JP2020001237A - Method for manufacturing patterned foam molded product - Google Patents

Method for manufacturing patterned foam molded product Download PDF

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JP2020001237A
JP2020001237A JP2018121693A JP2018121693A JP2020001237A JP 2020001237 A JP2020001237 A JP 2020001237A JP 2018121693 A JP2018121693 A JP 2018121693A JP 2018121693 A JP2018121693 A JP 2018121693A JP 2020001237 A JP2020001237 A JP 2020001237A
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molded product
molded article
foam
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JP7089276B2 (en
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泰平 一宮
Yasuhira Ichinomiya
泰平 一宮
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Sanwa Kako Co Ltd
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Abstract

To provide a method for manufacturing a patterned foam molded product capable of flexibly manufacturing a foam molded product with different patterns without changing a mold.SOLUTION: A method for manufacturing a patterned foam molded product 3 obtains an intermediate molded product 2 by forming a basic pattern M1 composed of a recessed part on an outer surface of a basic foam 1, and then obtains a patterned foam molded product 3 of which a final pattern M2 composed of a post-processing recessed part is exposed on an outer surface while disposing the intermediate molded product 2 between a pair of molds K1, K2 and pressurizing and heating the intermediate molded product 2 with the pair of molds K1, K2. Thus, a foam molded product 3 with different patterns can be flexibly manufactured without changing the molds K1, K2.SELECTED DRAWING: Figure 4

Description

本発明は、模様入り発泡体成形品の製造方法に関する。   The present invention relates to a method for producing a patterned foam molded article.

従来、外面に模様を有した発泡体成形品を得るために、模様に対応させた凹凸を設けてなる金型を使用して成形前の発泡体を加圧及び加熱することが行われていた（例えば、特許文献１を参照）。   Conventionally, in order to obtain a foam molded article having a pattern on the outer surface, it has been performed to pressurize and heat the foam before molding using a mold provided with irregularities corresponding to the pattern. (See, for example, Patent Document 1).

しかしながら、従来のものでは、発泡体成形品の外面模様が、金型の凹凸形状に限定されてしまうものとなる。このため、従来のものでは、比較的高額な設備である金型それ自体を変更しない限り、外面に異なる模様を有した発泡体成形品を得ることができなかった。換言すれば、従来の発泡体成形品の製造方法では、模様の異なる発泡体成形品を柔軟に製造することが著しく困難なものとなっていた。   However, in the conventional case, the outer surface pattern of the foam molded article is limited to the irregular shape of the mold. For this reason, in the conventional apparatus, a foam molded article having a different pattern on the outer surface cannot be obtained unless the mold itself, which is relatively expensive equipment, is changed. In other words, it has been extremely difficult to flexibly produce a foam molded article having a different pattern in the conventional method for producing a foam molded article.

特開昭５７−７７５３８号公報JP-A-57-77538

本発明は、以上のような事情に着目してなされたもので、金型を変更することなく、模様の異なる発泡体成形品を柔軟に製造し得る模様入り発泡体成形品の製造方法を提供することにある。   The present invention has been made in view of the above circumstances, and provides a method for manufacturing a patterned foam molded article capable of flexibly producing a foam molded article having a different pattern without changing a mold. Is to do.

すなわち、本発明は次の構成をなしている。   That is, the present invention has the following configuration.

請求項１に記載の発明は、基礎発泡体の外面に凹陥部からなる基礎模様を形成することにより中間成形品を得た後に、当該中間成形品を一対の金型間に配した上で当該一対の金型によって加圧及び加熱して、外面に加工後凹陥部からなる最終模様が表出した模様入り発泡体成形品を得るようにした模様入り発泡体成形品の製造方法である。   In the invention according to claim 1, after forming an intermediate molded product by forming a basic pattern consisting of a concave portion on the outer surface of the basic foam, the intermediate molded product is disposed between a pair of molds, and This is a method for producing a patterned foam molded article in which a patterned foam molded article in which a final pattern formed of a concave portion is exposed on the outer surface by applying pressure and heating by a pair of molds is obtained.

請求項２に記載の発明は、前記基礎発泡体が平板状をなしたものであり、前記金型の成形面を構成する主成形面が平面状をなしている請求項１記載の模様入り発泡体成形品の製造方法である。   According to a second aspect of the present invention, there is provided the patterned foam according to the first aspect, wherein the base foam has a flat shape, and a main forming surface constituting a forming surface of the mold has a flat shape. This is a method for manufacturing a molded article.

