JP7384396B2 - hollow structure plate - Google Patents

Description

The present invention relates to a lightweight and highly rigid hollow structural plate.

Conventionally, a resin plate-like body constituting a container, etc. has a core material having a substantially flat base part, a plurality of convex parts protruding from the base part, and a pair of upper and lower surface materials having a flat plate shape. A hollow structural plate is known that is configured by disposing a core material between a pair of surface materials and fixing them to each other (see, for example, Patent Document 1).

Japanese Patent Application Publication No. 2009-107144

By the way, in the core material described in Patent Document 1, a flat portion in which no convex portion is provided extends continuously from a predetermined side portion of the core material to the opposite side portion. If the hollow structural plate is bent along a portion, there is a concern that the hollow structural plate may be easily deformed and damaged.

The present invention has been made to solve the above-mentioned problems and the like, and its purpose is to provide a hollow structural plate that can improve strength and rigidity.

Below, each means suitable for solving the above problems will be explained in terms of sections. Note that effects specific to the corresponding means will be added as necessary.

Means 1. A core material comprising a substantially flat base portion, a plurality of convex portions protruding upwardly or downwardly from the base portion, and a pair of upper and lower surface materials each having a substantially flat shape. , a hollow structural plate in which the core material and the surface material are made of resin, and the core material is arranged between the pair of surface materials and fixed to each other,
The core material includes a connecting rib that connects the adjacent convex portions,
The core material is integrally formed by vacuum forming, and the connecting rib is formed so that a substantially flat base material constituting the core material is folded , and the folded base materials are overlapped. A hollow structural plate comprising welded parts that are welded to each other .

According to means 1, a connecting rib is provided that connects adjacent convex portions, and the connecting rib increases the strength and rigidity of the portion of the core material where the convex portion is not provided, and the convex portion The strength and rigidity of the part itself can also be increased. In particular, since the core material including the convex portions and the connecting ribs is integrally formed by vacuum forming, manufacturing workability is improved. Furthermore, since the connecting rib has a structure in which the base material is made of two layers, sufficient strength and rigidity of the connecting rib itself can be ensured. Therefore, it is possible to improve the strength and rigidity of the hollow structural plate without reducing the productivity of the hollow structural plate including the core material.

Further , by providing a welded portion in which the base materials are overlapped and welded to each other, the effect that the two layers of base materials cooperate with each other to suppress deformation etc. is further enhanced. Furthermore, by welding the folded base materials at the connection rib, deformation such as widening of the folded base materials can be prevented. Therefore, the strength and rigidity of the connecting rib provided with the welded portion and, by extension, the hollow structural plate can be further increased.

In addition, "the said welding part may be provided from the tip part of the said connection rib in the direction of protrusion from the said base part to the connection part with the said base part". In this case, the connecting rib itself becomes thicker, and the effects of the above-mentioned means 2, such as increasing the strength and rigidity of the connecting rib by the welded portion, are more pronounced. Further, the connecting portions of the base portion that are connected to the welded portions of the connecting ribs can be welded to each other, and deformation such as widening of the folded base materials at the connecting ribs can be more reliably prevented. Therefore, by providing the connecting ribs, the effect of increasing the strength of the hollow structural plate is further achieved.

Means 2. At least a part of the leading end of the connecting rib in the direction of protrusion from the base part is at the same height as a side surface of the leading end of the convex part in the direction of projection from the base part. Hollow structure plate as described.
According to means 2 , not only the tip of the protrusion in the protruding direction but also the tip of the connecting rib in the protruding direction is coated with another resin plate layer (which may be a surface material or another core material) constituting the hollow structural plate. good). Furthermore, for example, if the tip of the connecting rib in the protruding direction of the portion that connects with the convex portion is at the same height as the tip of the protruding portion, the portion on the tip side of the protruding direction of the convex portion is further reinforced. be able to. Therefore, by providing the connecting ribs, the effect of increasing the strength of the hollow structural plate is further achieved.

FIG. 3 is a perspective view showing a hollow structural plate. FIG. 3 is a partially enlarged sectional view of a hollow structural plate. FIG. 3 is an exploded perspective view of a hollow structural plate. It is a partially enlarged perspective view showing a core material. It is a partially enlarged perspective view including a partial cross section of a core material and a surface material. It is a partially enlarged perspective view including a partial cross section of a core material and a surface material. It is a partially enlarged perspective view including a partial cross section of a core material and a surface material in another embodiment. FIG. 7 is a partially enlarged perspective view including a partial cross section of a hollow structural plate in another embodiment. FIG. 7 is a partially enlarged perspective view including a partial cross section of a core material in another embodiment. FIG. 7 is a partially enlarged perspective view including a partial cross section of a core material in another embodiment. FIG. 7 is a schematic cross-sectional view showing a connecting rib in another embodiment.

