JP6985591B2 - Resin panel and manufacturing method - Google Patents

Description

The present invention relates to a resin panel and a manufacturing method.

In Patent Document 1, by joining the peripheral portions of the two resin skin material sheets to each other, an outer peripheral space is formed around the foam sandwiched between the resin skin material sheets, and the outer peripheral space is formed on the surface of the foam. A resin sandwich panel is disclosed in which a grid-shaped groove portion is provided and the groove portion and the outer peripheral space portion are communicated with each other. As a result, even if an air pool is unexpectedly formed when the foam and the resin skin material sheet are surface-bonded, the air can be dispersed in the outer peripheral space.

Japanese Unexamined Patent Publication No. 2015-1048887

When the technique disclosed in Patent Document 1 is applied to a resin sheet, when the thickness of the resin sheet is thick (example: 1.3 mm or more), the amount of heat of the resin sheet is sufficiently large at the time of welding, and the interview with the foam is performed. By welding, the area around the groove of the foam melts, and the groove of the foam almost disappears. As a result, the welded surfaces of the resin sheet and the foam become substantially flat with each other, are sufficiently welded, and the aesthetic appearance is improved.

However, when the thickness of the resin sheet is thin, the amount of heat of the resin sheet at the time of welding is not sufficient and the rigidity is low, so that the resin sheet follows the shape of the groove at the time of welding, and sufficient welding cannot be guaranteed. , The aesthetics may be spoiled.

The present invention has been made in view of such circumstances, and even when a thin resin sheet is used, it is possible to reduce the formation of an air reservoir between the resin sheet and the foam during welding. , A resin panel capable of reducing deformation of a resin sheet and a manufacturing method.

According to the present invention, the hanging step, the inserting step, and the mold clamping step are provided. In the hanging step, the first and second resin sheets are hung between the first and second molds, and in the insert step, the first and second resin sheets are hung. , The foam is welded to the first and second resin sheets, the first and second molds are molded in the mold clamping step, and the foam is arranged between the first and second resin sheets. The foam has a convex portion or a concave portion on the second facing surface on the side facing the second resin sheet, and the convex portion or the concave portion is independent in a reference region of 2 cm × 2 cm on the second facing surface. Two or more are provided.

In the method for manufacturing a resin panel according to the present invention, the foam has a convex portion or a concave portion on the second facing surface on the side facing the second resin sheet, and is contained in a 2 cm × 2 cm reference region of the second facing surface. , Two or more convex portions or concave portions are provided independently. As a result, the second resin sheet and the foam can partially contact the periphery of the convex portion or the concave portion, and the air pool can be dispersed to the outer edge. Further, even when the thickness of the second resin sheet is thin, the volume around the convex portion or the concave portion is smaller than that of the groove portion, so that the second resin sheet can be sufficiently melted and the aesthetic appearance is improved.

Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with each other.
Preferably, the reference region is 3 cm × 3 cm, and five or more of the convex portions or the concave portions are provided in the reference region in an independent state.
Preferably, three or more of the convex portions or the concave portions are provided independently in the adjacent reference region.
Preferably, the value of the total area of the convex portion or the concave portion in the reference region / the area of the reference region is 0.05 to 1.
Preferably, the height of the convex portion or the depth of the concave portion is 1/3 or less of the thickness of the foam.
Preferably, the distance between the convex portions or the concave portions is 3 mm or less.
Preferably, the convex portion is formed in a tapered shape toward the tip of the convex portion.
Preferably, each of the convex portions has a mountain shape.
Preferably, each of the recesses is discontinuous.
Preferably, the foam has a connecting surface that connects the first facing surface and the second facing surface, and a notched air pool space is formed on the connecting surface.
According to another aspect, a hollow resin molded body and a foam are provided, the foam is arranged in the resin molded body, and the foam is provided with a facing surface facing one surface of the resin molded body. The facing surface is provided with a convex portion or a concave portion, and two or more of the convex portion or the concave portion are provided independently in a reference region of 2 cm × 2 cm of the facing surface, and the convex portion or the concave portion is provided. A resin panel is provided in which a part is melted by a resin sheet forming the resin molded body.