請求項３に記載の発明は、前記金型の成形面と前記中間成形品との間に通気性のある布材を配した上で、前記中間成形品を前記金型により加熱及び加圧するようにした請求項１又は２記載の模様入り発泡体成形品の製造方法である。   The invention according to claim 3 is such that after arranging a breathable cloth material between the molding surface of the mold and the intermediate molded product, the intermediate molded product is heated and pressed by the mold. A method for producing a patterned foam molded article according to claim 1 or 2.

請求項４に記載の発明は、ルーター加工機を使用して前記基礎発泡体の外面を切削し、外面に前記凹陥部からなる基礎模様を有した中間成形品を得る請求項１、２又は３記載の模様入り発泡体成形品の製造方法である。   According to a fourth aspect of the present invention, an outer surface of the basic foam is cut using a router machine to obtain an intermediate molded product having a basic pattern formed of the concave portion on the outer surface. It is a manufacturing method of the patterned foamed molded article of the description.

請求項５に記載の発明は、前記中間成形品に形成された前記凹陥部の深さ寸法が３〜５ｍｍに設定されている請求項１、２、３又は４記載の模様入り発泡体成形品の製造方法である。   According to a fifth aspect of the present invention, there is provided the patterned foamed molded article according to any one of the first to third aspects, wherein the depth of the recess formed in the intermediate molded article is set to 3 to 5 mm. Is a manufacturing method.

請求項６に記載の発明は、前記模様入り発泡体成形品が、床面パネル又は壁面パネルである請求項１、２、３、４又は５記載の模様入り発泡体成形品の製造方法である。   The invention according to claim 6 is the method for producing a patterned foam molded article according to claim 1, 2, 3, 4, or 5, wherein the patterned foam molded article is a floor panel or a wall panel. .

以上説明したように本発明によれば、金型を変更することなく、模様の異なる発泡体成形品を柔軟に製造し得る模様入り発泡体成形品の製造方法を提供することができる。   As described above, according to the present invention, it is possible to provide a method for producing a patterned foam molded article that can flexibly produce a foam molded article having a different pattern without changing a mold.

本発明の一実施形態における中間成形品を示す斜視図。FIG. 1 is a perspective view showing an intermediate molded product according to an embodiment of the present invention. 同実施形態における金型を用いた製造工程を示す概略端面図。FIG. 4 is a schematic end view showing a manufacturing process using a mold in the same embodiment. 同実施形態における最終的な模様入り発泡体成形品を示す斜視図。FIG. 3 is a perspective view showing a final patterned foam molded article in the same embodiment. 同実施形態における模様入り発泡体成形品の製造工程の説明図。Explanatory drawing of the manufacturing process of the patterned foam molded article in the embodiment. 図１におけるＡ−Ａ線断面図。FIG. 2 is a sectional view taken along line AA in FIG. 1. 図３におけるＢ−Ｂ線断面図。FIG. 4 is a sectional view taken along line BB in FIG. 3. 図５におけるＸ部分拡大図。The X part enlarged view in FIG. 図６におけるＹ部分拡大図。The Y part enlarged view in FIG.

以下、本発明の一実施形態を、図１〜８を参照して説明する。   Hereinafter, an embodiment of the present invention will be described with reference to FIGS.

この実施形態は、本発明を、使用者の視覚により認識させ得る模様であるレンガ模様Ｍ２を表出させた模様入り発泡体成形品３の製造方法に適用したものである。   In this embodiment, the present invention is applied to a method for manufacturing a patterned foam molded article 3 in which a brick pattern M2 which is a pattern that can be visually recognized by a user is exposed.

図３等に示すように、模様入り発泡体成形品３は、略矩形板状をなしている。模様入り発泡体成形品３は、床面パネル又は壁面パネルとして好適に使用されるものとなっている。   As shown in FIG. 3 and the like, the patterned foam molded article 3 has a substantially rectangular plate shape. The patterned foam molded article 3 is suitably used as a floor panel or a wall panel.

模様入り発泡体成形品３は、図２に示すように、一対の金型Ｋ１、Ｋ２すなわち上下の金型Ｋ１、Ｋ２による加圧及び加熱による加工（いわゆる「熱圧成形」であり、以下において「熱圧成形」と称することがある。）を経て作られている。   As shown in FIG. 2, the patterned foam molded article 3 is processed by pressing and heating by a pair of dies K1 and K2, that is, upper and lower dies K1 and K2 (so-called “hot-press molding”. It may be referred to as “hot pressing”.)

