated board. FIG. 4 is an enlarged view of part 4 of FIG. 3. It is a figure explaining the structure of the 1st, 2nd recessed part, (A) is 5-5 sectional view taken on the line of FIG. 4, (B) is sectional drawing which shows the comparative example of (A). It is a figure explaining analysis conditions, (A) is a top view of a basic model, (B) is a B arrow view of (A). It is a bottom view of the analysis model concerning a 1st embodiment. It is a bottom view of the analysis model concerning a 2nd embodiment. It is a bottom view of the analysis model concerning a 3rd embodiment. It is a bottom view of the analysis model concerning a 4th embodiment. It is a perspective view of the vehicle rear part with which the resin laminated board was mounted | worn. 12 is a sectional view taken along line 12-12 of FIG.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

First, the resin laminate according to the first embodiment will be described.
As shown in FIG. 1, the resin laminate 100 has a three-layer structure including a front side sheet 120A, a back side sheet 120B, and a decorative material sheet 140 bonded to the outer surface of the front side sheet 120A. Such a resin laminated board 100 is used as, for example, a vehicle interior material. In FIG. 1, in order to clearly show the internal structure of the resin laminate 100, the periphery of the peripheral portion of the resin laminate 100 is omitted.

  As shown in FIG. 2, the resin laminated plate 100 includes a thin plate portion 100a having a plurality of first recesses 200S having a small depth and a thick plate portion 100b having a plurality of second recesses 200L having a large depth. Is done.

  As shown in FIG. 3, the resin laminated plate 100 has a rectangular outer shape, and the thin plate portion 100a is formed in a region in the vicinity of each side and with a constant width over the entire outer peripheral portion. The thick plate portion 100b is formed in a region on the center side and surrounded by the thin plate portion 100a.

Next, the configuration of the first recess 200S and the second recess 200L will be described in detail with reference to FIGS.
As shown in FIG. 4, the plurality of first recesses 200 </ b> S and the plurality of second recesses 200 </ b> L are arranged in a staggered pattern at substantially the same pitch P. The substantially same pitch may be a range in which the molding upper sheet is stretched by the interval between the first concave portion and the second concave portion and does not become thinner than other portions, and is between the first concave portion and the second concave portion. If it is a distance, it is necessary that there is no difference more than half the opening diameter a of the first recess and the second recess at each pitch, and the ratio of the sheet thickness at each part is in the range of 80 to 120%. It is preferable to be within.

  Moreover, as shown to FIG. 5 (A), the thin plate part 100a and the thick plate part 100b are continued through the level | step difference 101 formed in the back surface side sheet | seat 120B. The first concave portion 200S and the second concave portion 200L are welded to the inner surface 170 of the surface side sheet 120A, which is the surface opposite to the outer surface 150 to which the decorative material sheet 140 is bonded. The depth d1 of the first recess 200S and the depth d2 of the second recess 200L are the difference between the thickness t1 of the thin plate portion 100a and the thickness t2 of the thick plate portion 100b. The first recess 200S and the second recess 200L constitute a first rib 122S and a second rib 122L that connect between the inner surface 180 of the back sheet 120B and the inner surface 170 of the surface sheet 120A. The first concave portion 200S and the second concave portion 200L have a truncated cone shape, and have a shape in which the diameter is increased from the bottom 240S, 240L toward the openings 260S, 260L.

  The bottoms 240S and 240L are welded to the inner surface 170 of the top sheet 120A. A hollow portion 280 is formed between the front surface side sheet 120 </ b> A and the back surface side sheet 120 </ b> B, and the hollow portion 280 is closed on the peripheral end surface of the laminated structure board 100. The number of the first recesses 200 </ b> S and the second recesses 200 </ b> L may be appropriately set depending on the application of the resin laminate 100, but the higher the number, the higher the rigidity as compared with the weight.

