JP2006088627A - Composite molded article, its manufacturing method and manufacturing device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method to manufacture a composite molded article having a sheet laminated on the surface of a thermoplastic resin foamed article in high shaping accuracy, a manufacturing device used for it, and a composite molded article obtained by the above method. <P>SOLUTION: The manufacturing method for the composite molded article in which a skin comprising a thermoplastic resin sheet is laminated on the surface of a thermoplastic resin foamed article is characterized by the steps of stretching a thermoplastic resin sheet between the first mold and the second mold constituting a mold; forming a cavity which coincides with the appearance of the composite molded article manufactured by mold-clamping the first mold and second mold after this thermoplastic resin sheet is heated and softened; making a sheet pressure member approach the second mold through the cavity from the first mold side; pressing the softened thermoplastic resin sheet to the second mold side and subsequently returning the sheet pressure member to an original position; filling up the cavity with a thermoplastic resin foaming particles and subsequently carrying out molding in the mold by heating the mold to the temperature higher than a fusion temperature of thermoplastic resin foaming particles. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、熱可塑性樹脂シート（以下、シートと略記する。）からなる表皮と発泡合成樹脂成形品とが積層された複合成形品とその製造方法及び製造装置に関する。本発明の複合成形品は、例えば、ユニットバスの天井材等の住宅設備用部材、自動車の内装材（インストルメンタルパネル、ドアパネル、シートバックパネル、ステアリングホイール、取手等）、家具（椅子の座部等）、容器、内装材、壁面材、航空便用の軽量パレット等に用いられる。   The present invention relates to a composite molded article in which a skin made of a thermoplastic resin sheet (hereinafter abbreviated as a sheet) and a foamed synthetic resin molded article are laminated, a method for producing the same, and a production apparatus. The composite molded product of the present invention includes, for example, housing equipment members such as unit bath ceiling materials, automobile interior materials (instrumental panels, door panels, seat back panels, steering wheels, handles, etc.), furniture (chair seats). Etc.), containers, interior materials, wall materials, lightweight pallets for air mail, etc.

発泡合成樹脂成形品の表面改良目的として、耐久性の向上がある。従来、発泡合成樹脂成形品の表面改良の方法として、発泡合成樹脂成形品の表面に、ポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）、ハイインパクトポリスチレン（ＨＩＰＳ）等からなるシートを積層し、これを表皮とした複合成形品が提案されている。
従来、この種の複合成形品の製造方法として、上下一対の金型で、両型の合面に挟持されたシートを加熱してドローダウンさせ、また真空吸引することにより金型に沿うように予備成形し、該型内の熱と蒸気加熱による発泡樹脂材の発泡圧力とにより、同時成形する方法が提案されている（例えば、特許文献１参照。）。 The purpose of improving the surface of a foamed synthetic resin molded article is to improve durability. Conventionally, as a method of improving the surface of a foamed synthetic resin molded product, a sheet made of polypropylene (PP), polyethylene (PE), high impact polystyrene (HIPS), etc. is laminated on the surface of the foamed synthetic resin molded product, and this is applied to the skin. A composite molded product has been proposed.
Conventionally, as a method of manufacturing this type of composite molded product, a pair of upper and lower molds are used to heat and draw down a sheet sandwiched between the mating surfaces of both molds, and to draw along a mold by vacuum suction. A method has been proposed in which preforming is performed, and simultaneous molding is performed by the heat in the mold and the foaming pressure of the foamed resin material by steam heating (see, for example, Patent Document 1).

また、シートを第一成形型と第二成形型との間に設置し、軟化させ、型締めと同時に真空成形し、表皮材が配置された第一成形型と、多数の透孔を壁面に有する第二成形型との間に形成された成形空間部に充填されたポリオレフィン系樹脂発泡粒子を加熱し、融着させることによって表皮付き発泡成形体を製造する方法が提案されている（例えば、特許文献２参照。）。なお、特許文献２中には、成形の応用例として、プラグアシスト成形が記載されているが、その詳細については記載されていない。   Also, the sheet is placed between the first mold and the second mold, softened, vacuum-molded at the same time as the mold is clamped, and a number of through holes are provided on the wall surface. A method of manufacturing a foamed molded article with a skin by heating and fusing polyolefin-based resin foamed particles filled in a molding space formed between the second mold and the second mold (for example, has been proposed (for example, (See Patent Document 2). In Patent Document 2, plug assist molding is described as an application example of molding, but details thereof are not described.

また、両型間に表皮材をセットし、両型を近接させてこの表皮材の周縁を突出状態にあるセット枠体の先端と他方の型との間で挟持させて両型間に一方の型の型面とセット枠体と表皮材で囲まれる密閉室を形成し、前記表皮材を加熱軟化させつつ前記他方の型内に吸引圧をかけて軟化した表皮材を他方の型の型面に添わせたうえ前記セット枠体を抗体させつつ型締めして型面に軟化した表皮材が添装された他方の型と一方の型間に形成されるキャビティ部に所要量の発泡合成樹脂ビーズ材料を供給し、この発泡合成樹脂ビーズ材料をキャビティ部に供給される蒸気により加熱膨張された表皮材が発泡樹脂成形体の表面に一体化された表皮一体発泡成形品を成形する方法が提案されている（例えば、特許文献３参照。）。   Also, a skin material is set between both molds, and both molds are brought close to each other, and the periphery of the skin material is sandwiched between the tip of the set frame body in a protruding state and the other mold, and one of the two molds The mold surface of the mold is formed with a sealed chamber surrounded by the mold surface, the set frame and the skin material, and the skin material softened by applying suction pressure to the other mold while heating and softening the skin material. The required amount of foamed synthetic resin in the cavity formed between the other mold and the other mold in which the skin material softened on the mold surface by clamping the mold while allowing the set frame to be antibody is attached Proposed a method to form a skin-integrated foam-molded product in which a bead material is supplied and the foamed synthetic resin bead material is heated and expanded by the steam supplied to the cavity part and integrated with the surface of the foamed resin molding. (For example, see Patent Document 3).

また、表皮材付発泡成形品を製造するに当たり、(1)成形型のキャビティ内へ発泡性熱可塑性樹脂粒子を充填し、蒸気により加熱発泡成形させて融着一体化した成形品を製造する工程、(2)該発泡成形した成形品を一方の型に保持された状態で型開きする工程、(3)他方の型と該成形品との間に、加熱により軟化した表皮材シートを配置する工程、(4)他方の型を真空成形型として使用して該表皮材シートを真空成形すると同時に型締めを行い、一方の型に保持された該成形品をアシスト型として併用して該表皮材シートを成形品に成形・積層一体化する工程とを経て製造する方法が提案されている（例えば、特許文献４参照）。
特開２０００−２２９３２９号公報 特開２００４−７４６５３号公報 特開平８−１７０１号公報 特開平９−８５７６５号公報 Also, when manufacturing a foam-molded product with a skin material, (1) a process of manufacturing a molded product in which foaming thermoplastic resin particles are filled into a cavity of a mold and heat-foamed with steam and integrated by fusion. (2) a step of opening the molded product that has been foam-molded while being held in one mold, and (3) placing a skin sheet softened by heating between the other mold and the molded product. Step (4) Using the other mold as a vacuum mold, vacuum-molding the skin sheet simultaneously with clamping, and using the molded product held in one mold as an assist mold There has been proposed a method of manufacturing a sheet through a step of forming and stacking and integrating the sheet into a molded product (see, for example, Patent Document 4).
JP 2000-229329 A JP 2004-74653 A Japanese Patent Laid-Open No. 8-1701 JP-A-9-85765