模様入り発泡体成形品３は、熱圧成形を経ることによって、外面に設けられた加工後凹陥部ｈ２の存在によって、視覚的に把握され得る最終模様たるレンガ模様Ｍ２を表出させている。   The pattern-formed foam molded article 3 is subjected to hot-press molding, thereby displaying a brick pattern M2 as a final pattern that can be visually grasped by the presence of the recessed portion h2 after processing provided on the outer surface.

以下、模様入り発泡体成形品３の製造方法について、特に、図１〜８を参照して詳述する。なお、図４では、製造工程を概略的に示している。   Hereinafter, the method for producing the patterned foam molded article 3 will be described in detail with particular reference to FIGS. FIG. 4 schematically shows a manufacturing process.

まず、図４（ａ）に示すように、基材となる基礎発泡体１を準備する。この実施形態では、基礎発泡体１は、略矩形平板状をなしている。基礎発泡体１は、化学架橋剤で架橋した独立気泡ポリエチレン発泡体により構成されている。   First, as shown in FIG. 4A, a basic foam 1 as a base material is prepared. In this embodiment, the basic foam 1 has a substantially rectangular flat plate shape. The basic foam 1 is composed of a closed-cell polyethylene foam crosslinked with a chemical crosslinking agent.

次に、図４（ｂ）に示すように、基礎発泡体１の外面に、凹陥部ｈ１からなる基礎模様Ｍ１、すなわち最終的なレンガ模様Ｍ２の基礎となる基礎模様Ｍ１を形成することにより中間成形品２を得る。図５に示されている中間成形品２の厚み寸法ｗ１（基礎発泡体１の厚み寸法と同じである）は、１０〜２０ｍｍの範囲内に設定されることが望ましい。この実施形態では、中間成形品２の厚み寸法ｗ１は、１５ｍｍに設定されている。   Next, as shown in FIG. 4 (b), a basic pattern M1 composed of the recessed part h1, that is, a basic pattern M1 serving as a basis of the final brick pattern M2 is formed on the outer surface of the basic foam 1 to form an intermediate pattern. A molded article 2 is obtained. It is desirable that the thickness dimension w1 (same as the thickness dimension of the base foam 1) of the intermediate molded product 2 shown in FIG. 5 be set in the range of 10 to 20 mm. In this embodiment, the thickness dimension w1 of the intermediate molded product 2 is set to 15 mm.

中間成形品２に形成された基礎模様Ｍ１は、ルーター加工機（図示せず）を用いて基礎発泡体１の外面を部分的に削り、所定の深さ寸法ｄ１を有した凹陥部ｈ１を形成することにより設けられている。中間成形品２に設けられた凹陥部ｈ１は、底面部ｈ１１と、この底面部ｈ１１の両端部から当該底面部ｈ１１に対して略直交する方向に延びた側面部ｈ１２とを有しており、全体としてチャンネル状をなしている。   The basic pattern M1 formed on the intermediate molded product 2 is formed by partially shaving the outer surface of the basic foam 1 using a router machine (not shown) to form a recess h1 having a predetermined depth dimension d1. It is provided by doing. The concave portion h1 provided in the intermediate molded product 2 has a bottom surface h11 and side surfaces h12 extending from both ends of the bottom surface h11 in a direction substantially orthogonal to the bottom surface h11. It has a channel shape as a whole.

