JP2011037280A - Method for manufacturing laminated resin molded body - Google Patents

Method for manufacturing laminated resin molded body Download PDF

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JP2011037280A
JP2011037280A JP2010237390A JP2010237390A JP2011037280A JP 2011037280 A JP2011037280 A JP 2011037280A JP 2010237390 A JP2010237390 A JP 2010237390A JP 2010237390 A JP2010237390 A JP 2010237390A JP 2011037280 A JP2011037280 A JP 2011037280A
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raw material
molded body
resin molded
cavity
laminated resin
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Toshio Kazami
俊夫 風見
Ryutaro Nishibori
隆太郎 西堀
Minoru Shimojima
稔 下島
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Honda Motor Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To easily and efficiently manufacture a soft resin molded body by laminating a skin layer and a resin foamed body. <P>SOLUTION: A cavity 20 is formed by a lower mold 12, a first horizontal mold 14, a second horizontal mold 16 and an upper mold 18 which constitute a molding device 10. An injection machine 22 is installed to the first horizontal mold 14 so that a raw material 28 flows along the extending direction of the cavity 20, and an air blow pipe 30 is provided in the second horizontal mold 16. When the raw material 28 is injected from the injection machine 22, a gas such as a compressed air is supplied to the cavity 20 via the air blow pipe 30, and the material 28 is pressed to the side of the injection machine 22 by such a gas. During the closed cells 40 are formed in the material 28 in such a state, the pressure of the above gas is reduced. Thereby, the closed cells 40 disperse crack to communicate with each other to form the open cells. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は、予め所定形状に成形され且つ成形型のキャビティに配置された樹脂製表皮材の一端面に樹脂発泡体を設けることで積層樹脂成形体を得る積層樹脂成形体の製造方法に関する。   The present invention relates to a method for producing a laminated resin molded body in which a laminated resin molded body is obtained by providing a resin foam on one end surface of a resin skin material that has been previously molded into a predetermined shape and disposed in a cavity of a mold.

例えば、自動車のインストルメンタルパネルは、樹脂材からなる基材層、気泡が略均一に分散した樹脂発泡体からなる中間層、樹脂材からなる表皮層がこの順序で互いに接合された積層体から構成されている。中間層が樹脂発泡体であるために、クッション感覚に優れた軟質なものとなる。   For example, an automotive instrument panel is composed of a base material layer made of a resin material, an intermediate layer made of a resin foam in which bubbles are dispersed substantially uniformly, and a laminate in which a skin layer made of a resin material is joined together in this order. Has been. Since the intermediate layer is a resin foam, the intermediate layer is soft with excellent cushion feeling.

この種の積層体は、はじめに、表皮層の一端面に中間層を積層して積層樹脂成形体とし、次に、この積層樹脂成形体における中間層と、別途作製された基材層とが、真空成形機内で成形されながら接合されることによって製造される。   This type of laminate is first a laminated resin molded body by laminating an intermediate layer on one end surface of the skin layer, and then the intermediate layer in this laminated resin molded body and a separately prepared base material layer, It is manufactured by being joined while being molded in a vacuum forming machine.

ここで、前記積層樹脂成形体は、所定形状に予め成形された状態で成形用金型のキャビティに挿入された表皮層の一端面上に中間層を設けることで作製される（例えば、特許文献１参照）。具体的には、表皮層が挿入されたキャビティに、樹脂発泡体の原材料である主剤及び硬化剤を同時に供給する。主剤は、硬化剤に接触することによって硬化する。   Here, the laminated resin molded body is produced by providing an intermediate layer on one end surface of the skin layer inserted into the cavity of the molding die in a state of being molded in a predetermined shape (for example, Patent Documents). 1). Specifically, the main agent and the curing agent, which are raw materials for the resin foam, are simultaneously supplied to the cavity in which the skin layer is inserted. The main agent is cured by contacting the curing agent.