An embodiment will be described below with reference to the drawings. As shown in FIGS. 1 to 3, etc., the hollow structural board 1 of this embodiment is constructed by three resin board layers 2 made of polypropylene fixed to each other. The three-layer resin plate layer 2 includes a substantially flat base portion 4, a core material 3 having a plurality of convex portions 5 protruding (upwards) from the base portion 4, and a surface material having a substantially flat plate shape. 6. Then, the core material 3 is disposed between the upper and lower pair of surface materials 6, and they are thermally welded to each other to be integrated.

As shown in FIG. 4, etc., each convex portion 5 has a substantially truncated conical shape whose diameter gradually decreases toward the tip side (upper side) in the direction of protrusion from the base portion 4. ) A projecting peripheral wall portion 7 having a generally annular cross section and a generally flat top wall portion 8 closing an opening on the tip end side (upper side) of the peripheral wall portion 7 in the protruding direction. In this embodiment, the first row consisting of a plurality of convex portions 5 arranged at predetermined intervals in a direction parallel to a predetermined side portion when the core material 3 is viewed from above, and the second row are The convex portions 5 in the first row and the convex portions 5 in the second row are provided alternately in a direction perpendicular to the predetermined side portion, and the convex portions 5 in the first row are arranged in half in the direction parallel to the predetermined side portion. They are arranged with a pitch shift, and are also arranged with a half pitch shift in a direction perpendicular to the predetermined side portion. The convex portions 5 in the first row and the convex portions 5 in the second row are spaced apart from each other, and the convex portions 5 in the first row and the convex portions 5 in the second row are spaced apart from each other. They are also spaced apart from each other.

Further, the core material 3 includes a connecting rib 9 that connects the adjacent convex portions 5, that is, the convex portions 5 in the first row and the convex portions 5 in the second row. As shown in FIGS. 2, 5, 6, etc., each convex portion 5 is basically (unless formed at the edge of the core material 3) relative to the four adjacent convex portions 5. and are connected by a connecting rib 9 (extending in a direction oblique to the predetermined side portion). Furthermore, the core material 3 is integrally formed by vacuum forming. Therefore, the connecting ribs 9 are formed by folding the substantially flat base material 10 (see FIG. 4) that constitutes the core material 3 (see FIG. 5).

In this embodiment, the entire tip (upper side) of the connecting rib 9 in the direction of protrusion from the base 4 is at the same height as the tip (upper surface) of the protrusion 5 in the direction of protrusion from the base 4 . Furthermore, as shown in FIGS. 5 and 6, the connecting rib 9 includes a spaced part 11 where the folded base materials 10 are spaced apart, and a welded part where the folded base materials 10 are overlapped and welded to each other. 12. In this embodiment, the connection portion of the connecting rib 9 with each convex portion 5 is constituted by a spacing portion 11, and the intermediate position between each convex portion 5 is a welded portion 12. Further, the welded portion 12 is provided from the leading end of the connecting rib 9 in the direction of protrusion from the base portion 4 to the connecting portion with the base portion 4 . Further, portions of the base portion 4 that are connected to the welded portion 12 are welded to each other.

Although not shown in the drawings, the mold for forming the core material 3 includes a convex molding part that molds the inner surface of the convex part 5, and a convex molding part that is provided adjacent to the convex molding part to mold the connecting ribs 9. A rib molding portion for forming the base portion and a base molding portion for molding the base portion are provided. A pair of rib molding parts are provided corresponding to each connecting rib 9, and the pair of rib molding parts are spaced apart from each other by a certain distance, and the width of the end portions facing each other is as follows. They are configured to become gradually narrower toward the sides closer to each other. Then, the core material 3 is formed by vacuum suction (vacuuming) the heated and softened plate-shaped base material 10 (resin sheet) in accordance with the mold. Furthermore, regarding the region between the convex portions 5 of the vacuum-suctioned base material 10, in the rib forming portion, a two-layer structure spaced apart portion 11 is formed that is spaced apart from each other, and a pair of separated portions 11 for forming a predetermined connecting rib 9 are formed. A welded part 12 in which the folded base materials 10 are welded together is formed between the rib-formed parts.

As described in detail above, according to the present embodiment, the core material 3 is provided with the connecting ribs 9 that connect the adjacent convex portions 5, and the connecting ribs 9 allow the convex portions of the core material 3 to The strength and rigidity of the portion where the protrusion 5 is not provided can be increased, and the strength and rigidity of the convex portion 5 itself can also be increased. In particular, since the core material 3 including the convex portions 5 and the connecting ribs 9 is integrally formed by vacuum forming, manufacturing workability is improved. Furthermore, since the connecting rib 9 has a structure in which the base material 10 is made of two layers, sufficient strength and rigidity of the connecting rib 9 itself can be ensured. Therefore, the strength and rigidity of the hollow structural board 1 can be improved without reducing the productivity of the hollow structural board 1 including the core material 3.

