JP7629291B2 - Resin-coated long body - Google Patents

Description

The present invention relates to a resin-coated elongated body having a metal core member on the outer surface thereof and a resin coating layer made of synthetic resin.

As a resin-coated elongated body in which a resin layer is coated on the outer surface of a metal core material, the applicant has proposed a resin-coated elongated body in which a synthetic resin is used to form a resin layer on the outer surface of a metal core material, a part of the cross section is left uncoated without the resin layer, a dovetail-shaped retaining groove is provided near the boundary between the edge of the resin layer of the core material and the uncoated part, and a part of the resin layer is inserted into the retaining groove, the resin layer is provided to cover the opening of the retaining groove, and the opening of the retaining groove and the edge of the resin layer are provided in different positions, and the core material has a rectangular cross section, a resin layer is provided on the outside of three sides of the rectangle, and the remaining side is left uncoated (Patent Document 1).

The applicant has also proposed a resin-coated elongated body that includes a metal core material with an inwardly recessed surface formed on its outer surface along the longitudinal direction, and a resin coating layer that coats the outer surface of the core material, including the recessed surface, in which a dovetail-shaped anti-slip groove is formed on the recessed surface of the core material toward the inside of the core material, and a part of the resin coating layer is inserted into the anti-slip groove (Patent Document 2).

JP 2008-213198 A JP 2013-227777 A

When the outer surface of the core material is resin coated, the cross section of the core material may or may not be rectangular. In Patent Document 1, the core material has a rectangular cross section, so if part of the resin coating layer fits into the anti-slip groove, the risk of the resin coating layer coming off can be effectively reduced even if there is an uncoated portion on the cross section that is not covered with resin. In contrast, in Patent Document 2, the core material does not have a rectangular cross section, but has an inwardly recessed portion, so an anti-slip groove is also formed on the recessed surface to prevent the resin coating layer covering this recessed portion from peeling off.

The core material is generally hollow, and its cross-sectional shape is often elongated or horizontally elongated rather than rectangular, so to increase its strength, intermediate bars are formed to divide the hollow portion in the longitudinal direction. The intermediate bars also lead to increased strength in the vicinity where they are formed, so if the core material is elongated, they are often formed near the recessed portion mentioned above.

Here, an example of a case where the cross section of the core material is not rectangular is a stepped shape. In this case, the intermediate crosspiece is often formed from near the corner of the step toward the outer periphery of the opposing core material in order to increase the strength of the area near the corner.

In addition, when covering a stepped core material, there is a risk of the covering resin peeling off near the corners of the steps, so it is preferable to have a retaining groove, but this can result in bends or notches being formed near the corners, which can reduce the strength of the core material.

The present invention provides a resin-coated elongated body that solves the above problems and can prevent peeling and loss of strength of the coating resin near the corners of the steps when resin-coating a stepped core material.

In order to achieve the above object, the present invention has the following configuration.
That is, the resin-coated long body according to the present invention is a resin-coated long body including a metal core member having a step portion formed on the outer surface along the longitudinal direction and a hollow portion formed inside along the longitudinal direction, and a coating resin layer made of a synthetic resin that covers the outer surface of the core member including the step portion, the step portion having one side portion and the other side portion, the one side portion being connected to an intermediate rail formed toward the opposing outer surface, the other side portion having a dovetail-shaped first groove portion adjacent to the intermediate rail formed toward the inside of the core member, and the opening of the first groove portion formed to face the one side portion. A part of the coating resin layer penetrates into the interior, a dovetail-shaped anti-slip groove portion different from the first groove portion is formed on the outer surface of the core material toward the inside of the core material, a part of the coating resin layer penetrates into the anti-slip groove portion, and the anti-slip groove portion is formed on both sides of the one side portion and the other side portion, and each anti-slip groove portion is formed so that on the outer surface of the core material covered with the resin coating layer, the distance between the first groove portion and the anti-slip groove portion on the other side portion is longer than the distance between the first groove portion and the anti-slip groove portion on the one side portion.

According to the present invention, when resin-coating a stepped core material, peeling of the coating resin near the step can be suppressed and a decrease in the strength of the core material can be suppressed.

1 is an explanatory diagram showing one embodiment of a resin-coated long body according to the present invention; FIG. 2 is a partially enlarged view of the core material of FIG. 1 . FIG. 2 is a partially enlarged view of FIG. FIG. 11 is an explanatory diagram showing a comparative example of a core material. 10A and 10B are explanatory diagrams showing another embodiment of a resin-coated long body according to the present invention. 1 is a plan view showing one embodiment of a bench using a resin-coated long body according to the present invention; FIG. 8 is a side view of FIG. 7 is an enlarged cross-sectional view of line AA in FIG. 6.

Next, the best mode for carrying out the present invention will be specifically described with reference to the drawings. In the drawings, 10 is a core material, 20 is a coating resin layer that covers the outer surface 11 of the core material 10, and the resin-coated elongated body 100 according to the present invention is mainly composed of the core material 10 and the coating resin layer 20.