It is a partially cutaway perspective view of the resin panel 30 which concerns on one Embodiment of this invention. It is a figure which shows an example of the molding machine 1 which can be used in the manufacturing method of a resin panel 30. It is an enlarged view of the vicinity of the 1st and 2nd molds 21 and 22 and the 1st resin sheet 23a. It is a top perspective view of the foam 31 used for manufacturing the resin panel 30 which concerns on one Embodiment of this invention. It is a partially enlarged view around the region X of FIG. It is a bottom perspective view of the foam 31 which concerns on one Embodiment of this invention. It is a side view of the foam 31 seen from the arrow Y direction of FIG. It is a partially enlarged view of the region Z of FIG. It is a figure which shows the state which the 1st resin sheet 23a was sucked under reduced pressure from the state of FIG. It is a figure which shows the state which fixed the foam 31 to the 1st resin sheet 23a. It is a figure which shows the state which the 2nd resin sheet 23b hangs down. It is a figure which shows the state which the 2nd resin sheet 23b was sucked under reduced pressure from the state of FIG. It is sectional drawing which shows the state which the 1st and 2nd molds 21 and 22 are molded. It is a top view which shows the modification 1 of the foam 31. It is a top view which shows the modification 2 of the foam 31.

Hereinafter, embodiments of the present invention will be described. The various features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each characteristic item.

1. 1. Resin panel 30
As shown in FIG. 1, the resin panel 30 according to the embodiment of the present invention includes a hollow resin molded body 36 and a foam 31. A parting line PL is formed on the resin molded body 36. Further, the foam 31 is arranged in the resin molded body 36.

2. 2. Configuration of Molding Machine 1 Next, using FIGS. 2 and 3, a molding machine 1 that can be used to carry out the method for manufacturing the resin panel 30 according to the embodiment of the present invention will be described.

The molding machine 1 includes a resin supply device 2, a T-die 18, and first and second molds 21 and 22. The resin supply device 2 includes a hopper 12, an extruder 13, and an accumulator 17. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27. Hereinafter, each configuration will be described in detail.

<Hopper 12, extruder 13>
The hopper 12 is used to charge the raw material resin 11 into the cylinder 13a of the extruder 13. The form of the raw material resin 11 is not particularly limited, but is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as a polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, an ethylene-propylene copolymer and a mixture thereof. Further, additives such as glass fiber, talc, and pigment may be added to these. The raw material resin 11 is charged into the cylinder 13a from the hopper 12 and then heated in the cylinder 13a to be melted into a molten resin. Further, it is conveyed toward the tip of the cylinder 13a by the rotation of the screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and the molten resin is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device. The number of screws arranged in the cylinder 13a may be one or two or more.

<Accumulator 17, T-die 18>
The molten resin 11a is extruded from the resin extrusion port of the cylinder 13a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b slidable inside the cylinder 17a, and the molten resin 11a can be stored in the cylinder 17a. Then, by moving the piston 17b after a predetermined amount of the foamed resin is stored in the cylinder 17a, the foamed resin is pushed out from the slit provided in the T-die 18 through the connecting pipe 27 and hung down to be the first and second. The resin sheets 23a and 23b are formed.

<1st and 2nd molds 21 and 22>
The first and second resin sheets 23a and 23b are guided between the first and second molds 21 and 22. As shown in FIG. 3, the first mold 21 is provided with a large number of decompression suction holes (not shown), and the first resin sheet 23a is decompressed and sucked along the cavity 21b of the first mold 21. It is possible to shape it into a different shape. The cavity 21b has a shape having a recess 21c, and a pinch-off portion 21d is provided so as to surround the recess 21c. The second mold 22 is provided with a large number of decompression suction holes (not shown), and the second resin sheet 23b is decompressed and sucked to form a shape along the cavity 22b of the second mold 22. Is possible. The cavity 22b has a shape having a recess 22c, and a pinch-off portion 22d is provided so as to surround the recess 22c. Here, the decompression suction hole is a very small hole, one end of which is communicated through the inside of the first and second molds 21 and 22 to the inner surface of the cavities 21b and 22b, and the other end is connected to the decompression device. Has been done.

3. 3. Method for Manufacturing Resin Panel 30 Next, a method for manufacturing the resin panel 30 according to the embodiment of the present invention will be described with reference to FIGS. 3 to 13. The method of the present embodiment includes a hanging step, a shaping step, an insert step, and a mold clamping step. Hereinafter, it will be described in detail. In the present embodiment, the timing of processing the first resin sheet 23a and the second resin sheet 23b is staggered.