主剤には、発泡剤が含まれている。主剤及び硬化剤が充填された成形用金型を加熱すると、発泡剤の作用下に発泡が生じる。このようにして発泡した主剤が硬化することにより、中間層が形成される。   The main agent contains a foaming agent. When the molding die filled with the main agent and the curing agent is heated, foaming occurs under the action of the foaming agent. The intermediate layer is formed by curing the foamed main agent.

ところで、発泡樹脂中の気泡が独立気泡であると、積層体としては、押圧された際に変形し難いものとなる。そこで、独立気泡同士を連通させて連続気泡とする、いわゆる破泡が行われる。例えば、特許文献２には、樹脂発泡体からなる成形品を圧縮することによって破泡を行う従来技術が開示されている。また、特許文献３においては、樹脂発泡体からなる成形品の内部に圧縮空気を拡散させることによって破泡を行うことが提案されている。   By the way, if the bubbles in the foamed resin are closed cells, the laminate is difficult to be deformed when pressed. Therefore, so-called bubble breaking is performed in which closed cells are communicated to form continuous cells. For example, Patent Document 2 discloses a conventional technique for performing bubble breakage by compressing a molded product made of a resin foam. In Patent Document 3, it is proposed that bubbles are broken by diffusing compressed air into a molded article made of a resin foam.

特許第３６９８６６０号公報Japanese Patent No. 3698660 実公平３−１００２６号公報Japanese Utility Model Publication No.3-10026 特公平６−１８９２４号公報Japanese Patent Publication No. 6-18924

表皮層の一端面に積層された中間層（樹脂発泡体）に対して破泡を行う場合には、特許文献２に従来技術として記載されている真空減圧が採用されることがある。すなわち、成形用金型から積層樹脂成形体を取り出し、次に、該積層樹脂成形体の周囲の圧力を低減する手法である。   When foam breaking is performed on an intermediate layer (resin foam) laminated on one end surface of the skin layer, vacuum decompression described in Patent Document 2 as a conventional technique may be employed. That is, this is a technique of taking out the laminated resin molded body from the molding die and then reducing the pressure around the laminated resin molded body.

このように減圧がなされると、積層樹脂成形体の周囲の圧力に比して各独立気泡内の圧力が大きくなるため、該独立気泡の一部から微小な亀裂が生じる。この亀裂同士が連なることによって、連続気泡が形成される。亀裂の一部は樹脂発泡体の表面まで伝播するので、連続気泡には、大気が進入することになる。   When the pressure is reduced in this way, the pressure in each closed cell becomes larger than the pressure around the laminated resin molded body, so that a minute crack is generated from a part of the closed cell. Open cells are formed by the continuous cracks. Since part of the crack propagates to the surface of the resin foam, the atmosphere enters the open cells.

その後、積層樹脂成形体を再び成形用金型に挿入し、型閉じを行ってキャビティの排気を行う。これにより、気泡内に進入した大気が排出される。   Thereafter, the laminated resin molded body is again inserted into the molding die, the mold is closed, and the cavity is exhausted. Thereby, the air that has entered the bubbles is discharged.

しかしながら、上記のように型開き、破泡及び型閉じを行うことは煩雑である上、長時間を要することになる。   However, performing mold opening, bubble breaking and mold closing as described above is complicated and requires a long time.

また、積層樹脂成形体を取り出した後に周囲の圧力を低減して連続気泡の形成を行うと、積層樹脂成形体を拘束する枠体が存在しないため、積層樹脂成形体に不可避的な変形（寸法変化）が生じる。すなわち、積層樹脂成形体は、寸法変化が生じたまま成形用金型に戻され、この状態で前記の排気が行われる。結局、積層樹脂成形体を矯正することができないので、寸法精度が良好でなくなる。   In addition, when forming the open cells by reducing the surrounding pressure after taking out the laminated resin molded body, there is no frame body that restrains the laminated resin molded body, so inevitable deformation (dimensions) in the laminated resin molded body Change). That is, the laminated resin molded body is returned to the molding die with the dimensional change occurring, and the exhaust is performed in this state. Eventually, since the laminated resin molded body cannot be corrected, the dimensional accuracy is not good.