中間成形品２の外面に形成された凹陥部ｈ１の深さ寸法ｄ１は、３〜５ｍｍの範囲内に設定されている。凹陥部ｈ１の深さ寸法ｄ１が、３ｍｍよりも短い場合には、上下の金型Ｋ１、Ｋ２によって加圧及び加熱した後に表れる加工後凹陥部ｈ２により構成されるレンガ模様Ｍ２が著しく不明瞭になってしまうことが判明した。一方で、中間成形品２の外面に形成された凹陥部ｈ１の深さ寸法ｄ１が、５ｍｍよりも長い場合には、上下の金型Ｋ１、Ｋ２による加圧及び加熱を行った際に当該凹陥部ｈ１が均一的に変形せず、その結果、上下の金型Ｋ１、Ｋ２によって加圧及び加熱した後の加工後凹陥部ｈ２に外観を損ねる要素となるバリや歪み等が形成されてしまうことが判明した。換言すれば、中間成形品２における凹陥部ｈ１の深さ寸法ｄ１を、３〜５ｍｍに設定すれば、模様入り発泡体成形品３において加工後凹陥部ｈ２を構成している底面部ｈ２１及び側面部ｈ２２が適切な形態に保持されるものとなる。   The depth dimension d1 of the recess h1 formed on the outer surface of the intermediate molded product 2 is set in a range of 3 to 5 mm. When the depth dimension d1 of the concave portion h1 is shorter than 3 mm, the brick pattern M2 formed by the processed concave portion h2 that appears after being pressed and heated by the upper and lower molds K1 and K2 becomes extremely unclear. It turned out to be. On the other hand, when the depth dimension d1 of the concave portion h1 formed on the outer surface of the intermediate molded product 2 is longer than 5 mm, the concave portion h1 is pressed when the upper and lower dies K1 and K2 press and heat. The portion h1 is not uniformly deformed, and as a result, burrs and distortions, which are elements that impair the appearance, are formed in the recessed portion h2 after processing after being pressed and heated by the upper and lower molds K1 and K2. There was found. In other words, if the depth dimension d1 of the recess h1 in the intermediate molded product 2 is set to 3 to 5 mm, the bottom surface h21 and the side surfaces forming the recess h2 after processing in the patterned foam molded product 3 The part h22 is held in an appropriate form.

図４（ｃ）に示すように、上述した中間成形品２を得た後に、当該中間成形品２を一対の金型である上下の金型Ｋ１、Ｋ２間に配した上で、当該両金型Ｋ１、Ｋ２によって中間成形品２を所定の条件で加圧及び加熱する。上下の金型Ｋ１、Ｋ２は、それぞれ中間成形品２を向く側に成形面Ｋ１１、Ｋ２１を設けている。各成形面Ｋ１１、Ｋ２１は、中間成形品２の主たる外面に対面する主成形面Ｋ１１１、Ｋ２１１と、この主成形面Ｋ１１１、Ｋ２１１の周縁部に配された縁部成形面Ｋ１１２、Ｋ２１２とを備えている。   As shown in FIG. 4 (c), after obtaining the above-mentioned intermediate molded product 2, the intermediate molded product 2 is disposed between a pair of upper and lower dies K1 and K2, The intermediate molded product 2 is pressed and heated under predetermined conditions by the molds K1 and K2. The upper and lower dies K1 and K2 are provided with molding surfaces K11 and K21 on the side facing the intermediate molded product 2, respectively. Each of the molding surfaces K11 and K21 includes main molding surfaces K111 and K211 facing the main outer surface of the intermediate molded product 2, and edge molding surfaces K112 and K212 arranged around the periphery of the main molding surfaces K111 and K211. ing.

この実施形態では、主成形面Ｋ１１１、Ｋ２１１は、平面状をなしている。また、上下の金型Ｋ１、Ｋ２が密着しているとき、すなわち、上下の金型Ｋ１、Ｋ２により熱圧成形をしている際の主成形面Ｋ１１１、Ｋ２１１間の離間寸法は８ｍｍに設定されている。これにより、最終的な模様入り発泡体成形品３の厚み寸法ｗ２は、約８ｍｍに形成されるものとなっている。   In this embodiment, the main molding surfaces K111 and K211 are flat. When the upper and lower dies K1 and K2 are in close contact with each other, that is, when the upper and lower dies K1 and K2 are hot-pressed, the distance between the main molding surfaces K111 and K211 is set to 8 mm. ing. Thereby, the thickness dimension w2 of the final patterned foam molded article 3 is formed to be about 8 mm.

上下の金型Ｋ１、Ｋ２の各成形面Ｋ１１、Ｋ１２と中間成形品２との間には、通気性のある布材である上下のジャージＪ１、Ｊ２を配するようにしている。換言すれば、中間成形品２、及び、当該中間成形品２の外面を被覆する上下のジャージＪ１、Ｊ２を、両金型Ｋ１、Ｋ２を用いて加圧及び加熱して、最終的なレンガ模様Ｍ２を有した発泡体成形品３を得るようにしている。   Between the molding surfaces K11, K12 of the upper and lower dies K1, K2 and the intermediate molded product 2, upper and lower jerseys J1, J2, which are air-permeable cloth materials, are arranged. In other words, the intermediate molded product 2 and the upper and lower jerseys J1 and J2 that cover the outer surface of the intermediate molded product 2 are pressed and heated using both the dies K1 and K2 to obtain a final brick pattern. A foam molded article 3 having M2 is obtained.