  Then, the opening diameter of the first recess 200S and the opening diameter of the second recess 200L are set to the same dimension a. Further, by adjusting the tilt angle d of the first recess 200S and the tilt angle e of the second recess 200L (specifically, tilt angle d> slope angle e), the bottom diameter of the first recess 200S and the second The bottom diameter of the recess 200L is set to the same dimension b.

  Thus, by matching the opening diameter and the bottom diameter of the first recess 200S and the second recess 200L, the rigidity of the resin laminate 100 can be made uniform, the mold workability, and the thickness of the thick plate portion 100b. Formability can be improved.

  On the other hand, as shown in FIG. 5B, it is possible to make the opening diameter a the same and the inclination angle d the same. However, in this case, the bottom diameter b of the first recess 200S and the bottom diameter c of the second recess 200L are different. Mixing two types of recesses with different bottom diameters in a molded product makes the molded product non-uniform in rigidity, and is not preferable in terms of mold workability and thick plate portion moldability.

Next, the material of each sheet will be described in detail.
The sheet material that is a material of the front side sheet 120A and the back side sheet 120B is a sheet formed of an olefin resin such as polyethylene or polypropylene, or an amorphous resin. More specifically, the sheet materials P1 and P2 are preferably made of a resin material having a high melt tension from the viewpoint of preventing the occurrence of variations in thickness due to drawdown, neck-in, etc. In order to improve transferability and followability, it is preferable to use a resin material with high fluidity.

  More specifically, it is a polyolefin (for example, polypropylene, high density polyethylene) which is a homopolymer or copolymer of an olefin such as ethylene, propylene, butene, isoprene pentene, methyl pentene, etc., and has an MFR (JIS) at 230 ° C. According to K-7210, measured at a test temperature of 230 ° C. and a test load of 2.16 kg) of 3.0 g / 10 min or less, more preferably 0.3 to 1.5 g / 10 min, or acrylonitrile butadiene Amorphous resin such as styrene copolymer, polystyrene, high impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), MFR at 200 ° C. (test temperature 200 according to JIS K-7210) ℃, measured at a test load of 2.16 kg) is 3.0 to 60 g / 10 min More preferably, the melt tension at 230 ° C. at 30 to 50 g / 10 min (using a melt tension tester manufactured by Toyo Seiki Seisakusho Co., Ltd., preheating temperature 230 ° C., extrusion speed 5.7 mm / min, diameter 2.095 mm, length A strand is extruded from an orifice of 8 mm, and a tension when the strand is wound around a roller having a diameter of 50 mm at a winding speed of 100 rpm is 50 mN or more, preferably 120 mN or more.

  In order to prevent the sheet material from cracking due to impact, it is preferable that the hydrogenated styrene-based thermoplastic elastomer is added in an amount of less than 30 wt%, preferably less than 15 wt%. Specifically, a styrene-ethylene / butylene-styrene block copolymer, a styrene-ethylene / propylene-styrene block copolymer, a hydrogenated styrene-butadiene rubber and a mixture thereof are suitable as the hydrogenated styrene thermoplastic elastomer. The styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to JIS K-7210) is 1.0 to 10 g / 10. Minutes, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more. Further, the sheet materials P1 and P2 may contain an additive. Examples of the additive include inorganic fillers such as silica, mica, talc, calcium carbonate, glass fiber, and carbon fiber, plasticizer, and stabilizer. , Colorants, antistatic agents, flame retardants, foaming agents and the like. Specifically, silica, mica, glass fiber or the like is added in an amount of 50 wt% or less, preferably 30 to 40 wt%, based on the molding resin.

  In the case where the decorative material sheet 140 is provided on the surface of the sheet material that is the material of the front side sheet, the decorative material sheet 140 is an object that improves appearance, decoration, and contact with the molded product (for example, in the case of a cargo floor board, It is configured for the purpose of protecting the luggage placed on the upper surface of the board). The material of the decorative material sheet 140 is a fiber skin material, a sheet-like skin material, a film-like skin material, or the like. As the material of such a fiber skin material, synthetic fibers such as polyester, polypropylene, polyamide, polyurethane, acrylic and vinylon, semi-synthetic fibers such as acetate and rayon, regenerated fibers such as viscose rayon and copper ammonia rayon, cotton, hemp, Examples thereof include natural fibers such as wool and silk, or blended fibers thereof.