しかしながら、前述した特許文献１〜４に記載された従来技術には、それぞれ次のような問題があった。
特許文献１〜３に記載された製造方法では、シート状の表皮材をキャビティ表面に沿うように予備成形しているが、真空引きのみでは形状精度が十分出し切れない。
特許文献４に記載された製造方法では、発泡樹脂粒子の成形後、一度型開きをし、シートを挿入してからシートの成形となるので、成形工程が２工程となり、非常に効率が悪い。 However, the conventional techniques described in Patent Documents 1 to 4 described above have the following problems.
In the manufacturing methods described in Patent Documents 1 to 3, the sheet-shaped skin material is preformed so as to follow the cavity surface, but the shape accuracy cannot be sufficiently obtained only by vacuuming.
In the manufacturing method described in Patent Document 4, after molding the foamed resin particles, the mold is once opened and the sheet is molded after the sheet is inserted. Therefore, the molding process has two processes, which is very inefficient.

本発明は前記事情に鑑みてなされ、熱可塑性樹脂発泡成形品の表面にシートが積層された複合成形品を高い成形精度で製造するための製造方法、それに用いる製造装置、及び前記方法で得られた複合成形品の提供を目的とする。   The present invention has been made in view of the above circumstances, and is obtained by a manufacturing method for manufacturing a composite molded product in which a sheet is laminated on the surface of a thermoplastic resin foam molded product with high molding accuracy, a manufacturing apparatus used therefor, and the method described above. The purpose is to provide a composite molded product.

前記目的を達成するため、本発明は、成形型を構成する第１の型と第２の型の間にシートを張設し、該シートを加熱、軟化せしめた後、第１の型と第２の型を型締めして製造する複合成形品の外形と合致するキャビティを形成し、第１の型側からキャビティを通してシート押圧部材を第２の型に近接せしめ、軟化したシートを第２の型側に押圧し、次いでシート押圧部材を元の位置に戻し、キャビティ内に熱可塑性樹脂発泡粒子を充填し、次いで成形型を熱可塑性樹脂発泡粒子の融着温度以上の温度に加熱して型内成形し、熱可塑性樹脂発泡成形品の表面にシートからなる表皮が積層されてなる複合成形品を製造することを特徴とする複合成形品の製造方法を提供する。   In order to achieve the above object, the present invention stretches a sheet between the first mold and the second mold constituting the mold, heats and softens the sheet, and then the first mold and the second mold. Forming a cavity that matches the outer shape of the composite molded product manufactured by clamping the mold of the second mold, passing the cavity from the first mold side through the cavity, and bringing the softened sheet into the second mold Press to the mold side, then return the sheet pressing member to its original position, fill the cavity with thermoplastic resin foam particles, and then heat the mold to a temperature equal to or higher than the fusion temperature of the thermoplastic resin foam particles. Provided is a method for producing a composite molded product, characterized by producing a composite molded product that is formed by internal molding and a sheet skin is laminated on the surface of a thermoplastic resin foam molded product.

本発明の複合成形品の製造方法において、シート押圧部材によって軟化したシートを第２の型側に押圧するとともに、真空吸引又は圧空によりシートを第２の型に沿わせることが好ましい。   In the method for producing a composite molded article of the present invention, it is preferable that the sheet softened by the sheet pressing member is pressed to the second mold side, and the sheet is made to conform to the second mold by vacuum suction or air pressure.

本発明の複合成形品の製造方法において、第２の型に複数の凹部を有し、これらの凹部にシート押圧部材が進退可能に設けられていることが好ましい。   In the method for producing a composite molded article of the present invention, it is preferable that the second mold has a plurality of recesses, and a sheet pressing member is provided in these recesses so as to be able to advance and retract.

本発明の複合成形品の製造方法において、シートは、熱可塑性樹脂単層シート又は複数枚のシートやフィルムを積層してなる積層シート又は複数枚のシートやフィルムを重ねたシートであることが好ましい。   In the method for producing a composite molded article of the present invention, the sheet is preferably a thermoplastic resin single-layer sheet, a laminated sheet obtained by laminating a plurality of sheets or films, or a sheet obtained by laminating a plurality of sheets or films. .

本発明の複合成形品の製造方法において、シートは、熱可塑性樹脂発泡シート又はそれを含む積層シートであることが好ましい。   In the method for producing a composite molded article of the present invention, the sheet is preferably a thermoplastic resin foam sheet or a laminated sheet including the same.

本発明の複合成形品の製造方法において、型内成形して得られた成形品の熱可塑性樹脂発泡成形品が露出している面に新たにシートを重ね、型内成形し、熱可塑性樹脂発泡成形品の表面をシートからなる表皮で覆った複合成形品を製造することもできる。   In the method for producing a composite molded product according to the present invention, a sheet is newly laminated on the surface of the molded product obtained by molding in the mold, and the foamed molded product is exposed, molded in the mold, and foamed with the thermoplastic resin. It is also possible to manufacture a composite molded product in which the surface of the molded product is covered with a skin made of a sheet.

また本発明は、前述した本発明に係る製造方法により得られた複合成形品を提供する。   The present invention also provides a composite molded product obtained by the manufacturing method according to the present invention described above.

また本発明は、多数の蒸気穴が穿設された第１の型と第２の型から構成された成形型と、第１の型が固定された第１の外装体と、第２の型が固定された第２の外装体とを備え、第１の外装体と第２の外装体とを接近させた時、第１の型と第２の型が型締めされて成形型内に製造する複合成形品の外形と合致するキャビティが形成され、熱可塑性樹脂発泡粒子をキャビティ内に供給する供給管路が接続され、かつ第１の型と第２の型の間に張設したシートを第１の型側からキャビティを通して第２の型側に押圧するシート押圧部材とを備えたことを特徴とする複合成形品の製造装置を提供する。   The present invention also provides a molding die composed of a first die and a second die having a large number of steam holes, a first exterior body to which the first die is fixed, and a second die. And a second exterior body to which the first exterior body and the second exterior body are brought close to each other, and the first mold and the second mold are clamped and manufactured in the mold. A sheet that is formed with a cavity that matches the outer shape of the composite molded article, is connected to a supply pipe that supplies thermoplastic resin foam particles into the cavity, and is stretched between the first mold and the second mold. Provided is a composite molded product manufacturing apparatus comprising a sheet pressing member that presses from a first mold side to a second mold side through a cavity.

本発明の複合成形品の製造装置において、第２の型に複数の凹部を有し、これらの凹部にシート押圧部材が進退可能に設けられていることが好ましい。   In the composite molded article manufacturing apparatus of the present invention, it is preferable that the second mold has a plurality of recesses, and a sheet pressing member is provided in these recesses so as to be able to advance and retract.

本発明の複合成形品の製造装置において、シート押圧部材が熱可塑性樹脂発泡粒子をキャビティ内に供給するフィーダーと一体的に設けられたことが好ましい。   In the composite molded product manufacturing apparatus of the present invention, it is preferable that the sheet pressing member is provided integrally with a feeder that supplies thermoplastic resin foam particles into the cavity.