ここで、上下のジャージＪ１、Ｊ２は、上下の金型Ｋ１、Ｋ２による熱圧成形の工程において、中間成形品２における基礎模様Ｍ２を含めた外表面の略全域を被覆するものとなっている。このため、上下のジャージＪ１、Ｊ２は、その素材に特有の微細な網目に基づいて、中間成形品２における外表面の略全域に同一態様の微細な外面特性（微細な凹凸形状）を付与し得るものとなっている。また、上下のジャージＪ１、Ｊ２は、上下の金型Ｋ１、Ｋ２による加工を経た後に、当該金型Ｋ１、Ｋ２から最終的な模様入り発泡体成形品３を取り出しやすくさせている。   Here, the upper and lower jerseys J1 and J2 cover substantially the entire outer surface including the basic pattern M2 of the intermediate molded product 2 in the step of hot pressing with the upper and lower molds K1 and K2. . For this reason, the upper and lower jerseys J1 and J2 impart the same mode of fine outer surface characteristics (fine irregularities) to almost the entire outer surface of the intermediate molded product 2 based on the fine mesh unique to the material. It is gaining. In addition, the upper and lower jerseys J1 and J2 make it easier to take out the final patterned foam molded article 3 from the dies K1 and K2 after working with the upper and lower dies K1 and K2.

上下の金型Ｋ１、Ｋ２による中間成形品２に対する加熱温度は、１２０°Ｃ〜１６０°Ｃの範囲内に設定されている。この実施形態においては、金型Ｋ１、Ｋ２による加熱温度は１４６°Ｃに設定されている。   The heating temperature for the intermediate molded product 2 by the upper and lower dies K1, K2 is set in the range of 120 ° C to 160 ° C. In this embodiment, the heating temperature of the dies K1 and K2 is set to 146 ° C.

上下の金型Ｋ１、Ｋ２による中間成形品２に対する加圧力は、５０ｋｇ／ｃｍ2〜１５０ｋｇ／ｃｍ2の範囲内に設定されている。この実施形態においては、金型による加圧力は、１００ｋｇ／ｃｍ2に設定されている。 Pressure applied by the upper and lower molds K1, K2 to the intermediate molded article 2 is in the range of 50kg / cm 2 ~150kg / cm 2 . In this embodiment, the pressure applied by the mold is set to 100 kg / cm 2 .

上下の金型Ｋ１、Ｋ２によって、中間成形品２を熱圧成形する時間（すなわち、上下の金型Ｋ１、Ｋ２による加圧及び加熱の時間）は、８分に設定されている。   The time during which the intermediate molded product 2 is hot-pressed by the upper and lower dies K1 and K2 (that is, the time of pressurization and heating by the upper and lower dies K1 and K2) is set to 8 minutes.

基礎模様Ｍ１を有した中間成形品２を、上下の金型Ｋ１、Ｋ２により加圧及び加熱した後に、当該中間成形品２を約２０分かけて常温すなわち室温に相当する温度である１０°Ｃ〜３５°Ｃまで冷却した段階で、両金型Ｋ１、Ｋ２を開く。この実施形態においては、中間成形品２を２０分かけて２４°Ｃにまで冷却した後、両金型Ｋ１、Ｋ２から最終的な成形品を離脱させるようにしている。そして、ジャージＪ１、Ｊ２を加圧及び加熱後の発泡体成形品３の表面からはがすようにして取り除き、図４（ｄ）に示すような最終的なレンガ模様Ｍ２を表出させた模様入り発泡体成形品３が得られる。   After the intermediate molded product 2 having the basic pattern M1 is pressed and heated by the upper and lower dies K1 and K2, the intermediate molded product 2 is heated to room temperature, that is, 10 ° C., which is a temperature corresponding to room temperature, over about 20 minutes. At the stage of cooling to ~ 35 ° C, both dies K1 and K2 are opened. In this embodiment, after the intermediate molded product 2 is cooled down to 24 ° C. over 20 minutes, the final molded product is released from both dies K1 and K2. Then, the jerseys J1 and J2 are peeled off from the surface of the foam molded article 3 after pressurization and heating, and the foamed pattern with the final brick pattern M2 as shown in FIG. The molded article 3 is obtained.