  Among these, polypropylene or polyester is preferable and polyester is more preferable from the viewpoints of touch, durability, and moldability. The yarn used for the fiber skin material is, for example, polyester: (3-5) denier × (50-100) mm or other fineness of 3-15 denier, and a staple spun yarn having a fiber length of about 2-5 inches Polyester with bundles of thin flexible filaments: about 150 to 1000 denier / 30 to 200 filaments = about 5 denier × 30 to 200 multifilaments, or polyester: 400 to 800 deniers per filament -It is preferable to use in combination with a filament.

  Examples of the structure of the decorative material sheet 140 include non-woven fabrics, woven fabrics, knitted fabrics, and fabrics obtained by raising them. The woven fabric includes not only a plain structure in which the woven structure is tangled up and down in order, but also various changed woven forms in which some yarns are entangled and jumped. Among these, since there is no directionality with respect to elongation, a non-woven fabric is preferable because it can be easily formed into a three-dimensional shape and has excellent surface feel and texture. Here, the non-woven fabric means a cloth-like product in which fibers are stacked in parallel or alternately or are randomly dispersed to form a web, and then the fibers that become the web are joined. Among these, it is preferable that it is a nonwoven fabric manufactured by the needle punch method from a viewpoint of the three-dimensional shape reproducibility of a molded article, and an external appearance characteristic. In addition, since the nonwoven fabric obtained by the needle punch method has lower strength and higher elongation than the woven fabric and has a large degree of deformation in any direction, it improves the strength of the nonwoven fabric and stabilizes its dimensions. For this reason, it is more preferable to attach a binder to the woven fabric or to punch the web and the nonwoven fabric with overlapping needles. From these things, it is more preferable that the decorative material sheet 140 is a polypropylene nonwoven fabric or a polyester nonwoven fabric. In this case, since the decorative material sheet 140 itself is thermoplastic, it can be used for another purpose by being heated and deformed after separation and collection. For example, if the main resin layer is made of polypropylene and the decorative material sheet 140 is made of a polypropylene nonwoven fabric, the main resin layer and the decorative material sheet 140 of the molded product are the same material, which facilitates recycling.

On the other hand, if the decorative material sheet 140 is a polyester non-woven fabric, the melting point of the main resin layer composed of polypropylene and the fiber skin material are different, so that when the decorative material sheet 140 is bonded to a molded product, it is altered or deformed by heat. Or problems such as failure to adhere to the correct position can be suppressed. In this case, the moldability, rigidity, appearance and durability are also excellent. Further, the tensile strength of the decorative material sheet 140 is preferably 15 kg / cm ² or more from the viewpoint of three-dimensional shape reproducibility and moldability, and the elongation is preferably 30% or more. In addition, the value of this tensile strength and elongation is measured based on JIS-K-7113 at the temperature of 20 degreeC. As the sheet-like skin material and film-like skin material, thermoplastic elastomer, embossed resin layer, resin layer with printed layer attached to the outer surface, synthetic leather, non-slip mesh-shaped skin layer, etc. can be used. .

The resin laminate 100 having the above configuration is manufactured by the following manufacturing method.
First, two sheet materials made of a thermoplastic resin corresponding to the front side sheet 120A and the back side sheet 120B are disposed between a pair of split molds in a molten state. Next, a plurality of protrusions provided on one split mold are used to form a plurality of first recesses 200S and second recesses 200L by recessing one sheet material toward the other sheet material, and a pair of split molds. Clamp the mold. As a result, the bottoms 240S and 240L of the plurality of first recesses 200S and the second recess 200L are welded to the other sheet material, and the two sheet materials are connected by the plurality of first ribs 122S and second ribs 122L. Then, a resin laminate 100 having a hollow structure is obtained.

