Source: http://www.google.com/patents/US7878229?ie=ISO-8859-1&dq=7,496,943
Timestamp: 2014-03-13 23:23:39
Document Index: 91423309

Matched Legal Cases: ['Application No. 200610079886', 'Application No. 200610079885', 'Application No. 200610079886', 'Application No. 200610079885', 'Application No. 200610079886', 'Application No. 03', 'Application No. 2003', 'Application No. 2003', 'Application No. 2008', 'Application No. 2008']

Patent US7878229 - Hollow structure plate, manufacturing method thereof, manufacturing device ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsIntroduction guides 12 are provided above and below a sheet-introduction opening portion of a pressure-reduced chamber 10, and heating means 17 is provided between the introduction guides. Each resin sheet 3 is attracted and attached respectively to the circumferential surface of a corresponding emboss...http://www.google.com/patents/US7878229?utm_source=gb-gplus-sharePatent US7878229 - Hollow structure plate, manufacturing method thereof, manufacturing device thereof, and sound absorbing structure plateAdvanced Patent SearchPublication numberUS7878229 B2Publication typeGrantApplication numberUS 12/003,754Publication dateFeb 1, 2011Filing dateDec 31, 2007Priority dateMar 26, 2002Also published asCN1281404C, CN1649724A, DE60334084D1, EP1491327A1, EP1491327A4, EP1491327B1, US7754312, US20050126852, US20080113128, US20080128080, WO2003080326A1Publication number003754, 12003754, US 7878229 B2, US 7878229B2, US-B2-7878229, US7878229 B2, US7878229B2InventorsMasahiko Nakajima, Takeshi Miyazaki, Takayuki Oda, Kenji KozukaOriginal AssigneeUbe Nitto Kasei Co., Ltd.Export CitationBiBTeX, EndNote, RefManPatent Citations (22), Non-Patent Citations (16), Classifications (82), Legal Events (1) External Links: USPTO, USPTO Assignment, EspacenetHollow structure plate, manufacturing method thereof, manufacturing device thereof, and sound absorbing structure plateUS 7878229 B2Abstract Introduction guides 12 are provided above and below a sheet-introduction opening portion of a pressure-reduced chamber 10, and heating means 17 is provided between the introduction guides. Each resin sheet 3 is attracted and attached respectively to the circumferential surface of a corresponding emboss roller 11 by reducing pressure. Pins 112 of the emboss roller 11 are truncated cone-shaped. The ratio of the total area of the lower bases of the pins 112 to the area of the circumferential surface of the emboss roller is 0.5 or more. The rising angle θ of the pin side face, in the vertical plane including the central axis of the pins 112, is in the range from 50 degrees to 70 degrees. Furthermore, a multilayered hollow structure plate 140 is formed by attaching non-air-permeable sheets 130 onto both the front and back of a core member obtained by fusing together hollow protrusions 112 in two thermoplastic resin sheets. A sound absorbing material 150 is provided on at least one of the front and back side thereof, and small holes 114 a opened in the multilayered hollow structure plate are formed in liner portions 114 and the non-air permeable sheet 130 only in the positions that matches the liner portions 114. Images(10) Claims(4)
CROSS-REFERENCES TO RELATED APPLICATIONS This application is a divisional of U.S. patent application Ser. No. 10/509,225, which is the National Stage of International Application No. PCT/JP03/03742, filed Mar. 26, 2003.
TECHNICAL FIELD The present invention relates to hollow structure plates, methods and apparatuses for manufacturing the same, and sound absorbing structure plates.
BACKGROUND ART Plastic hollow structure plates, such as flute-shaped plastic cardboards (product name: Danplate manufactured by Ube-Nitto Kasei Co., Ltd.), corrugated plastic cardboards, plastic structure plates in which columnar independent air compartments are formed (product name: Plapearl manufactured by Kawakami Sangyo Co., Ltd.), are lightweight and have excellent water resistance, heat resistance, chemical resistance and other properties, and thus have conventionally been used in various applications such as building panels, containers, various boxes, and interior materials for, for example, houses, buildings, offices, and vehicles (e.g., see JP 2000-326430A as a honeycomb structure plate).
Among these, hollow structure plates in which columnar independent air compartments (hereinafter, referred to as �hollow protrusions�) are formed are known to have no difference in strength between the vertical and the horizontal directions, compared with corrugated plastic cardboards or flute-shaped plastic cardboards.