本発明の複合成形品の製造装置において、トランスファー成形機を主体とする構成であることが好ましい。   The composite molded product manufacturing apparatus of the present invention preferably has a configuration mainly including a transfer molding machine.

本発明の複合成形品の製造方法は、第１の型と第２の型の間に張設した熱可塑性樹脂シートを加熱、軟化した後、シート押圧部材によってシートを押圧し、その後キャビティ内に熱可塑性樹脂発泡粒子を供給し、型内成形して複合成形品を製造するので、シートを型内面の形状に沿うように精度良く成形でき、目的形状に合致した寸法精度に優れた複合成形品を製造することができる。
本発明の複合成形品は、本発明に係る製造方法によって得られたものなので、目的形状に合致した寸法精度に優れたものとなる。
本発明の複合成形品の製造装置は、第１の型と第２の型の間に張設したシートを第１の型側からキャビティを通して第２の型側に押圧するシート押圧部材を備えているので、このシートを加熱軟化後、シート押圧部材によって押圧し、その後キャビティ内に熱可塑性樹脂発泡粒子を供給し、型内成形して複合成形品を製造することによって、シートを型内面の形状に沿うように精度良く成形でき、目的形状に合致した寸法精度に優れた複合成形品を製造することができる。 In the method for producing a composite molded article according to the present invention, the thermoplastic resin sheet stretched between the first mold and the second mold is heated and softened, and then the sheet is pressed by the sheet pressing member, and then is inserted into the cavity. Since thermoplastic resin foam particles are supplied and molded in-mold to produce a composite molded product, the sheet can be accurately molded to conform to the shape of the inner surface of the mold, and a composite molded product with excellent dimensional accuracy that matches the target shape Can be manufactured.
Since the composite molded article of the present invention is obtained by the production method according to the present invention, it has excellent dimensional accuracy that matches the target shape.
The apparatus for manufacturing a composite molded article of the present invention includes a sheet pressing member that presses a sheet stretched between a first mold and a second mold from the first mold side to the second mold side through a cavity. Therefore, after heat softening the sheet, the sheet is pressed by the sheet pressing member, and then the thermoplastic resin foam particles are supplied into the cavity and molded in-mold to produce a composite molded product. Therefore, it is possible to manufacture a composite molded product that can be molded with high accuracy and conform to the target shape and excellent in dimensional accuracy.

以下、図面を参照して本発明の実施形態を説明する。
図１は本発明に係る複合成形品の製造装置の一例を示す図であり、この図中、符号１は成形装置、２は熱可塑性樹脂シート（以下、シートと記す。）、３は第１の型、４は第２の型、５は第１の外装体、６は第２の外装体、７は供給管路、８，９は蒸気導入管、１０，１１は冷却水導入管、１２，１３は真空吸引管、１４，１５はドレン排出管、１６はストッパ、１７はキャビティ、１８は成形型、１９はシート押圧部材、２０はフィーダーである。 Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a view showing an example of an apparatus for producing a composite molded article according to the present invention. In this figure, reference numeral 1 is a molding apparatus, 2 is a thermoplastic resin sheet (hereinafter referred to as a sheet), and 3 is a first. , 4 is a second mold, 5 is a first exterior body, 6 is a second exterior body, 7 is a supply pipe, 8 and 9 are steam introduction pipes, 10 and 11 are cooling water introduction pipes, 12 , 13 are vacuum suction pipes, 14 and 15 are drain discharge pipes, 16 is a stopper, 17 is a cavity, 18 is a molding die, 19 is a sheet pressing member, and 20 is a feeder.

この成形装置１は、多数の蒸気穴が穿設された第１の型３と第２の型４とから構成された成形型１８と、第１の型３が固定された第１の外装体５と、第２の型４が固定された第２の外装体６とを備え、第１の外装体５と第２の外装体６とを接近させた時、第１の型３と第２の型４が型締めされて成形型１８内に製造する複合成形品の外形と合致するキャビティ１７が形成され、第１の型３と第２の型４の接触部又はその近傍にシート２を第１の型３と第２の型４の間に張設するシート保持具１６が設けられ、第１の型３に熱可塑性樹脂発泡粒子をキャビティ１７内に供給する供給管路７が接続され、かつ第１の型３と第２の型４の間に張設したシート２を第１の型３側からキャビティ１７を通して第２の型４側に押圧するシート押圧部材１９とを備えた構成になっている。   The molding apparatus 1 includes a molding die 18 composed of a first die 3 and a second die 4 having a large number of vapor holes, and a first exterior body to which the first die 3 is fixed. 5 and a second exterior body 6 to which the second mold 4 is fixed. When the first exterior body 5 and the second exterior body 6 are brought close to each other, the first mold 3 and the second exterior body 6 The mold 4 is clamped to form a cavity 17 that matches the outer shape of the composite molded product manufactured in the mold 18, and the sheet 2 is placed at or near the contact portion between the first mold 3 and the second mold 4. A sheet holder 16 that is stretched between the first mold 3 and the second mold 4 is provided, and a supply pipe line 7 that supplies thermoplastic resin foam particles into the cavity 17 is connected to the first mold 3. The sheet pressing member 19 presses the sheet 2 stretched between the first mold 3 and the second mold 4 from the first mold 3 side through the cavity 17 to the second mold 4 side. It has a configuration which includes a.

第１の外装体５と第２の外装体６は、それぞれ第１の型３と第２の型４を固定した状態で、離間又は接近する方向（進退方向）に移動可能とされ、第１の外装体５と第２の外装体６とを接近させた時、第１の型３と第２の型４が型締めされて成形型１８内にキャビティ１７が形成され（型締め状態）、この型締め状態から一方又は両方を離間方向に移動させることで型開きできるように構成されている。これらの外装体及び型の移動は、いずれか一方を他方に対して進退方向に移動させてもよいし、両方を進退方向に移動させる構成としてもよい。また図１では、第１の型３を上側に、第２の型４を下側に配置し、第１の型３（又は両方の型）を上下動させて成形を行う横型の成形装置１を例示しているが、第１の型３と第２の型４を左右に配置し、第１の型３（又は両方の型）を水平方向に移動させて成形を行う縦型の成形装置とすることもできる。縦型の成形装置であれば、横型の成形装置と比べてコンパクトに構成でき、成形装置の設置スペースを節約できる利点がある。   The first exterior body 5 and the second exterior body 6 are movable in the direction of separating or approaching (advancing and retracting directions) in a state where the first mold 3 and the second mold 4 are fixed, respectively. When the exterior body 5 and the second exterior body 6 are brought close to each other, the first mold 3 and the second mold 4 are clamped to form the cavity 17 in the mold 18 (clamped state). The mold can be opened by moving one or both of the mold clamping states in the separating direction. As for the movement of these exterior bodies and molds, either one may be moved in the advance / retreat direction relative to the other, or both may be moved in the advance / retreat direction. In FIG. 1, the horizontal mold forming apparatus 1 is configured such that the first mold 3 is disposed on the upper side, the second mold 4 is disposed on the lower side, and the first mold 3 (or both molds) is moved up and down to perform molding. However, the first mold 3 and the second mold 4 are arranged on the left and right, and the first mold 3 (or both molds) is moved in the horizontal direction to perform the vertical molding apparatus. It can also be. A vertical molding apparatus can be configured more compactly than a horizontal molding apparatus, and has the advantage of saving installation space for the molding apparatus.