以上説明したように、本実施形態に係る模様入り発泡体成形品３の製造方法は、基礎発泡体１の外面に凹陥部ｈ１からなる基礎模様Ｍ１を形成することにより中間成形品２を得た後に、当該中間成形品２を一対の金型たる上下の金型Ｋ１、Ｋ２間に配した上で当該金型Ｋ１、Ｋ２によって加圧及び加熱して、外面に加工後凹陥部ｈ２からなる最終模様たるレンガ模様Ｍ２が表出した模様入り発泡体成形品３を得るようにしたものである。このため、金型Ｋ１、Ｋ２を変更することなく、模様の異なる発泡体成形品３を柔軟に製造し得る模様入り発泡体成形品３の製造方法を提供することができるものとなる。   As described above, in the method of manufacturing the patterned foam molded article 3 according to the present embodiment, the intermediate molded article 2 is obtained by forming the basic pattern M1 including the concave portion h1 on the outer surface of the basic foam 1. After that, the intermediate molded product 2 is disposed between the upper and lower molds K1 and K2 as a pair of molds, and then pressurized and heated by the molds K1 and K2. This is to obtain a patterned foam molded article 3 in which a brick pattern M2 is exposed. For this reason, it is possible to provide a method of manufacturing a patterned foam molded article 3 that can flexibly produce a foam molded article 3 having a different pattern without changing the molds K1 and K2.

つまり、基礎発泡体１の外面に凹陥部ｈ１からなる任意の基礎模様Ｍ１を設けることにより中間成形品２を生成し、その後に、金型Ｋ１、Ｋ２によって中間成形品２を加熱及び加圧して、最終的な模様入り発泡体成形品３を得るようにしている。このため、本実施形態に示す模様入り発泡体成形品３の製造方法であれば、金型Ｋ１、Ｋ２に設けた凹凸形状に依存することなく、中間成形品２に多様な基礎模様Ｍ１を設けることによって、模様の異なる発泡体成形品３を柔軟に製造することができるものとなる。   That is, the intermediate molded product 2 is generated by providing an arbitrary basic pattern M1 including the concave portion h1 on the outer surface of the basic foam 1, and thereafter, the intermediate molded product 2 is heated and pressed by the molds K1 and K2. Thus, a final patterned foam molded article 3 is obtained. For this reason, according to the method for manufacturing the patterned foamed molded product 3 shown in the present embodiment, various basic patterns M1 are provided on the intermediate molded product 2 without depending on the irregularities provided on the dies K1 and K2. This makes it possible to flexibly manufacture foam molded articles 3 having different patterns.

基礎発泡体１が平板状をなしたものである。そして、上下の金型Ｋ１、Ｋ２の成形面Ｋ１１、Ｋ２１を構成する主成形面Ｋ１１１、Ｋ２１１が平面状をなしている。このため、上下の金型Ｋ１、Ｋ２は、極めてシンプルな形態のものを採用することができ、当該金型Ｋ１、Ｋ２を変更することなく、外面の模様が異なる板状の発泡体成形品３を柔軟に製造することができるものとなっている。   The basic foam 1 has a flat shape. The main molding surfaces K111 and K211 forming the molding surfaces K11 and K21 of the upper and lower dies K1 and K2 are flat. For this reason, the upper and lower molds K1 and K2 can adopt extremely simple forms, and the plate-shaped foam molded product 3 having a different outer surface pattern can be used without changing the molds K1 and K2. Can be manufactured flexibly.

上下の金型Ｋ１、Ｋ２の成形面Ｋ１１、Ｋ２１と中間成形品２との間に通気性のある布材である上下のジャージＪ１、Ｊ２を配した上で、中間成形品３を上下の金型Ｋ１、Ｋ２により加熱及び加圧している。このため、金型Ｋ１、Ｋ２による熱圧成形の工程を終えた結果、中間成形品３における基礎模様Ｍ２を含むすべての表出面に、ジャージ素材の微細な編み目に基づいた微細な凹凸形状を付与することができ、結果として最終的な発泡体成形品３の外面として使用される領域に均一した視覚的及び触覚的な特性を付与し得るものとなっている。つまり、加工後凹陥部ｈ２と、当該加工後凹陥部ｈ２に隣接する平面部分とによって外面特性が異なることによる不具合、例えば、埃の蓄積度合いの違いが生じてしまったり、手触り感の不均一性が生じてしまったりするという不具合を好適に解消し得るものとなっている。   The upper and lower jerseys J1 and J2, which are air-permeable cloth materials, are arranged between the molding surfaces K11 and K21 of the upper and lower dies K1 and K2 and the intermediate molded product 2, and the intermediate molded product 3 is moved to the upper and lower molds. Heat and pressure are applied by the molds K1 and K2. For this reason, as a result of finishing the hot-press forming process using the dies K1 and K2, fine irregularities based on fine stitches of the jersey material are provided to all exposed surfaces including the basic pattern M2 in the intermediate molded product 3. As a result, uniform visual and tactile properties can be imparted to the area used as the outer surface of the final foam molded article 3. That is, a defect due to a difference in outer surface characteristics between the recessed portion h2 after processing and a flat portion adjacent to the recessed portion h2 after processing, for example, a difference in the degree of accumulation of dust occurs, or a non-uniform touch feeling. This can suitably solve the problem of the occurrence of the problem.

