JP2000210967A - Manufacture of foamed molding with skin and foamed molding with skin - Google Patents
Manufacture of foamed molding with skin and foamed molding with skinInfo
- Publication number
- JP2000210967A JP2000210967A JP11017163A JP1716399A JP2000210967A JP 2000210967 A JP2000210967 A JP 2000210967A JP 11017163 A JP11017163 A JP 11017163A JP 1716399 A JP1716399 A JP 1716399A JP 2000210967 A JP2000210967 A JP 2000210967A
- Authority
- JP
- Japan
- Prior art keywords
- foamed
- molded article
- skin
- particles
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
- Laminated Bodies (AREA)
Abstract
Description
【0001】[0001]
【発明の属する技術分野】本発明は表皮付き発泡成形体
の製造方法及び表皮付き発泡成形体に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foamed article with a skin and a foamed article with a skin.
【0002】[0002]
【従来の技術及び発明が解決しようとする課題】ブロー
成形等によって得られる中空成形体の内部に熱可塑性樹
脂発泡粒子を充填し、スチーム等によって加熱して発泡
粒子相互を融着させて得られる表皮付き発泡成形体は、
箱型容器、建築パネル、緩衝材、自動車内装材等の各種
の分野において広く利用されている。この種の表皮付き
発泡成形体を製造する場合、中空成形体がスチーム透過
性に乏しいと、加熱用スチームが中空成形体内に充填さ
れた発泡粒子間に充分に浸透し難い。2. Description of the Prior Art A hollow molded article obtained by blow molding or the like is filled with expanded thermoplastic resin particles and heated by steam or the like to fuse the expanded particles to each other. The foam molded body with skin is
It is widely used in various fields such as box-shaped containers, building panels, cushioning materials, and automobile interior materials. In the case of producing such a foamed molded article with a skin, if the hollow molded article has poor steam permeability, it is difficult for the heating steam to sufficiently penetrate between the foamed particles filled in the hollow molded article.
【0003】このような問題を解決し得る方法として、
中空成形体内に充填した発泡粒子層内にスチーム供給用
ピンを差し込み、発泡粒子層の内部にまでスチームが浸
透するようにし、発泡粒子相互が融着する前にスチーム
供給用ピンを抜き取る方法が提案されている(特公昭6
2−19293号公報、実公昭62−9073号公報
等)。しかしながら、発泡粒子として、一般に略球状発
泡粒子が用いられているため、中空成形体内に充填され
た発泡粒子の深層部までスチームが浸透し難いことか
ら、中空成形体内に充填した発泡粒子相互の融着性や、
発泡粒子と中空成形体との融着性がある場合、融着性に
劣る表皮付き発泡成形体しか得られないという問題があ
った。特に、複雑な構造のものや、厚さが厚い表皮付き
発泡成形体を得ようとした場合には、上記した融着不良
は著しくなるという問題があった。[0003] As a method that can solve such a problem,
A method is proposed in which a steam supply pin is inserted into the foamed particle layer filled in the hollow molded body so that steam penetrates into the foamed particle layer, and the steam supply pin is removed before the foamed particles are fused together. (Tokuko Sho 6
No. 2-19293, Japanese Utility Model Publication No. 62-9073, etc.). However, since generally spherical foamed particles are generally used as the foamed particles, it is difficult for steam to penetrate to the deep portion of the foamed particles filled in the hollow molded body. Wearability,
In the case where the foamed particles and the hollow molded body have a fusion property, there is a problem that only a foamed molded article with a skin having poor fusion property can be obtained. In particular, when an attempt is made to obtain a foamed molded article having a complex structure or a thick skin, there is a problem that the above-mentioned defective fusion is remarkable.
【0004】本発明は上記従来の問題を解決するために
なされたもので、発泡体片相互の融着性が優れた表皮付
き発泡成形体を製造することのできる方法及び優れた表
皮付き発泡成形体を提供することを目的とする。SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems, and is intended to provide a method for producing a foamed molded article with a skin having excellent fusion property between foam pieces, and an excellent foamed molding with a skin. The purpose is to provide the body.
【0005】[0005]
【課題を解決するための手段】即ち本発明の表皮付き発
泡成形体の製造方法は、熱可塑性樹脂発泡体片が熱可塑
性樹脂からなる中空成形体の内部に充填され、該発泡体
片を加熱媒体により加熱して発泡体片相互間を融着させ
る表皮付き発泡成形体の製造方法であって、該発泡体片
が最密充填時の空間率が45%以上の形状であることを
特徴とする。本発明において、熱可塑性樹脂からなる中
空成形体の内部に充填する熱可塑性樹脂発泡体片は筒状
の熱可塑性樹脂発泡粒子であることが好ましい。That is, in the method for producing a foamed molded article with a skin according to the present invention, a thermoplastic resin foam piece is filled in a hollow molded article made of a thermoplastic resin, and the foam piece is heated. What is claimed is: 1. A method for producing a foamed molded article having a skin, wherein the foamed piece is fused by heating with a medium, wherein the foamed piece has a shape having a void fraction of 45% or more at the time of close packing. I do. In the present invention, the thermoplastic resin foam pieces to be filled in the hollow molded body made of a thermoplastic resin are preferably tubular thermoplastic resin foam particles.
【0006】また本発明の表皮付き発泡成形体は、連通
した空隙を有する熱可塑性樹脂発泡体片成形体の表面の
少なくとも一部を、熱可塑性樹脂からなる中空成形体に
て被覆してなる表皮付き発泡成形体であって、該発泡体
片成形体の空隙率が5%以上であることを特徴とする。The foamed molded article with a skin according to the present invention comprises a skin formed by covering at least a part of the surface of a molded piece of a thermoplastic resin foam having communicating voids with a hollow molded article made of a thermoplastic resin. A foam molded article with a foam, wherein the porosity of the foam piece molded article is 5% or more.
【0007】[0007]
【発明の実施の形態】本発明において用いる熱可塑性樹
脂発泡体片の基材樹脂としては、ポリ塩化ビニル等の塩
化ビニル系樹脂、ポリスチレン等のポリスチレン系樹
脂、ポリエチレン系樹脂、ポリプロピレン系樹脂等のポ
リオレフィン系樹脂、ポリメチルメタクリレート等のア
クリル系樹脂、ポリカーボネート樹脂等が挙げられる。
上記ポリエチレン系樹脂やポリプロピレン系樹脂として
は、例えば低密度ポリエチレン、中密度ポリエチレン、
高密度ポリエチレン、直鎖状低密度ポリエチレン、直鎖
状超低密度ポリエチレン、エチレン−プロピレンブロッ
ク共重合体、エチレン−プロピレンランダム共重合体、
エチレン−ブテンブロック共重合体、エチレン−ブテン
ランダム共重合体、エチレン−酢酸ビニル共重合体、エ
チレン−メチルメタクリレート共重合体、エチレン−メ
タクリル酸共重合体の分子間を金属イオンで架橋したア
イオノマー系樹脂、プロピレン単独重合体、プロピレン
−エチレンランダム共重合体、プロピレン−ブテンラン
ダム共重合体、プロピレン−エチレンブロック共重合
体、プロピレン−ブテンブロック共重合体、ポリブテ
ン、ポリペンテン、プロピレン−エチレン−ブテン三元
共重合体、プロピレン−アクリル酸共重合体、プロピレ
ン−無水マレイン酸共重合体等が挙げられる。また、こ
れらの他に、エチレン、プロピレン、ブテン、ペンテン
等のオレフィン系モノマーと、これらオレフィン系モノ
マーと共重合し得るスチレン等のモノマーとの共重合体
も使用することができる。DESCRIPTION OF THE PREFERRED EMBODIMENTS The base resin of the thermoplastic resin foam piece used in the present invention includes vinyl chloride resins such as polyvinyl chloride, polystyrene resins such as polystyrene, polyethylene resins and polypropylene resins. Examples include polyolefin resins, acrylic resins such as polymethyl methacrylate, and polycarbonate resins.
Examples of the polyethylene-based resin and polypropylene-based resin, for example, low-density polyethylene, medium-density polyethylene,
High-density polyethylene, linear low-density polyethylene, linear ultra-low-density polyethylene, ethylene-propylene block copolymer, ethylene-propylene random copolymer,
Ionomer system in which the molecules of ethylene-butene block copolymer, ethylene-butene random copolymer, ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer, and ethylene-methacrylic acid copolymer are crosslinked with metal ions. Resin, propylene homopolymer, propylene-ethylene random copolymer, propylene-butene random copolymer, propylene-ethylene block copolymer, propylene-butene block copolymer, polybutene, polypentene, propylene-ethylene-butene ternary Copolymers, propylene-acrylic acid copolymers, propylene-maleic anhydride copolymers and the like can be mentioned. In addition, a copolymer of an olefin monomer such as ethylene, propylene, butene, and pentene and a monomer such as styrene copolymerizable with the olefin monomer can also be used.
【0008】上記熱可塑性樹脂のなかでも、緩衝性、圧
縮歪回復性が良好な、ポリオレフィン系樹脂が好まし
く、なかでも低密度ポリエチレン、中密度ポリエチレ
ン、高密度ポリエチレン、直鎖状低密度ポリエチレン、
直鎖状超低密度ポリエチレン等のポリエチレン系樹脂
や、ポリプロピレン、ポリブテン、プロピレン−エチレ
ン共重合体、プロピレン−ブテン共重合体、プロピレン
−エチレン−ブテン三元共重合体が好ましく、特にプロ
ピレン−エチレンランダム共重合体、プロピレン−ブテ
ンランダム共重合体、プロピレン−エチレン−ブテン三
元共重合体、直鎖状低密度ポリエチレンが好ましい。[0008] Among the above thermoplastic resins, polyolefin resins having good buffering property and compressive strain recovery property are preferable. Among them, low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene,
Polyethylene resins such as linear ultra-low density polyethylene, and polypropylene, polybutene, propylene-ethylene copolymer, propylene-butene copolymer, propylene-ethylene-butene terpolymer are preferred, and propylene-ethylene random is particularly preferred. A copolymer, a propylene-butene random copolymer, a propylene-ethylene-butene terpolymer, and a linear low-density polyethylene are preferred.
【0009】上記ポリオレフィン系樹脂は、過酸化物や
放射線により架橋したものを用いても、無架橋のまま用
いても良いが、生産工程が簡易で、リサイクルの可能な
無架橋のものが好ましい。The above-mentioned polyolefin resin may be cross-linked by peroxide or radiation or may be used without cross-linking, but is preferably a non-cross-linked resin which has a simple production process and is recyclable.