本例示において、第１の外装体５と第１の型３との間の空間、及び第２の外装体６と第２の型４との間の空間には、蒸気導入管８，９、冷却水導入管１０，１１、真空吸引管１２，１３及びドレン排出管１４，１５がそれぞれ一本づつ接続されている。   In this example, the space between the first exterior body 5 and the first mold 3 and the space between the second exterior body 6 and the second mold 4 include steam introduction pipes 8, 9, The cooling water introduction pipes 10 and 11, the vacuum suction pipes 12 and 13, and the drain discharge pipes 14 and 15 are connected one by one.

キャビティ１７内に熱可塑性樹脂発泡粒子を供給する供給管路７は、従来より熱可塑性樹脂発泡成形品の製造において用いられている構造のものを使用でき、例えばエアー吹き込みにより熱可塑性樹脂発泡粒子を吸引してキャビティ１７内に搬送し、キャビティ１７内に必要量の熱可塑性樹脂発泡粒子を充填するものが使用される。   The supply pipe line 7 for supplying the thermoplastic resin expanded particles into the cavity 17 can have a structure conventionally used in the manufacture of thermoplastic resin foam molded products. For example, the foamed thermoplastic resin particles are blown by air blowing. A material that is sucked and conveyed into the cavity 17 and is filled with a necessary amount of foamed thermoplastic resin particles is used.

シート保持具１６は、第１の型３と第２の型４の間にシート２を張設できればよく、特に限定されず、従来公知の各種保持具を用いることができる。本例示では、第２の型４の上端側にシート２を張設している。なお、複合成形品に合成樹脂製の枠材等を残した状態で成形を行う場合、この枠材等にシート２の縁を挟持する部分を設けてシート保持具１６の機能を持たせ、第２の型４の上端に、シートを挟持させた枠材等を固定し、これによってシート２を張設する構成としてもよい。   The sheet holder 16 is not particularly limited as long as the sheet 2 can be stretched between the first mold 3 and the second mold 4, and various conventionally known holders can be used. In this example, the sheet 2 is stretched on the upper end side of the second mold 4. When molding is performed with a synthetic resin frame material or the like left in the composite molded product, a portion for sandwiching the edge of the sheet 2 is provided in the frame material or the like to provide the function of the sheet holder 16. A frame member or the like that sandwiches the sheet may be fixed to the upper end of the mold 4 and the sheet 2 may be stretched.

本例示において、シート押圧部材１９は、複数の凹部を持つ第２の型４の各凹部に対応する位置に複数個が設けられ、これらの凹部にシート押圧部材１９が進退可能となるように第１の型３側に取り付けられている。このシート押圧部材１９は、熱可塑性樹脂発泡粒子を供給するフィーダー２０と一体的に設けられており、第２の型４の各凹部にシート２を押圧できるとともに、各凹部にフィーダー２０を通して熱可塑性樹脂発泡粒子を供給できるようになっている。   In the present example, a plurality of sheet pressing members 19 are provided at positions corresponding to the respective recesses of the second mold 4 having a plurality of recesses, and the sheet pressing member 19 can be advanced and retracted in these recesses. 1 is attached to the mold 3 side. The sheet pressing member 19 is provided integrally with a feeder 20 for supplying thermoplastic resin foam particles, and can press the sheet 2 against each recess of the second mold 4 and is also thermoplastic through the feeder 20 into each recess. Resin foam particles can be supplied.

この成形装置１は、第１の型３と第２の型４の間に張設したシート２を第１の型３側からキャビティ１７を通して第２の型４側に押圧するシート押圧部材を備えているので、この熱可塑性樹脂シートを加熱軟化後、シート押圧部材によって押圧し、その後キャビティ内に熱可塑性樹脂発泡粒子を供給し、型内成形して複合成形品を製造することによって、熱可塑性樹脂シートを型内面の形状に沿うように精度良く成形でき、目的形状に合致した寸法精度に優れた複合成形品を製造することができる。   The molding apparatus 1 includes a sheet pressing member that presses the sheet 2 stretched between the first mold 3 and the second mold 4 from the first mold 3 side through the cavity 17 to the second mold 4 side. Therefore, the thermoplastic resin sheet is heated and softened, and then pressed by a sheet pressing member. Thereafter, the thermoplastic resin foam particles are supplied into the cavity and molded in-mold to produce a composite molded product. The resin sheet can be accurately molded so as to conform to the shape of the inner surface of the mold, and a composite molded product having excellent dimensional accuracy matching the target shape can be manufactured.

次に、図２を参照して本発明に係る複合成形品の製造方法の第１例を説明する。なお本例示は、前述した成形装置１を用い、本発明の方法を実施する場合を例示する。図２は、第１の型３と第２の型４の間にシート２を張設し（図２（ａ）参照）、該シート２を加熱、軟化せしめた後、第１の型３と第２の型４を型締めして製造する複合成形品の外形と合致するキャビティ１７を形成し（図２（ｂ）参照）、第１の型３側からキャビティ１７を通してシート押圧部材１９を第２の型４に近接せしめ、軟化したシート２を第２の型４側に押圧し（図２（ｃ）参照）、次いでシート押圧部材１９を元の位置に戻し（図２（ｄ）参照）、キャビティ１７内に熱可塑性樹脂発泡粒子を充填し、次いで成形型１８を熱可塑性樹脂発泡粒子の融着温度以上の温度に加熱して型内成形し（図２（ｅ）参照）、熱可塑性樹脂発泡成形品２１の表面にシート２からなる表皮が積層されてなる複合成形品２２を製造し、成形型から取り出す（図２（ｆ）参照）、各工程によって複合成形品２２を得る各工程を示す断面図である。   Next, a first example of a method for producing a composite molded product according to the present invention will be described with reference to FIG. In addition, this illustration illustrates the case where the method of this invention is implemented using the shaping | molding apparatus 1 mentioned above. FIG. 2 shows that the sheet 2 is stretched between the first mold 3 and the second mold 4 (see FIG. 2A), the sheet 2 is heated and softened, and then the first mold 3 and A cavity 17 that matches the outer shape of the composite molded product that is manufactured by clamping the second mold 4 is formed (see FIG. 2B), and the sheet pressing member 19 is moved through the cavity 17 from the first mold 3 side. 2 is brought close to the mold 4 and the softened sheet 2 is pressed toward the second mold 4 (see FIG. 2C), and then the sheet pressing member 19 is returned to its original position (see FIG. 2D). Then, the thermoplastic resin foam particles are filled into the cavity 17, and then the molding die 18 is heated to a temperature equal to or higher than the fusion temperature of the thermoplastic resin foam particles (see FIG. 2 (e)). A composite molded product 22 in which the skin made of the sheet 2 is laminated on the surface of the resin foam molded product 21 is manufactured, and from the mold Put Ri (see FIG. 2 (f)), it is a sectional view showing the steps of obtaining a composite molded product 22 by the respective steps.