DISCLOSURE OF INVENTION (1) A hollow structure plate according to the present invention is a hollow structure plate formed by fusing a plurality of hollow protrusions that are projected in each of two thermoplastic resin sheets with the hollow protrusions facing against one another. The hollow protrusions are truncated cone-shaped. A ratio of a total area of a lower base of each of the hollow protrusions to an area of a circumferential surface, i.e., a ratio between the total area of the lower base (opening) portions of the hollow protrusions and the area of the liner portions in which the hollow protrusions are not formed, is in a range from 0.3 to 0.9. A rising angle of a side face of each of the hollow protrusions in a vertical plane including a central axis of the hollow protrusion is in a range from 50 degrees to 70 degrees.
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory diagram showing a hollow structure plate of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, preferred embodiments of the present invention will be described with reference of the accompanying drawings in detail.
As shown in FIG. 1, the hollow structure plate of the present invention is formed by fusing a plurality of hollow protrusions (referred to as �pins� or �emboss pins� in the examples) 112, 112 that are projected (embossed) in two thermoplastic resin sheets 110, 110A with the end faces attached to each other, and characterized by the following: the pins 112, 112 are truncated cone-shaped; the ratio of the total area of the lower bases of the pins 112, 112 to the circumferential surface is in the range from 0.3 to 0.9; and the rising angle of the side face of each pin 112, 112 in the vertical plane including the central axis of the pin 112, 112 is in the range from 50 degrees to 70 degrees. Such a hollow structure plate also can be constituted by attaching non-air-permeable sheets (not shown) made of thermoplastic resin sheets to liner portions (i.e., portions between the pins 112, 112 in the thermoplastic resin sheets 110, 110 a) 114, 114 on both the front and back sides thereof.
EXAMPLE 1 OF THE HOLLOW STRUCTURE PLATE A homopropylene sheet (melting point: 165� C., softening point: 120� C.) having a thickness of 0.5 mm and a Metsuke (weight per unit area) of 500 g/m2 in the melted state was placed on a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 2 mm and diameter of the lower base 11 e is 8 mm, were arranged in a staggered lattice arrangement with a pin interval (interval between the rising portions 11 g) of 2 mm, and vacuum molding was performed in off-line. The obtained two embossed sheets were attached in such a manner that the pins thereof were attached with an ultrasonic fusing apparatus. Using this as a core member, homopropylene sheets having a thickness of 0.25 mm and a Metsuke of 250 g/m2 were attached as face material to the front and the back of this core member. Thus, a hollow structure plate having a thickness of 10.5 mm and a Metsuke of 1500 g/m2 was obtained. Thereafter, a bending test was performed according to JIS K7203. Regarding the bending elasticity gradient, a load when a flexure of 1 cm occurred was obtained based on the straight portion of a load-flexure curve obtained by the above-described bending measurement, and this was taken as the bending elasticity gradient.
EXAMPLE 2 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 2 mm and diameter of the lower base 11 e is 6 mm, were arranged in a staggered lattice arrangement with a pin interval of 2 mm. Thereafter, a bending test was performed.
EXAMPLE 3 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 2 mm and diameter of the lower base 11 e is 6 mm, were arranged in a staggered lattice arrangement with a pin interval of 4 mm. Thereafter, a bending test was performed.
EXAMPLE 4 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 4 mm and diameter of the lower base 11 e is 8 mm, were arranged in a staggered lattice arrangement with a pin interval of 2 mm. Thereafter, a bending test was performed.
EXAMPLE 5 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 2 mm and diameter of the lower base 11 e is 10 mm, were arranged in a staggered lattice arrangement with a pin interval of 2 mm. Thereafter, a bending test was performed.
EXAMPLE 6 OF THE HOLLOW STRUCTURE PLATE The pin was configured to have a step. A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameters of the upper base 11 d, the inner side of the intermediate state, the outer side of the intermediate stage, and the lower base 11 e are 1.5 mm, 3 mm, 5 mm, and 6 mm, respectively, were arranged in a staggered lattice arrangement with a pin interval of 2 mm. Thereafter, a bending test was performed.
COMPARATIVE EXAMPLE 1 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 4 mm and diameter of the lower base 11 e is 6 mm, were arranged in a staggered lattice arrangement with a pin interval of 4 mm. Thereafter, a bending test was performed.