すなわち、従来技術に係る積層樹脂成形体の製造方法には、連続気泡を形成するために繁雑な作業を行う必要があるとともに生産効率が低く、さらに、寸法精度が良好ではないという不具合が顕在化している。   In other words, the conventional method for producing a laminated resin molded body requires a complicated operation to form open cells, has a low production efficiency, and has a problem that the dimensional accuracy is not good. ing.

本発明は上記した問題を解決するためになされたもので、十分に軟質な積層樹脂成形体を簡便に、しかも、効率よく製造することが可能な積層樹脂成形体の製造方法を提供することを目的とする。   The present invention has been made to solve the above-described problems, and provides a method for producing a laminated resin molded body capable of easily and efficiently producing a sufficiently soft laminated resin molded article. Objective.

前記の目的を達成するために、本発明は、予め所定形状に成形され且つ成形型のキャビティに配置された樹脂製成形体の一端面に樹脂発泡体を設けることで積層樹脂成形体を得る積層樹脂成形体の製造方法であって、
供給手段から供給された原材料が前記キャビティを流動している最中に、前記キャビティに気体を供給して前記原材料を押圧し、
前記原材料に発泡が生じている最中に、前記気体の圧力を低減して破泡を行うことを特徴とする。 In order to achieve the above-mentioned object, the present invention provides a laminated resin molded body obtained by providing a resin foam on one end face of a resin molded body that has been previously molded into a predetermined shape and disposed in a cavity of a mold. A method for producing a resin molded body, comprising:
While the raw material supplied from the supply means is flowing through the cavity, gas is supplied to the cavity to press the raw material,
While foaming is occurring in the raw material, the gas pressure is reduced to perform bubble breakage.

本発明においては、樹脂発泡体の原材料（例えば、主剤及び硬化剤）の流動を抑制するように気体が供給される。この気体が原材料を囲繞して擬似的な殻を形成し、この殻の中で原材料が押圧される。従って、原材料中で生成した独立気泡の圧力と、供給された気体の圧力とが均衡することになる。   In this invention, gas is supplied so that the flow of the raw material (for example, main ingredient and hardening | curing agent) of a resin foam may be suppressed. This gas surrounds the raw material to form a pseudo shell, in which the raw material is pressed. Therefore, the pressure of the closed bubbles generated in the raw material and the pressure of the supplied gas are balanced.

そして、発泡が継続している最中に前記気体の圧力が低減されると、前記殻が原材料から取り除かれた状態となる。その結果、独立気泡の圧力が原材料の周囲の圧力に比して大きくなり、このため、独立気泡を起点として亀裂が伝播し始める。この亀裂同士が連なることによって、連続気泡が形成される。   When the pressure of the gas is reduced while foaming continues, the shell is removed from the raw material. As a result, the pressure of closed cells becomes larger than the pressure around the raw material, and cracks start to propagate from the closed cells. Open cells are formed by the continuous cracks.

すなわち、本発明によれば、積層樹脂成形体を形成した後に真空減圧等の煩雑な後作業を行うことなく連続気泡を形成することができる。このため、作業が簡素化するとともに、積層樹脂成形体を得るまでの時間が著しく短縮される。   That is, according to the present invention, open cells can be formed without forming complicated post-work such as vacuum decompression after forming the laminated resin molding. For this reason, the work is simplified and the time until the laminated resin molded body is obtained is remarkably shortened.

しかも、このようにして作製された積層樹脂成形体は、真空減圧等の公知の破泡手法によって形成された連続気泡を具備する積層樹脂成形体に比して軟質であり、クッション感覚が著しく良好である。   Moreover, the laminated resin molded body thus produced is softer than the laminated resin molded body having open cells formed by a known bubble breaking technique such as vacuum decompression, and the cushion feeling is remarkably good. It is.