本発明の方法において用いるシート２としては、熱可塑性樹脂単層シート又は複数枚のシートやフィルムを積層してなる積層シート又は複数枚のシートやフィルムを重ねたシートであることが好ましい。この熱可塑性樹脂としては、例えばポリエチレン、ポリプロピレン、ポリスチレン、ポリエチレンテレフタレート（ＰＥＴ）などが挙げられる。また、このシート２は、非発泡のシート又はフィルムのみから形成しても良いし、低倍率の発泡樹脂シートを用いてもよい。低倍率の発泡樹脂シートとしては、密度１４０〜５００ｋｇ／ｍ^３の発泡ポリスチレン系樹脂シートに、表層としてハイインパクトポリスチレンフィルムが積層された積層シートなどが好ましい。 The sheet 2 used in the method of the present invention is preferably a thermoplastic resin single-layer sheet, a laminated sheet obtained by laminating a plurality of sheets or films, or a sheet obtained by laminating a plurality of sheets or films. Examples of the thermoplastic resin include polyethylene, polypropylene, polystyrene, and polyethylene terephthalate (PET). The sheet 2 may be formed only from a non-foamed sheet or film, or a low-magnification foamed resin sheet may be used. As the low-magnification foamed resin sheet, a laminated sheet in which a high impact polystyrene film is laminated as a surface layer on a foamed polystyrene resin sheet having a density of 140 to 500 kg / m ³ is preferable.

また熱可塑性樹脂発泡粒子としては、例えば、ポリエチレン、ポリプロピレン、ポリスチレン、ポリエチレンテレフタレート（ＰＥＴ）などの樹脂を適当な密度に予備発泡させた予備発泡粒子などが用いられる。本発明において好ましい熱可塑性樹脂発泡粒子としては、密度５０〜２００ｋｇ／ｍ^３の範囲のポリスチレン系樹脂発泡粒子などが挙げられる。 As the thermoplastic resin expanded particles, for example, pre-expanded particles obtained by pre-expanding a resin such as polyethylene, polypropylene, polystyrene, polyethylene terephthalate (PET) to an appropriate density are used. Examples of preferable thermoplastic resin foam particles in the present invention include polystyrene resin foam particles having a density in the range of 50 to 200 kg / m ³ .

これらの材料を用い、本発明の方法によって複合成形品を製造するには、まず、図２（ａ）に示すように、型開き状態にある第１、第２の型３，４のうち、第２の型４側にシート２を張設する。前述したように、複合成形品に合成樹脂製の枠材等を残した状態で成形を行う場合、この枠材等にシート２の縁を挟持する部分を設けてシート保持具１６の機能を持たせ、第２の型４の上端に、シート２を挟持させた枠材等を固定し、これによってシート２を張設することが望ましい。   In order to produce a composite molded article using these materials by the method of the present invention, first, as shown in FIG. 2 (a), among the first and second molds 3 and 4 in the mold open state, The sheet 2 is stretched on the second mold 4 side. As described above, when molding is performed in a state in which a synthetic resin frame material or the like is left in the composite molded product, a portion for sandwiching the edge of the sheet 2 is provided in the frame material or the like to have the function of the sheet holder 16. In addition, it is desirable to fix a frame member or the like sandwiching the sheet 2 to the upper end of the second mold 4 and thereby tension the sheet 2.

次に、蒸気を第１の外装体５と第２の外装体６の内部に供給し、シート２を加熱、軟化させる。この加熱温度、加熱時間は、シート２の材質、厚みに応じて適宜設定される。   Next, steam is supplied into the first exterior body 5 and the second exterior body 6 to heat and soften the sheet 2. The heating temperature and heating time are appropriately set according to the material and thickness of the sheet 2.

次に、図２（ｂ）に示すように第１の型３と第２の型４を型締めし、製造する複合成形品の外形と合致するキャビティ１７を形成し、さらに図２（ｃ）に示すように、第１の型３側からキャビティ１７を通してシート押圧部材１９を第２の型４に近接せしめ、軟化したシート２を第２の型４側に押圧する。このシート押圧部材１９によるシート２の押圧とともに、真空吸引または圧空によってシート２を第２の型４側に押圧することが好ましい。   Next, as shown in FIG. 2B, the first mold 3 and the second mold 4 are clamped to form a cavity 17 that matches the outer shape of the composite molded product to be manufactured. As shown, the sheet pressing member 19 is brought close to the second mold 4 through the cavity 17 from the first mold 3 side, and the softened sheet 2 is pressed to the second mold 4 side. Along with the pressing of the sheet 2 by the sheet pressing member 19, it is preferable to press the sheet 2 toward the second mold 4 by vacuum suction or compressed air.

図４は、シート押圧部材１９により、加熱軟化したシート２を第２の型４側に押圧する工程を示す概略図であり、本例示では、複数の凹部２４を持った第２の型４を用い、かつこれらの凹部２４のそれぞれに対応させて複数のシート押圧部材１９を進退可能に設けた構成になっている。シート押圧部材１９の押圧動作により、加熱軟化したシート２は第２の型４のそれぞれの凹部２４に沿って押し付けられるので、複数の凹部２４を有するような複雑形状の複合成形品でも製造可能である。   FIG. 4 is a schematic diagram illustrating a process of pressing the heat-softened sheet 2 against the second mold 4 by the sheet pressing member 19. In this example, the second mold 4 having a plurality of recesses 24 is illustrated. A plurality of sheet pressing members 19 are provided so as to be able to advance and retreat in correspondence with each of the concave portions 24. Since the heat-softened sheet 2 is pressed along the respective recesses 24 of the second mold 4 by the pressing operation of the sheet pressing member 19, even a complex molded product having a plurality of recesses 24 can be manufactured. is there.

図５に示すように、このシート押圧部材１９の先端部には、円板状の押圧部２５が設けられている。押圧部２５の中央には、フィーダ２０を通して送られる熱可塑性樹脂発泡粒子を噴出する粒子供給口２７が設けられている。このシート押圧部材１９の中心には、粒子供給口２７に開口する通路が設けられ、この通路には図示しない駆動手段に接続された開閉棒２６が進退可能に設けられている。この開閉棒２６を押圧部２５に対し退避方向に移動させることで、粒子供給口２７が開かれ、熱可塑性樹脂発泡粒子が噴出し、開閉棒２６を前進させることで熱可塑性樹脂発泡粒子の供給を停止できるようになっている。   As shown in FIG. 5, a disc-shaped pressing portion 25 is provided at the distal end portion of the sheet pressing member 19. In the center of the pressing portion 25, a particle supply port 27 for ejecting thermoplastic resin foam particles sent through the feeder 20 is provided. In the center of the sheet pressing member 19, a passage opening to the particle supply port 27 is provided, and an opening / closing rod 26 connected to a driving means (not shown) is provided in the passage so as to be able to advance and retreat. By moving the opening / closing bar 26 in the retracting direction with respect to the pressing portion 25, the particle supply port 27 is opened, the foamed thermoplastic resin particles are ejected, and the opening / closing bar 26 is advanced to supply the expanded thermoplastic resin particles. Can be stopped.