【0010】本発明において、中空成形体の内部に充填
される熱可塑性樹脂発泡体片としては、最密充填時の空
間率が45%以上、好ましくは50~70%の形状を有
するものが良い。空間率が45%未満であると、加熱媒
体の透過性が悪く発泡体片相互間の融着が悪い表皮付き
発泡成形体しか得られないため好ましくない。上記のよ
うな形状を有するものを、1種又は2種以上混合して用
いることができる。上記最密充填時の空間率とは、熱可
塑性樹脂発泡体片の一定量をメスシリンダー等の目盛り
付き容器に充填し、容器を上下に振動させて熱可塑性樹
脂発泡体片を圧縮することなく、発泡体片の嵩が最小と
なるようにした時の、容器の目盛りから求められる一定
量の発泡体片の体積を見掛けの体積:A(cm3 ) と
し、次に見掛けの体積を測定した後の発泡体片を、アル
コールを入れた目盛り付き容器のアルコール中に沈めて
アルコールのみの時の容積からの増加分から、一定量の
発泡体片の真の体積:B(cm3 ) を求め、見掛け体
積:Aと真の体積:Bとから下記式より求められるもの
である。In the present invention, the thermoplastic resin foam pieces to be filled in the hollow molded article have a porosity of 45% or more at the time of closest packing, preferably 50 to 70%. . If the porosity is less than 45%, the permeability of the heating medium is poor, and only the foamed molded article with skin having poor fusion between the foam pieces can be obtained. One having the above shape can be used alone or in combination of two or more. The porosity at the time of the close-packing is that a fixed amount of the thermoplastic resin foam piece is filled into a graduated container such as a measuring cylinder, and the container is vibrated up and down without compressing the thermoplastic resin foam piece. When the volume of the foam piece was minimized, the volume of the foam piece of a certain amount obtained from the scale of the container was set to an apparent volume: A (cm 3 ), and then the apparent volume was measured. Subsequent foam pieces were immersed in alcohol in a graduated container containing alcohol, and a certain amount of the true volume of foam pieces: B (cm 3 ) was determined from the increase from the volume of alcohol alone, The apparent volume: A and the true volume: B are obtained from the following formula.
【0011】[0011]
【数1】空間率(%)={(A−B)/A}×100## EQU1 ## Space ratio (%) = {(AB) / A} × 100
【0012】本発明方法において発泡体片を融着させる
加熱媒体としては、スチーム、熱風等が挙げられるが、
工業的に有利なスチームが好ましい。The heating medium for fusing the foam pieces in the method of the present invention includes steam, hot air and the like.
Industrially advantageous steam is preferred.
【0013】また本発明において成形に用いる熱可塑性
樹脂発泡体片としては、上記熱可塑性樹脂を基材樹脂と
する、筒状の発泡粒子や、長さ:Lと直径:Dとの間
に、L/D≧4なる関係を有する柱状の発泡粒子や、表
面に突起を有する発泡粒子が好ましい。In the present invention, the thermoplastic resin foam pieces used for molding include cylindrical foam particles having the above-mentioned thermoplastic resin as a base resin, and a length between L: D and D: D. Columnar foamed particles having a relationship of L / D ≧ 4 and foamed particles having projections on the surface are preferable.
【0014】以下、熱可塑性樹脂発泡体片として、熱可
塑性樹脂発泡粒子を用いた場合を例に説明するが、特に
断りのない限り、熱可塑性樹脂発泡粒子に代えて、チッ
プ状物、粉砕物等を用いた場合にも、同様の技術を適用
することができる。Hereinafter, a case where foamed thermoplastic resin particles are used as the foamed thermoplastic resin pieces will be described as an example. However, unless otherwise specified, chip-shaped materials and pulverized materials are used instead of the thermoplastic resin foamed particles. The same technique can be applied to the case of using such a method.
【0015】筒状の発泡粒子としては、外部に連通する
中空穴を有する形状であるとともに(以下、中空穴が外
部に連通する方向を「穴方向」と呼ぶ。)、(a)穴方
向に垂直な断面(以下、この断面を「垂直断面」と呼
ぶ。)における外周形状及び中空穴形状が共に円形であ
るもの、(b)垂直断面における外周形状及び中空穴形
状が共に多角形であるもの、(c)垂直断面における外
周形状、中空穴形状のいずれか一方が円形で、他方が多
角形であるもの、(d)上記(a)〜(c)の如き断面
形状を有するものを、その外周において互いに複数結合
せしめたもの、(e)穴方向に垂直な、どの断面におい
ても突起が設けられた上記(a)〜(d)の如き断面形
状を有するもの、(f)ある垂直断面においては上記
(a)〜(d)の如き断面形状を有しており、別の垂直
断面においては突起が設けられた上記(a)〜(d)の
如き断面形状を有するもの等を例示することができる。The cylindrical foamed particles have a shape having a hollow hole communicating with the outside (hereinafter, the direction in which the hollow hole communicates with the outside is referred to as "hole direction"), and (a) the hole direction. The outer peripheral shape and the hollow hole shape in a vertical cross section (hereinafter, this cross section is referred to as “vertical cross section”) are both circular, and (b) the outer peripheral shape and the hollow hole shape in the vertical cross section are both polygonal , (C) one of the outer peripheral shape and the hollow hole shape in the vertical cross section is circular and the other is polygonal, and (d) the one having the cross sectional shape as described in (a) to (c) above. (E) perpendicularly to the hole direction, having a cross-sectional shape as described in (a) to (d) above, provided with projections in any cross section, (f) in a certain vertical cross section Is as described in (a) to (d) above. Has a surface shape, in another vertical cross-section can be exemplified such as those having such cross-sectional shape of the protrusion is provided (a) ~ (d).
【0016】図1の(ア)〜(ソ)に示す発泡粒子のう
ち、上記(a)に対応するものとしては、(ア)の発泡
粒子が、(b)に対応するものとしては(イ)〜(エ)
の発泡粒子が、(c)に対応するものとしては(オ)、
(カ)の発泡粒子が、(d)に対応するものとしては
(キ)、(ク)の発泡粒子が、(e)に対応するものと
しては(ケ)〜(ス)の発泡粒子が、(f)に対応する
ものとしては(セ)、(ソ)の発泡粒子が挙げられる。
尚、図1において、1は発泡粒子、Pは中空穴、eは突
起を示す。Of the expanded particles shown in FIGS. 1A to 1S, those corresponding to the above (a) correspond to the expanded particles of (A), and those corresponding to (b) correspond to (a). ) ~ (D)
The foamed particles of (c) correspond to (c),
The expanded particles of (f) correspond to (d) and (g) as those corresponding to (d), and the expanded particles of (q) to (s) as corresponding to (e), What corresponds to (f) includes the foamed particles (c) and (so).
In FIG. 1, 1 indicates expanded particles, P indicates a hollow hole, and e indicates a protrusion.
【0017】図1に示した発泡粒子は、本発明において
用い得る筒状の発泡粒子の一例に過ぎず、この他にも垂
直断面における外周形状や中空穴形状が楕円状、正多角
形以外の多角形状となるもの、穴方向に沿って発泡粒子
の一部がくびれているもの、穴方向に沿って発泡粒子が
捩れているもの、垂直断面においてその中心から中空穴
がずれているもの等、筒状の発泡粒子であればいかなる
形状のものも使用可能である。尚、本発明において、垂
直断面形状がC字型等になるように筒状発泡粒子の一部
が切り裂かれた形状のものも筒状の発泡粒子に含めるも
のとする。The expanded particles shown in FIG. 1 are merely examples of cylindrical expanded particles that can be used in the present invention. In addition, the outer peripheral shape and hollow hole shape in the vertical cross section are other than elliptical and regular polygon. Polygonal, foamed particles are partly constricted along the hole direction, foamed particles are twisted along the hole direction, hollow holes are shifted from the center in the vertical cross section, etc. Any shape can be used as long as it is cylindrical expanded particles. In the present invention, tubular foamed particles having a shape in which a part of the tubular foamed particles is cut so as to have a C-shaped vertical cross section are also included in the tubular foamed particles.
【0018】上記筒状の発泡粒子は、垂直断面における
最大外径:Dと、穴方向に沿った最大長さ:Lとの比、
L/Dが0.2〜5.0、特に0.5〜2.0であるこ
とが好ましい。筒状の発泡粒子のL/Dが0.2〜5.
0の範囲にある場合には、発泡粒子の中空成形体内部へ
の充填性が良好になるとともに、発泡粒子相互の融着性
が良好となるため好ましい。上記最大外径:Dは、図1
の(ア)、(キ)、(ケ)、(セ)に示す如く垂直断面
における外周と接する2本の平行する接線間の距離の最
大値であり、ノギスにより測定することができる。ま
た、Lについても図1(ア)、(ケ)に示す如き最大長
さであり、ノギスにより測定することができる。The above-mentioned tubular expanded particles have a ratio of a maximum outer diameter D in a vertical cross section to a maximum length L in the hole direction.
It is preferable that L / D is 0.2 to 5.0, especially 0.5 to 2.0. L / D of the cylindrical expanded particles is 0.2 to 5.
When it is in the range of 0, it is preferable because the filling property of the foamed particles into the hollow molded article becomes good and the fusion property between the foamed particles becomes good. The maximum outer diameter D is shown in FIG.
As shown in (a), (g), (g), and (se), this is the maximum value of the distance between two parallel tangents that are in contact with the outer periphery in the vertical cross section, and can be measured with a caliper. Also, L has the maximum length as shown in FIGS. 1A and 1K, and can be measured with a caliper.
【0019】図1に示す(ア)〜(ク)の発泡粒子のよ
うに突起eを有さないものは、発泡粒子を中空成形体内
部に充填する際の充填機内等における発泡粒子の詰まり
が生じ難く、中空成形体内部に均一な充填をし易いため
好ましい。更に、(ア)、(キ)、(ク)の発泡粒子の
ように垂直断面における外周形状及び中空穴形状がとも
に円形であるものは、発泡粒子の製造が比較的容易であ
るため好ましい。As shown in FIGS. 1 (a) to 1 (c), the foamed particles having no projection e, such as the foamed particles shown in FIGS. This is preferable because it hardly occurs and uniform filling can be easily performed inside the hollow molded body. Further, those having both a circular outer peripheral shape and a hollow hole shape in a vertical cross section, such as the foamed particles (a), (g), and (h), are preferable because the production of the foamed particles is relatively easy.
【0020】本発明において上記筒状の発泡粒子の他
に、中空穴がなく突起のみを有する発泡粒子や柱状の発
泡粒子も使用可能であるが、柱状の発泡粒子の場合、図
2に示すように垂直断面における最大外径:Dと長さ:
Lとの間に、L/D≧4なる関係が成り立つことが必要
であり、特に7≧L/D≧4であることが好ましい。柱
状の発泡粒子としては、図2に示したような円柱状のも
のに限らず、多角柱状のもの等も用いることができる。
L/Dの値が4に満たないと、最密充填時の空間率が4
5%以上得られないことがあるため、発泡粒子相互の融
着性が劣ってしまい好ましくない。中空穴がなく突起を
有する発泡粒子の場合、図4に示す(ア)、(イ)のよ
うに、発泡粒子の長さ:Lの方向に対して垂直などの断
面においても、外周に突起eが存在するように形成され
ていること、また更に該断面において3又は4個の突起
を有するものが発泡粒子の製造上、安定生産性の面で好
ましく、その長さ:Lと最大外径:Dとの比:L/D
が、0.5〜2.0であることが発泡粒子の中空成形体
内部への充填時の充填性の面で好ましい。In the present invention, besides the above-mentioned tubular foamed particles, foamed particles having only protrusions without hollow holes and columnar foamed particles can be used. In the case of columnar foamed particles, as shown in FIG. Outer diameter in vertical section perpendicular to: D and length:
It is necessary that the relationship of L / D ≧ 4 is satisfied with L, and it is particularly preferable that 7 ≧ L / D ≧ 4. The columnar foamed particles are not limited to the columnar ones shown in FIG. 2, but may be polygonal ones.