3.1 Foam 31
First, the foam 31 used for manufacturing the resin panel 30 will be described. As shown in FIGS. 1 to 8, the foam 31 is a bead foam that is arranged in the resin molded body 36 and has a foaming ratio of 25 to 60 times, and has a thickness of 15 to 25 mm after molding. Can be used. The foaming ratio is preferably 30 to 55 times, more preferably 40 to 50 times. The foam 31 is selected from a resin that can be welded to the first resin sheet 23a and the second resin sheet 23b. The foam 31 includes an facing surface facing one surface of the resin molded body 36. In the present embodiment, as shown in FIGS. 4 to 8, the foam 31 has a first facing surface 31f on the side facing the first resin sheet 23a (described later with reference to FIG. 3) and a second resin sheet 23b. A second facing surface 31s facing (described later with reference to FIG. 3) and a connecting surface 32 connecting the first facing surface 31f and the second facing surface 31s are provided. Further, the facing surface is provided with a convex portion 34. Here, as shown in FIGS. 4, 5 and 8, in the present embodiment, the foam 31 is provided with a convex portion 34 on the second facing surface 31s. Here, as shown in FIG. 8, in the present embodiment, the convex portion 34 is formed in a tapered shape toward the tip of the convex portion 34. In other words, each of the convex portions 34 has a mountain shape.

As a method of providing the convex portion 34 on the surface of the foam 31, there is a method of forming the convex portion 34 on the surface of the flat foam by post-processing. Further, as another method, there is a method of forming the convex portion 34 by providing a shape corresponding to the convex portion 34 in the mold at the time of foam molding and transferring the mold shape. Here, in the former case, the work man-hours increase, and in the latter case, the transfer shape is limited. Therefore, when the latter method is adopted, among the tapered shapes, a simple shape such as a mountain shape, particularly an arc-shaped convex portion or a frustum-shaped convex portion is preferable. The shape of the convex portion 34 is not limited to these, and a convex portion formed on the surface of the foam 31 by transferring the mesh shape provided in the mold or a plurality of convex portions may coexist. ..

As shown in FIG. 5, two or more convex portions 34 are provided independently in the reference region S surrounded by the broken line of the second facing surface 31s. Here, the reference region S is a partial region of the foam 31 in a plan view. Further, the state in which the convex portions 34 are independent in the reference region S means that the plurality of convex portions 34 are discontinuous at least in the reference region S. Further, as shown in FIG. 8, in the present embodiment, the convex portion 34 is a portion protruding from the second facing surface 31s. Here, the definition of the convex portion 34 is not limited to this, and for example, as shown in FIG. 8, when the height d from the second facing surface 31s is set, the portion protruding by 1 / 2d or more is the convex portion 34. May be.

As shown in FIG. 5, in the present embodiment, 100 convex portions 34 are provided in the reference region S. The number of convex portions 34 in the reference region S is, for example, 1 to 500. Preferably, the number of convex portions 34 in the reference region S is 2 to 400, more preferably 5 to 300, still more preferably 9 to 200. Specifically, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, The number is 250, 300, 350, 400, 450, 500, and may be within the range between any two of the numerical values exemplified here.

Further, in the present embodiment, the size of the reference region S is a square of 2 cm × 2 cm, and 100 convex portions 34 are provided. Further, the distance between the convex portions 34 is 3 mm or less. The size of the reference region S is, for example, 4 to 2,500 cm ² . Specifically, it is 2 cm × 2 cm, 3 cm × 3 cm, 5 cm × 5 cm, 10 cm × 10 cm, 20 cm × 20 cm, 25 cm × 25 cm, 50 cm × 50 cm. The reference region S may be other than a square, and may be, for example, a rectangle, a circle, an ellipse, a triangle, a polygon, a star, or the like.

Here, when the reference region S is 3 cm × 3 cm, it is preferable that five or more convex portions 34 are provided in the reference region S in an independent state (225 in the present embodiment). Further, when observing the adjacent reference regions S, it is preferable that three or more convex portions 34 are provided independently in the adjacent reference regions S.

