JP2019038209A - Hollow structure plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a hollow structure plate having reduced warpage. SOLUTION: A surface material 3 made of a thermoplastic resin sheet is laminated on an upper surface side of a hollow convex portion molded sheet 2 made of one thermoplastic resin sheet in which a plurality of hollow convex portions 21 are formed at intervals. In the hollow structure plate 1 provided with the concave portion 31 in contact with the upper surface portion of the convex portion 21, the surface material 3 has a first virtual horizontal line passing through the contact point between the upper surface portion edge of the convex portion 21 and the surface material 3 and the concave portion. The angle θ1 formed by the first virtual inclined line extending from the starting point on the upper surface side to the contact point is 120 ° ≦ θ1 ≦ 150 °, and the contact point is formed from the starting point on the lower surface side of the first virtual horizontal line and the convex portion 21. The angle θ2 formed by the second virtual inclined line extending to is 110 ° ≤ θ2 ≤ 140 °, and the distance from the first virtual horizontal line to the second virtual horizontal line passing through the starting point on the upper surface side of the recess 31. Hollow structure plate 1 in which d is d ≧ 50 μm. [Selection diagram] Fig. 1

Description

  The present invention relates to a hollow structure plate. More specifically, the present invention relates to a hollow structure plate with reduced warpage.

  Resin-made hollow structural boards are lightweight, have excellent chemical resistance, water resistance, heat insulation, sound insulation and resilience, and are easy to handle. It is used in a wide range of fields such as architectural materials such as panel materials for ceilings and automobiles. For example, Patent Document 1 discloses a corrugated member made of a synthetic resin material in which an uneven waveform is repeated at a predetermined pitch between two sheets made of a synthetic resin material arranged in parallel at a predetermined interval. A hollow structure plate in a sandwiched state is disclosed.

  Further, Patent Document 2 discloses a so-called “twin cone” (registered trademark) type hollow structure in which a plurality of convex portions projecting from two thermoplastic resin sheets are heat-sealed in a state of abutting each other. A plate is disclosed. This type of hollow structure board is used in various fields such as automobile interior materials, logistics materials, and building materials.

  Such a hollow structure plate, as disclosed in Patent Documents 1 to 5, etc., further laminates one or more thermoplastic resin sheets on the thermoplastic resin sheet formed with a plurality of convex portions, Manufactured by fusing. However, there is a problem that warpage occurs in the hollow structure plate as a finished product due to a difference in cooling shrinkage between the front surface side and the back surface side of the laminated thermoplastic resin sheets.

  As a technique related to this warpage problem, in Patent Document 6, in a hollow extrusion molded body having a multilayer structure of two or more layers, the melting point of the inner layer and the outer layer is different, and the outer layer is set to a temperature lower by 2 to 18 ° C. Thus, a technique is disclosed in which the inner layer and the outer layer are solidified at the same time so that the shrinkage is uniform and the warpage is controlled.

JP 2003-170515 A JP 2007-83407 A International Publication No. 2003/80326 Pamphlet JP 2010-99867 A JP 2008-213262 A JP-A-8-11184

  However, the above-described technique has a problem in that it is a concentric molded product, the resin used for manufacturing is restricted, and the structure is limited to a two-layer structure. Therefore, development of further technology for reducing warpage has been demanded.

  Then, in view of such a situation, the main object of the present invention is to provide a hollow structure plate with reduced warpage.

  As a result of earnest research on the structure of the hollow structure plate, the inventor of the present application pays attention to the angle and distance of a certain location, and by controlling these values within a predetermined range, a hollow structure plate with reduced warpage is obtained. The inventors have found that the present invention can be obtained and have completed the present invention.