If the value of L / D is less than 4, the porosity at the time of closest packing is 4
Since 5% or more may not be obtained, the fusion property between the expanded particles is inferior, which is not preferable. In the case of foamed particles having no hollow holes and having protrusions, as shown in FIGS. 4A and 4B, even in a cross section perpendicular to the direction of the length L of the foamed particles, a protrusion e is formed on the outer periphery. Are preferably formed in such a manner that the particles have three or four protrusions in the cross section in view of the production stability of the expanded particles, and the length: L and the maximum outer diameter: Ratio with D: L / D
Is preferably 0.5 to 2.0 in view of the filling property when the expanded particles are filled into the hollow molded article.
【0021】上記したように本発明においては、図1に
示した如き各種の筒状の発泡粒子、図2に示した如きL
/D≧4の柱状の発泡粒子や、図4に示した如き突起を
有する発泡粒子を用いることができるが、特に熱可塑性
発泡粒子の基材樹脂がオレフィン系樹脂である場合、熱
可塑性樹脂中空成形体内部で発泡粒子同士を融着させる
ことが難しい。このため、加熱媒体を深層部まで浸透さ
せ、確実に融着させることのできる、図1の(ア)、
(オ)に示した如き筒状の発泡粒子、特に円筒状の発泡
粒子が好ましい。尚、図1の(ア)、(オ)に示した如
き円筒形状の発泡粒子や図2に示した如き円柱状の発泡
粒子は、垂直断面の外周形状が真円形でなくとも、略円
形を有していれば良い。As described above, in the present invention, various types of cylindrical foamed particles as shown in FIG.
Columnar foamed particles of / D ≧ 4 and foamed particles having protrusions as shown in FIG. 4 can be used. In particular, when the base resin of the thermoplastic foamed particles is an olefin resin, the thermoplastic resin hollow is used. It is difficult to fuse the foamed particles together inside the molded body. For this reason, the heating medium can penetrate to the deep part and can be reliably fused.
A tubular expanded particle as shown in (e), particularly a cylindrical expanded particle, is preferable. The cylindrical foamed particles as shown in FIGS. 1A and 1E and the cylindrical foamed particles as shown in FIG. 2 have a substantially circular shape even if the outer peripheral shape of the vertical cross section is not a true circle. You only need to have it.
【0022】特に上記筒状の発泡粒子は、平均粒子重量
が1〜50mgのものが好ましいが、より好ましくは平
均粒子重量が1〜10mgのものである。平均粒子重量
が1mgに満たない発泡粒子は製造そのものが困難であ
り、50mgを超えると成形時の中空成形体への充填性
が悪くなり易い。また平均粒子重量によっても異なる
が、例えば平均粒子重量が1〜10mgの筒状の発泡粒
子の場合、任意の垂直断面における中空穴の最小径をd
MIN 、同じ垂直断面における外周の最小径をDMI N とし
た時、dMIN が0.5mm以上で、且つdMIN /DMIN
の値が0.30〜0.90であることが好ましく、より
好ましくはdMIN が1.0mm以上で、且つdMIN /D
MIN の値が0.40〜0.85である。尚、dMIN の上
限は20mm、特に10mm以下であることが好まし
い。In particular, the cylindrical expanded particles preferably have an average particle weight of 1 to 50 mg, and more preferably have an average particle weight of 1 to 10 mg. It is difficult to produce foamed particles having an average particle weight of less than 1 mg, and if the average particle weight is more than 50 mg, the filling property of the hollow molded article during molding tends to be poor. Although it depends on the average particle weight, for example, in the case of cylindrical expanded particles having an average particle weight of 1 to 10 mg, the minimum diameter of the hollow hole in an arbitrary vertical cross section is d.
MIN, at the same time that the minimum diameter of the outer circumference was set to D MI N in vertical section, d MIN is 0.5mm or more, and d MIN / D MIN
Is preferably 0.30 to 0.90, more preferably d MIN is 1.0 mm or more, and d MIN / D
The value of MIN is 0.40 to 0.85. Note that the upper limit of d MIN is preferably 20 mm, particularly preferably 10 mm or less.
【0023】dMIN とDMIN との間に上記関係が成り立
つ円筒形状の発泡粒子を用いて成形すると、収縮率が小
さく、粒子相互の融着性がより良好な表皮付き発泡成形
体を得ることができる。またdMIN /DMIN の値が0.
90を超える発泡粒子は、製造そのものが難しいという
問題があるとともに、寸法安定性に欠ける表皮付き発泡
成形体となり易い。When molded using cylindrical foamed particles satisfying the above relationship between d MIN and D MIN , it is possible to obtain a foamed molded article with a skin having a small shrinkage and a better fusion property between particles. Can be. The value of d MIN / D MIN is 0.
The foamed particles having a particle size exceeding 90 have a problem that the production itself is difficult and tend to be a foamed molded article with a skin lacking in dimensional stability.
【0024】尚、図1の(キ)、(ク)、(ソ)等のよ
うに複数の中空穴が存在する場合には、その全ての中空
穴について、また(ケ)〜(ソ)等のように外周に突起
が設けられている場合には突起を除いた形状について、
上記の関係が満たされていることが好ましい。When there are a plurality of hollow holes as shown in (g), (h) and (so) in FIG. 1, all of the hollow holes, (g) to (so), etc. If the protrusion is provided on the outer periphery as in the shape excluding the protrusion,
Preferably, the above relationship is satisfied.
【0025】本発明方法では発泡体片として、上記した
発泡粒子を用いるため、中空成形体が加熱媒体の透過性
を有していなくても、中空成形体内に充填された発泡体
片の深層部まで、加熱媒体が発泡体片間を透過して到達
し、この結果、中空成形体の内側付近に位置して充填さ
れた発泡体片が充分に加熱され、中空成形体内側付近の
発泡体片相互間が確実に融着され、中空成形体の内面側
が発泡体片と融着性を有する素材である場合、発泡体片
と中空成形体との間が確実に融着される。In the method of the present invention, since the above-mentioned expanded particles are used as the foam pieces, even if the hollow molded body does not have the permeability of the heating medium, the deep layer portion of the foam pieces filled in the hollow molded body can be obtained. Until the heating medium penetrates between the foam pieces and arrives. As a result, the filled foam piece located near the inside of the hollow molded article is sufficiently heated, and the foam piece near the inside of the hollow molded article is heated. In the case where the spaces between the foam pieces and the hollow molded body are reliably fused together, and the inner surface side of the hollow molded body is made of a material having a fusibility with the foam piece, the fusion between the foam pieces and the hollow molded body is ensured.
【0026】上記発泡粒子は、例えば密閉容器内で熱可
塑性樹脂粒子と発泡剤とを分散媒に分散させ、攪拌しな
がら加熱して樹脂粒子中に発泡剤を含浸させ、次いで発
泡温度にて樹脂粒子と分散媒とを容器内より低圧下(通
常は、大気圧下)に放出し、樹脂粒子を発泡させる等の
方法によって得ることができる。The foamed particles are prepared by dispersing thermoplastic resin particles and a foaming agent in a dispersion medium in a closed container and heating the mixture with stirring to impregnate the resin particles with the foaming agent. The particles and the dispersion medium can be obtained by a method in which the resin particles are released under a lower pressure (usually, atmospheric pressure) from the container and the resin particles are foamed.
【0027】発泡粒子製造に用いる熱可塑性樹脂粒子
は、基材樹脂を押出機内で溶融混練した後、ダイスから
ストランド状に押出して冷却した後、適宜長さに切断す
る等の方法で得ることができるが、押出機内で基材樹脂
を溶融混練する際に、必要に応じてタルク、炭酸カルシ
ウム、硼砂、水酸化アルミニウム、ホウ酸亜鉛等の無機
物を添加して樹脂と溶融混練し、樹脂粒子中にこれらの
無機物を含有せしめても良い。また用途や目的に応じ、
黒色、灰色、茶色、黄色、赤色、桃色、緑色、青色等の
着色顔料や染料を添加して着色することもできる。樹脂
粒子中に上記無機物や着色顔料、染料等を添加する場
合、これらの分散性を考慮して、通常はマスターバッチ
法を採用する。無機物や着色顔料、染料の添加量は、通
常、樹脂粒子100重量部当たり、0.001〜5重量
部である。樹脂粒子中に無機物を含有させると、発泡粒
子の発泡倍率を向上でき、また気泡径を二次発泡性、寸
法安定性において好適な50〜350μmに調整するこ
とができる。The thermoplastic resin particles used for the production of foamed particles can be obtained by, for example, melting and kneading the base resin in an extruder, extruding it from a die into a strand, cooling it, and cutting it into appropriate lengths. Although it is possible, when melt-kneading the base resin in the extruder, if necessary, an inorganic substance such as talc, calcium carbonate, borax, aluminum hydroxide, zinc borate, etc. is added and melt-kneaded with the resin, and the resin particles are mixed. These inorganic substances may be added to the mixture. Also, depending on the application and purpose,
Coloring can also be performed by adding a coloring pigment or dye such as black, gray, brown, yellow, red, pink, green, and blue. When the above-mentioned inorganic substances, coloring pigments, dyes and the like are added to the resin particles, a masterbatch method is usually adopted in consideration of their dispersibility. The amount of the inorganic substance, the coloring pigment, and the dye is usually 0.001 to 5 parts by weight per 100 parts by weight of the resin particles. When an inorganic substance is contained in the resin particles, the expansion ratio of the expanded particles can be improved, and the diameter of the cells can be adjusted to 50 to 350 μm, which is preferable in terms of secondary expandability and dimensional stability.
【0028】溶融した樹脂をダイスから押出す際に、得
ようとする発泡粒子の断面形状と略相似形状の樹脂押出
口を有するダイス(例えば筒状発泡粒子を得る場合は筒
状発泡粒子の垂直断面形状と略相似形状の樹脂押出口を
有するダイス)を用いることにより、目的形状の発泡粒
子と相似形状の樹脂粒子を得ることができ、このような
樹脂粒子を用いて上記したように発泡を行えば、目的形
状の発泡粒子を得ることができる。When a molten resin is extruded from a die, a die having a resin extrusion port having a shape substantially similar to the cross-sectional shape of the foamed particles to be obtained (for example, in the case of obtaining cylindrical foamed particles, a vertical By using a die having a resin extrusion port having a substantially similar cross-sectional shape, resin particles having a similar shape to the foamed particles having the desired shape can be obtained. As described above, foaming is performed using such resin particles. If it is carried out, it is possible to obtain foamed particles having a desired shape.