As shown in FIGS. 5 and 8, the value of the total area of the convex portion 34 in the reference region S / the area of the reference region S is, for example, 0.05 to 1. Preferably, such value is preferably 0.1 to 0.8, more preferably 0.2 to 0.7, still more preferably 0.3 to 0.6. Specifically, for example, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, and here. It may be in the range between any two of the exemplified values. When the value of the total area of the convex portion 34 / the area of the reference region S in the reference region S is 1, for example, an embodiment in which the convex portions 34 having a quadrangular pyramid shape are spread without gaps can be mentioned.

Here, the area of the convex portion 34 is the area when the convex portion 34 is vertically projected onto the second facing surface 31s. As described above, when the portion protruding from the second facing surface 31s by 1 / 2d or more is the convex portion 34, the portion protruding from the second facing surface 31s by 1 / 2d or more is the second facing surface 31s. This is the area when projected vertically to.

As shown in FIG. 8, in the present embodiment, the height d of the convex portion 34 is 1/3 or less of the thickness of the foam 31. Preferably, such a value is 1/10 or less, more preferably 1/20 or less. Specifically, for example, it is 1/50, 1/40, 1/30, 1/20, 1/10, 1/5, 1/3 or less, and is a range between any two of the numerical values exemplified here. It may be inside.

The height d of the convex portion 34 is preferably 0.05 to 10 mm. If it is 0.05 mm or less, there is a high possibility of welding before the air is completely discharged from the gap between the convex portions 34, and if it is 10 mm or more, it is difficult to provide the set number of convex portions 34 in S in the reference region. Because.

The value of the surface area including the convex portion 34 in the reference region S / the area of the reference region S is, for example, 1.01 to 2.0. Preferably, such value is 1.03 to 1.5, more preferably 1.05 to 1.3. Specifically, for example, 1.01, 1.03, 1.05, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, It is 1.9 and 2.0, and may be within the range between any two of the numerical values exemplified here.

Further, as shown in FIG. 6, a groove 35 is provided in the first facing surface 31f of the foam 31. Further, a notched air pool space is formed on the connecting surface 32. Specifically, of the connecting surface 32, the first air collecting space 33f is provided on the side of the first facing surface 31f, and the second air collecting space 33s is provided on the side of the second facing surface 31s. Then, each of the grooves 35 communicates with the first air pool space 33f. The significance of the first air pool space 33f and the second air pool space 33s will be described later with reference to FIGS. 10 and 13.

As described above, the resin panel 30 according to the present embodiment has a structure in which the foam 31 is arranged in the resin molded body 36. Here, as shown in FIG. 1, a fine convex portion 34 is formed on the foam 31 before the resin panel 30 is manufactured, but when the resin panel 30 is completed, the second resin sheet 23b is convex. The portion 34 is melted, and the second facing surface 31s has a flat shape (described later with reference to FIG. 13). In other words, a part of the convex portion 34 is melted by the second resin sheet 23b forming the resin molded body 36.

Next, each step will be described. In the following, as the first and second resin sheets 23a and 23b, polypropylene mixed with talc is used, and as the foam 31, polypropylene having a foaming magnification of 45 times is used.

3.2 First resin sheet 23a
3.2.1 Hanging step In the hanging step, as shown in FIG. 3, the foam 31 is arranged between the first and second molds 21 and 22 using a jig (not shown). At this time, the first facing surface 31f is arranged so as to face the first mold 21 and the second facing surface 31s faces the second mold 22.

Then, the first resin sheet 23a formed by extruding the molten foam resin from the slit of the T die 18 and hanging it between the first and second molds 21 and 22 is hung. In the present embodiment, the temperature of the first resin sheet 23a at this time is about 200 ° C. The thickness of the first resin sheet 23a is preferably 0.5 to 1 mm, but may be 1 to 1.5 mm. In the present embodiment, direct vacuum forming is performed using the first and second resin sheets 23a and 23b extruded from the T die 18 as they are, so that the first and second resin sheets 23a and 23b are at room temperature before molding. The solidified first and second resin sheets 23a and 23b are not heated before molding. Here, in FIG. 3, the foam 31 is shown between the first and second resin sheets 23a and 23b during the hanging step, but in the hanging step, the foam 31 is made to stand by at another place. You may leave it.