以上から諒解されるように、本発明によれば、原材料の流動を抑制する方向に気体を供給し、且つ発泡の継続中に前記気体の圧力を低減するという極めて簡便な操作を行うことにより、軟質な積層樹脂成形体を効率よく製造することができる。   As can be seen from the above, according to the present invention, by performing a very simple operation of supplying gas in a direction to suppress the flow of raw materials and reducing the pressure of the gas during the continuation of foaming, A soft laminated resin molded product can be produced efficiently.

なお、気体の供給開始時の圧力は、前記原材料の流動を停止可能な程度とすることが好ましい。この場合、前記殻によって原材料を確実に囲繞することができるので、連続気泡を形成することが一層容易となるからである。   In addition, it is preferable that the pressure at the time of starting supply of gas is made into the grade which can stop the flow of the said raw material. In this case, since the raw material can be surely surrounded by the shell, it is easier to form open cells.

本発明によれば、樹脂発泡体の原材料の流動を抑制するように気体を供給して前記原材料を押圧し、その後、前記気体の圧力を低減することで、原材料中に形成された独立気泡の圧力を該原材料の周囲の圧力に比して高くし、各独立気泡から亀裂を伝播させて連なり合わせて連続気泡を形成するようにしている。このため、連続気泡を形成するための真空減圧等の後作業が不要となるので、積層樹脂成形体の製造作業が簡素となるとともに、該積層樹脂成形体を効率よく製造することが可能となる。   According to the present invention, the gas is supplied so as to suppress the flow of the raw material of the resin foam, the raw material is pressed, and then the pressure of the gas is reduced, so that the closed cells formed in the raw material are reduced. The pressure is made higher than the pressure around the raw material, and cracks are propagated from the individual closed cells to join together to form open cells. For this reason, after-work such as vacuum decompression for forming open cells is not necessary, the manufacturing operation of the laminated resin molded body is simplified, and the laminated resin molded body can be efficiently manufactured. .

本実施の形態に係る積層樹脂成形体の製造方法を実施するための成形装置の要部縦断面構成図である。It is a principal part longitudinal cross-section block diagram of the shaping | molding apparatus for enforcing the manufacturing method of the laminated resin molding which concerns on this Embodiment. 図１の成形装置のキャビティに樹脂発泡体の原材料を充填しながら第２横型側から圧縮エアを導入している状態を示す要部縦断面構成図である。FIG. 2 is a vertical cross-sectional view of a main part showing a state in which compressed air is introduced from a second horizontal mold side while filling a resin foam raw material into a cavity of the molding apparatus of FIG. 1. 各独立気泡から伝播した亀裂が連なり合って連続気泡が形成された状態を拡大して示す要部縦断面拡大図である。It is a principal part longitudinal cross-sectional enlarged view which expands and shows the state in which the crack propagated from each closed cell continued and the continuous bubble was formed.

以下、本発明に係る積層樹脂成形体の製造方法につき好適な実施の形態を挙げ、添付の図面を参照して詳細に説明する。   Hereinafter, preferred embodiments of the method for producing a laminated resin molded body according to the present invention will be described in detail with reference to the accompanying drawings.

図１は、本実施の形態に係る積層樹脂成形体の製造方法を実施するための成形装置１０の要部縦断面構成図である。この成形装置１０は、下型１２、第１横型１４、第２横型１６及び上型１８を成形型として有し、これら型１２、１４、１６、１８の各々には、図示しない変位機構（例えば、流体圧シリンダ等）が取り付けられている。すなわち、下型１２、第１横型１４、第２横型１６及び上型１８は、前記変位機構の作用下に互いに離間・接近が可能であり、互いに接近した際に型閉じがなされてキャビティ２０が形成される一方、互いに離間した際に型開きがなされる。   FIG. 1 is a main part longitudinal cross-sectional configuration diagram of a molding apparatus 10 for carrying out the method for producing a laminated resin molded body according to the present embodiment. The molding apparatus 10 includes a lower mold 12, a first horizontal mold 14, a second horizontal mold 16, and an upper mold 18 as molding molds. Each of the molds 12, 14, 16, and 18 has a displacement mechanism (not shown) (for example, , Fluid pressure cylinders, etc.) are attached. That is, the lower mold 12, the first horizontal mold 14, the second horizontal mold 16, and the upper mold 18 can be separated from and approached to each other under the action of the displacement mechanism. On the other hand, the mold is opened when they are separated from each other.