【0029】発泡粒子製造に用いる上記分散媒として
は、樹脂粒子を溶解させないものであれば良く、例えば
水、エチレングリコール、グリセリン、メタノール、エ
タノール等が挙げられるが、通常は水が使用される。ま
た発泡剤としては、通常、プロパン、ブタン、ヘキサ
ン、シクロブタン、シクロヘキサン、トリクロロフロロ
メタン、ジクロロフロロメタン、クロロフロロメタン、
トリフロロメタン、1,1,1,2-テトラフロロエタン、1-ク
ロロ-1,1- ジフロロエタン、1,1-ジフロロエタン、1-ク
ロロ-1,2,2,2- テトラフロロエタン等の揮発性発泡剤
や、窒素、二酸化炭素、アルゴン、空気等の無機ガス系
発泡剤が用いられる。また揮発性発泡剤と無機ガス系発
泡剤との混合発泡剤を使用することもできる。これらの
うち、オゾン層破壊の虞れがなく、安価な無機ガス系発
泡剤が好ましく、特に窒素、二酸化炭素、空気が好まし
い。窒素、空気以外の上記発泡剤の使用量は、通常、樹
脂粒子100重量部当たり、2〜50重量部であり、ま
た窒素、空気の場合、その使用量は密閉容器内へ圧入す
る圧力範囲が5〜60kgf/cm2 Gとなるように添
加することが好ましい。発泡剤の使用量は、得ようとす
る発泡粒子の発泡倍率等に応じて適宜調整する。The dispersion medium used for producing the foamed particles may be any one which does not dissolve the resin particles, and includes, for example, water, ethylene glycol, glycerin, methanol, ethanol and the like, but water is usually used. Further, as the blowing agent, usually, propane, butane, hexane, cyclobutane, cyclohexane, trichlorofluoromethane, dichlorofluoromethane, chlorofluoromethane,
Volatilization of trifluoromethane, 1,1,1,2-tetrafluoroethane, 1-chloro-1,1-difluoroethane, 1,1-difluoroethane, 1-chloro-1,2,2,2-tetrafluoroethane, etc. A foaming agent and an inorganic gas-based foaming agent such as nitrogen, carbon dioxide, argon, and air are used. It is also possible to use a mixed foaming agent of a volatile foaming agent and an inorganic gas-based foaming agent. Among these, inexpensive inorganic gas-based foaming agents which do not cause a risk of destruction of the ozone layer are preferable, and nitrogen, carbon dioxide, and air are particularly preferable. The amount of the foaming agent used other than nitrogen and air is usually 2 to 50 parts by weight per 100 parts by weight of the resin particles. In the case of nitrogen and air, the amount used is within the pressure range for press-fitting into a closed container. It is preferable to add so as to be 5 to 60 kgf / cm 2 G. The amount of the foaming agent used is appropriately adjusted according to the expansion ratio of the foamed particles to be obtained.
【0030】上記樹脂粒子と発泡剤とを分散媒に分散さ
せて加熱するに際し、樹脂粒子相互の融着を防止するた
め、融着防止剤を分散媒に添加することができる。融着
防止剤としては分散媒に溶解せず、加熱によって溶融し
ないものであれば無機系、有機系を問わず使用可能であ
るが、一般には無機系のものが好ましい。無機系の融着
防止剤としては、カオリン、タルク、マイカ、酸化アル
ミニウム、酸化チタン、水酸化アルミニウム等の粉体が
好適である。融着防止剤は、平均粒径0.001〜10
0μm、特に0.01〜30μmのものが好ましい。融
着防止剤は樹脂粒子100重量部に対し、通常、0.0
1〜10重量部を添加することが好ましい。また分散助
剤として、ドデシルベンゼンスルホン酸ナトリウム、オ
レイン酸ナトリウム等のアニオン系界面活性剤を併用す
ることができる。分散助剤は樹脂粒子100重量部当た
り、通常、0.001〜5重量部を分散媒に添加するこ
とが好ましい。When the resin particles and the foaming agent are dispersed in a dispersion medium and heated, a fusion inhibitor may be added to the dispersion medium in order to prevent fusion between the resin particles. As the anti-fusing agent, any inorganic or organic one can be used as long as it does not dissolve in the dispersion medium and does not melt by heating. In general, an inorganic one is preferable. Powders such as kaolin, talc, mica, aluminum oxide, titanium oxide, and aluminum hydroxide are suitable as the inorganic anti-fusion agent. The anti-fusing agent has an average particle size of 0.001 to 10
It is preferably 0 μm, particularly preferably 0.01 to 30 μm. The anti-fusing agent is usually used in an amount of 0.0
It is preferable to add 1 to 10 parts by weight. An anionic surfactant such as sodium dodecylbenzenesulfonate and sodium oleate can be used in combination as a dispersing aid. It is preferable that the dispersing agent is usually added to the dispersion medium in an amount of 0.001 to 5 parts by weight per 100 parts by weight of the resin particles.
【0031】尚、発泡粒子は発泡前の樹脂粒子よりも全
体の寸法が大きくなっているが、通常、発泡粒子のd
MIN /DMIN 及びL/Dの値と、これに対応する未発泡
の樹脂粒子のdMIN ´/DMIN ´及びL´/D´の値と
は殆ど変わらず、未発泡の樹脂粒子のdMIN ´/DMIN
´、L´/D´の値が前記条件を満たしていれば、発泡
粒子のdMIN /DMIN 、L/Dの値も前記条件を概ね満
たしている。The foamed particles have a larger overall size than the resin particles before foaming.
The values of MIN / D MIN and L / D and the corresponding values of d MIN ′ / D MIN ′ and L ′ / D ′ of the unfoamed resin particles are almost the same, MIN ´ / D MIN
As long as the values of 'and L' / D 'satisfy the above conditions, the values of d MIN / D MIN and L / D of the expanded particles also generally satisfy the above conditions.
【0032】尚、本発明において用いる熱可塑性樹脂発
泡粒子以外のチップ状物、粉砕物等の発泡体片を得る手
段としては、チップ状物については熱可塑性樹脂を押出
機先端から棒状に押出し発泡させ押出発泡直後にカッタ
ー刃によりスライスすることによりチップ状の発泡体と
して得ることができる。また粉砕物については、既存の
発泡粒子成形体や発泡シート等を粉砕機により粉砕する
ことにより得ることができる。As means for obtaining foam pieces such as chips and pulverized products other than foamed thermoplastic resin particles used in the present invention, for the chip-shaped materials, thermoplastic resin is extruded into a rod shape from the tip of an extruder. By slicing with a cutter blade immediately after extrusion foaming, a chip-shaped foam can be obtained. The pulverized product can be obtained by pulverizing an existing foamed particle molded article, foamed sheet or the like with a pulverizer.
【0033】本発明において熱可塑性樹脂からなる中空
成形体の基材樹脂は、上記した熱可塑性樹脂発泡体片の
基材樹脂と同様なものが挙げられる。In the present invention, the base resin of the hollow molded article made of a thermoplastic resin is the same as the base resin of the thermoplastic resin foam piece described above.
【0034】本発明において中空成形体としては、射出
成形、ブロー成形等の方法で、所望の形状に成形したも
のを用いることができる。例えばブロー成形で中空成形
体を得るには、熱可塑性樹脂のパリソンを金型上方より
降下させ、金型でパリソンを挟み、パリソン内にエアー
ブローピンより空気を吹き込んでパリソンを膨らませる
とともに、金型に設けた吸引穴より吸引してパリソンを
金型内面に密着させることで中空成形体を形成する。ま
た予め成形したものではなくとも良く、中空成形体と表
皮付き発泡成形体とを同一の金型で製造しても良く、例
えば熱可塑性樹脂の中空成形体を成形した後、発泡体片
を中空成形体に充填して表皮付き発泡成形体としても良
い。中空成形体は未発泡、発泡の単層構造のものに限ら
ず、未発泡層や発泡層等を有する多層構造のものであっ
ても良い。また、中空成形体の内面側は、発泡体片と融
着性を有する素材を用いても、融着性をもたない素材を
用いてもかまわないが、高強度、高剛性の表皮付き発泡
体成形体を要求する場合は、融着性を有する素材で構成
されていることが、発泡体片成形体と中空成形体との融
着性に優れた表皮付き発泡成形体が得られるために好ま
しい。中空成形体の肉厚は1〜5mmのものが好まし
い。中空成形体の肉厚が1mm未満であると中空成形体
の形状保持が悪くなる虞れがあり、5mmを超えると表
皮付き発泡成形体の重量が重くなることから好ましくな
い。中空成形体の形状としては、例えば貫通した筒状、
底のある筒状、中空板状、箱型容器状等の形状のものを
用いることができる。In the present invention, as the hollow molded article, a molded article having a desired shape by a method such as injection molding or blow molding can be used. For example, in order to obtain a hollow molded body by blow molding, the parison of the thermoplastic resin is lowered from above the mold, the parison is sandwiched by the mold, air is blown into the parison from the air blow pin to inflate the parison, and The hollow molded body is formed by sucking the parison through the suction hole provided in the mold and bringing the parison into close contact with the inner surface of the mold. Also, it is not necessary to mold the molded article in advance, and the hollow molded article and the foamed molded article with the skin may be manufactured by the same mold.For example, after molding a hollow molded article of a thermoplastic resin, the foam piece is hollowed out. The molded article may be filled into a foamed article with a skin. The hollow molded body is not limited to an unfoamed or foamed single-layer structure, but may be a multilayered structure having an unfoamed layer, a foamed layer, and the like. The inner surface of the hollow molded body may be made of a material having a fusibility with the foam piece or a material having no fusibility. When a molded body is required, it can be formed of a material having fusibility, because a foamed molded article with a skin excellent in fusibility between a foam piece molded body and a hollow molded body can be obtained. preferable. The thickness of the hollow molded body is preferably 1 to 5 mm. If the thickness of the hollow molded article is less than 1 mm, the shape retention of the hollow molded article may be deteriorated. If the thickness exceeds 5 mm, the weight of the foamed molded article with skin is not preferable. As the shape of the hollow molded body, for example, a penetrating cylindrical shape,
A shape such as a cylindrical shape with a bottom, a hollow plate shape, or a box-shaped container shape can be used.
【0035】熱可塑性樹脂発泡粒子と熱可塑性樹脂から
なる中空成形体との融着性を有する素材は、熱可塑性樹
脂発泡粒子の基材樹脂の違いによって異なる。熱可塑性
樹脂発泡粒子の基材樹脂が、例えばポリプロピレン系樹
脂である場合、熱可塑性樹脂からなる中空成形体の基材
樹脂もポリプロピレン系樹脂やポリプロピレン系熱可塑
性エラストマーであること、発泡粒子の基材樹脂がポリ
エチレン系樹脂である場合には、熱可塑性樹脂からなる
中空成形体の基材樹脂もポリエチレン系樹脂であること
が好ましいが、発泡粒子と融着性を有するものであれば
これらに限定されない。The material having the fusion property between the thermoplastic resin foam particles and the hollow molded body made of the thermoplastic resin differs depending on the difference of the base resin of the thermoplastic resin foam particles. When the base resin of the thermoplastic resin expanded particles is, for example, a polypropylene resin, the base resin of the hollow molded body made of the thermoplastic resin is also a polypropylene resin or a polypropylene thermoplastic elastomer, and the base of the expanded particles. When the resin is a polyethylene-based resin, the base resin of the hollow molded body made of a thermoplastic resin is also preferably a polyethylene-based resin, but is not limited thereto as long as the resin has fusibility with the foamed particles. .