3.2.2 Forming step Next, as shown in FIG. 9, the first resin sheet 23a is sucked under reduced pressure by the first mold 21 and shaped into a shape along the cavity 21b of the first mold 21. .. Further, by this point, a jig (not shown) is set in the foam 31. The jig supports the foam 31 by sucking the second facing surface 31s side of the foam 31 with a suction cup or the like provided on the jig. Then, after the first resin sheet 23a is shaped in the shaping step, the first resin sheet 23a is cooled to 70 to 90 ° C., and then the insert step described later is started. In other words, a resin cooling step is provided before the insert step described later. Here, in the present embodiment, the temperature of the first resin sheet 23a at about 200 ° C. is waited to cool down to 70 to 90 ° C. The temperature is preferably 72 to 88 ° C, more preferably 74 to 86 ° C, still more preferably 76 to 84 ° C. Specifically, for example, it is 70, 72, 74, 76, 78, 80, 82, 84, 86, 88, 90 ° C., and may be within the range between any two of the numerical values exemplified here. .. As the temperature, it is preferable to adopt an average value. For example, the average value of the temperatures of the nine points of the first resin sheet 23a can be adopted. Here, the temperature of the first resin sheet 23a can be measured by a non-contact temperature sensor or the like.

Here, the temperature of the first resin sheet 23a differs depending on the type of resin and the presence or absence of additives (glass fiber, talc, pigment, etc.). Therefore, the cooling temperature differs depending on the resin used.

3.2.3 Inserting process Next, after the hanging process, the first resin sheet is cooled to 70 to 90 ° C., and then the inserting process is started. In other words, after the first resin sheet is shaped in the shaping step, the first resin sheet is cooled to 70 to 90 ° C., and then the insert step is started. In the insert step, as shown in FIG. 10, the foam 31 is moved by a jig (not shown) and fixed to the first resin sheet 23a. Here, in the present embodiment, since the foam 31 is a foam, the foam 31 is fixed to the first resin sheet 23a by melting the foam by the heat of the first resin sheet 23a. In the present embodiment, the rigidity of the first resin sheet 23a is improved by waiting for the temperature of the first resin sheet 23a to cool down to 70 to 90 ° C., so that the first resin sheet 23a is formed in the groove 35 of the foam 31. It is possible to reduce the alignment.

Further, since the groove 35 provided in the first facing surface 31f of the foam 31 communicates with the first air pool space 33f, it is unintentionally formed between the first resin sheet 23a and the first facing surface 31f. The air pool can be dispersed in the first air pool space 33f through the groove 35. As a result, even the first resin sheet 23a whose temperature has cooled can be sufficiently welded to the first facing surface 31f.

3.3 Second resin sheet 23b
3.3.1 Hanging step In the hanging step, as shown in FIG. 11, a molten foam resin was extruded from the slit of the T-die 18 and drooped between the first and second molds 21 and 22. The second resin sheet 23b is hung down. In the present embodiment, the temperature of the second resin sheet 23b at this time is about 200 ° C. The thickness of the second resin sheet 23b is preferably 0.5 to 1 mm.

3.3.2 Shaped step Next, as shown in FIG. 12, the second resin sheet 23b is sucked under reduced pressure by the second mold 22 and shaped into a shape along the cavity 22b of the second mold 22. ..

3.4 Mold clamping process In the mold clamping process, as shown in FIG. 13, the first and second molds 21 and 22 are mold-clamped. Unlike the first resin sheet 23a, the second resin sheet 23b does not wait for cooling to 70 to 90 ° C., and the second resin sheet 23b and the second facing surface 31s are partially in contact with each other at the convex portion 34. Therefore, the convex portion 34 provided on the second facing surface 31s of the foam 31 melts depending on the temperature of the second resin sheet 23b even when the thickness of the second resin sheet 23b is relatively thin. As a result, the second facing surface 31s has a substantially flat shape.
Here, at the time of mold clamping, the temperature of the first resin sheet 23a is lower than the temperature of the second resin sheet 23b.

In the present embodiment, the second resin sheet 23b and the second facing surface 31s are not in surface contact with each other, but the second resin sheet 23b and the convex portion 34 are in partial contact with each other. It is less likely that an air pool is formed between the second resin sheet 23b and the second facing surface 31s, as compared with the case of providing the above. Further, if an air pool is still formed, the air pool can be dispersed in the second air pool space 33s through a portion of the first facing surface 31f other than the convex portion 34. Further, the temperature of the first resin sheet 23a is cooled to 70 to 90 ° C., but the temperature of the second resin sheet 23b is before cooling. Therefore, the pinch-off portions 21d and 22d allow the first resin sheet 23a and the second resin sheet to cool down. 23b is sufficiently welded to form a parting line PL.