この場合、キャビティ２０は水平方向に延在する。そして、第１横型１４には、樹脂発泡体の原材料となる主剤及び硬化剤を供給する供給手段としての注入機２２が設置されている。すなわち、この注入機２２には、キャビティ２０に主剤を供給するための主剤供給管２４と、該主剤に添加される硬化剤を供給するための硬化剤供給管２６が連結されている。主剤及び硬化剤は注入機２２内で混合され、原材料２８として注入機２２からキャビティ２０に供給される。   In this case, the cavity 20 extends in the horizontal direction. The first horizontal mold 14 is provided with an injection machine 22 as a supply means for supplying a main agent and a curing agent as raw materials for the resin foam. That is, a main agent supply pipe 24 for supplying the main agent to the cavity 20 and a hardener supply pipe 26 for supplying a hardener added to the main agent are connected to the injector 22. The main agent and the curing agent are mixed in the injector 22 and supplied as a raw material 28 from the injector 22 to the cavity 20.

また、第２横型１６には、キャビティ２０の延在方向に沿って延在する貫通孔２９が形成されており、この貫通孔２９には、送気管３０が挿入されている。この送気管３０の先端部は第２横型１６の側面外方から突出しており、さらに、レギュレータ３２を介してガス供給管３４が連結されている。図示しないガス供給源に連結された該ガス供給管３４には、バルブ３６が介装されている。   Further, a through hole 29 extending along the extending direction of the cavity 20 is formed in the second horizontal mold 16, and an air supply pipe 30 is inserted into the through hole 29. The leading end of the air supply pipe 30 protrudes from the outside of the side surface of the second horizontal mold 16, and a gas supply pipe 34 is connected via a regulator 32. A valve 36 is interposed in the gas supply pipe 34 connected to a gas supply source (not shown).

この中、レギュレータ３２には、該レギュレータ３２を操作する図示しないアクチュエータと、該アクチュエータを制御する図示しないアクチュエータ制御手段とが付設されている。   Among these, the regulator 32 is provided with an actuator (not shown) for operating the regulator 32 and an actuator control means (not shown) for controlling the actuator.

一方、バルブ３６は、電気的ないし光学的通信手段（図示せず）を介して該バルブ３６の開度を制御するバルブ開度制御手段（図示せず）に接続されている。バルブ３６の開度は、このバルブ開度制御手段の指令信号により、段階的又は連続的に変更可能である。   On the other hand, the valve 36 is connected to valve opening degree control means (not shown) for controlling the opening degree of the valve 36 via electrical or optical communication means (not shown). The opening degree of the valve 36 can be changed stepwise or continuously by a command signal of the valve opening degree control means.

前記アクチュエータ制御手段及び前記バルブ開度制御手段は、同一の制御盤内に制御回路として設けられており、この制御盤によって成形装置１０の一連の動作が制御される。   The actuator control means and the valve opening degree control means are provided as a control circuit in the same control panel, and a series of operations of the molding apparatus 10 are controlled by this control panel.

以上の構成において、下型１２、第１横型１４、第２横型１６及び上型１８の各々には、図示しない排気通路が複数個形成されている。また、キャビティ２０には、樹脂材からなり、且つ下型１２の上端面の形状に対応する形状に成形された表皮層３８が挿入されている。   In the above configuration, a plurality of exhaust passages (not shown) are formed in each of the lower mold 12, the first horizontal mold 14, the second horizontal mold 16, and the upper mold 18. Further, a skin layer 38 made of a resin material and formed into a shape corresponding to the shape of the upper end surface of the lower mold 12 is inserted into the cavity 20.