Furthermore, the connecting rib 9 includes a welded portion 12 in which the folded base materials 10 are overlapped and welded to each other. Therefore, the effect that the two layers of base material 10 cooperate to suppress deformation and the like is further enhanced. Furthermore, by welding the folded base materials 10 at the connecting ribs 9, deformation such as widening of the folded base materials 10 can be prevented. Therefore, the strength and rigidity of the connecting rib 9 including the welded portion 12 and, by extension, the hollow structural plate 1 can be further increased.

Further, the welded portion 12 is provided from the tip of the connecting rib 9 in the direction of protrusion from the base portion 4 to the connecting portion with the base portion 4 . As a result, the connecting rib 9 itself becomes thicker, and the above-mentioned effects such as increasing the strength and rigidity of the connecting rib 9 by the welded portion 12 are more prominently exhibited. Furthermore, it is possible to weld the connecting portions of the base portion 4 with the welding portions 12 of the connecting ribs 9, and it is possible to more reliably prevent deformation such as widening of the folded base material 10 at the connecting ribs 9. In addition, the base portion 4 of the core material 3 and the (lower) surface material 6 can be more suitably welded. Therefore, by providing the connecting ribs 9, the effect of increasing the strength of the hollow structural plate 1 is further achieved.

In addition, the tip of the connecting rib 9 in the direction of protrusion from the base portion 4 (in this example, the entire area of the connecting rib 9) is at the same height as the side surface of the tip of the convex portion 5 in the direction of protrusion from the base portion 4. ing. Therefore, the portion on the tip side in the protruding direction of the convex portion 5 that is connected to the connecting rib 9 can be further reinforced. Furthermore, not only the tip of the protrusion 5 in the protruding direction but also the tip of the connecting rib 9 in the protruding direction is connected ( welding). Therefore, by providing the connecting ribs 9, the effect of increasing the strength of the hollow structural plate 1 is further achieved.

Note that the present invention is not limited to the content described in the above embodiment, and may be implemented as follows, for example. Of course, other applications and modifications not exemplified below are also possible.

(a) In the above embodiment, the hollow structural board 1 is composed of two surface materials 6 and one core material 3, but as shown in FIGS. It is also possible to configure it by a material 6 and two core materials 3. That is, a pair of core members 3 are prepared, and the surfaces of the convex portions 5 on the tip side in the direction of protrusion from the base portion 4 (and the tips of the connecting ribs 9 in the direction of protrusion from the base portion 4) are brought into contact with each other. The hollow structure plate may be constructed by heat welding the two surface materials 6, and then arranging and heat welding the pair of surface materials 6 with the pair of core materials 3 sandwiched therebetween.

Further, in the above embodiment, the core material 3 and the surface material 6 are thermally welded, but for example, the core material 3 and the surface material 6 may be fixed using a thermoplastic resin as an adhesive layer. It may be configured as follows. Furthermore, a fiber sheet, a metal sheet, a rubber sheet, etc. may be interposed between the surface material 6 and the core material 3 for the purpose of reinforcement, and the surface of the surface material 6 may be Fiber sheets, printed resin films, rubber sheets, and metal sheets for the purpose of processing (improving design, anti-slip, etc.) or improving durability (shock absorption, etc.) etc. may be attached.

(b) In the above embodiment, the welded portion 12 is provided in the connecting rib 9 from the tip of the connecting rib 9 in the direction of protrusion from the base portion 4 to the connecting portion with the base portion 4. For example, as shown in FIG. As shown in FIG. 10, the formation range of the welded part 12 is from the tip of the connecting rib 9 in the direction of protrusion from the base part 4 to the intermediate position in the height direction of the connecting rib 9 (the area where the base part The fourth side may be a separating part 11).

Further, in the above embodiment, the entire tip (upper side) of the connecting rib 9 in the direction of protrusion from the base 4 is at the same height as the tip (upper surface) of the protrusion 5 in the direction of protrusion from the base 4. However, a portion thereof may be at the same height as the tip of the protruding portion 5 in the protruding direction. For example, the tip of the separating part 11 in the protruding direction is at the same height as the tip of the protruding part 5, and the tip of the welding part 12 in the protruding direction is closer to the base than the tip of the separating part 11 in the protruding direction. It may also be configured to be located on the 4th side (with a shorter protrusion length).

Furthermore, for example, the entire connecting rib 9 may be configured to be located closer to the base portion 4 than the tip end of the convex portion 5 in the protruding direction (the protruding length is shorter). In addition, in the above embodiment, the core material 3 is vacuum-formed using a mold equipped with a convex molding section for molding the inner surface of the convex portion 5, but the outer surface of the convex portion 5 is The core material may be vacuum-formed using a mold having a convex molding section and the like.