【0036】上記した熱可塑性樹脂発泡粒子と融着性を
有する中空成形体の素材としては、使用する熱可塑性樹
脂発泡粒子の基材樹脂の融点以下の融点を有するものを
選択すると、発泡粒子と中空成形体との融着性が更に良
好となり好ましい。As the material of the above-mentioned hollow molded article having a fusion property with the expanded thermoplastic resin particles, if a material having a melting point lower than the melting point of the base resin of the expanded thermoplastic resin particles to be used is selected, This is preferable because the fusion property with the hollow molded body is further improved.
【0037】中空成形体が多層構造の場合、表面側(熱
可塑性樹脂発泡体片と接しない側)を構成する素材とし
ては、上記した熱可塑性樹脂発泡体片との融着性を有す
る素材の他に、熱可塑性樹脂発泡体片と融着性を有さな
いポリ塩化ビニル等や、ポリエステル系樹脂等の素材も
用いることができる。In the case where the hollow molded article has a multilayer structure, the material constituting the surface side (the side not in contact with the thermoplastic resin foam piece) may be the above-mentioned material having a fusion property with the thermoplastic resin foam piece. In addition, a material such as polyvinyl chloride or the like, which does not have a fusion property with a thermoplastic resin foam piece, or a polyester resin can be used.
【0038】高強度、高剛性の表皮付き発泡成形体を得
ようとする際は、中空成形体の素材(多層構造の場合に
は、少なくとも内面側の素材)と、発泡体片の基材樹脂
とは、上記したように相互に熱融着性を有するような素
材を選択することが好ましい。特に本発明の表皮付き発
泡成形体を、例えば自動車内装材やバンパー等の車両用
として用いる場合、耐熱性、剛性、エネルギー吸収性、
リサイクル性等を考慮すると、中空成形体の素材、発泡
体片の基材樹脂ともに、ポリプロピレン系樹脂を選択す
ることが好ましい。また本発明の表皮付き発泡成形体を
寝具、家具等に使用する場合、クッション性等を考慮す
ると、発泡体片の基材樹脂としてポリエチレン系樹脂、
特に直鎖状低密度ポリエチレンが好ましく、中空成形体
の素材(或いは中空成形体の内面側の素材)も、これと
熱融着性を有するポリエチレン系樹脂を選択することが
好ましい。In order to obtain a high-strength, high-rigidity foamed molded article with a skin, the material of the hollow molded article (at least the material on the inner surface side in the case of a multilayer structure) and the base resin of the foam piece are used. It is preferable to select materials having mutual heat-fusion properties as described above. In particular, when the foamed molded article with a skin of the present invention is used for a vehicle such as an automobile interior material or a bumper, heat resistance, rigidity, energy absorption,
In consideration of recyclability and the like, it is preferable to select a polypropylene resin for both the material of the hollow molded article and the base resin of the foam piece. Further, when the foamed molded article with a skin of the present invention is used for bedding, furniture, etc., in consideration of cushioning properties and the like, a polyethylene resin as a base resin of the foam piece,
In particular, linear low-density polyethylene is preferable, and it is preferable to select a polyethylene-based resin having heat-fusibility with the material of the hollow molded body (or the material on the inner surface side of the hollow molded body).
【0039】また本発明の表皮付き発泡成形体におい
て、連通した空隙を有する発泡体片成形体を得るため
に、中空成形体内に充填される発泡体片としては、前述
した通り最密充填時の空間率が45%以上の形状である
ことを必要とするが、更に筒状の発泡粒子、特に円筒状
の発泡粒子が好ましい。前記発泡体片を用いたため発泡
体片相互の融着性に優れ、中空成形体の内層側が発泡体
片と融着生を有する場合、発泡体片成形体と中空成形体
との融着性に優れた表皮付き発泡成形体である。本発明
の表皮付き発泡成形体において連通した空隙を有する発
泡体片成形体の空隙率は5%以上であることが好まし
い。さらに5〜75%の空隙率が好ましく、特に10〜
45%の空隙率が好ましい。空隙率が5%未満の発泡体
片成形体であると、通気性のある断熱パネル、吸音、防
音のパネル等、更に濾過材、透水材、保水材等として利
用できないため好ましくない。上記発泡体片成形体の空
隙率(%)は、発泡体片成形体サンプルの外形寸法(2
5mm×25mm×100mm)より求めた体積をa
(cm3 )、該サンプルをアルコールを入れた目盛り付
き容器のアルコール中に沈めた時の、目盛りの上昇分か
ら求められるサンプルの真の体積をb(cm3 )とした
とき、下記式より求められる値である。In the foam molded article with a skin according to the present invention, the foam pieces to be filled into the hollow molded article are, as described above, in order to obtain a foam piece molded article having communicating voids, as described above. It is necessary that the porosity has a shape of 45% or more, but more preferably cylindrical foamed particles, particularly cylindrical foamed particles. Since the foam pieces are used, the foam pieces have excellent fusion property with each other, and when the inner layer side of the hollow molded body has a fusion with the foam pieces, the fusion property between the foam piece molded article and the hollow molded body is improved. It is an excellent foam molded article with a skin. In the foamed molded article with a skin of the present invention, the porosity of the foam piece molded article having voids communicating with each other is preferably 5% or more. Further, a porosity of 5 to 75% is preferable,
A porosity of 45% is preferred. It is not preferable that the foam piece having a porosity of less than 5% cannot be used as a gas-permeable heat insulating panel, a sound-absorbing panel, a sound-absorbing panel, or a filtering material, a water-permeable material, or a water-retaining material. The porosity (%) of the above-mentioned foam piece molded product is determined by measuring the outer dimensions (2
5 mm x 25 mm x 100 mm)
(Cm 3 ), where b (cm 3 ) is the true volume of the sample obtained from the amount of increase in the scale when the sample is submerged in alcohol in a graduated container containing alcohol, and is obtained from the following equation. Value.
【0040】[0040]
【数2】空隙率(%)={1−(b/a)}×100## EQU2 ## Porosity (%) = {1- (b / a)} × 100
【0041】本発明の表皮付き発泡体を得る方法として
は、例えば、ブロー成形機により中空成形体を得て、金
型に中空成形体を装着し、発泡体片を金型に装着した中
空成形体内部に充填して成形し、表皮付き成形体を得る
方法、中空成形体を成形する機能をも有する金型で中空
成形体の成形と表皮付き発泡体の成形とを行う方法、中
空成形体自体に剛性が有る場合には、金型を使用しない
で中空成形体内部に発泡体片を充填して表皮付き発泡体
を得る方法が挙げられる。As a method for obtaining a foamed body with a skin of the present invention, for example, a hollow molded body is obtained by a blow molding machine, the hollow molded body is mounted on a mold, and the hollow molded body is mounted on a mold. A method of obtaining a molded body with a skin by filling the inside of the body and molding, a method of molding a hollow molded body and a molding of a foam with a skin with a mold also having a function of molding the hollow molded body, a hollow molded body When the foam has a rigidity, a method of obtaining a foam with a skin by filling a foam piece inside the hollow molded body without using a mold is used.
【0042】上記表皮付き発泡成形体を得る金型は、例
えば凹型と凸型とからなる合せ金型で、表皮付き発泡成
形体を金型面の冷却により間接冷却するための空間を有
し、発泡体片を中空成形体内に充填するフィーダー、加
熱媒体を供給、エアー又は加熱媒体を吸引させるスリッ
ト状又は円形状の孔を多数配置したピンを有している。
特に中空成形体を成形する機能をも有する場合には、パ
リソンを膨らませるためのエアーブローピンを金型下方
より挿入するための穴が金型に設けられている。The mold for obtaining the foamed molded article with the skin is, for example, a combination mold composed of a concave mold and a convex mold, and has a space for indirectly cooling the foamed molded article with the skin by cooling the mold surface. It has a feeder for filling the foam piece into the hollow molded body, a pin having a large number of slit or circular holes for supplying a heating medium and sucking air or the heating medium.
In particular, when the mold also has a function of molding a hollow molded body, a hole is provided in the mold for inserting an air blow pin for expanding the parison from below the mold.
【0043】また本発明において中空成形体自体で剛性
が有る場合、発泡体片が最密充填時の空間率45%以上
の形状であることから、スチームが発泡体片の相互に透
過しやすいため、スチーム圧力が低くできる。よって、
中空成形体の強度があれば上記のような表皮付き発泡成
形体製造用金型がなくとも可能である。Further, in the present invention, when the hollow molded article itself has rigidity, since the foam piece has a shape having a porosity of 45% or more at the time of close packing, steam easily penetrates into each other. , Steam pressure can be reduced. Therefore,
If the strength of the hollow molded body is high, it is possible without the mold for producing a foamed molded body with a skin as described above.
【0044】図3は本発明の表皮付き発泡成形体2の一
例を示し、3は中空成形体、4は発泡体片1の相互を融
着させて形成される発泡体片成形体である。図5は本発
明の表皮付き発泡成形体を製造装置の一例を略図的に示
すもので、図中、5は金型、6は中空成形体の内部に発
泡体片を充填するフィーダーである。この充填方法とし
ては、圧縮充填方法、加圧充填方法等の公知の充填法を
採用することができる。また7、8は加熱用スチームを
供給したり、供給されたスチームを吸引したり、スチー
ムのドレンを吸引するためのピンで、該ピン7、8は、
エアシリンダー9、10にガイドされて摺動し、金型5
内に装着された中空成形体3内に充填された発泡体片1
の層内への差し込みや、引き抜きが可能に構成されてい
る。上記のピンは発泡体片よりも小さい孔、スリット状
又は円形状の孔が多数あいており、中空成形体の大きさ
により一本または、複数本挿入させ成形することができ
る。FIG. 3 shows an example of a foam molded article 2 with a skin according to the present invention, 3 is a hollow molded article, and 4 is a foam piece molded article formed by fusing the foam pieces 1 to each other. FIG. 5 schematically shows an example of an apparatus for manufacturing a foamed molded article with a skin according to the present invention. In the figure, reference numeral 5 denotes a mold, and reference numeral 6 denotes a feeder for filling the hollow molded article with foam pieces. As the filling method, a known filling method such as a compression filling method and a pressure filling method can be adopted. Reference numerals 7 and 8 denote pins for supplying heating steam, sucking the supplied steam, and sucking the drain of steam.