本実施の形態に係る積層樹脂成形体の製造方法は、上記のように構成された成形装置１０を用い、以下のようにして実施される。   The manufacturing method of the laminated resin molded body according to the present embodiment is performed as follows using the molding apparatus 10 configured as described above.

先ず、注入機２２に対し、主剤供給管２４から主剤を供給するとともに硬化剤供給管２６から硬化剤を供給する。注入機２２内で混合された主剤及び硬化剤は、原材料２８として注入機２２からキャビティ２０に供給される。なお、原材料２８がキャビティ２０に充填される最中、該キャビティ２０に残留していた大気は、原材料２８に押圧されることに伴い、前記排気通路を介してキャビティ２０の外部に排出される。   First, the main agent is supplied from the main agent supply pipe 24 to the injector 22 and the curing agent is supplied from the hardener supply pipe 26. The main agent and the curing agent mixed in the injector 22 are supplied from the injector 22 to the cavity 20 as a raw material 28. In addition, while the raw material 28 is filled in the cavity 20, the air remaining in the cavity 20 is discharged to the outside of the cavity 20 through the exhaust passage as it is pressed by the raw material 28.

ここで、本実施の形態においては、原材料２８の充填を開始した直後、ないし所定量の原材料２８が導入された後、図２に示すように、前記ガス供給源から前記ガス供給管３４及び前記送気管３０を介して、キャビティ２０に圧縮エアを導入する。なお、圧縮エアに代替して窒素、アルゴン等を導入するようにしてもよい。   Here, in the present embodiment, immediately after starting the filling of the raw material 28 or after a predetermined amount of the raw material 28 has been introduced, as shown in FIG. Compressed air is introduced into the cavity 20 through the air supply pipe 30. Note that nitrogen, argon, or the like may be introduced instead of compressed air.

圧縮エアは、原材料２８の流動方向に対して逆方向に流通するように導入される。このため、原材料２８は、圧縮エアによって該原材料２８の流動方向と逆方向に押圧され、その結果、該原材料２８の充填速度が第２横型１６側から低減し、最終的に、原材料２８が停止する。換言すれば、本実施の形態においては、原材料２８を停止させることが可能な圧力で圧縮エアがキャビティ２０に供給される。   The compressed air is introduced so as to flow in the direction opposite to the flow direction of the raw material 28. For this reason, the raw material 28 is pressed by the compressed air in the direction opposite to the flow direction of the raw material 28. As a result, the filling speed of the raw material 28 is reduced from the second horizontal mold 16 side, and finally the raw material 28 stops. To do. In other words, in the present embodiment, compressed air is supplied to the cavity 20 at a pressure that can stop the raw material 28.

その一方で、原材料２８中の主剤に含まれた発泡剤が発泡して独立気泡４０が生成するとともに、硬化剤の作用下に主剤が硬化し始める。これにより、原材料２８の樹脂発泡体４２への変化が開始される。   On the other hand, the foaming agent contained in the main material in the raw material 28 foams to generate closed cells 40, and the main material begins to cure under the action of the curing agent. Thereby, the change to the resin foam 42 of the raw material 28 is started.

上記したように、本実施の形態においては、第２横型１６側から圧縮エアが導入され、このために原材料２８（樹脂発泡体４２）の流動が停止している。従って、原材料２８（樹脂発泡体４２）は、圧縮エアに囲繞された状態となる。換言すれば、原材料２８（樹脂発泡体４２）は、擬似的に、圧縮エアによって形成される圧縮性の殻に覆われる。そして、この状態で、原材料２８（樹脂発泡体４２）中の発泡が継続される。従って、生成した独立気泡４０内の圧力は、擬似的な殻（圧縮エア）の圧力と均衡する。   As described above, in the present embodiment, compressed air is introduced from the second horizontal mold 16 side, and thus the flow of the raw material 28 (resin foam 42) is stopped. Accordingly, the raw material 28 (resin foam 42) is surrounded by the compressed air. In other words, the raw material 28 (resin foam 42) is artificially covered with a compressible shell formed by compressed air. In this state, foaming in the raw material 28 (resin foam 42) is continued. Therefore, the pressure in the generated closed cell 40 is balanced with the pressure of the pseudo shell (compressed air).