ルーター加工機（図示せず）を使用して基礎発泡体１の外面を切削し、外面に凹陥部ｈ１からなる基礎模様Ｍ１を有した中間成形品２を得るようにしている。このため、ルーター加工機により、基礎発泡体１の外面に多様な凹陥部ｈ１からなる基礎模様Ｍ１を形成することにより、基礎模様Ｍ１の異なる多様な中間成形品２を製造することができるものとなっている。   The outer surface of the base foam 1 is cut using a router machine (not shown) to obtain an intermediate molded product 2 having a base pattern M1 including a recess h1 on the outer surface. For this reason, by forming a basic pattern M1 including various concave portions h1 on the outer surface of the basic foam 1 by a router processing machine, it is possible to manufacture various intermediate molded products 2 having different basic patterns M1. Has become.

中間成形品２形成された凹陥部ｈ１の深さ寸法ｄ１が、３〜５ｍｍに設定されている。このため、上下の金型Ｋ１、Ｋ２による熱圧成形（加熱及び加圧）を経ても、視認可能な最終模様Ｍ２を適切に表出させ得るとともに最終模様Ｍ２を構成する加工後凹陥部ｈ２が外観を損ねない適切な仕上がり具合のものとなる。   The depth d1 of the recess h1 formed in the intermediate molded product 2 is set to 3 to 5 mm. For this reason, even after hot-press forming (heating and pressing) using the upper and lower molds K1 and K2, the visible final pattern M2 can be appropriately exposed, and the post-processing recess h2 constituting the final pattern M2 is formed. Appropriate finish that does not impair the appearance is obtained.

模様入り発泡体成形品３が、床面パネル又は壁面パネルであるため、この模様入り発泡体成形品３の製造方法により多様なバリエーションの模様を設けた発泡体成形品を好適に得ることができるものとなる。   Since the patterned foam molded article 3 is a floor panel or a wall panel, a foam molded article provided with various variations of patterns can be suitably obtained by the method of manufacturing the patterned foam molded article 3. It will be.

なお、本発明は、以上に詳述した実施形態に限られるものではない。   Note that the present invention is not limited to the embodiment described in detail above.

基礎発泡体の形状は、種々のものを採用することができるものであり、上述した実施形態に示したものに限定されるものではない。   Various shapes can be adopted as the shape of the basic foam, and the shape is not limited to the shape shown in the above-described embodiment.

基礎発泡体の素材は、種々のものを適用することができるものであり、上述した実施形態に示したものに限定されるものではない。   Various materials can be applied to the material of the basic foam, and the material is not limited to those described in the above embodiments.

基礎発泡体の構成についても、上述した実施形態に示したものには限られない。例えば、基礎発泡体が、複数枚の発泡体シートを組み合わせて構成されたものであってもよい。   The configuration of the basic foam is not limited to that shown in the above-described embodiment. For example, the base foam may be a combination of a plurality of foam sheets.

中間成形品に表出する基礎模様は、外面の一部に形成されていればよく、外面の全面に形成されている必要はない。例えば、中間成形品が平板状をなすものである場合は、少なくとも、一方側の外面に基礎模様を形成したものであればよい。   The basic pattern appearing on the intermediate molded product only needs to be formed on a part of the outer surface, and need not be formed on the entire outer surface. For example, when the intermediate molded product has a flat plate shape, it is sufficient that the basic pattern is formed on at least one outer surface.

金型における中間成形品の外面に対応する部位は、必ずしも平面状をなしたものに限られるものではない。   The portion corresponding to the outer surface of the intermediate molded product in the mold is not necessarily limited to a planar shape.

布材は、ジャージに限られず、種々の布を適用することができる。   The cloth material is not limited to the jersey, and various cloths can be applied.