Further, in the above embodiment, the connecting rib 9 is provided with the separating portion 11 and the welded portion 12, and the connecting rib 9 is provided with portions having different longitudinal cross-sectional shapes in the extending direction. They may be configured to be the same. For example, the entire connecting rib 9 may be composed of the welded part 12, or the entire connecting rib 9 may be composed of the separating part 11 (the entire connecting rib 9 is shown in FIGS. 11(a) to 11(f)). ). However, in order to define the formation position of the connecting rib 9, it is desirable that the connecting portion of the connecting rib 9 with the convex portion 5 be the spaced portion 11 (so that a mold is provided with a rib forming portion). On the other hand, since the welded portion 12 is provided on the connecting rib 9 (especially the closer the welded portion 12 is provided to the convex portion 5), if a crushing force is applied to the convex portion 5, Deformation of the convex portion 5 can be more reliably prevented. For example, the portion of the connecting rib 9 including both ends connected to the convex portion 5 is configured as shown in FIGS. 11(a), (c), (e), and (f). The portion including the central portion may be configured as shown in FIGS. 11(a), (b), (c), and (d).

Further, in the above embodiment, all the connecting ribs 9 have the same shape, but connecting ribs of different shapes may be used together. The thickness of the welded portion 12 may vary depending on various factors such as the height of the connecting rib 9 and the width of the separating portion 11, but basically, the thickness of the welded portion 12 may vary depending on various factors such as the height of the connecting rib 9 and the width of the separating portion 11. It's thicker than thick.

(c) In the above embodiment, the number, arrangement, shape, etc. of the convex portions 5 of the core material 3 are not particularly limited and can be changed as appropriate. For example, the convex portions 5 may be provided in a matrix. Further, the peripheral wall portion 7 of the convex portion 5 does not have to be an annular shape with a horizontal cross-sectional shape of a perfect circle, but may be a polygonal annular shape such as a triangular, square, or hexagonal shape, or an elliptical annular shape. You can. Further, the top wall portion 8 of the convex portion 5 does not have to be flat, and may have a shape that swells slightly outward of the convex portion 5 before the core material 3 is fixed to another resin plate layer 2. Alternatively, the convex portion 5 may be slightly recessed inward. In addition, in the above embodiment, all the convex portions 5 are connected via the connecting ribs 9, but for example, there may be convex portions 5 that are not connected, and there may be convex portions 5 that are not connected to each other. A configuration may be adopted in which the convex portion 5 is connected to the convex portion 5, but not connected to the convex portion 5 adjacent to the left.

(d) In the above embodiment, the hollow structural board 1 (the core material 3 and the surface material 6) is made of polypropylene, but it may be made of other resin materials such as polyethylene, PET, polyamide, polyolefin, etc. Good too. Although not specifically mentioned in the above embodiment, the hollow structural board 1 can be used as a constituent material for containers, pallets, carts, shelves, etc., for partitions, or as panels/rugs for protecting objects. Applicable. Furthermore, in the above embodiment, the upper surface material 6 and the lower surface material 6 are arranged on the outer periphery of the hollow structural board 1 so that the core material 3 (convex portions 5, etc.) is not visible from the outer periphery of the hollow structural board 1. Alternatively, a closing plate may be attached to the outer periphery of the hollow structural plate 1 to close the gap between the upper surface material 6 and the lower surface material 6 (by heat welding). etc.). In this case, while improving the design, it is possible to reinforce the outer periphery of the hollow structural plate 1 and prevent the ingress of dust and the like.

DESCRIPTION OF SYMBOLS 1... Hollow structural board, 2... Resin plate layer, 3... Core material, 4... Base part, 5... Convex part, 6... Surface material, 7... Peripheral wall part, 8... Top wall part, 9... Connecting rib, 10... Base material, 11...Separated part, 12... Welded part.

Claims (2)

A core material comprising a substantially flat base portion, a plurality of convex portions protruding upwardly or downwardly from the base portion, and a pair of upper and lower surface materials each having a substantially flat shape. , a hollow structural plate in which the core material and the surface material are made of resin, and the core material is arranged between the pair of surface materials and fixed to each other,
The core material includes a connecting rib that connects the adjacent convex portions,
The core material is integrally formed by vacuum forming, and the connecting rib is formed so that a substantially flat base material constituting the core material is folded , and the folded base materials are overlapped. A hollow structural plate comprising welded parts that are welded to each other . At least a part of the leading end of the connecting rib in the direction of protrusion from the base part is at the same height as a side surface of the leading end of the convex part in the direction of projection from the base part. The hollow structural plate described in .

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