That is, in the present invention, a surface material made of a thermoplastic resin sheet is laminated on the upper surface side of a hollow convex molded sheet made of a single thermoplastic resin sheet in which a plurality of hollow convex portions are formed at intervals. The surface material is a hollow structural plate having a concave portion in contact with the upper surface portion of the convex portion, a first virtual horizontal line passing through a contact point between the upper surface edge of the convex portion and the surface material, and an upper surface side of the concave portion. The angle θ1 formed by the first virtual inclined line extending from the starting point to the contact point is 120 ° ≦ θ1 ≦ 150 °, and the first virtual horizontal line and the first extending from the starting point on the lower surface side of the convex portion to the contact point. An angle θ2 formed by two virtual inclined lines is 110 ° ≦ θ2 ≦ 140 °, and a distance d from the first virtual horizontal line to the second virtual horizontal line passing through the starting point on the upper surface side of the concave portion is A hollow structural plate is provided wherein d ≧ 50 μm.
In the present invention, when the upper surface portion of the convex portion is an arc, an angle θ3 formed by the arc tangent at the contact point and the first virtual horizontal line may be −50 ° ≦ θ3 ≦ 50 °. it can.

  ADVANTAGE OF THE INVENTION According to this invention, the hollow structure board with which curvature was reduced can be provided. Note that the effects described here are not necessarily limited, and may be any of the effects described in the present disclosure.

It is a perspective view showing typically the structure of a 1st embodiment of hollow structure board 1 concerning the present invention. It is a cross-sectional schematic diagram which shows typically the cross-section of 1st Embodiment of the hollow structure board 1 which concerns on this invention. FIG. 3 is an enlarged schematic diagram of a portion surrounded by a broken line in FIG. 2. It is a cross-section part expansion schematic diagram which shows typically the partial expansion of the cross-section of 2nd Embodiment of the hollow structure board 1 which concerns on this invention. A is a perspective view schematically showing the structure of the first embodiment of the hollow convex molded sheet 2, and B is a schematic view when viewed from the arrow direction of A. FIG. It is a perspective view which shows typically the structure of 3rd Embodiment of the hollow structure board 1 which concerns on this invention. It is a perspective view which shows typically the structure of 4th Embodiment of the hollow structure board 1 which concerns on this invention. It is a perspective view which shows typically the structure of 5th Embodiment of the hollow structure board 1 which concerns on this invention. It is a perspective view which shows typically the structure of 6th Embodiment of the hollow structure board 1 which concerns on this invention. It is a perspective view which shows typically the structure of 2nd Embodiment of the hollow convex-molding sheet | seat 2. FIG. It is a conceptual diagram which shows an example of the manufacturing method of the hollow structure board 1 which concerns on this invention. It is a figure which shows the measuring method of the curvature of a hollow structure board.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments for carrying out the present invention will be described in detail with reference to the drawings. In addition, embodiment described below shows an example of typical embodiment of this invention, and, thereby, the range of this invention is not interpreted narrowly.

1. Hollow structure board 1
FIG. 1 is a perspective view schematically showing a structure of a first embodiment of a hollow structure plate 1 according to the present invention, and FIG. 2 shows a cross-sectional structure of the first embodiment of the hollow structure plate 1 according to the present invention. It is a cross-sectional schematic diagram shown typically. The hollow structural plate 1 according to the present invention is formed from a thermoplastic resin sheet on the upper surface side of a hollow convex molded sheet 2 made of a single thermoplastic resin sheet in which a plurality of hollow convex portions 21 are formed at intervals. The surface material 3 is laminated, and the surface material 3 includes a concave portion 31 in contact with the upper surface portion 211 of the convex portion 21.

  In the present invention, the surface material 3 is provided with a recess 31. When the flat sheet is a flat sheet, a continuous residual stress is generated in the sheet surface, so that the surface material shrinks over the entire surface. On the other hand, by providing the concave portion 31, the warpage of the hollow structure plate 1 can be controlled by canceling out the shrinkage at the contact point between the upper surface portion edge of the convex portion 21 and the surface material 3.