The effects of the resin laminate 100 described above will be described.
Let us consider a case where the thickness of the resin laminate is made uniform.
When some bending load is applied to the supported resin laminate, the resin laminate deforms with a deflection amount corresponding to this load. In general, in order to suppress the amount of bending without changing the material and shape, measures are taken to increase the thickness of the resin laminate, but if the thickness of the resin laminate is uniform, the mass of the resin laminate increases as the thickness increases. Inevitably increases.

  In this respect, the resin laminated plate 100 includes a thin plate portion 100a and a thick plate portion 100b thicker than the thin plate portion 100a. For example, when the resin laminated board 100 is used as a structure in which both ends of the back sheet 120B are supported and the center of the decorative material sheet 140 receives a bending load, the thick plate formed in a wide area on the center The rigidity is increased by 100b, and the amount of bending can be suppressed. As a result, the rigidity of the resin laminate 100 can be increased reasonably without increasing the mass.

  In addition, since the plurality of first recesses 200S and the plurality of second recesses 200L are disposed at substantially the same pitch P, the rigidity of the resin laminate 100 can be made uniform. At the same time, the processability and moldability of the mold are improved and the appearance is improved.

  In addition, the thickness of each of the front side sheet 120A and the back side sheet 120B can be individually reduced to the maximum as long as necessary strength is ensured, and weight reduction and thickness reduction can be achieved. Therefore, in the resin laminated board 100, further rigidity improvement is realizable, ensuring lightweight and thinning.

  Next, in order to investigate a suitable region for forming the thick plate portion 100b in the resin laminate, an analysis model is set for each of the second to fourth embodiments described below, including the first embodiment, and CAE Analysis by (Computer Aided Engineering) was performed. Details will be described below.

(Analysis example)
○ Analysis software used CATIA V5 GPS / GAS module (linear analysis)
Analysis condition The analysis condition will be described with reference to FIG.
Basic Model As shown in FIG. 6A, the basic model M used for the analysis corresponds to a form in which the front side sheet (FIG. 1, reference numeral 120A) is welded to the rear side sheet (FIG. 1, reference numeral 120B). The rectangular shape has a long side length W of 288 mm and a short side length L of 208 mm. Note that the analysis is performed with a 1/4 model of the basic model M in consideration of the symmetrical shape.

Load condition As shown in FIG. 6 (B), the upper surface of the basic model M corresponds to the outer surface of the surface side sheet (FIG. 5 (A), code diagram 150), and a load F is placed at the center of the upper surface. Add The surface to which the load F is applied is a circular surface having a diameter D. The size of the load F is 196 N, the diameter D is 60 mm, and the thickness t is 7 mm.

Constraint conditions Constraint portions R and R that support the short side end of the basic model M are set, and the width W1 of the constraint portion R is 24 mm.

-Material conditions The material of the model assumed the material which added the talc to the polypropylene, the elastic modulus was 825 MPa, the Poisson's ratio was 0.45, and the density was 1.0 g / cm < ³ >.

○ Analysis models M1-M4
Analysis models M1 to M4 including a thin plate portion and a thick plate portion are set with respect to the basic model M having a uniform thickness t. In the analysis models M1 to M4, the thickness of the thick plate portion is 10 mm. However, by adjusting the thickness of each sheet, each mass of the analysis models M1 to M4 is made the same as the mass of the basic model.

  Each analysis model will be described with reference to FIGS. In each figure, the hatched portion indicates the region of the thick plate portion.

・ Analysis model M1
As shown in FIG. 7, in the analysis model M1, in the basic model M, a region A1 formed with a width W2 along the four sides of the rectangle is a thin plate portion 100a, and a region A2 surrounded by the thin plate portion 100b is a thick plate. Part 100b. The width W2 was set to 29 mm, and the thick plate portion 100b was formed closer to the center than the restraining portion (FIG. 6, symbol R). The thickness of the thin plate portion 100a was 7 mm, and the thickness of the thick plate portion 100b was 10 mm. This analysis model M1 corresponds to the resin laminate 100 of the first embodiment.