シート押圧部材１９によるシート押圧後、図２（ｄ）に示すように、シート押圧部材１９を上昇させる。この状態でシート２は、第２の型４の内面に沿って配置されている。シート押圧部材１９の上昇時、シート押圧部材１９の押圧部２５先端面は、第１の型３のキャビティ側の面と一致又はほぼ一致することが望ましい。   After the sheet is pressed by the sheet pressing member 19, the sheet pressing member 19 is raised as shown in FIG. In this state, the sheet 2 is disposed along the inner surface of the second mold 4. When the sheet pressing member 19 is raised, it is desirable that the front end surface of the pressing portion 25 of the sheet pressing member 19 coincides with or substantially coincides with the cavity side surface of the first mold 3.

次に、第１の型３と第２の型４が型締めされ、第２の型４側にシート２が付着した状態にある成形型１８のキャビティ１７内に、供給管路７を通して熱可塑性樹脂発泡粒子を供給し、キャビティ１７内を熱可塑性樹脂発泡粒子で満たす。   Next, the first mold 3 and the second mold 4 are clamped, and thermoplasticity is passed through the supply pipe 7 into the cavity 17 of the mold 18 in a state where the sheet 2 is attached to the second mold 4 side. Resin foam particles are supplied to fill the cavity 17 with thermoplastic resin foam particles.

次いで、図２（ｅ）に示すように、蒸気導入管８，９を通して各外装体の内部に蒸気を導入し、成形型１８を蒸気加熱して型内成形する。この加熱によりキャビティ１７内の熱可塑性樹脂発泡粒子が膨張し、シート２を第２の型４側に押し付けるように圧力を加える。これによってシート２は第２の型４の形状に沿って綺麗に成形される。また、この加熱でキャビティ１７内の熱可塑性樹脂発泡粒子同士が融着し、熱可塑性樹脂発泡成形品２１が形成されるとともに、シート２に接した熱可塑性樹脂発泡粒子がシート２に融着し、熱可塑性樹脂発泡成形品２１の表面にシート２が積層した複合成形品２１が得られる。   Next, as shown in FIG. 2 (e), steam is introduced into the respective exterior bodies through the steam introduction pipes 8 and 9, and the molding die 18 is steam-heated to be molded in the mold. By this heating, the expanded thermoplastic resin particles in the cavity 17 are expanded, and pressure is applied so as to press the sheet 2 against the second mold 4 side. Thus, the sheet 2 is neatly formed along the shape of the second mold 4. Further, by this heating, the thermoplastic resin foam particles in the cavity 17 are fused together to form the thermoplastic resin foam molded article 21, and the thermoplastic resin foam particles in contact with the sheet 2 are fused to the sheet 2. The composite molded product 21 in which the sheet 2 is laminated on the surface of the thermoplastic resin foam molded product 21 is obtained.

次いで、冷却水導入管１０，１１からの冷却水導入、ドレン排出管１４，１５からの排水、真空吸引管１２，１３からの排気、排気中止後に空気導入などの操作を行って成形型１８を冷却した後、図２（ｆ）に示すように、第１の型３を第２の型４から離して型開きし、複合成形品２２を型から取り出す。   Next, operations such as introducing cooling water from the cooling water introduction pipes 10 and 11, draining from the drain discharge pipes 14 and 15, exhausting from the vacuum suction pipes 12 and 13, and introducing air after stopping the exhausting are performed to form the mold 18. After cooling, as shown in FIG. 2 (f), the first mold 3 is separated from the second mold 4 and the mold is opened, and the composite molded product 22 is taken out of the mold.

この複合成形品の製造方法は、第１の型３と第２の型４の間に張設したシート２を加熱、軟化した後、シート２をシート押圧部材１９によって押圧し、その後キャビティ１７内に熱可塑性樹脂発泡粒子を供給し、型内成形して複合成形品２２を製造するので、シート２を型内面の形状に沿うように精度良く成形でき、目的形状に合致した寸法精度に優れた複合成形品２２を製造することができる。   In this method of manufacturing a composite molded article, the sheet 2 stretched between the first mold 3 and the second mold 4 is heated and softened, then the sheet 2 is pressed by the sheet pressing member 19, and then the inside of the cavity 17. Since the thermoplastic resin foam particles are supplied to the mold and molded into the mold to produce the composite molded product 22, the sheet 2 can be molded with good accuracy along the shape of the inner surface of the mold, and the dimensional accuracy matched to the target shape is excellent. The composite molded product 22 can be manufactured.

図６及び図７は、前述した本発明に係る複合成形品の製造方法を用いて製造された複合成形品の一例を示す図であり、図６は複合成形品２２の斜視図、図７は複合成形品２２の要部断面図である。
この複合成形品２２は、熱可塑性樹脂発泡成形品２１の一面側にシート２からなる表皮が積層された構造になっており、この表皮側を意匠面として用いられる。本発明において、複合成形品２２の形状、寸法は特に限定されない。この複合成形品２２の用途としては、例えばユニットバスの天井材等の住宅設備用部材、自動車の内装材（インストルメンタルパネル、ドアパネル、シートバックパネル、ステアリングホイール、取手等）、家具（椅子の座部等）、容器、内装材、壁面材、航空便用の軽量パレット等が挙げられるが、これらに限定されない。 6 and 7 are views showing an example of a composite molded product manufactured using the above-described method for manufacturing a composite molded product according to the present invention. FIG. 6 is a perspective view of the composite molded product 22, and FIG. 3 is a cross-sectional view of a main part of a composite molded product 22. FIG.
The composite molded product 22 has a structure in which a skin made of the sheet 2 is laminated on one surface side of the thermoplastic resin foam molded product 21, and this skin side is used as a design surface. In the present invention, the shape and dimensions of the composite molded product 22 are not particularly limited. Applications of the composite molded product 22 include, for example, housing equipment members such as unit bath ceiling materials, automobile interior materials (instrumental panels, door panels, seat back panels, steering wheels, handles, etc.), furniture (chair seats). Part, etc.), containers, interior materials, wall materials, lightweight pallets for air mail, and the like.

図３は、本発明に係る複合成形品の製造方法の第２例を示す図である。この例示では、図２（ｆ）に示すように、型内成形を終えた複合成形品２２の熱可塑性樹脂発泡成形品２１が露出している面に新たにシート２を重ね（図３（ｇ）参照）、型内成形し、熱可塑性樹脂発泡成形品２１の表面をシートからなる表皮で覆った複合成形品２３を製造する（図３（ｈ）参照）ことを特徴としている。   FIG. 3 is a view showing a second example of the method for producing a composite molded article according to the present invention. In this example, as shown in FIG. 2 (f), the sheet 2 is newly overlaid on the surface of the composite molded product 22 after the in-mold molding has been exposed (FIG. 3 (g) )), And a composite molded product 23 is manufactured by molding in-mold and covering the surface of the thermoplastic resin foam molded product 21 with a skin made of a sheet (see FIG. 3 (h)).

この複合成形品２３は、熱可塑性樹脂発泡成形品２１の表面をシートからなる表皮で覆ったものなので、複合成形品２３の機械強度、耐久性、耐湿性、外観、衛生性などを向上させることができる。   Since the composite molded product 23 is obtained by covering the surface of the thermoplastic resin foam molded product 21 with a sheet skin, the mechanical strength, durability, moisture resistance, appearance, hygiene, and the like of the composite molded product 23 are improved. Can do.