  More specifically, the inclined portion 32 of the surface material 3 is molecularly oriented with the inclined portion 32 in the horizontal direction, and the direction of residual stress is also generated in the horizontal direction with the inclined portion 32. In addition, the inclined portion 213 of the hollow convex molded sheet 2 is molecularly oriented in the horizontal direction with the inclined portion 213, and the direction of residual stress is also generated in the horizontal direction with the inclined portion 213. These shrink in the molecular orientation direction when cured and shrunk, but the directionality differs between the inclined portion 32 of the surface material 3 and the inclined portion 213 of the hollow convex molded sheet 2, and even if these stresses are combined, it becomes zero Don't be. Therefore, by providing the surface material 3 with the concave portion 31, the surface material 3 is contracted by making the sum of the shrinkage force of the indentation surface (horizontal plane where the first virtual horizon exists) and these two stresses become zero. Since these cancel each other, warpage can be reduced.

  FIG. 3 is an enlarged schematic view of a portion surrounded by a broken line in FIG. In the present invention, an angle θ1 formed by the first virtual horizontal line passing through the contact point between the upper surface edge of the convex portion 21 and the surface material 3 and the first virtual inclined line extending from the starting point on the upper surface side of the concave portion 31 to the contact point. Is 120 ° ≦ θ1 ≦ 150 °, and the angle θ2 formed by the first virtual horizontal line and the second virtual inclined line extending from the starting point on the lower surface side of the convex portion 21 to the contact point (FIG. 3). ) Is 110 ° ≦ θ2 ≦ 140 °, and a distance d (see FIG. 3) from the first virtual horizontal line to the second virtual horizontal line passing through the starting point on the upper surface side of the recess 31 is d ≧ 50 μm. It is characterized by being. By controlling θ1, θ2, and d within this range, it is possible to provide the hollow structure plate 1 with reduced warpage.

  When θ1 <120 °, molding of the resin near the contact becomes unsatisfactory, and the shape of the recess 31 cannot be obtained. Further, when θ1> 150 °, the surface material 3 is less different from a flat surface, and it is difficult to obtain a warp reduction effect.

  When θ2 <110 °, the resin near the contact cannot be molded, and the shape of the convex portion 21 cannot be obtained. Further, when θ2> 140 °, the angle of the convex portion 21 becomes loose, and the rigidity of the hollow structural plate cannot be sufficiently obtained.

  In the present invention, it is preferable that 130 ° ≦ θ1 ≦ 150 °. Further, it is preferable that 120 ° ≦ θ2 ≦ 140 °. Thereby, the hollow structure board 1 with which curvature was reduced more can be provided.

  Further, in the present invention, by setting d ≧ 50 μm, the shrinkage of the surface material 3 works in the vertical direction in addition to the horizontal direction, and an effect of reducing warpage is exhibited. More specifically, there are three forces: the stress in the inclined direction of the inclined portion 32 of the surface material 3, the stress in the inclined direction of the inclined portion 213 of the hollow convex molded sheet 2, and the shrinkage force of the recessed surface in the surface material 3. Since it comes to balance, shrinkage can be reduced. In addition, when d <50 μm, the recess of the concave portion 31 becomes too small, the surface material 3 itself becomes nearly flat, and stress in the vertical direction of the inclined portion 32 of the surface material 3 is less likely to be generated. It is difficult to obtain the effect.

  In the present invention, d ≧ 100 μm is preferable, and d ≧ 200 μm is more preferable. Thereby, the hollow structure board 1 with which curvature was reduced more can be provided.

  In this specification, as shown in FIG. 2, for convenience, the upper surface side of the convex portion 21 or the side on which the surface material 3 is laminated is referred to as “upper surface side”, and the opening side of the convex portion 21 is referred to as “lower surface side”. However, in the hollow structure board 1 which is an actual product, there is no distinction between these.

  FIG. 4 is a cross-sectional partial enlarged schematic view schematically showing a partial enlargement of the cross-sectional structure of the second embodiment of the hollow structure plate 1 according to the present invention. In the hollow structure plate 1 according to the present invention, when the upper surface portion 211 of the convex portion 21 is an arc, an angle θ3 formed by the arc tangent at the contact and the first virtual horizontal line is −50 ° ≦ θ3. It is preferable that ≦ 50 °. Thereby, the hollow structure board 1 with which curvature was reduced more can be provided. In this specification, in FIG. 4, θ3 is defined as + (plus) when a tangent line is drawn counterclockwise from the first virtual horizontal line, and θ3 is defined as − (minus) when a tangent line is drawn clockwise. .