・ Analysis model 2
As shown in FIG. 8, the analysis model M2 is a second embodiment according to the present invention. In the basic model M, a region A3 extending in a band shape so as to connect two restraint portions (FIG. 6, reference symbol R) is formed. Provide. Five rows of such belt-like regions A3 are provided in a direction orthogonal to the direction in which the region A3 extends, and these five rows of belt-like regions A3 are the thick plate portions 100b, and the remaining region A4 is the thin plate portion 100a. The width W3 of the region A3 is 20 mm, and the separation distance L1 is 12.5 mm. The five rows of regions A3 are obtained by dividing the region A2 of the analysis model M1 into five. Also in the analysis model M2, the thick plate portion 100b is formed closer to the center than the restraining portion (FIG. 5, symbol R). The thickness of the thin plate portion 100a was 7 mm, and the thickness of the thick plate portion 100b was 10 mm.

・ Analysis model M3
As shown in FIG. 9, the analysis model M3 is a third embodiment according to the present invention. In the basic model M, a region A1 formed with a width W2 along four sides of the rectangle is a thick plate portion 100b. A region A2 surrounded by the thick plate portion 100b is defined as a thin plate portion 100a. The width W2 was set to 29 mm, and the thick plate portion 100b was placed on the restraining portion (FIG. 6, symbol R). The thickness of the thin plate portion 100a was 7 mm, and the thickness of the thick plate portion 100b was 10 mm.

・ Analysis model M4
As shown in FIG. 10, the analysis model M4 is a fourth embodiment according to the present invention. In the basic model M, the analysis model M4 is formed in a belt shape along the restraint portion (FIG. 6, symbol R) (parallel to the short side). An extending region A5 is provided. Five rows of such belt-like regions A5 are provided in a direction orthogonal to the direction in which the region A5 extends, and these five rows of belt-like regions A5 are the thick plate portions 100b, and the remaining region A6 is the thin plate portion 100a. The width W4 of the area A5 is 20 mm, and the separation distance L2 is 15 mm. The five rows of regions A5 are obtained by dividing the region A2 of the analysis model M1 into seven. Also in the analysis model M2, the thick plate portion 100b is formed on the center side with respect to the restraining portion (FIG. 6, symbol R). The thickness of the thin plate portion 100a was 7 mm, and the thickness of the thick plate portion 100b was 10 mm.

-Method Based on the above analysis conditions, the basic model M and the analysis models M1 to M4 are analyzed, and the respective deflection amounts δ are obtained.

Results / Analysis results of the deflection amount δ of the basic model M and the analysis models M1 to M4 are shown in Table 1.

  As shown in Table 1, the deflection amount δ was 19.8 mm in the basic model with a uniform thickness t. On the other hand, in the analysis model M1, the deflection amount δ is 13.5 mm, and it was confirmed that the deformation was sufficiently suppressed. Therefore, it can be said that it is effective to widely form the thick plate portion 100b on the center side as in the resin laminated material of the first embodiment (FIG. 1, reference numeral 100).

  In the analysis model M2, the deflection amount δ is 14.3 mm, and it has been confirmed that deformation is sufficiently suppressed. Therefore, it can be said that it is effective to use a plurality of regions extending in a strip shape so as to connect between supported end portions as in the analysis model M2 (second embodiment).

  In the analysis model M3, the amount of deflection δ was 16.6 mm, and it was confirmed that deformation was sufficiently suppressed. Therefore, it can be said that it is effective to use a thick plate portion that includes both supported end portions and has a predetermined width along the outer periphery as in the analysis model M3 (third embodiment).

  In the analysis model M4, the deflection amount δ was 25.5 mm, which exceeded the deflection amount of the basic model M. The region of the thick plate portion 100b (FIG. 10, reference A5) in the analysis model M4 extends along the restraining portion (FIG. 6, reference R). On the other hand, in the analysis model M2 similar to the analysis model M4, the region of the thick plate portion 100b (FIG. 8, symbol A3) extends in a direction orthogonal to the restraint portion (FIG. 6, symbol R), and deformation is suppressed. Good results were obtained.