［実施例］
図１に示す装置を用い、本発明の製造方法に従って図６に示す外観を有する複合成形品を製造した。図６中の寸法Ａは４００ｍｍ、Ｂは３００ｍｍ、Ｈ０は２５ｍｍ、図８の寸法Ｃは３０ｍｍとした。原料、成形型、成形条件及び成形工程は下記の通りとした。 [Example]
Using the apparatus shown in FIG. 1, a composite molded article having the appearance shown in FIG. 6 was manufactured according to the manufacturing method of the present invention. The dimension A in FIG. 6 was 400 mm, B was 300 mm, H0 was 25 mm, and the dimension C in FIG. 8 was 30 mm. The raw material, mold, molding conditions and molding process were as follows.

（原料）：シート２として、厚さ１ｍｍのハイインパクトポリスチレンシート（ＲＰ東プラ社製、品名：ＮＯＡＳＴＩＣ−Ｍ）を用いた。
また、熱可塑性樹脂発泡粒子として、発泡ポリスチレン樹脂粒子（積水化成品工業社製、品名：ＨＤＳ４０）を嵩倍率４０倍に発泡させたものを用いた。
（成形型）：第１の型３は平板状であり、第２の型４は９個の凹部を有している。 (Raw material): As the sheet 2, a high impact polystyrene sheet having a thickness of 1 mm (manufactured by RP TOPLA, product name: NOASTIC-M) was used.
Further, as the foamed thermoplastic resin particles, those obtained by foaming expanded polystyrene resin particles (manufactured by Sekisui Chemical Co., Ltd., product name: HDS40) at a bulk magnification of 40 times were used.
(Molding die): The first die 3 has a flat plate shape, and the second die 4 has nine concave portions.

（成形条件及び成形工程）
１．シート２を第２の型４の開口部に張設した。
２．第１の型３と第２の型４を型締めした。
３．シート２を下記の条件で加熱軟化した。
・第１の型３：蒸気圧０．１１ＭＰａ、３０秒間。
・第２の型４：蒸気圧０．１１ＭＰａ、３０秒間。
４．第２の型４側から０．８５ＭＰａで３０秒間真空引きをして、シート２を第２の型４側に引き寄せた。
５．真空成形開始から３秒後に、第１の型３から９本のシート押圧部材１９を第２の型４の凹部２４へ押し出した。この押し出しは、凹部深さＨ０＝２５ｍｍに対し、図４に示す押出長さＤが２３ｍｍとした。
６．その後、第１の型３にシート押圧部材１９を戻す。
７．第２の型４側のシート２と第１の型３の間に発泡ポリスチレン樹脂粒子を充填し、成形型２０を１２０℃、２０秒間蒸気加熱し、冷却後、複合成形品２２を取り出した。 (Molding conditions and molding process)
1. The sheet 2 was stretched in the opening of the second mold 4.
2. The first mold 3 and the second mold 4 were clamped.
3. The sheet 2 was softened by heating under the following conditions.
First mold 3: Vapor pressure 0.11 MPa, 30 seconds.
Second mold 4: Vapor pressure 0.11 MPa, 30 seconds.
4). A vacuum was drawn from the second mold 4 side at 0.85 MPa for 30 seconds, and the sheet 2 was drawn to the second mold 4 side.
5. Three seconds after the start of vacuum forming, nine sheet pressing members 19 from the first mold 3 were pushed out into the recesses 24 of the second mold 4. In this extrusion, the extrusion length D shown in FIG. 4 was 23 mm with respect to the recess depth H0 = 25 mm.
6). Thereafter, the sheet pressing member 19 is returned to the first mold 3.
7). The expanded polystyrene resin particles were filled between the sheet 2 on the second mold 4 side and the first mold 3, the mold 20 was heated by steam at 120 ° C. for 20 seconds, and after cooling, the composite molded product 22 was taken out.

（評価）
得られた複合成形品の外観を図８に示す。得られた複合成形品は、９個の角形凸部がシャープで成形精度が非常に良好であった。寸法的には、第２の型４の凹部深さＨ０＝２５ｍｍに対し、図８中の凸部高さＨ１＝２５ｍｍとなり、第２の型４の表面にシート２が十分接触し、精度良く成形できた。 (Evaluation)
The appearance of the obtained composite molded product is shown in FIG. The obtained composite molded article had nine square convex portions that were sharp and the molding accuracy was very good. In terms of dimensions, the convex portion height H1 in FIG. 8 is 25 mm with respect to the concave portion depth H0 = 25 mm of the second die 4, and the sheet 2 is sufficiently in contact with the surface of the second die 4 with high accuracy. I was able to mold it.

［比較例］
実施例と同じ原料と成形型を用い、成形工程５．のシート押圧部材１９による押し出しを行わなかった他は、実施例と同様の成形条件と成形工程で複合成形品を製造した。 [Comparative example]
4. Using the same raw materials and mold as in the example, molding process A composite molded article was manufactured under the same molding conditions and molding process as those of the example except that the sheet pressing member 19 was not extruded.

得られた複合成形品の外観を図９に示す。この複合成形品は、９個の凸部が丸みを帯び、成形型通りの成形品が得られておらず、成形精度が悪かった。寸法的には、第２の型４の凹部深さＨ０＝２５ｍｍに対し、図９中の凸部高さＨ２＝２２ｍｍとなり、第２の型４の表面にシート２が十分接触することなく成形が行われていた。   The appearance of the obtained composite molded product is shown in FIG. In this composite molded product, nine convex portions were rounded, and a molded product according to the mold was not obtained, and the molding accuracy was poor. In terms of dimensions, the convex portion height H2 in FIG. 9 is 22 mm with respect to the concave portion depth H0 = 25 mm of the second die 4, and the sheet 2 is molded without sufficient contact with the surface of the second die 4. Was done.

本発明に係る複合成形品の製造装置の一例を示す、成形装置の断面図である。It is sectional drawing of the shaping | molding apparatus which shows an example of the manufacturing apparatus of the composite molded product which concerns on this invention. 本発明に係る複合成形品の製造方法の第１例を工程順に示す断面図である。It is sectional drawing which shows the 1st example of the manufacturing method of the composite molded product which concerns on this invention to process order. 本発明に係る複合成形品の製造方法の第２例を工程順に示す断面図である。It is sectional drawing which shows the 2nd example of the manufacturing method of the composite molded product which concerns on this invention to process order. シート押圧部材によるシート押圧を示す概略図である。It is the schematic which shows the sheet | seat press by a sheet | seat press member. シート押圧部材を例示し、（ａ）は正面図、（ｂ）は底面図である。A sheet | seat press member is illustrated, (a) is a front view, (b) is a bottom view. 本発明に係る複合成形品を例示する斜視図である。It is a perspective view which illustrates the composite molded product which concerns on this invention. 本発明に係る複合成形品を例示する要部断面図である。It is principal part sectional drawing which illustrates the composite molded product which concerns on this invention. 本発明に係る実施例で製造した複合成形品の側面図である。It is a side view of the composite molded product manufactured in the Example which concerns on this invention. 比較例で製造した複合成形品の側面図である。It is a side view of the composite molded product manufactured by the comparative example.