この発泡が継続している最中、レギュレータ３２を操作することによって圧縮エアの供給圧力を低減する。すなわち、減圧を行う。   While the foaming continues, the supply pressure of the compressed air is reduced by operating the regulator 32. That is, pressure reduction is performed.

この減圧に伴い、原材料２８（樹脂発泡体４２）を覆う擬似的な殻が取り除かれる。その結果、独立気泡４０の圧力がキャビティ２０内の圧力を上回るようになり、このため、図３に示すように、各独立気泡４０を起点として亀裂４４が伝播する。この亀裂４４同士は最終的に互いに連なり、これにより、連続気泡４６が形成される。同時に、キャビティ２０の全体が原材料２８で満たされるとともに、該原材料２８の樹脂発泡体４２への変化が起こる。勿論、樹脂発泡体４２は表皮層３８に接合し、これにより、表皮層３８上に樹脂発泡体４２（中間層）が積層された積層樹脂成形体が得られるに至る。   With this decompression, the pseudo shell covering the raw material 28 (resin foam 42) is removed. As a result, the pressure of the closed bubbles 40 exceeds the pressure in the cavity 20, and as a result, as shown in FIG. 3, the crack 44 propagates starting from each closed cell 40. The cracks 44 are finally connected to each other, whereby an open cell 46 is formed. At the same time, the entire cavity 20 is filled with the raw material 28, and a change of the raw material 28 to the resin foam 42 occurs. Of course, the resin foam 42 is bonded to the skin layer 38, thereby obtaining a laminated resin molded body in which the resin foam 42 (intermediate layer) is laminated on the skin layer 38.

このように、原材料２８をキャビティ２０に充填する際、該キャビティ２０に対して圧縮エアを供給し、且つ原材料２８内で発泡が継続している最中に圧縮エアの圧力を低減することにより、原材料２８から樹脂発泡体４２を形成している間に連続気泡４６を設けることが可能となる。   Thus, when filling the raw material 28 into the cavity 20, by supplying compressed air to the cavity 20 and reducing the pressure of the compressed air while foaming continues in the raw material 28, The open cell 46 can be provided while the resin foam 42 is formed from the raw material 28.

その後、前記変位機構の作用下に、下型１２、第１横型１４、第２横型１６及び上型１８を互いに離間するように変位させれば型開きが行われ、積層樹脂成形体が露呈する。上記したように、この積層樹脂成形体における樹脂発泡体４２には既に連続気泡４６が形成されており、従って、従来技術のように、真空減圧等を行う必要がない。   Thereafter, when the lower mold 12, the first horizontal mold 14, the second horizontal mold 16, and the upper mold 18 are displaced so as to be separated from each other under the action of the displacement mechanism, the mold opening is performed, and the laminated resin molded body is exposed. . As described above, the open cell 46 is already formed in the resin foam 42 in this laminated resin molded body, and therefore, it is not necessary to perform vacuum decompression or the like as in the prior art.

すなわち、本実施の形態によれば、連続気泡４６を形成するための煩雑な後作業（真空減圧等）を行う必要がない。そして、このために積層樹脂成形体を得るまでの時間も著しく短縮される。要するに、積層樹脂成形体を簡便に、しかも、効率よく製造することができる。その上、本実施の形態に係る製造方法によって作製された積層樹脂成形体は、真空減圧等、従来公知の破泡手法によって得られた連続気泡を有する積層樹脂成形体に比して軟質であり、クッション感覚が著しく良好である。   That is, according to the present embodiment, it is not necessary to perform a complicated post-operation (vacuum decompression or the like) for forming the open cell 46. For this reason, the time required to obtain a laminated resin molded body is also significantly shortened. In short, the laminated resin molded body can be produced easily and efficiently. Moreover, the laminated resin molded body produced by the manufacturing method according to the present embodiment is softer than a laminated resin molded body having open cells obtained by a conventionally known bubble breaking technique such as vacuum decompression. The cushion feeling is remarkably good.