Is not particularly weight of the hollow plate 1 limited and is preferably 300~3000g / m ^2, more preferably to 400~2000g / m ^2, it is particularly preferable that the 450~1000g / m ^2. Thereby, weight reduction of the hollow structure board 1 can be achieved.

  Although the thickness of the hollow structure board 1 is not specifically limited, It is preferable to set it as 1.5-55 mm. By setting the thickness to 1.5 mm or more, it is possible to prevent the hollow structure plate 1 from becoming too thin and to produce the hollow structure plate 1 in which bending rigidity is maintained. In addition, by setting the height to 55 mm or less, the height of the convex portion 21 in the hollow convex portion molding sheet 2 can be controlled, and the thickness of the side wall of the convex portion 21 can be prevented from being drafted too thin. It is possible to produce a hollow structure plate 1 that is less likely to generate.

  Although the structure of the hollow structural plate 1 according to the present invention is not particularly limited, as shown in FIG. 1, the hollow convex molded sheet 2 is formed with a plurality of elliptical truncated cone-shaped or truncated cone-shaped convex portions 21 on one surface. Further, it can be made of a single thermoplastic resin sheet, and the surface material 3 can be laminated on the upper surface side of the convex portion 21. In addition, the hollow structure board of this structure can be manufactured by the manufacturing method shown in FIG.

<Hollow convex molded sheet 2>
The hollow convex molded sheet 2 is composed of a single thermoplastic resin sheet in which a plurality of hollow convex portions are formed at intervals.

  As shown in FIG. 1 and the like, the hollow convex portion molded sheet 2 may be formed with a convex portion 21 only on one surface of the hollow convex portion molded sheet 2, or as shown in FIGS. Convex portions 21 may be formed on both surfaces of the convex portion forming sheet 2.

  As shown in FIG. 2, as long as the convex part 21 has the upper surface part 211 and the opening part 212, the form will not be specifically limited, It can design freely. For example, various shapes such as an elliptical frustum shape or a truncated cone shape shown in FIG. 1, etc., a triangular frustum shape shown in FIG. 8, a polygonal frustum shape such as a quadrangular frustum shape shown in FIG. Can be designed in any shape. Moreover, as shown in FIG. 9, it can also design to the form which combined these shapes.

  In the present invention, when the surface material 3 and the skin material 4 to be described later are laminated on the hollow convex molding sheet 2, the starting point is reduced and the peel strength from the surface material 3 and the skin material 4 is improved. As shown in FIG. 8, corners such as a polygonal frustum shape and a polygonal column shape can be designed to be round.

  In the present invention, among these, it is preferable to design the convex portion 21 in an elliptical truncated cone shape, a truncated cone shape, or a polygonal truncated cone shape. Thereby, in addition to facilitating the design in the manufacturing process, when the convex portion 21 is formed using a mold, the manufacturing cost of the mold can be reduced.

  In the present invention, it is particularly preferable that the convex portion 21 is designed in an elliptical truncated cone shape or a truncated cone shape. When the shape of the convex part 21 is designed in these shapes, the hollow surface in the surface material 3 contracts uniformly, so that the hollow structure plate 1 with further reduced warpage can be provided.

  Furthermore, in the present invention, the aspect ratio of the convex portion 21 is not particularly limited, but is preferably 1.3 or less, and more preferably 1.23 or less. Thereby, the hollow structure board 1 with which curvature was reduced more can be provided. In this case, the convex portion 21 is preferably designed in an elliptical truncated cone shape or a truncated cone shape. Thereby, since stress gathers uniformly in the center part and cancels each other, the hollow structure board 1 with further reduced warpage can be provided. In the present specification, the aspect ratio of the convex portion 21 is defined as a ratio (a1 / a2) between the length a1 in the major axis direction and the length a2 in the minor axis direction of the opening 212 of the convex portion 21. .

  In the present invention, the plurality of convex portions 21 may all have the same form, or two or more forms may be freely selected and combined. In the present invention, as shown in FIG. 9, a step can be provided in the middle of the convex portion 21, or a wave can be provided in the middle of the convex portion 21.