Guided by the air cylinders 9 and 10 slid, the mold 5
Foam piece 1 filled in hollow molded body 3 mounted inside
Can be inserted into the layer or pulled out. The above-mentioned pin has many holes smaller than the foam piece, slit-shaped or circular holes, and can be formed by inserting one or a plurality of holes depending on the size of the hollow molded body.
【0045】本発明において表皮付き発泡成形体を得る
方法の一例として、金型5内に中空成形体3を装着した
後、フィーダー6より発泡体片1を中空成形体3内に充
填し、次いで中空成形体3内に充填された発泡体片1の
層内に差し込まれたピン7、8の一方より、加熱用スチ
ームを供給することにより発泡体片1を加熱する方法を
用いることができるが、この際に他方のピンよりスチー
ムを吸引することによりスチームの流れが円滑になり、
供給したスチームを発泡体片1間に満遍なく浸透させる
ことができる。またピンを所定時間毎に交替して加熱、
吸引を行うことにより、更に円滑にスチームを供給する
ことができる。加熱用スチーム供給後、ピン7、8の一
方又は両方から吸引することにより、発泡体片1間に溜
まっている熱やドレンを効率よく排出することができ
る。このようにして加熱、冷却した後、ピン7、8を抜
き取り、得られた成形体を金型5から取り出して養生す
る。養生は、60℃、大気圧下で24時間程度行うこと
が好ましい。As an example of a method for obtaining a foamed molded article with a skin in the present invention, after mounting the hollow molded article 3 in the mold 5, the foam piece 1 is filled into the hollow molded article 3 from the feeder 6, A method of heating the foam piece 1 by supplying steam for heating from one of the pins 7 and 8 inserted into the layer of the foam piece 1 filled in the hollow molded body 3 can be used. In this case, the steam is smoothed by sucking the steam from the other pin,
The supplied steam can be uniformly penetrated between the foam pieces 1. In addition, the pins are replaced every predetermined time and heated,
By performing suction, steam can be supplied more smoothly. After the heating steam is supplied, the heat or the drain accumulated between the foam pieces 1 can be efficiently discharged by suctioning from one or both of the pins 7 and 8. After heating and cooling in this manner, the pins 7 and 8 are pulled out, and the obtained molded body is taken out of the mold 5 and cured. Curing is preferably performed at 60 ° C. under atmospheric pressure for about 24 hours.
【0046】本発明の発泡体片成形体の表面の少なくと
も一部を熱可塑性樹脂からなる中空成形体にて被覆して
なる表皮付き発泡成形体としては、例えば熱可塑性発泡
体片成形体の全面を被覆した表皮付き発泡成形体、貫通
した筒状の中空成形体と発泡体片成形体とからなる開口
部の二面が被覆されていない表皮付き発泡成形体、底の
ある筒状の中空成形体と発泡体片成形体とからなる開口
部の一面が被覆されていない表皮付き発泡成形体等が挙
げられる。本発明の表皮付き発泡成形体の用途として
は、例えばパレット、台車等の流通分野、断熱パネル、
防音パネル等の建築分野、濾過材、透水材等の土木分
野、各種浮力用部材、自動車内装用、バンパー材、家
具、寝具等が挙げられる。The foamed molded article with a skin obtained by covering at least a part of the surface of the molded foam piece of the present invention with a hollow molded article made of a thermoplastic resin is, for example, the entire surface of the molded thermoplastic foam piece. Foamed molded article with a skin, a foamed molded article with a skin that is not covered on two sides of an opening portion composed of a cylindrical hollow molded article penetrated and a foam piece molded article, and a cylindrical hollow molded article with a bottom A foamed molded article with a skin, which is not covered with one surface of the opening formed by the body and the foam piece molded article, is exemplified. Examples of the use of the foamed molded article with a skin of the present invention include, for example, a pallet, a distribution field such as a trolley, an insulating panel,
Examples include the construction field such as soundproof panels, the civil engineering field such as filtration materials and water permeable materials, various buoyancy members, automobile interiors, bumper materials, furniture, bedding, and the like.
【0047】[0047]
【実施例】以下、実施例を挙げて本発明を更に詳細に説
明する。EXAMPLES Hereinafter, the present invention will be described in more detail with reference to examples.
【0048】実施例1 エチレン−プロピレンブロック共重合体(MI=0.6
g/10分(230℃、荷重2.16kgf)、融点1
61℃、エチレン含量7.0重量%)の層と、内層がプ
ロピレン−エチレンランダム共重合体(MI=8g/1
0分、融点132℃、エチレン含量5.8重量%)の層
からなる2層構成のパリソン(プロピレン−エチレンラ
ンダム共重合体の層が内面側)を共押出法によって押出
機より押出し、このパリソンを中空成形体製造用金型
(縦400mm×横250mm×深さ100mm)の上
方から金型に供給し、パリソン内に空気を吹き込みなが
ら金型を型締めし、冷却して中空成形体(肉厚2.6m
m)を得た。次にこの中空成形体を、発泡粒子供給用フ
ィーダーを備えた表皮付き発泡成形体製造用の金型(縦
396mm×横248mm×深さ100mm)内に装着
して型締めした後、プロピレン−エチレンランダム共重
合体(エチレン含量2.4重量%、融点146℃)を基
材樹脂とする、図1の(ア)に示す形状の円筒形状の発
泡粒子(平均粒子重量2mg、嵩発泡倍率20倍、d
MIN =1.6mm、DMIN =2.5mm、dMIN /D
MIN =0.64、L=3.5mm、L/D=1.0、粒
子内圧2.0kg/cm2 (絶対圧))を中空成形体内
に充填した。Example 1 Ethylene-propylene block copolymer (MI = 0.6
g / 10 minutes (230 ° C, load 2.16 kgf), melting point 1
61 ° C., an ethylene content of 7.0% by weight) and an inner layer made of a propylene-ethylene random copolymer (MI = 8 g / 1)
A parison having a two-layer structure (a layer of a propylene-ethylene random copolymer on the inner side) consisting of 0 minute, melting point of 132 ° C. and ethylene content of 5.8% by weight was extruded from an extruder by a coextrusion method. Is supplied to the mold from above a mold (400 mm long × 250 mm wide × 100 mm deep) for manufacturing a hollow molded body, the mold is clamped while blowing air into a parison, and the hollow molded body (meat) is cooled. 2.6m thick
m). Next, the hollow molded body is mounted in a mold (396 mm in length, 248 mm in width, and 100 mm in depth) provided with a feeder for supplying foamed particles and used for producing a foamed molded body with a skin, and then closed with propylene-ethylene. Using a random copolymer (ethylene content: 2.4% by weight, melting point: 146 ° C.) as a base resin, cylindrical foamed particles having a shape shown in FIG. 1A (average particle weight: 2 mg, bulk expansion ratio: 20 times) , D
MIN = 1.6 mm, D MIN = 2.5 mm, d MIN / D
MIN = 0.64, L = 3.5 mm, L / D = 1.0, particle internal pressure 2.0 kg / cm 2 (absolute pressure)) were filled in the hollow molded body.
【0049】中空成形体内に発泡粒子を充填する際、中
空成形体内に差し込まれた両方のピンより中の空気を吸
引しながら充填した後、充填された発泡粒子の層内に差
し込んだ片方のピンから、吸引しながらもう一方のピン
よりスチームを5秒間供給し、次いでスチームを供給し
ていたピンと吸引していたピンを交換し、吸引しながら
スチームを5秒間供給し、発泡粒子の層内に残存する空
気を排気した後、150℃のスチームを両方のピンから
発泡粒子の層内に供給して発泡粒子を加熱成形した。次
いで、発泡粒子の層(この時点では発泡粒子は相互に融
着している。)内に差し込んだピンにより吸引冷却した
後、型を開いて表皮付き発泡成形体を取り出した。この
成形体を60℃、大気圧下で24時間養生し、室温下で
保持した。成形に用いた発泡粒子の諸物性を表1に、成
形条件を表2に、得られた表皮付き発泡成形体の諸物性
を表3に示す。When the hollow molded body is filled with the foamed particles, the air is filled while sucking air from both pins inserted into the hollow molded body, and then one of the pins inserted into the layer of the filled foamed particles is filled. Then, steam is supplied from the other pin while sucking for 5 seconds, and then the pin that has supplied steam and the pin that is sucking are exchanged. Steam is then supplied for 5 seconds while sucking, and the steam is supplied into the layer of expanded particles. After exhausting the remaining air, steam at 150 ° C. was supplied from both pins into the layer of the foamed particles to heat-mold the foamed particles. Next, after cooling by suction with a pin inserted into a layer of the foamed particles (at this time, the foamed particles are fused to each other), the mold was opened and the foamed molded article with a skin was taken out. This molded body was cured at 60 ° C. under atmospheric pressure for 24 hours and kept at room temperature. Table 1 shows the physical properties of the foamed particles used for molding, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with a skin obtained.
【0050】[0050]
【表1】 [Table 1]
【0051】[0051]
【表2】 [Table 2]
【0052】[0052]
【表3】 [Table 3]
【0053】※1 中空成形体製造用金型及び表皮付き
発泡成形体製造用金型の深さ ※2 rPP:プロピレン−エチレンランダム共重合体 bPP:プロピレン−エチレンブロック共重合体 LLD:直鎖状低密度ポリエチレン HDPE:高密度ポリエチレン ※3 rPP:プロピレン−エチレンランダム共重合体 bPP:プロピレン−エチレンブロック共重合体 LLD:直鎖状低密度ポリエチレン* 1 Depth of mold for producing hollow molded article and mold for producing foam molded article with skin * 2 rPP: propylene-ethylene random copolymer bPP: propylene-ethylene block copolymer LLD: linear Low density polyethylene HDPE: High density polyethylene * 3 rPP: Propylene-ethylene random copolymer bPP: Propylene-ethylene block copolymer LLD: Linear low density polyethylene
【0054】※4 折り曲げ破断試験:発泡体片(発泡
粒子)の融着性を評価し、具体的には図5に示すように
表皮付き発泡成形体の内部(A)と表皮付近(B)とか
ら切り出したサンプル(サイズ:25mm×25mm×
100mm)を折り曲げて破断させ、各々の破断面を観
察し、 ○・・・発泡体片(発泡粒子)の大部分に材料破壊が起
こっている。 △・・・発泡体片(発泡粒子)の材料破壊と発泡粒子相
互間の界面剥離が混在している。 ×・・・発泡体片(発泡粒子)相互間の大部分が界面剥
離している。として評価した。* 4 Bending rupture test: The fusion property of the foam pieces (expanded particles) was evaluated. Specifically, as shown in FIG. 5, the inside of the foamed molded article with the skin (A) and the vicinity of the skin (B) Sample (size: 25 mm x 25 mm x
(100 mm) was bent and broken, and each fracture surface was observed. ○: Most of the foam pieces (foamed particles) were broken. Δ: Material destruction of foam pieces (foam particles) and interfacial peeling between foam particles are mixed. X: Most of the foam pieces (expanded particles) are peeled off at the interface. Was evaluated.