Figure 1 is an explanatory diagram showing one embodiment of a resin-coated elongated body 100 according to the present invention, and shows a perspective view of the resin-coated elongated body 100 formed in the front-rear direction, cut vertically. Figure 2 is a partial enlarged view of the upper right end portion of the core material 10 in Figure 1, and Figure 3 is a partial enlarged view of the upper right end portion of the resin-coated elongated body 100 in Figure 1. Unless otherwise specified, the left-right and up-down directions of the resin-coated elongated body 100 are the same as those in Figure 1, and the description will be based on this.

In this embodiment, the core material 10 is a hollow, elongated body made of aluminum alloy with a continuous, uniform cross section. That is, the core material 10 has a thin-walled portion 12 forming the outer surface 11 and an inner hollow portion 13, and the thin-walled portion 12 has an upper surface portion 12a and a lower surface portion 12b that are formed with a gap between them vertically. In addition, the upper surface portion 12a and the lower surface portion 12b are connected by a crosspiece material 14 formed along the vertical direction, and the hollow portion 13 is divided into multiple portions in the left-right direction.

The core material 10 has a step portion 30 recessed inward at the side end, and in this embodiment, the step portion 30 is located at the upper right end and the lower left end. As shown in FIG. 2, the step portion 30 at the upper right end has one side portion 31 formed in a direction intersecting with the upper surface portion 12a, and the other side portion 32 that forms the step portion 30 with the one side portion 31. The one side portion 31 is connected to the lower surface portion 12b via the intermediate bar 40 from the vicinity of the intersection with the other side portion 32. In this embodiment, at the upper right end of the core material 10, the one side portion 31 is formed downward from the right end of the upper surface portion 12a and is connected to the other side portion 32 at the vertical middle portion of the core material 10, and the one side portion 31 is further connected to the intermediate bar 40 formed toward the lower surface portion 12b through the hollow portion 13. The one side portion 31 and the intermediate bar 40 are formed in the same direction.

In addition, at the lower right end of the core material 10, the lower surface portion 12b extends further right than the right end of the upper surface portion 12a, and a rising portion 12c is formed that rises upward from the right end of the lower surface portion 12b. The upper end of the rising portion 12c reaches the middle of the core material 10 in the height direction and is connected to the other side portion 32.

On the other side 32, a dovetail-shaped groove 33 is formed inside the core material 10, i.e., in FIG. 2, the upper side is the opening 33a and faces downward. The groove 33 has the opening 33a, a bottom 33b wider than the opening 33a, side walls 33c, 33c formed diagonally downward from both ends of the opening 33a and connected to both ends of the bottom 33b, and a space 33d surrounded by these. The groove 33 is adjacent to the intermediate rail 40.

Figure 4 is an explanatory diagram showing a comparative example of a core material. That is, Figure 4 shows a comparative example in which the structure near the groove portion 33 of the step portion 30 is different from that of Figure 2. As shown in Figure 4, when the groove portion 133 is formed at a position including the intersection of one side portion 131 and the other side portion 132, the space portion 133d of the groove portion 133 is located between the one side portion 131 and the intermediate bar 140 over the entire width of the one side portion 131 or the intermediate bar 140.

As a result, a bend is formed by the groove 133 near the point where one side 131 connects to the intermediate crosspiece 140. When this happens, when a load is applied to the core material 110, it becomes more likely to deform starting from the bend by the groove 133.

2, in this embodiment in which the groove 33 is adjacent to the intermediate rail 40, the above-mentioned deformation is less likely to occur. Here, the state in which the groove 33 is adjacent to the intermediate rail 40 means that the opening edge 33e on one side 31 side of the opening 33a of the groove 33 is located outside the one side 31 or the area when the one side 31 is virtually extended, and the one side 31 is formed integrally with the intermediate rail 40 from the opening edge 33e on the one side 31 side of the groove 33 through the side wall 33c to the bottom 33b. It is more preferable that the end of the one side 31 side of the space 33d of the groove 33 is in contact with the outside of the area when the one side 31 is virtually extended, or is located outside of that area.

As in this embodiment, the core material 10 is preferably made of aluminum or an aluminum alloy, which is easy to extrude and lightweight, but other metals may also be used.

The step 30 formed at the lower left end of the core material 10 has a vertical and horizontal relationship that is reversed from that of the step 30 at the right end, and the same components as those already explained are given the same reference numerals and their explanations are omitted.

As shown in Figures 1 and 2, the resin-coated elongated body 100 is formed by coating the outer surface 11 of the core material 10 with synthetic resin by thermoforming such as extrusion molding, and a portion of the molten synthetic resin penetrates into the grooves 33 during thermoforming to form the coating resin layer 20. By having the resin penetrate into the grooves 33, peeling of the coating resin near the steps 30 can be suppressed.