  In the hollow convex molded sheet 2, the angle θ4 (see FIG. 2) formed by the horizontal plane imaginary from the opening 212 of the convex portion 21 and the convex portion 21 is not particularly limited, but is preferably 45 ° or more. When θ4 is set to 45 ° or more, for example, when a load is applied to the hollow structure plate 1 from the outside, sufficient strength can be obtained. This is because the number of convex portions 21 per unit area increases, so that the total adhesion area between the surface material 3 and the upper surface portion 211 is increased, and peeling from the surface material 3 can be prevented, and the shape of the convex portions 21 is increased. This is considered to be derived from the improvement in strength in the thickness direction derived from.

  Furthermore, θ4 is more preferably 45 ° or more and less than 80 °. Thereby, the rigidity of the hollow structure board 1 which concerns on this invention can be improved. In the present invention, θ4 may not always be constant, and the convex portion 21 may be asymmetric with respect to the central axis.

  Further, in the present invention, when the shape of the convex portion 21 is designed to be an elliptic frustum shape or a truncated cone shape, the length of the diameter of the upper surface portion 211 is not particularly limited, but is preferably 1.5 to 8 mm. Thereby, the compressive strength in the thickness direction of the hollow structure board 1 can be improved.

  In the present invention, when the shape of the convex portion 21 is designed to be an elliptical truncated cone shape or a truncated cone shape, the length of the diameter of the opening 212 is not particularly limited, but is preferably 3 to 15 mm. Thereby, the compressive strength in the thickness direction of the hollow structure board 1 can be improved.

  In the hollow convex molded sheet 2, the shortest distance L (see B in FIG. 5) between the openings 212 in the two convex portions 21 is not particularly limited, but is preferably 5 mm or less. By setting L to 5 mm or less, the number of convex portions 21 per unit area increases, and sufficient compressive strength can be obtained in the thickness direction.

  Furthermore, L is more preferably 1.5 mm or less. By setting L to 1.5 mm or less, it becomes easy to control warpage in the hollow structure plate 1 according to the present invention.

  L is preferably 0.5 mm or more. By setting L to 0.5 mm or more, the shapeability of the liner portion (a portion where the convex portion 21 does not exist when the convex portion 21 is viewed from a certain direction; see B in FIG. 5) is improved. In the present invention, L does not always have to be constant.

  In this invention, the arrangement | sequence form of the convex part 21 is not specifically limited, For example, the convex part 21 can be arranged in a grid | lattice form, zigzag form, or irregularly. In the present invention, it is particularly preferable to arrange the convex portions 21 in a staggered manner among these. Thereby, the hollow structure board 1 with which the curvature was further reduced can be provided, maintaining the compressive strength in the thickness direction of the hollow structure board 1 which concerns on this invention.

  In this specification, in order to arrange the convex portions 21 in a staggered manner, as shown in FIG. 8, when viewed along a predetermined reference direction, adjacent ones are arranged so as to be different from each other. State is also included.

  Further, when the convex portions 21 are arranged in a staggered pattern, an angle θ5 formed by a line connecting the centers of the convex portions 21 in the horizontal direction and a line connecting the centers of the convex portions 21 in the oblique direction (see FIG. 5). B) is not particularly limited, but is preferably 60 °. Thereby, the rigidity of the hollow structure board 1 can be improved. The “square lattice shape” means an arrangement when θ5 = 90 °.

  The form of the upper surface portion 211 is not particularly limited, and may be an ellipse, a perfect circle, a polygon such as a triangle, a quadrangle, or the like, but is particularly preferably an ellipse or a perfect circle.

  The form of the opening 212 is not particularly limited, and may be an ellipse, a perfect circle, a polygon such as a triangle, a quadrangle, or the like, but is particularly preferably an ellipse or a perfect circle.

  The height h (see FIG. 2) of the convex portion 21 is not particularly limited, but is preferably 1.3 mm or more. By setting h to 1.3 mm or more, the hollow structure plate 1 having high rigidity can be obtained. H is preferably 50 mm or less. By setting h to 50 mm or less, the side wall portion of the convex portion 21 can be prevented from becoming too thin, and deformation (buckling) of the hollow convex portion molded sheet 2 can be prevented.