【0055】※5 表皮材と発泡体片(発泡粒子)の融
着性は、表皮付き発泡成形体を幅15mmに切り出した
サンプルにおける表皮材の90°剥離試験を行い、剥離
面の発泡体片(発泡粒子)の状態を観察し、 ○・・・発泡体片(発泡粒子)の大部分に材料破壊が起
こっている。 ×・・・発泡体片(発泡粒子)の大部分が界面剥離して
いる。として評価した。* 5 The fusion property between the skin material and the foam piece (foamed particles) was determined by conducting a 90 ° peel test of the skin material on a sample obtained by cutting a foam molded article with a skin into a width of 15 mm. The state of the (foamed particles) was observed. ○: Most of the foam pieces (foamed particles) were broken. ×: Most of the foam pieces (expanded particles) are peeled off at the interface. Was evaluated.
【0056】実施例2 嵩発泡倍率10倍の、図1の(ア)に示す円筒形状の発
泡粒子を使用した他は、実施例1と同様の条件で表皮付
き発泡成形体を得た。使用した発泡粒子の諸物性を表1
に、成形条件を表2に、得られた表皮付き発泡成形体の
諸物性を表3に示す。Example 2 A foamed molded article with a skin was obtained under the same conditions as in Example 1, except that the cylindrical expanded particles having a bulk expansion ratio of 10 times and shown in FIG. 1A were used. Table 1 shows the physical properties of the expanded particles used.
Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with a skin.
【0057】実施例3 中空成形体製造用金型及び表皮付き発泡成形体製造用金
型の深さを150mmとした他は、実施例1と同様の条
件で表皮付き発泡成形体を得た。使用した発泡粒子の諸
物性を表1に、成形条件を表2に、得られた表皮付き発
泡成形体の諸物性を表3に示す。Example 3 A foamed molded article with a skin was obtained under the same conditions as in Example 1 except that the depth of the mold for producing a hollow molded article and the mold for producing a foamed molded article with a skin were 150 mm. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0058】実施例4 中空成形体の肉厚を1.5mmとした他は、実施例3と
同様の条件で表皮付き発泡成形体を得た。使用した発泡
粒子の諸物性を表1に、成形条件を表2に、得られた表
皮付き発泡成形体の諸物性を表3に示す。Example 4 A foamed molded article with a skin was obtained under the same conditions as in Example 3 except that the thickness of the hollow molded article was 1.5 mm. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0059】実施例5 中空成形体を成形する機能をも有する表皮付き発泡成形
体の製造用金型(深さ150mm)にパリソンを供給し
て中空成形体を成形した後、金型に挟まれた状態にある
中空成形体内に発泡粒子を充填して成形した他は、実施
例4と同様の条件にして表皮付き発泡成形体を得た。使
用した発泡粒子の諸物性を表1に、成形条件を表2に、
得られた表皮付き発泡成形体の諸物性を表3に示す。Example 5 A parison was supplied to a mold (depth: 150 mm) for producing a foamed molded article having a skin, which also has a function of molding a hollow molded article, and the hollow molded article was molded. A foamed molded article with a skin was obtained under the same conditions as in Example 4, except that the foamed particles were filled and molded into the hollow molded article in the state of being folded. Table 1 shows various physical properties of the foamed particles used, and Table 2 shows molding conditions.
Table 3 shows various physical properties of the foamed molded article with a skin.
【0060】実施例6 中空成形体として、内層側が直鎖状低密度ポリエチレン
(MI=1.3g/10分(190℃、荷重2.16k
gf)、融点124℃)の層、外層側が高密度ポリエチ
レン(MI=0.8g/10分、融点134℃)の層か
らなる2層構成のものを用い、直鎖状低密度ポリエチレ
ン(MI=1.3g/10分、融点124℃)を基材樹
脂とする、図1の(ア)に示す形状の円筒形状の発泡粒
子(平均粒子重量2mg、嵩発泡倍率20倍、dMIN =
1.3mm、DMIN =2.8mm、dMIN /DMIN =
0.46、L=3.2mm、L/D=1.0、内圧1.
0kg/cm2 (絶対圧))のものを用いた他は、実施
例1と同様の条件で表皮付き発泡成形体を得た。使用し
た発泡粒子の諸物性を表1に、成形条件を表2に、得ら
れた表皮付き発泡成形体の諸物性を表3に示す。Example 6 As a hollow molded article, the inner layer side was a linear low-density polyethylene (MI = 1.3 g / 10 min (190 ° C., load 2.16 k
gf), a layer having a melting point of 124 ° C.) and a layer having a high density polyethylene (MI = 0.8 g / 10 min, melting point of 134 ° C.) on the outer layer side. (A) (1.3 g / 10 min, melting point 124 ° C.) as a base resin, cylindrical foamed particles (average particle weight 2 mg, bulk expansion ratio 20 times, d MIN =
1.3 mm, D MIN = 2.8 mm, d MIN / D MIN =
0.46, L = 3.2 mm, L / D = 1.0, internal pressure 1.
A foamed molded article with a skin was obtained under the same conditions as in Example 1 except that the pressure was 0 kg / cm 2 (absolute pressure). Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0061】実施例7 中空成形体製造用金型及び表皮付き発泡成形体製造用金
型の深さを150mmとした他は、実施例6と同様の条
件で表皮付き発泡成形体を得た。使用した発泡粒子の諸
物性を表1に、成形条件を表2に、得られた表皮付き発
泡成形体の諸物性を表3に示す。Example 7 A foam molded article with a skin was obtained under the same conditions as in Example 6, except that the depth of the mold for producing a hollow molded article and the mold for producing a foam molded article with a skin were 150 mm. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0062】実施例8 発泡粒子としてL/D=5の円柱状発泡粒子を用いた他
は、実施例4と同様にして成形した。使用した発泡粒子
の諸物性を表1に、成形条件を表2に、得られた表皮付
き発泡成形体の諸物性を表3に示す。Example 8 Molding was carried out in the same manner as in Example 4, except that cylindrical expanded particles having L / D = 5 were used as expanded particles. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0063】実施例9 発泡粒子として、図4の(ア)に示す形状のものを用い
た他は、実施例4と同様にして成形した。使用した発泡
粒子の諸物性を表1に、成形条件を表2に、得られた表
皮付き発泡成形体の諸物性を表3に示す。Example 9 Molding was carried out in the same manner as in Example 4 except that the expanded particles having the shape shown in FIG. 4A were used. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0064】実施例10 中空成形体として直鎖状低密度ポリエチレン(MI=
1.3g/10分、融点124℃)の単層構造のものを
用いた他は実施例6と同様の条件で表皮付き発泡成形体
を得た。使用した発泡粒子の諸物性を表1に、成形条件
を表2に、得られた表皮付き発泡成形体の諸物性を表3
に示す。Example 10 A linear low-density polyethylene (MI =
A foamed molded article with a skin was obtained under the same conditions as in Example 6, except that a single-layer structure (1.3 g / 10 minutes, melting point: 124 ° C.) was used. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
Shown in
【0065】実施例11 中空成形体として実施例4の中空成形体を用いた他は実
施例7と同様の条件で表皮付き発泡成形体を得た。使用
した発泡粒子の諸物性を表1に、成形条件を表2に、得
られた表皮付き発泡成形体の諸物性を表3に示す。Example 11 A foam molded article with a skin was obtained under the same conditions as in Example 7 except that the hollow molded article of Example 4 was used as the hollow molded article. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0066】比較例1 発泡粒子形状が略球状である点を除いて実施例1と同様
の条件で成形した。使用した発泡粒子の諸物性を表1
に、成形条件を表2に、得られた表皮付き発泡成形体の
諸物性を表3に示す。Comparative Example 1 Molding was carried out under the same conditions as in Example 1 except that the expanded particle shape was substantially spherical. Table 1 shows the physical properties of the expanded particles used.
Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with a skin.
【0067】比較例2 中空成形体の肉厚を1.5mmとした点を除き、比較例
1と同様の条件で成形した。使用した発泡粒子の諸物性
を表1に、成形条件を表2に、得られた表皮付き発泡成
形体の諸物性を表3に示す。Comparative Example 2 A hollow molded body was molded under the same conditions as in Comparative Example 1 except that the thickness of the hollow molded body was 1.5 mm. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0068】比較例3 中空成形体製造用金型及び表皮付き発泡成形体製造用金
型の深さを150mmとした他は、比較例1と同様の条
件で表皮付き発泡成形体を得た。使用した発泡粒子の諸
物性を表1に、成形条件を表2に、得られた表皮付き発
泡成形体の諸物性を表3に示す。Comparative Example 3 A foamed molded article with a skin was obtained under the same conditions as in Comparative Example 1 except that the depth of the mold for producing a hollow molded article and the mold for producing a foamed molded article with a skin were 150 mm. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0069】比較例4 発泡粒子の形状として略球状発泡粒子を用いた他は、実
施例7と同様の条件で表皮付き発泡成形体を得た。使用
した発泡粒子の諸物性を表1に、成形条件を表2に、得
られた表皮付き発泡成形体の諸物性を表3に示す。Comparative Example 4 A foamed molded article with a skin was obtained under the same conditions as in Example 7, except that substantially spherical expanded particles were used as the expanded particles. Table 1 shows the physical properties of the foamed particles used, Table 2 shows the molding conditions, and Table 3 shows the physical properties of the foamed molded article with the obtained skin.
【0070】[0070]
【発明の効果】以上説明したように本発明方法は、熱可
塑性樹脂発泡体片を熱可塑性樹脂からなる中空成形体の
内部に充填し、該発泡体片を加熱媒体により加熱して発
泡体片相互間を融着させる表皮付き発泡成形体の製造方
法において、該発泡体片として最密充填時の空間率45
%以上の形状のものを用いるため、中空成形体が加熱媒
体の透過性に乏しいものであっても、中空成形体の内部
に充填された発泡体片の間に加熱媒体が充分に透過し、
この結果、中空成形体の内部に充填された発泡体片が良
好に融着されるとともに、中空成形体の厚さが厚くなっ
た場合や、形状が複雑になった場合でも、発泡体片相互
の融着性に優れた表皮付き発泡成形体を得ることができ
る。また、中空成形体の内層側が発泡体片と融着性を有
する場合、発泡体片成形体と中空成形体との融着性に優
れた表皮付き発泡成形体を得ることができる。更に本発
明方法では、発泡体片の成形時に発泡体片成形体と中空
成形体とを一体にすることができるため、表皮付き発泡
成形体の製造効率に優れる。また熱可塑性樹脂からなる
中空成形体の内部に充填する熱可塑性樹脂発泡体片が筒
状発泡粒子の場合、発泡体片(発泡粒子)の基材樹脂が
オレフィン系樹脂の場合であっても、加熱媒体を深層部
まで浸透させることができ発泡粒子を確実に融着させる
ことができる。よって融着性に優れた表皮付き発泡成形
体が得られる。As described above, according to the method of the present invention, a thermoplastic resin foam piece is filled in a hollow molded article made of a thermoplastic resin, and the foam piece is heated by a heating medium to form a foam piece. In the method for producing a foamed molded article with a skin to be fused together, a void fraction of 45 at the time of closest packing is used as the foam piece.