As described above, the groove 33 is located on the other side 32, adjacent to the intermediate rail 40. Here, in the core material 10, the upper surface 12a and the lower surface 12b are formed with anti-slip grooves 15 having a similar shape to the groove 33. Here, the resin coating layer 20 has a larger shrinkage rate during thermal change (when cooling) than the metal core material 10, and since the resin near the groove 33 and the anti-slip groove 15 is less likely to move, the resin between them behaves as if it is shrinking. Therefore, the greater the distance between the groove 33 and the anti-slip groove 15, the greater the shrinkage that occurs, and the greater the tensile force that tries to pull out the resin in the groove 33 due to the shrinkage. In this embodiment, the adjacent retaining groove 15 on the other side 32 side is longer than the groove 33, so when the above-mentioned shrinkage occurs, the resin in the groove 33 is pulled relatively strongly toward the other side 32 side. However, compared to when the groove 33 is formed near the corner of the step 30 as shown in FIG. 3, or when it is formed on one side 31 (not shown), the resin in the groove 33 is less likely to be pulled out in this embodiment in which the groove 33 is formed on the other side 32, and peeling of the coating resin layer 20 near the step 30 can be effectively suppressed.

As the synthetic resin for forming the coating resin layer 20, it is preferable to use a thermoplastic synthetic resin that melts during thermoforming and can flow into the groove portion 33 of the dovetail shape, and examples of such resins include polyethylene, polypropylene, ABS resin, AAS resin, and polyvinyl chloride resin. If a thermoplastic synthetic resin that has adhesive properties with metal materials is used as the synthetic resin for forming the coating resin layer 20, the outer surface 11 of the core material 10 and the coating resin layer 20 are bonded to each other, making it even more difficult to remove the coating resin layer 20. Examples of thermoplastic synthetic resins that have adhesive properties with the core material 10 include copolymers of α-olefins and unsaturated carboxylic acids such as EVA (ethylene vinyl acetate copolymer), PVB (polyvinyl butyral), modified polyethylene modified with maleic anhydride, modified polypropylene, and EAA resin. The synthetic resins described above may also be appropriately mixed with fillers such as silica powder, mica powder, talc, glass fiber, calcium carbonate, aluminum hydroxide, calcium hydroxide, clay, minerals, microballoons, metal powder, wood powder, and cellulose powder such as pulp.

Figure 5 is an explanatory diagram showing another embodiment of a resin-coated elongated body 200 of the present invention. It differs from the resin-coated elongated body 100 shown in Figures 1 and 2 in that the cross-sectional shape of the core material 10 is formed in a substantially arc shape. Other configurations are the same, for example, the core material 10 has a step 30 at its side end, the position of the groove 33 formed in the step 30, and the outer surface 11 of the core material 10 is coated with a synthetic resin to form a coating resin layer 20. Therefore, the same components as those already described are given the same reference numerals and their description will be omitted.

Figures 6 to 8 show an embodiment of a bench 300 using the resin-coated elongated bodies 100, 200 according to the present invention, with Figure 6 being a plan view, Figure 7 being a side view, and Figure 8 being a cross-sectional view taken along the line A-A in Figure 6. In this way, in the resin-coated elongated bodies 100, 200 shown in Figures 1 and 4, the stepped portions 30 of the profile members 10 fit together via the resin coating layer 20 to form the seat and backrest of the bench 300.

According to the present invention, when resin-coating a stepped core material, peeling of the coating resin near the step can be suppressed and a decrease in the strength of the core material can be suppressed, making it suitable for use in deck materials, louver materials, benches, etc.

10 Core material 11 Outer surface 12 Thin portion 12a Upper surface portion 12b Lower surface portion 12c Rising portion 13 Hollow portion 14 Crosspiece material 15 Anti-slip groove portion 20 Resin coating layer 30 Step portion 31 One side portion 32 The other side portion 33 Groove portion 33a Opening portion 33b Bottom portion 33c Side wall portion 33d Space portion 33e Opening edge 33e
40 Intermediate rail 100, 200 Resin-coated elongated body 110 Core material 131 One side portion 132 The other side portion 133 Groove portion 133d Space portion 140 Intermediate rail 300 Bench

Claims (1)

A resin-coated elongated body comprising a metal core member having a step portion formed on an outer surface thereof along a longitudinal direction and a hollow portion formed inside thereof along the longitudinal direction, and a coating resin layer made of a synthetic resin that coats the outer surface of the core member including the step portion,
The step portion has one side portion and another side portion,
The one side portion is connected to an intermediate bar formed toward the opposing outer surface,
A first groove portion having a dovetail shape adjacent to the intermediate rail is formed in the other side portion toward the inside of the core material,
a part of the coating resin layer is inserted into the first groove portion formed so that an opening faces the one side portion,
a dovetail-shaped retaining groove portion different from the first groove portion is formed on an outer surface of the core material toward an inside of the core material, and a part of the coating resin layer is inserted into the retaining groove portion;
The retaining groove is formed on both sides of the one side portion and the other side portion,
A resin-coated long body, characterized in that on the outer surface of the core material coated with a resin coating layer, each anti-slip groove portion is formed so that the distance between the first groove portion and the anti-slip groove portion on the other side portion is longer than the distance between the first groove portion and the anti-slip groove portion on the one side portion.

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