  In the present invention, a structure in which the flow path F as shown in FIG. 10 exists in a part of the sheet can be adopted as the structure of the hollow convex molded sheet 2. In the present invention, the shape of the flow path F, the cross-sectional structure, and the like are not particularly limited. In addition, the arrow k shown in FIG. 10 shows the formation direction of the flow path F. The direction in which the flow path F is formed is not particularly limited. For example, as shown in FIG. 10, the flow path F can be formed in an oblique direction as viewed from the arrow g direction.

  The material of the hollow convex molding sheet 2 is not particularly limited as long as it is a thermoplastic resin. Usually, one or two or more thermoplastic resins that can be used for the hollow structure plate can be used in any combination. .

  Examples of the thermoplastic resin include polyethylene (PE), polypropylene (PP), polystyrene (PS), polyurethane, polycarbonate (PC), polymethyl methacrylate (PMMA), and polyvinyl chloride (PVC).

  As the material of the hollow convex molded sheet 2, the low density polyethylene, the high density polyethylene (HDPE), the linear low density polyethylene, the ultra low density polyethylene, the polypropylene are particularly preferable from the viewpoints of processability, cost, weight and physical properties. Olefin resins such as homopolymers, polypropylene random copolymers, and polypropylene block copolymers are preferred. In the present invention, engineering plastics such as ABS resin and polycarbonate can also be used in order to obtain higher rigidity.

The basis weight of the hollow convex molded sheet 2 is not particularly limited, but is preferably 250 g / m ² or more. By setting the basis weight to 250 g / m ² or more, the convex portion 21 can be molded well.

  In the present invention, the hollow convex molding sheet 2 and the thermoplastic resin forming the surface material 3 and the skin material 4 described later include fillers such as talc, mica and calcium carbonate, glass fibers, aramid fibers, carbon fibers and the like. Chopped strands may be added.

  In addition, the hollow convex molding sheet 2 and the thermoplastic resin forming the surface material 3 and the skin material 4 described later are modified to improve flame retardancy, conductivity, wettability, slipperiness and weather resistance. Colorants such as quality agents and pigments may be added.

  In addition, although the hollow convex-shaped sheet | seat 2, the surface material 3 and the skin material 4 which are mentioned later may be formed with the same material, you may form with a mutually different material in the range which can be heat-seal | fused.

<Surface material 3>
In this invention, the surface material 3 which consists of a thermoplastic resin sheet is laminated | stacked on the upper surface side of the hollow convex part shaping | molding sheet 2 mentioned above. Further, the surface material 3 includes a concave portion 31 in contact with the upper surface portion 211 of the convex portion 21. In the present invention, as shown in FIG. 9, a skin material 4 to be described later may be further laminated on the surface material 3.

  If the material of the surface material 3 is a thermoplastic resin, it will not specifically limit, Usually, the thermoplastic resin which can be used for a hollow structure board can be used combining 1 type (s) or 2 or more types freely. In addition, since the specific example of a thermoplastic resin is the same as that of what was mentioned above, description is omitted here.

  As the material of the surface material 3, in particular, from the viewpoint of processability, cost, weight and physical properties, low density polyethylene, high density polyethylene (HDPE), linear low density polyethylene, ultra low density polyethylene, polypropylene homopolymer, Olefin resins such as polypropylene random copolymers and polypropylene block copolymers are preferred. In the present invention, engineering plastics such as ABS resin and polycarbonate can also be used in order to obtain higher rigidity.

The basis weight of the surface material 3 is not particularly limited, but is preferably 100 g / m ² or more, and more preferably 200 g / m ² or more. By setting the basis weight to 100 g / m ² or more, it is possible to prevent the surface material 3 from becoming too thin and torn when the surface material 3 is laminated on the hollow convex molded sheet 2.

  The thickness of the surface material 3 is not particularly limited, but is preferably 0.1 mm or more. By setting the thickness to 0.1 mm or more, the rigidity of the hollow structure plate 1 can be maintained.