COMPARATIVE EXAMPLE 2 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 2 mm and diameter of the lower base 11 e is 4 mm, were arranged in a staggered lattice arrangement with a pin interval of 4 mm. Thereafter, a bending test was performed.
COMPARATIVE EXAMPLE 3 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 6 mm and diameter of the lower base 11 e is 8 mm, were arranged in a staggered lattice arrangement with a pin interval of 4 mm. Thereafter, a bending test was performed.
COMPARATIVE EXAMPLE 4 OF THE HOLLOW STRUCTURE PLATE Molding was performed in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 4 mm and diameter of the lower base 11 e is 6 mm, were arranged in a staggered lattice arrangement with a pin interval of 2 mm. Webbing occurred, and a satisfactory hollow structure plate was not obtained.
COMPARATIVE EXAMPLE 5 OF THE HOLLOW STRUCTURE PLATE A hollow structure plate was obtained in the same manner as Example 1, using a vacuum molding plate having a width of 70 mm and a length of 200 mm in which pins 11 b, whose height is 5 mm and whose diameter of the upper base 11 d is 2 mm and diameter of the lower base 11 e is 12 mm, were arranged in a staggered lattice arrangement with a pin interval of 2 mm. Thereafter, a bending test was performed.
FIGS. 2( a) to 2(d) show preferable embodiments in which the hollow structure plate is used as a sound absorbing structure plate of the present invention. The sound absorbing structure plate shown in these figures is provided with a hollow structure plate 140 and a sound absorbing material 150. The hollow structure plate 140 is constituted by attaching non-air-permeable sheets 130, 130A made of thermoplastic resin sheets to liner portions (i.e., portions between the hollow protrusions 112, 112 in the thermoplastic resin sheets 110, 110 a) 114, 114 of the core member 120 on both the front and back sides thereof. The core member 120 is formed by fusing a plurality of hollow protrusions (also referred to as �pins� or �emboss pins�) 112, 112 that are projected (embossed) in two thermoplastic resin sheets 110 and 110A with their end faces attached facing each other. The sound absorbing material 150 is made of porous material that is attached to at least one of the two faces of the front and the back of the hollow structure plate 140. Small holes 114 a, 130 a that are opened toward the closed spaces 142, 142 in the hollow structure plate 140 are formed in the liner portions 114 of the thermoplastic resin sheet 110 that is positioned on the side to which the sound absorbing material 150 is attached, and in the non-air permeable sheet 130 only at the positions that match the liner portions 114.
EXAMPLE 1 A homopolypropylene sheet (melting point: 165� C., softening point: 120� C.) having a thickness of 0.5 mm and a Metsuke (weight per unit area) of 500 g/m2 in the melted state was placed on a vacuum molding plate having a length of 1000 mm and a width of 1000 mm in which hollow protrusions (emboss pins), whose height is 5.5 mm and whose diameter of the upper base is 2 mm and diameter of the lower base is 6 mm, were arranged in a staggered lattice arrangement with a pin interval of 2 mm, and vacuum molding was performed in off-line. The ends of the protrusions of the obtained two embossed sheets were thermally fused. Using this as a core member, homopolypropylene sheets having a thickness of 0.25 mm and a Metsuke of 250 g/m2 were attached as face material to the front and the back of this core member. Thus, a hollow structure plate having a total thickness of 11.5 mm and a Metsuke of 1500 g/m2 was obtained. Thereafter, a hole-opening process was performed to one of the liner portions of the hollow structure plate such that holes of φ 1.0 were formed at an equal pitch at an opening ratio of 0.36%. The sound absorption coefficient of this perforated hollow structure plate of 1�1 m was measured in a small reverberant chamber (manufactured by Nittobo Acoustic Engineering Co., Ltd.).
EXAMPLE 2 A hollow structure plate was obtained in the same manner as in Example 1, and then a hole-opening process was performed to one of the liner portions of the hollow structure plate such that holes of φ 2.5 mm were formed at an equal pitch at an opening ratio of 0.36%. The sound absorption coefficient of this perforated hollow structure plate was measured in a small reverberant chamber.
EXAMPLE 3 A hollow structure plate was obtained in the same manner as in Example 1, and then a hole-opening process was performed to one of the liner portions of the hollow structure plate such that holes of φ 4.0 mm were formed at an equal pitch at an opening ratio of 0.36%. The sound absorption coefficient of this perforated hollow structure plate was measured in a small reverberant chamber.