  From the results of the analysis model M4 and the analysis model M2, when the region of the thick plate portion is strip-shaped and has a plurality of rows, the strip-shaped region may be formed so as to extend from one restraint portion toward the other restraint portion. It can be said that it is effective.

  Therefore, even if it is the structure of the analysis model M4, when the long side part of a rectangle is restrained, the thick board part 100b acts effectively and it can suppress the amount of bending.

  In addition, although 2nd-4th embodiment demonstrated as an analysis model, it can be set as the same structure as the resin laminated board (FIG. 1, code | symbol 100) of 1st Embodiment except the area | region which provides a thick board part. In that case, the same effects as those of the resin laminate of the first embodiment can be obtained.

Next, as an example of using the resin laminate, an example of using it on a luggage board of an automobile will be described with reference to FIG.
A rear seat 306 including a rear seat cushion 302 and a pair of left and right rear seat backs 304 is installed behind the interior of the automobile. The rear seat back 304 can be reclined back and forth with respect to the rear seat cushion 302, and can be folded forward by being largely folded down. A luggage room 308 is formed behind the rear seat back 304, and a storage box 310 for storing tools and spare tires and a luggage board 300 are placed on the floor panel of the luggage room 308.

  The luggage board 300 follows the standing / tilting operation of the luggage board main body 312A and the left and right rear seat backs 304 that are placed so as to cover the entire upper opening of the storage box 310 so as to form the bottom surface of the luggage room 308. It consists of a pair of left and right auxiliary board portions 312B and 312B.

  The luggage board main body 312A and the left and right auxiliary board portions 312B and 312B are interior materials that cover the opening of the storage box 310 and the space behind the rear seat back 304, and are also support bodies on which various loads are placed. By using a resin laminate (FIG. 1, reference numeral 100) for the luggage board main body 312A and the left and right auxiliary boards 312B and 312B, which require design and rigidity, a high-quality luggage board 300 is used. Can be obtained.

Next, an example in which the luggage board main body 312A is formed of a resin laminate (FIG. 1, reference numeral 100) will be described with reference to FIG.
As shown in FIG. 12, the luggage board main body 312 </ b> A has a three-layer structure including a front side sheet 120 </ b> A, a back side sheet 120 </ b> B, and a decorative material sheet 140. The luggage board body 312A has a rectangular outer shape, and the left and right end portions on the short side are supported by the left and right side walls 310a and 310a of the storage box 310 to close the storage space 310b from above. Further, a load F indicated by a white arrow is applied on the luggage board main body 312A due to luggage or the like.

  The left and right side walls 310a and 310a correspond to a restraint part (FIG. 6, symbol R) of the CAE analysis example, and the load F corresponds to a load (FIG. 6, symbol F) of the CAE analysis example. Therefore, based on the CAE analysis result, in the luggage board main body 312A, the region (the end on the short side) in contact with the side walls 310a and 310a is formed by the thin plate portion 100a, and the central side (storage space) from the side walls 310a and 310a. 310b side) part or the whole is formed by the thick plate portion 100b.

  Then, even if the load F is applied on the luggage board main body 312A, the deflection amount δ is suppressed due to the high rigidity of the thick plate portion 100b. Therefore, the luggage board main body 312A having high rigidity can be obtained without increasing the mass.

  Although the embodiments of the present invention have been described in detail above, various modifications or changes can be made by those skilled in the art without departing from the scope of the present invention. For example, in the embodiment, it has been described as an interior material for automobiles, but is not limited thereto, and is applicable not only to general vehicles such as railway vehicles, airplanes and ships, but also to special vehicles such as amusement park vehicles. In particular, in the case of a special vehicle, a resin interior material is suitable because an aesthetic appearance including color is emphasized for infants. Further, in the embodiment, it has been described as a flat interior material, but is not limited thereto, and can be applied to applications having a three-dimensional shape such as a ceiling material, an instrument panel, for example. It is possible to secure the necessary thickness while achieving the rigidity that can be achieved and the outer shape can be maintained. Furthermore, the thick plate portion having the second concave portion only needs to be relatively thick with respect to the thin plate portion having the first concave portion, and can be set to an arbitrary thickness. The thickness can be different depending on the part of the laminate.