  In the present invention, the hollow structural plate 1 may have a plurality of surface materials 3, and in this case, the thickness of the plurality of surface materials 3 may be the same or different. Moreover, each surface material can also be formed with the same material, and can also be formed with a different material.

<Skin material 4>
In the present invention, as shown in FIG. 9, a skin material 4 can be further laminated on the lower surface side of the hollow convex portion forming sheet 2 described above and the surface material 3 described above. When the hollow structure board 1 according to the present invention includes the skin material 4, the hollow structure board 1 can be provided with characteristics according to applications such as design properties, sound absorption characteristics, and heat insulation properties.

  The material of the skin material 4 is not specifically limited, Usually, the material which can be used as a skin material of a hollow structure board can be freely selected and used according to the intended use. Examples thereof include thermoplastic resin sheets, resin woven fabrics, nonwoven fabrics, braided fabrics, knitted fabrics, metal sheets made of stainless steel, aluminum, copper, and the like, organic or inorganic porous sheets, and the like. In addition, a laminated sheet obtained by laminating a plurality of the same or different kinds of sheets can be used as the skin material.

  In the present invention, the hollow structural plate 1 may have a plurality of skin materials 4, and in this case, the thickness of the plurality of skin materials 4 may be the same or different. Moreover, each skin material can also be formed with the same material, and can also be formed with a different material.

2. Manufacturing method of hollow structure board 1 Since the structure of the hollow structure board 1 which concerns on this invention has the characteristics, the manufacturing method is not specifically limited. That is, for the production of the hollow structure plate 1 according to the present invention, one or more kinds of methods usually used for producing the hollow structure plate can be freely selected and used. In FIG. 11, an arrow j indicates the flow direction of the hollow structure plate 1.

  FIG. 11 is a conceptual diagram showing an example of a method for manufacturing the hollow structure plate 1 according to the present invention. In the manufacturing method shown in FIG. 11, the hollow convex molded sheet 2 having the structure shown in FIG. 5 is first manufactured by pressing the molten thermoplastic resin P from both sides with the molds D1 and D2. Next, from the extruder 102 provided with the T-die 101 at the tip, the surface material 3 formed by extruding a thermoplastic resin into a sheet shape is heat-bonded by using a roller R provided with a heating means to form a hollow convex portion. It laminates | stacks on the shaping | molding sheet 2, and the hollow structure board 1 which concerns on this invention is manufactured.

In the manufacturing method shown in FIG. 11, detailed manufacturing conditions and the like are not particularly limited, but the surface material 3 in a molten state at 120 to 250 ° C. is formed on the hollow convex molded sheet 2 softened at 60 to 180 ° C. In the roller R, it is preferable to press-press at ² to 30 kg / cm ² . Thereby, the moldability of the recessed part 31 becomes favorable.

  Although not shown, when laminating the skin material 4 on the hollow structure plate 1, in the manufacturing method shown in FIG. 11, the roller R provided with heating means, a flat roller with a flat surface, etc. The manufacturing method etc. which laminate | stack the skin material 4 on the hollow convex-molding sheet 2 and the surface material 3 further can be employ | adopted.

  Hereinafter, the present invention will be described in more detail based on examples. In addition, the Example demonstrated below shows an example of the typical Example of this invention, and, thereby, the range of this invention is not interpreted narrowly.

1. Test Method and Test Results First, hollow structure plates of Examples 1 to 6 and Comparative Examples 1 to 4 shown in Table 1 below were produced. The hollow structure plates of Examples 1 to 6 and Comparative Examples 1 to 4 were produced by the manufacturing method shown in FIG. 11 of the structure shown in FIGS.

  In Table 1, PP represents polypropylene, PC represents polycarbonate, and PVC represents polyvinyl chloride. In Table 1, the definitions of θ1, θ2, and d are the same as those described in this specification.

  Each numerical value (θ1, θ2, and d) in Table 1 was measured using a microscope from the cross section of the hollow structure plate.

  Next, “warping” in each hollow structure plate was evaluated.