% Or more, even if the hollow molded article has poor permeability to the heating medium, the heating medium sufficiently permeates between the foam pieces filled inside the hollow molded article,
As a result, the foam pieces filled into the hollow molded body are fused well, and even when the thickness of the hollow molded body becomes thick or the shape becomes complicated, Can be obtained. Further, when the inner layer side of the hollow molded article has a fusion property with the foam piece, a foam molded article with a skin excellent in the fusion property between the foam piece molded article and the hollow molded article can be obtained. Further, according to the method of the present invention, the foam piece molded article and the hollow molded article can be integrated at the time of molding the foam piece, so that the production efficiency of the foam molded article with skin is excellent. Further, when the thermoplastic resin foam pieces to be filled into the hollow molded body made of a thermoplastic resin are cylindrical foamed particles, even when the base resin of the foam pieces (foamed particles) is an olefin-based resin, The heating medium can penetrate to the deep layer, and the expanded particles can be reliably fused. Thus, a foamed molded article with a skin having excellent fusion property can be obtained.
【0071】また本発明の表皮付き発泡成形体は、連通
した空隙を有する熱可塑性樹脂発泡体片成形体の表面の
少なくとも一部を熱可塑性樹脂からなる中空成形体にて
被覆してなる表皮付き発泡成形体であって、該発泡体片
成形体は空隙率が5%以上であり、実施例に示したよう
に折り曲げ破断試験において大部分が界面剥離してしま
うことがなく、良好に発泡体片同士が融着しているもの
であるため、強度、通気性、吸音性等に優れ、建築分野
では通気性のある断熱パネル、吸音、防音のパネル等、
更に土木分野では濾過材、透水材、保水材等として好適
に利用することができる効果を有する。Further, the foamed molded article with a skin of the present invention has a skin formed by covering at least a part of the surface of a thermoplastic resin foam piece molded article having communicating voids with a hollow molded article made of a thermoplastic resin. The foam molded article has a porosity of 5% or more, and most of the foam piece does not peel off at the interfacial surface in a bending fracture test as shown in Examples. Since the pieces are fused together, they have excellent strength, air permeability, sound absorption, etc., and in the construction field, air-permeable insulation panels, sound absorption, soundproofing panels, etc.
Further, in the field of civil engineering, it has an effect that it can be suitably used as a filtering material, a water permeable material, a water retaining material, and the like.
【図1】本発明において用いる発泡体片の形状の一例を
示す略図である。FIG. 1 is a schematic view showing an example of the shape of a foam piece used in the present invention.
【図2】本発明において用いる柱状の発泡粒子の一例を
示す略図である。FIG. 2 is a schematic view showing an example of columnar expanded particles used in the present invention.
【図3】本発明の表皮付き発泡成形体の一例を示す縦断
面図である。FIG. 3 is a longitudinal sectional view showing an example of a foam molded article with a skin according to the present invention.
【図4】本発明において用いる突起を有する発泡粒子の
一例を示す略図である。FIG. 4 is a schematic view showing an example of a foamed particle having a projection used in the present invention.
【図5】本発明の表皮付き発泡成形体の製造過程の一例
を示す断面略図である。FIG. 5 is a schematic sectional view showing an example of a production process of the foam molded article with a skin of the present invention.
1 発泡体片 2 表皮付き発泡成形体 3 中空成形体 4 発泡体片成形体 5 表皮付き発泡成形体製造用金型 6 フィーダー 7、8 ピン 9、10 エアシリンダー DESCRIPTION OF SYMBOLS 1 Foam piece 2 Foam molded article with skin 3 Hollow molded article 4 Foam piece molded article 5 Mold for producing foam molded article with skin 6 Feeder 7, 8 pin 9, 10 Air cylinder
───────────────────────────────────────────────────── フロントページの続き (72)発明者 平 晃暢 栃木県宇都宮市駒生町1078−4 カーサア イ202 (72)発明者 所 寿男 栃木県宇都宮市砥上町282−1 ブランシ ュール砥上103 Fターム(参考) 4F100 AK01A AK01B AK64 BA02 CA01B DA11B DD31A DE01B DJ01B GB90 JB16A JB16B YY00B 4F212 AA05 AA08 AA11 AG03 AG20 AH26 AH48 AH56 AK01 UA07 UB01 UB14 UC01 UC06 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Akinori Taira 1078-4 Komao-cho, Utsunomiya-city, Tochigi 2022. 4F100 AK01A AK01B AK64 BA02 CA01B DA11B DD31A DE01B DJ01B GB90 JB16A JB16B YY00B 4F212 AA05 AA08 AA11 AG03 AG20 AH26 AH48 AH56 AK01 UA07 UB01 UB14 UC01 UC06
Claims (3)
らなる中空成形体の内部に充填され、該発泡体片を加熱
媒体により加熱して発泡体片相互間を融着させる表皮付
き発泡成形体の製造方法であって、該発泡体片が最密充
填時の空間率が45%以上の形状であることを特徴とす
る表皮付き発泡成形体の製造方法。1. A foam molding with a skin in which a thermoplastic resin foam piece is filled into a hollow molded body made of a thermoplastic resin, and the foam piece is heated by a heating medium to fuse the foam pieces to each other. A method for producing a foam, wherein the foam piece has a shape having a voidage of 45% or more at the time of closest packing.
に充填する熱可塑性樹脂発泡体片が、筒状の熱可塑性樹
脂発泡粒子である請求項1記載の表皮付き発泡成形体の
製造方法。2. The method for producing a foamed molded article with a skin according to claim 1, wherein the thermoplastic resin foam pieces to be filled in the hollow molded article made of a thermoplastic resin are tubular thermoplastic resin foamed particles.
体片成形体の表面の少なくとも一部を、熱可塑性樹脂か
らなる中空成形体にて被覆してなる表皮付き発泡成形体
であって、該発泡体片成形体の空隙率が5%以上である
ことを特徴とする表皮付き発泡成形体。3. A foamed molded article with a skin obtained by covering at least a part of the surface of a molded article of a thermoplastic resin foam having communicating voids with a hollow molded article made of a thermoplastic resin. A foam molded article with a skin, wherein the porosity of the foam piece molded article is 5% or more.
Priority Applications (1)
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JP01716399A JP4503720B2 (en) | 1999-01-26 | 1999-01-26 | Method for producing foamed article with skin |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP01716399A JP4503720B2 (en) | 1999-01-26 | 1999-01-26 | Method for producing foamed article with skin |
Publications (2)
Publication Number | Publication Date |
---|---|
JP2000210967A true JP2000210967A (en) | 2000-08-02 |
JP4503720B2 JP4503720B2 (en) | 2010-07-14 |
Family
ID=11936304
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JP01716399A Expired - Fee Related JP4503720B2 (en) | 1999-01-26 | 1999-01-26 | Method for producing foamed article with skin |
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Cited By (9)
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JP2003039512A (en) * | 2001-08-01 | 2003-02-13 | Sumitomo Chem Co Ltd | Thermoplastic resin foamed molded object |
JP2006077484A (en) * | 2004-09-10 | 2006-03-23 | Kaneka Corp | Thermal insulation panel and its manufacturing method |
JP2006240285A (en) * | 2005-02-01 | 2006-09-14 | Kaneka Corp | Thermoplastic resin in-mold foamed molded product and its manufacturing method |
JP2008036822A (en) * | 2006-08-01 | 2008-02-21 | Kaneka Corp | Mold for in-mold foam molding of synthetic resin formed particles and molding method |
JP2016028883A (en) * | 2014-07-18 | 2016-03-03 | 株式会社ジェイエスピー | Skin material coating foam particle molding production method |
KR20180085136A (en) * | 2017-01-18 | 2018-07-26 | 코스파 주식회사 | Laminate for sound insulation |
WO2018147464A1 (en) * | 2017-02-13 | 2018-08-16 | 旭化成株式会社 | Resin foamed particles, resin foam molded body, and laminated body |
JP2018171829A (en) * | 2017-03-31 | 2018-11-08 | 旭化成株式会社 | Laminate |
US11235553B2 (en) | 2018-04-09 | 2022-02-01 | Asahi Kasei Kabushiki Kaisha | Foam molded product and method of producing same |
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JPH07137121A (en) * | 1993-11-15 | 1995-05-30 | Showa Denko Kk | Molded piece having resin foamed layer and manufacture thereof |
JPH07137068A (en) * | 1993-11-16 | 1995-05-30 | Jsp Corp | Foamed polymer body having gaps communicating with one another |
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JPH08155999A (en) * | 1994-11-29 | 1996-06-18 | Nippon G Ii Plast Kk | Bead foaming molding method and bead foamed molded form |
JPH11207759A (en) * | 1998-01-26 | 1999-08-03 | Jsp Corp | Manufacture of foam molded body with skin and foam molded body with skin |
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JPH06339979A (en) * | 1992-07-13 | 1994-12-13 | Aron Kasei Co Ltd | Method for molding foamed body having skin |
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JPH08103581A (en) * | 1994-10-03 | 1996-04-23 | Jsp Corp | Cushion material |
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JP2003039512A (en) * | 2001-08-01 | 2003-02-13 | Sumitomo Chem Co Ltd | Thermoplastic resin foamed molded object |
JP2006077484A (en) * | 2004-09-10 | 2006-03-23 | Kaneka Corp | Thermal insulation panel and its manufacturing method |
JP2006240285A (en) * | 2005-02-01 | 2006-09-14 | Kaneka Corp | Thermoplastic resin in-mold foamed molded product and its manufacturing method |
JP2008036822A (en) * | 2006-08-01 | 2008-02-21 | Kaneka Corp | Mold for in-mold foam molding of synthetic resin formed particles and molding method |
JP2016028883A (en) * | 2014-07-18 | 2016-03-03 | 株式会社ジェイエスピー | Skin material coating foam particle molding production method |
US10766166B2 (en) | 2014-07-18 | 2020-09-08 | Jsp Corporation | Method for producing skin-covered, expanded bead molded article |
KR20180085136A (en) * | 2017-01-18 | 2018-07-26 | 코스파 주식회사 | Laminate for sound insulation |
KR101911790B1 (en) * | 2017-01-18 | 2018-10-26 | 코스파 주식회사 | Laminate for sound insulation |
WO2018147464A1 (en) * | 2017-02-13 | 2018-08-16 | 旭化成株式会社 | Resin foamed particles, resin foam molded body, and laminated body |
US10882970B2 (en) | 2017-02-13 | 2021-01-05 | Asahi Kasei Kabushiki Kaisha | Resin foam particles, resin foam shaped product, and laminate |
JP2018171829A (en) * | 2017-03-31 | 2018-11-08 | 旭化成株式会社 | Laminate |
US11235553B2 (en) | 2018-04-09 | 2022-02-01 | Asahi Kasei Kabushiki Kaisha | Foam molded product and method of producing same |
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