DESCRIPTION OF SYMBOLS 100 Resin laminated board 100a Thin plate part 100b Thick board part 120A Front side sheet 120B Back side sheet 122S 1st rib 122L 2nd rib 200S 1st recessed part 200L 2nd recessed part 240S Bottom 240L Bottom 260S Opening 260L Opening 280 Hollow part 300 Luggage board ( Vehicle interior materials)
312A Luggage board body (vehicle interior material)
312B Auxiliary board (vehicle interior material)
a opening diameter b bottom diameter c bottom diameter d inclination angle of the first recess e inclination angle of the second recess t1 thickness of the thin plate portion t2 thickness of the thick plate portion A1 to A5 region of the thick plate portion F load M1 to M4 analysis model ( Resin laminate material)
P pitch

Claims (6)

Comprising two sheets overlaid at a hollow portion, and the one sheet is recessed into the hollow portion provided with a plurality of recesses, by welding the bottom of the plurality of recesses in the other sheet, the two sheets a between the sheet resin laminate formed by connecting in said plurality of recesses,
The plurality of recesses include a plurality of first recesses and a plurality of second recesses having a relatively large depth relative to the first recess.
Substantially the resin laminate, and the thin portion having a plurality of first recess, and a thick plate portion having a plurality of second recesses, in constructed, the plurality of first recesses and the plurality of second recesses Arranged at the same pitch ,
The plurality of first recesses and the plurality of second recesses increase in diameter from the bottom toward the opening, and the slope angle of the slope of the first recess is relative to the slope angle of the slope of the second recess. The resin laminate is characterized in that the opening diameter of the first recess and the opening diameter of the second recess are the same . The two sheets are provided with two sheets stacked with a hollow part therebetween, and one sheet is recessed in the hollow part to provide a plurality of concave parts, and the bottoms of the plurality of concave parts are welded to the other sheet. A resin laminate formed by connecting the sheets with the plurality of recesses,
The plurality of recesses include a plurality of first recesses and a plurality of second recesses having a relatively large depth relative to the first recess.
  The resin laminated plate includes a thin plate portion having the plurality of first recesses and a thick plate portion having the plurality of second recesses, and the plurality of first recesses and the plurality of second recesses are substantially omitted. Arranged at the same pitch,
  The plurality of first recesses and the plurality of second recesses are enlarged in diameter from the bottom toward the opening, and the bottom diameter dimension of the first recess is relatively larger than the bottom diameter dimension of the second recess. A resin laminate, wherein the opening diameter of the first recess and the opening diameter of the second recess are the same. Wherein the plurality of first recesses and the plurality of second recesses, the resin laminate according to claim 1 or claim 2 wherein, characterized in that it is formed in a frustoconical shape whose diameter increases toward the opening from the bottom .   The difference between the depth of the first recess and the depth of the second recess is the difference between the thickness of the thin plate portion and the thickness of the thick plate portion, and the thickness of the thin plate portion is between the two sheets. Is the thickness of the resin laminate formed by connecting the plurality of first recesses, and the thickness of the thick plate portion is the resin formed by connecting the two sheets with the plurality of second recesses. The resin laminate according to any one of claims 1 to 3, wherein the laminate is a thickness of the laminate.   Two sheets in a molten state are arranged in a split mold, and a plurality of protrusions for forming the plurality of recesses provided in one split mold are provided with the plurality of recesses in one molten sheet, The resin laminate is formed by connecting the two sheets with the plurality of recesses by welding the bottoms of the plurality of recesses to the other sheet in a molten state. The resin laminate according to any one of claims 1 to 4.   6. The thickness according to claim 1, wherein a thickness of the one sheet provided with the plurality of recesses is thinner than a thickness of the other sheet. Resin laminate.

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