[Evaluation method of warpage]
As shown in FIG. 12, the hollow structure plate (width 1250 mm × length 1250 mm) including the four corners is placed on a surface plate using a stainless steel straight ruler, and each hollow structure plate is lifted from the surface plate. Height was measured. Table 1 shows the maximum lift height among the eight warpage measurement results.

2. Discussion As for the hollow structure board of Examples 1-6, all curvature was 3 mm or less, and curvature was reduced. On the other hand, as for the hollow structure board of Comparative Examples 1-4, all the curvature was 8 mm or more, and the curvature was not reduced compared with the hollow structure board of Examples 1-6.

  Therefore, from this test result, an angle θ1 formed by the first virtual horizontal line passing through the contact point between the upper surface edge of the convex portion and the surface material and the first virtual inclined line extending from the starting point on the upper surface side of the concave portion to the contact point is defined as 120 ° ≦ θ1 ≦ 150 °, and an angle θ2 formed by the first virtual horizontal line and a second virtual inclined line extending from the starting point on the lower surface side of the convex portion to the contact point is 110 ° ≦ θ2 ≦ 140 ° In addition, by setting the distance d from the first imaginary horizontal line to the second imaginary horizontal line passing through the starting point on the upper surface side of the recess, d ≧ 50 μm, a hollow structure plate with reduced warpage can be provided. I understood.

  According to the present invention, it is possible to provide a hollow structure plate with reduced warpage. Therefore, the hollow structure board according to the present invention can be suitably used in a wide range of fields such as physical distribution uses such as box materials and packing materials, architectural uses such as wall and ceiling panel materials, and automobile interiors.

1: hollow structure board 2: hollow convex part molding sheet 21: convex part 211: upper surface part 212: opening 213: slope part 3 of hollow convex part molding sheet 2: surface material 31: concave part 32: slope part of surface material 3 4: Skin material 101: T die 102: Extruder R: Roller D1, D2 provided with heating means: Die P: Molten thermoplastic resin θ1: Top surface edge of convex portion 21 and surface material 3 Angle θ2 formed by the first virtual horizontal line passing through the contact point and the first virtual inclined line extending from the starting point on the upper surface side of the concave portion 31 to the contact point: from the starting point on the lower surface side of the first virtual horizontal line and the convex portion 21 Angle θ3 formed by the second virtual inclined line extending to the contact point: When the upper surface portion 211 of the convex portion 21 is an arc, an angle θ4 formed by the tangent line of the arc at the contact point and the first virtual horizontal line is convex. The horizontal plane imaginary from the opening 212 of the part 21 and the convex part 21 form. Degree θ5: Angle formed by a line connecting the centers of the convex parts 21 in the horizontal direction and a line connecting the centers of the convex parts 21 in the oblique direction h: Height L of the convex part 21: Opening part of the convex part 21 Shortest distance F between 212: flow path g: arrow k: flow path F forming direction j: flow direction of hollow structure plate 1

Claims (2)

A surface material made of a thermoplastic resin sheet is laminated on the upper surface side of a hollow convex molded sheet made of a single thermoplastic resin sheet formed with a plurality of hollow convex portions at intervals, and the surface material is In the hollow structure plate provided with a concave portion in contact with the upper surface portion of the convex portion,
An angle θ1 formed by a first virtual horizontal line passing through the contact point between the upper surface edge of the convex part and the surface material and a first virtual inclined line extending from the starting point on the upper surface side of the concave part to the contact point is 120 ° ≦ θ1 ≦ 150 °,
An angle θ2 formed by the first virtual horizontal line and a second virtual inclined line extending from the starting point on the lower surface side of the convex portion to the contact point is 110 ° ≦ θ2 ≦ 140 °, and
A hollow structure plate, wherein a distance d from the first imaginary horizontal line to a second imaginary horizontal line passing through the starting point on the upper surface side of the recess is d ≧ 50 μm.   2. The angle θ <b> 3 formed by the tangent of the arc at the contact point and the first virtual horizontal line when the upper surface portion of the convex portion is an arc is −50 ° ≦ θ3 ≦ 50 °. Hollow structure board.