符号の説明Explanation of symbols

１…成形装置、２…シート（熱可塑性樹脂シート）、３…第１の型、４…第２の型、５…第１の外装体、６…第２の外装体、７…供給管路、８，９…蒸気導入管、１０，１１…冷却水導入管、１２，１３…真空吸引管、１４，１５…ドレン排出管、１６…シート保持具、１７…キャビティ、１８…成形型、１９…シート押圧部材、２０…フィーダー、２１…熱可塑性樹脂発泡成形品、２２，２３…複合成形品、２４…凸部、２５…押圧部、２６…開閉棒、２７…粒子供給口。
DESCRIPTION OF SYMBOLS 1 ... Molding apparatus, 2 ... Sheet (thermoplastic resin sheet), 3 ... 1st type | mold, 4 ... 2nd type | mold, 5 ... 1st exterior body, 6 ... 2nd exterior body, 7 ... Supply line , 8, 9 ... Steam introduction pipes, 10, 11 ... Cooling water introduction pipes, 12, 13 ... Vacuum suction pipes, 14, 15 ... Drain discharge pipes, 16 ... Sheet holders, 17 ... Cavities, 18 ... Molds, 19 DESCRIPTION OF SYMBOLS ... Sheet pressing member, 20 ... Feeder, 21 ... Thermoplastic resin foam molded product, 22, 23 ... Composite molded product, 24 ... Convex part, 25 ... Pressing part, 26 ... Opening / closing rod, 27 ... Particle supply port.

Claims (11)

成形型を構成する第１の型と第２の型の間に熱可塑性樹脂シートを張設し、該熱可塑性樹脂シートを加熱、軟化せしめた後、第１の型と第２の型を型締めして製造する複合成形品の外形と合致するキャビティを形成し、第１の型側からキャビティを通してシート押圧部材を第２の型に近接せしめ、軟化した熱可塑性樹脂シートを第２の型側に押圧し、次いでシート押圧部材を元の位置に戻し、キャビティ内に熱可塑性樹脂発泡粒子を充填し、次いで成形型を熱可塑性樹脂発泡粒子の融着温度以上の温度に加熱して型内成形し、熱可塑性樹脂発泡成形品の表面に熱可塑性樹脂シートからなる表皮が積層されてなる複合成形品を製造することを特徴とする複合成形品の製造方法。   A thermoplastic resin sheet is stretched between the first mold and the second mold constituting the mold, and the thermoplastic resin sheet is heated and softened, and then the first mold and the second mold are molded. A cavity that matches the outer shape of the composite molded product to be manufactured is formed, the sheet pressing member is brought close to the second mold through the cavity from the first mold side, and the softened thermoplastic resin sheet is placed on the second mold side. Then, the sheet pressing member is returned to the original position, the thermoplastic resin foam particles are filled into the cavities, and then the mold is heated to a temperature equal to or higher than the fusion temperature of the thermoplastic resin foam particles to be molded in the mold. A method for producing a composite molded product, comprising producing a composite molded product in which a surface made of a thermoplastic resin sheet is laminated on a surface of a thermoplastic resin foam molded product. シート押圧部材によって軟化した熱可塑性樹脂シートを第２の型側に押圧するとともに、真空吸引又は圧空により熱可塑性樹脂シートを第２の型に沿わせることを特徴とする請求項１に記載の複合成形品の製造方法。   2. The composite according to claim 1, wherein the thermoplastic resin sheet softened by the sheet pressing member is pressed toward the second mold side, and the thermoplastic resin sheet is placed along the second mold by vacuum suction or compressed air. Manufacturing method of molded products. 第２の型に複数の凹部を有し、これらの凹部にシート押圧部材が進退可能に設けられていることを特徴とする請求項１又は２に記載の複合成形品の製造方法。   The method for producing a composite molded article according to claim 1, wherein the second mold has a plurality of recesses, and a sheet pressing member is provided in these recesses so as to be able to advance and retreat. 熱可塑性樹脂シートが、熱可塑性樹脂単層シート又は複数枚のシートやフィルムを積層してなる積層シート又は複数枚のシートやフィルムを重ねたシートである請求項１〜３のいずれかに記載の複合成形品の製造方法。   The thermoplastic resin sheet is a thermoplastic resin single-layer sheet or a laminated sheet obtained by laminating a plurality of sheets or films, or a sheet obtained by stacking a plurality of sheets or films. A method for producing a composite molded product. 熱可塑性樹脂シートが、熱可塑性樹脂発泡シート又はそれを含む積層シートである請求項１〜３のいずれかに記載の複合成形品の製造方法。   The method for producing a composite molded article according to any one of claims 1 to 3, wherein the thermoplastic resin sheet is a thermoplastic resin foam sheet or a laminated sheet including the same. 型内成形して得られた成形品の熱可塑性樹脂発泡成形品が露出している面に新たに熱可塑性樹脂シートを重ね、型内成形し、熱可塑性樹脂発泡成形品の表面を熱可塑性樹脂シートからなる表皮で覆った複合成形品を製造することを特徴とする請求項１〜５のいずれかに記載の複合成形品の製造方法。   A thermoplastic resin sheet is newly stacked on the exposed surface of the molded product obtained by in-mold molding, and the surface of the thermoplastic resin foam-molded product is molded into the thermoplastic resin. A method for producing a composite molded article according to any one of claims 1 to 5, wherein a composite molded article covered with a skin made of a sheet is produced. 請求項１〜６のいずれかに記載の製造方法により得られた複合成形品。   A composite molded article obtained by the production method according to claim 1. 多数の蒸気穴が穿設された第１の型と第２の型から構成された成形型と、第１の型が固定された第１の外装体と、第２の型が固定された第２の外装体とを備え、第１の外装体と第２の外装体とを接近させた時、第１の型と第２の型が型締めされて成形型内に製造する複合成形品の外形と合致するキャビティが形成され、熱可塑性樹脂発泡粒子をキャビティ内に供給する供給管路が接続され、かつ第１の型と第２の型の間に張設した熱可塑性樹脂シートを第１の型側からキャビティを通して第２の型側に押圧するシート押圧部材とを備えたことを特徴とする複合成形品の製造装置。   A molding die composed of a first die and a second die having a large number of steam holes, a first exterior body to which the first die is fixed, and a second die to which the second die is fixed. Of the composite molded product manufactured in the mold by clamping the first mold and the second mold when the first exterior body and the second exterior body are brought close to each other. A cavity that matches the outer shape is formed, a supply pipe that supplies thermoplastic resin foam particles into the cavity is connected, and a thermoplastic resin sheet that is stretched between the first mold and the second mold is the first. An apparatus for manufacturing a composite molded product, comprising: a sheet pressing member that presses from the mold side to the second mold side through the cavity. 第２の型に複数の凹部を有し、これらの凹部にシート押圧部材が進退可能に設けられていることを特徴とする請求項８に記載の複合成形品の製造装置。   9. The apparatus for producing a composite molded article according to claim 8, wherein the second mold has a plurality of recesses, and a sheet pressing member is provided in these recesses so as to advance and retreat. シート押圧部材が熱可塑性樹脂発泡粒子をキャビティ内に供給するフィーダーと一体的に設けられたことを特徴とする請求項９に記載の複合成形品の製造装置。   The apparatus for producing a composite molded article according to claim 9, wherein the sheet pressing member is provided integrally with a feeder for supplying thermoplastic resin foam particles into the cavity. トランスファー成形機を主体とする請求項８〜１０のいずれかに記載の複合成形品の製造装置。
The apparatus for producing a composite molded product according to any one of claims 8 to 10, mainly comprising a transfer molding machine.

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