中間成形品の基礎模様は、ルーター加工機を用いて作られたものに限定されるものではなく、ルーター加工機以外の加工手段により基礎模様を形成してよいのはもちろんのことである。   The basic pattern of the intermediate molded article is not limited to one formed using a router processing machine, and it goes without saying that the basic pattern may be formed by processing means other than the router processing machine.

その他、各部の具体的構成についても上記実施形態に限られるものではなく、本発明の趣旨を逸脱しない範囲で種々変形が可能である。   In addition, the specific configuration of each unit is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the present invention.

１…基礎発泡体
２…中間成形品
３…模様入り発泡体成形品
Ｍ１…基礎模様
Ｍ２…最終模様（レンガ模様）
Ｋ１、Ｋ２…金型（上の金型、下の金型） DESCRIPTION OF SYMBOLS 1 ... Basic foam 2 ... Intermediate molded product 3 ... Foam molded product with a pattern M1: Basic pattern M2 ... Final pattern (brick pattern)
K1, K2 ... mold (upper mold, lower mold)

Claims (6)

基礎発泡体の外面に凹陥部からなる基礎模様を形成することにより中間成形品を得た後に、当該中間成形品を一対の金型間に配した上で当該一対の金型によって加圧及び加熱して、外面に加工後凹陥部からなる最終模様が表出した模様入り発泡体成形品を得るようにした模様入り発泡体成形品の製造方法。 After obtaining an intermediate molded product by forming a basic pattern consisting of a concave portion on the outer surface of the basic foam, the intermediate molded product is disposed between a pair of dies, and then pressed and heated by the pair of dies. Then, a method for producing a patterned foam molded article, wherein a patterned foam molded article in which a final pattern formed of a concave portion is formed on the outer surface after the processing is obtained. 前記基礎発泡体が平板状をなしたものであり、前記金型の成形面を構成する主成形面が平面状をなしている請求項１記載の模様入り発泡体成形品の製造方法。 2. The method for producing a patterned foam molded article according to claim 1, wherein the basic foam has a flat shape, and a main molding surface constituting a molding surface of the mold has a planar shape. 前記金型の成形面と前記中間成形品との間に通気性のある布材を配した上で、前記中間成形品を前記金型により加熱及び加圧するようにした請求項１又は２記載の模様入り発泡体成形品の製造方法。 The air-permeable cloth material is arranged between the molding surface of the mold and the intermediate molded product, and the intermediate molded product is heated and pressed by the mold. A method for producing a patterned foam molded article. ルーター加工機を使用して前記基礎発泡体の外面を切削し、外面に前記凹陥部からなる基礎模様を有した中間成形品を得る請求項１、２又は３記載の模様入り発泡体成形品の製造方法。 The patterned foam molded article according to claim 1, 2 or 3, wherein an outer surface of the basic foam is cut using a router machine to obtain an intermediate molded article having a basic pattern formed of the concave portion on the outer surface. Production method. 前記中間成形品に形成された前記凹陥部の深さ寸法が３〜５ｍｍに設定されている請求項１、２、３又は４記載の模様入り発泡体成形品の製造方法。 The method for producing a patterned foam molded article according to claim 1, 2, 3, or 4, wherein a depth dimension of the recess formed in the intermediate molded article is set to 3 to 5 mm. 前記模様入り発泡体成形品が、床面パネル又は壁面パネルである請求項１、２、３、４又は５記載の模様入り発泡体成形品の製造方法。 The method for producing a patterned foam molded article according to claim 1, wherein the patterned foam molded article is a floor panel or a wall panel.
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JP2000089908A (en) * 1998-09-08 2000-03-31 Sanwa Kako Co Ltd Mouse pad and its manufacture
JP2004097508A (en) * 2002-09-10 2004-04-02 Toto Ltd Toilet seat
JP2007176053A (en) * 2005-12-28 2007-07-12 Inoac Corp Manufacturing method for polyolefin foam product, and mold

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5634435A (en) * 1979-08-31 1981-04-06 Kanto Leather Kk Preparation of foamed ornamental material with protection coating
JPS6322631A (en) * 1986-07-16 1988-01-30 Kinugawa Rubber Ind Co Ltd Preparation of decoration molding for automobiles
JPH0649650U (en) * 1992-12-14 1994-07-08 三和化工株式会社 Agricultural work table
JPH10315313A (en) * 1997-05-14 1998-12-02 Sanwa Kako Co Ltd Post-forming method of crosslinked polyethylene foam
JP2000089908A (en) * 1998-09-08 2000-03-31 Sanwa Kako Co Ltd Mouse pad and its manufacture
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