As a result, molded bodies having a shape along the cavities 21b and 22b of the first and second molds 21 and 22 can be obtained.

Then, the molded body is taken out from the first and second molds 21 and 22, and the burr 26 on the outer side of the pinch-off portions 21d and 22d is removed to obtain the resin panel 30 shown in FIG.

<Modification 1>
Next, a modification 1 of the foam 31 according to the present embodiment will be described with reference to FIG. As shown in FIG. 14, grooves 35 having a narrow interval may be provided in a grid pattern on the second facing surface 31s of the foam 31. In the first modification, the portion of the second facing surface 31s other than the groove 35 functions in the same manner as the above-mentioned convex portion 34.

<Modification 2>
Next, a modification 2 of the foam 31 according to the present embodiment will be described with reference to FIG. As shown in FIG. 15, in the second modification, the recess 37 is provided in the second facing surface 31s on the side facing the second resin sheet 23b, and the recess 37 is provided in the reference region S (see FIG. 5) of the second facing surface 31s. Two or more recesses 37 are provided independently. In this modification, the recesses 37 are each discontinuously provided. Here, the concave portion 37 is formed by a convex portion 34 continuously provided on the second facing surface 31s. Further, the depth of the recess 37 is preferably 1/3 or less of the thickness of the foam 31.

<Others>
Grooves 35 may be provided on the first facing surface 31f and the second facing surface 31s.
The convex portion 34 may be provided on the first facing surface 31f and the second facing surface 31s.
-The convex portion may be thinned out.

1: Molding machine 2: Resin supply device 11: Raw material resin 11a: Molten resin 12: Hopper 13: Extruder 13a: Cylinder 17: Accumulator 17a: Cylinder 17b: Piston 18: T-die 21: First mold 21b: Cavity 21c : Recessed portion 21d: Pinch-off portion 22: Second mold 22b: Cavity 22c: Convex portion 22d: Pinch-off portion 23a: First resin sheet 23b: Second resin sheet 25: Connecting pipe 26: Burr 27: Connecting pipe 30: Made of resin Panel 31: Foam 31f: First facing surface 31s: Second facing surface 32: Connecting surface 33f: First air pool space 33s: Second air pool space 34: Convex portion 35: Groove 36: Resin molded body 37: Recessed portion PL: Parting line

Claims (9)

Equipped with a hanging process, an insert process, and a mold clamping process,
In the hanging step, the first and second resin sheets are hung between the first and second molds.
In the insert step, the foam is welded to the first and second resin sheets.
In the mold clamping step, the first and second molds are molded and molded.
The foam is arranged between the first and second resin sheets,
The foam has a convex portion on the second facing surface on the side facing the second resin sheet, and 10 or more of the convex portions are provided in a reference region of 2 cm × 2 cm on the second facing surface in an independent state. Be,
The convex portion is formed in a tapered shape toward the tip of the convex portion.
A method for manufacturing a resin panel in which the convex portion is melted by the second resin sheet and the second facing surface has a substantially flat shape in the mold clamping step. The reference area is 3 cm × 3 cm.
The method according to claim 1, wherein five or more of the convex portions are provided independently in the reference region. The method according to claim 1, wherein three or more of the convex portions are provided independently in the adjacent reference region. The method according to any one of claims 1 to 3, wherein the value of the total area of the convex portion / the area of the reference region in the reference region is 0.05 to 1. The method according to any one of claims 1 to 4, wherein the height of the convex portion is 1/3 or less of the thickness of the foam. The method according to any one of claims 1 to 5, wherein the distance between the convex portions is 3 mm or less. The method according to any one of claims 1 to 6, wherein each of the convex portions has a mountain shape. The foam has a connecting surface that connects the first facing surface and the second facing surface.
The method according to any one of claims 1 to 7, wherein a notched air pool space is formed on the connecting surface. Equipped with a hollow resin molded body and a foam
The foam is placed in the resin molding body and
The foam has a facing surface facing one surface of the resin molded body.
The facing surface is provided with a convex portion and has a convex portion.
Two or more of the convex portions are provided independently in the reference region of 2 cm × 2 cm on the facing surface.
A part of the convex portion is melted by the resin sheet forming the resin molded body.
Resin panel.

Images