EXAMPLE 4 A hollow structure plate was obtained in the same manner as in Example 1, and then a hole-opening process was performed to one of the liner portions of the hollow structure plate such that holes of φ 2.5 mm were formed at an equal pitch at an opening ratio of 0.19%. The sound absorption coefficient of this perforated hollow structure plate was measured in a small reverberant chamber.
EXAMPLE 5 A hollow structure plate was obtained in the same manner as in Example 1, and then a hole-opening process was performed to one of the liner portions of the hollow structure plate such that holes of φ 2.5 mm were formed at an equal pitch at an opening ratio of 0.66%. The sound absorption coefficient of this perforated hollow structure plate was measured in a small reverberant chamber.
EXAMPLE 6 A hollow structure plate was obtained in the same manner as in Example 1, and then a soft urethane foam having a thickness of 6 mm was attached as a sound absorbing material to the face having the holes of this hollow structure plate, so that a multilayered hollow structure plate was produced. Then, the sound absorption coefficient was measured in a small reverberant chamber (t=1 means a thickness of 1 mm).
EXAMPLE 7 A hollow structure plate having holes was obtained in the same manner as in Example 2, and then an air-permeable surface material having a thickness of 6 mm and a soft urethane foam (t=5) were attached as sound absorbing materials to the face having the holes of this hollow structure plate, so that a multilayered hollow structure plate was produced. Then, the sound absorption coefficient was measured in a small reverberant chamber.
COMPARATIVE EXAMPLE 1 A hollow structure plate was produced in the same manner as in Example 1, and the sound absorption coefficient was measured in a small reverberant chamber.
COMPARATIVE EXAMPLE 2 The sound absorption coefficient of a soft urethane foam having a thickness of 6 mm was measured in a small reverberant chamber.
COMPARATIVE EXAMPLE 3 A hollow structure plate was obtained in the same manner as in Example 1, and a multilayered hollow structure plate was produced by attaching a sound absorbing material made of a foam material under the same conditions as in Example 6, except that no holes were opened. Then, the sound absorption coefficient was measured according to the reverberant chamber method. The sound absorption coefficient in certain frequencies of Comparative Example 3 is shown in Table 2.
FIG. 7 shows the entire configuration of an apparatus to which the method of the present invention is applied. In FIG. 7, T-dies 2 are provided at each end of a pair of extruders 1 that are arranged in parallel. As regards the thermoplastic resin sheets 3 extruded from the T-dies 2, protrusions of the resin sheets 3 are molded and the sheets are attached using a molding apparatus or a manufacturing apparatus of the present invention (hereinafter, referred to as a �manufacturing apparatus�, but both mean the same) 4 that performs both molding of protrusions and attachment. Thereafter, surface materials 6 are laminated on the upper and the lower surfaces thereof with a laminating apparatus 5, and the laminated sheets are taken up by a take-up device 7 at a predetermined speed. Then, the sheets are sequentially cut by a cutting device, which is not shown, so as to be completed as a product.
Among the above, the manufacturing apparatus 4 that is the main part of the present invention is provided with, as shown in FIGS. 8 to 10, a pair of pressure-reduced chambers 10 that are formed half-divided into the upper and the lower portions; emboss rollers 11 that are supported with bearings in the pressure-reduced chambers 10 and whose circumferential surfaces face the side of opening portions 10 a that are opened in the juncture position of the pressure-reduced chambers 10; sheet-introduction plates 12 that are arranged in the upper and the lower inner sides of the opening portions 10 a and are inclined toward the direction of the contact line, i.e., a contact point, on the circumferential surface of the emboss roller 11 (hereinafter, referred to as �contact point�); a plurality of border rollers 15 that are supported rotatably inside the opposite sides of the pressure-reduced chambers 10; a pair of border-roller-receiving and quasi-sealing members 14 that are opposed to the border rollers 15 with a small gap and are arranged on both the sides of each emboss roller 11 to quasi-seal both the sides of each emboss roller 15 in the pressure-reduced chambers 10; rear plates 16 that are arranged horizontally toward the contact point direction in the back of the emboss rollers 12 and are continuous toward the rear opening portion 10 b of each pressure-reduced chamber 10; and a heater for heating 17 having a triangular cross section that is provided between the introduction plates 12.
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