この積層樹脂成形体には、真空成形機において樹脂発泡体４２側に基材層が積層されると同時に該基材層とともに成形が施され、これにより、自動車のインストルメンタルパネル等の最終製品が製造される。勿論、この最終製品も、クッション感覚が著しく優れたものとなる。   In the laminated resin molded body, a base material layer is laminated on the resin foam 42 side in a vacuum molding machine, and at the same time, molding is performed together with the base material layer, whereby an end product such as an instrument panel of an automobile is formed. Manufactured. Of course, this final product also has a very good cushion feeling.

以上のように、本実施の形態によれば、一層軟質な積層樹脂成形体を簡便に、しかも、効率よく製造することができる。   As described above, according to the present embodiment, a softer laminated resin molded body can be easily and efficiently manufactured.

なお、上記した実施の形態においては、水平方向に延在するキャビティ２０を例示して説明したが、キャビティ２０の形状は特にこれに限定されるものではなく、如何なる形状のものであってもよい。   In the above-described embodiment, the cavity 20 extending in the horizontal direction has been described as an example. However, the shape of the cavity 20 is not particularly limited thereto, and may be any shape. .

また、圧縮エア等の供給開始時の圧力は、原材料２８を停止可能な程度に特に限定されるものではなく、少なくとも、原材料２８の流動を遅延させる程度であればよい。   Further, the pressure at the start of supplying compressed air or the like is not particularly limited to such an extent that the raw material 28 can be stopped, and may be at least as long as the flow of the raw material 28 is delayed.

１０…成形装置 １２、１４、１６、１８…型
２０…キャビティ ２２…注入機
２８…原材料 ３２…レギュレータ
３４…ガス供給管 ３８…表皮層
４０…独立気泡 ４２…樹脂発泡体
４４…亀裂 ４６…連続気泡 DESCRIPTION OF SYMBOLS 10 ... Molding apparatus 12, 14, 16, 18 ... Mold 20 ... Cavity 22 ... Injection machine 28 ... Raw material 32 ... Regulator 34 ... Gas supply pipe 38 ... Skin layer 40 ... Closed cell 42 ... Resin foam 44 ... Crack 46 ... Continuous Bubbles

Claims (2)

予め所定形状に成形され且つ成形型のキャビティに配置された樹脂製成形体の一端面に樹脂発泡体を設けることで積層樹脂成形体を得る積層樹脂成形体の製造方法であって、
供給手段から供給された原材料が前記キャビティを流動している最中に、前記キャビティに気体を供給して前記原材料を押圧し、
前記原材料に発泡が生じている最中に、前記気体の圧力を低減して破泡を行うことを特徴とする積層樹脂成形体の製造方法。 A method for producing a laminated resin molded body, which is formed in advance into a predetermined shape and obtains a laminated resin molded body by providing a resin foam on one end surface of a resin molded body disposed in a cavity of a mold,
While the raw material supplied from the supply means is flowing through the cavity, gas is supplied to the cavity to press the raw material,
A method for producing a laminated resin molded article, wherein foaming is performed by reducing the pressure of the gas while foaming occurs in the raw material. 請求項１記載の製造方法において、前記気体は、前記原材料の流動を停止可能な圧力で供給が開始されることを特徴とする積層樹脂成形体の製造方法。   2. The manufacturing method according to claim 1, wherein supply of the gas is started at a pressure capable of stopping the flow of the raw material.
JP2010237390A 2010-10-22 2010-10-22 Method for manufacturing laminated resin molded body Pending JP2011037280A (en)

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JP2004114646A (en) * 2002-09-30 2004-04-15 Toyota Motor Corp Foam molding device and method therefor
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JPS63199616A (en) * 1987-02-13 1988-08-18 Toyota Motor Corp Monolithic foam molding method
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JP2004114646A (en) * 2002-09-30 2004-04-15 Toyota Motor Corp Foam molding device and method therefor
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