JP4165527B2 - Method for producing thermoplastic resin molded article - Google Patents

Method for producing thermoplastic resin molded article Download PDF

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JP4165527B2
JP4165527B2 JP2005155169A JP2005155169A JP4165527B2 JP 4165527 B2 JP4165527 B2 JP 4165527B2 JP 2005155169 A JP2005155169 A JP 2005155169A JP 2005155169 A JP2005155169 A JP 2005155169A JP 4165527 B2 JP4165527 B2 JP 4165527B2
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thermoplastic resin
foam sheet
mold
recess
resin foam
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JP2005306044A (en
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暁 花田
信裕 臼井
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Sumitomo Chemical Co Ltd
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Description

本発明は、熱可塑性樹脂製発泡シートに部分的に熱可塑性樹脂製の機能性部材が融着されてなる熱可塑性樹脂成形品の製造方法に関する。   The present invention relates to a method for producing a thermoplastic resin molded product in which a thermoplastic resin functional member is partially fused to a thermoplastic resin foam sheet.

従来、熱可塑性樹脂製非発泡シートに熱可塑性樹脂製部材が融着または接着により取り付けた製品は広く知られている。   Conventionally, products in which a thermoplastic resin member is attached to a non-foamed sheet made of thermoplastic resin by fusion or adhesion are widely known.

しかしながら、かかる従来の製品には、熱可塑性樹脂製部材の熱可塑性樹脂製非発泡シートからの引抜き強度のばらつきが大きいという欠点がある。
本発明の目的は、熱可塑性樹脂シートに熱可塑性樹脂製部材が設けられた熱可塑性樹脂成形品であって、引抜き強度の均一性に優れる成形品の効率的な製造方法を提供することにある。 However, such a conventional product has a drawback in that the variation in the drawing strength of the thermoplastic resin member from the non-foamed sheet made of thermoplastic resin is large.
An object of the present invention is to provide an efficient method for producing a molded product having a thermoplastic resin sheet and a thermoplastic resin member provided with a thermoplastic resin member and having excellent uniformity of pull-out strength. .

本発明者らは、上記従来技術の問題を解決するために鋭意検討を行い、所定形状に賦形された熱可塑性樹脂製発泡シートに、部分的に熱可塑性樹脂製の機能性部材が融着されてなる熱可塑性樹脂成形品が、該機能性部材の熱可塑性樹脂製発泡シートからの引抜き強度のばらつきが小さいことを見出すとともに、その有効な製造方法を見出し、本発明を完成した。   In order to solve the above-described problems of the prior art, the present inventors have conducted intensive studies, and a functional member made of a thermoplastic resin is partially fused to a thermoplastic resin foam sheet shaped into a predetermined shape. The thermoplastic resin molded product thus found has a small variation in the pulling strength of the functional member from the thermoplastic resin foam sheet, and an effective manufacturing method has been found, thereby completing the present invention.

すなわち、本発明は、所定形状に賦形された熱可塑性樹脂製発泡シートに、部分的に熱可塑性樹脂製の機能性部材が融着されてなる熱可塑性樹脂成形品の製造方法であって、下記の工程を含むことを特徴とする方法を提供する。
（１） 少なくとも一方に前記機能性部材の形状の凹部が形成された一対の金型間に、予め所定形状に賦形された熱可塑性樹脂製発泡シートを供給する工程
（２） 金型を閉じて、前記凹部の開口部を熱可塑性樹脂製発泡シートで塞ぐ工程
（３） 金型を閉じて前記凹部の開口部を熱可塑性樹脂製発泡シートで塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して前記熱可塑性樹脂成形品を形成する工程
（４） 工程（３）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程 That is, the present invention is a method for producing a thermoplastic resin molded article in which a thermoplastic resin functional member is partially fused to a thermoplastic resin foam sheet shaped into a predetermined shape, A method comprising the following steps is provided.
(1) A step of supplying a thermoplastic resin foam sheet preliminarily shaped into a predetermined shape between a pair of molds in which at least one of the functional member-shaped recesses is formed (2) Closing the mold (3) Closing the opening of the recess with a thermoplastic resin foam sheet (3) Close the mold and close the opening of the recess with the thermoplastic resin foam sheet so that it passes through the recess. A molten thermoplastic resin is supplied to the recess through a resin passage provided in the mold, and the thermoplastic resin and the thermoplastic resin foam sheet are fused and integrated to form the thermoplastic resin molded article. Step (4) Step of cooling the thermoplastic resin molded product formed in Step (3) and removing it from the mold

また、本発明は、所定形状に賦形された熱可塑性樹脂製発泡シートに、部分的に熱可塑性樹脂製の機能性部材が融着されてなる熱可塑性樹脂成形品の製造方法であって、下記の工程を含むことを特徴とする方法を提供する。
（１） 熱可塑性樹脂製発泡シートを加熱し軟化させる工程
（２） 熱可塑性樹脂製発泡シートを賦形するための成形部を有し、少なくとも一方の金型の該成形部に前記機能性部材の形状の凹部が形成された雄雌一対の金型間に、工程（１）で軟化させた熱可塑性樹脂製発泡シートを供給する工程
（３） 金型を閉じて、熱可塑性樹脂製発泡シートを所定形状に賦形する工程
（４） 金型を閉じて工程（３）で賦形した熱可塑性樹脂製発泡シートで前記凹部の開口部を塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して前記熱可塑性樹脂成形品を形成する工程
（５） 工程（４）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程 Further, the present invention is a method for producing a thermoplastic resin molded article in which a thermoplastic resin functional member is partially fused to a thermoplastic resin foam sheet shaped into a predetermined shape, A method comprising the following steps is provided.
(1) Step of heating and softening a foamed sheet made of thermoplastic resin (2) A molded part for shaping the foamed sheet made of thermoplastic resin, and the functional member in the molded part of at least one mold A step of supplying the thermoplastic resin foam sheet softened in the step (1) between a pair of male and female molds each having a recess having a shape of (3), the mold being closed, and the thermoplastic resin foam sheet (4) Closing the mold and closing the mold with the thermoplastic resin foam sheet molded in the process (3), the mold is formed so as to pass through the recess. A step of supplying a molten thermoplastic resin to the recess through a resin passage provided therein, and fusing and integrating the thermoplastic resin and the thermoplastic resin foam sheet to form the thermoplastic resin molded article (5) Thermoplastic resin molded product formed in step (4) Cooled, step of removing from the mold

また、本発明は、所定形状に賦形された熱可塑性樹脂製発泡シートに、部分的に熱可塑性樹脂製の機能性部材が融着されてなる熱可塑性樹脂成形品の製造方法であって、下記の工程を含むことを特徴とする方法を提供する。
（１） 熱可塑性樹脂製発泡シートを加熱し軟化させる工程
（２） 熱可塑性樹脂製発泡シートを賦形するための成形部を有し、該成形部に前記機能性部材の形状の凹部が形成された金型を使用し、工程（１）で軟化させた熱可塑性樹脂製発泡シートを真空成形、圧空成形または真空圧空成形により所定形状に賦形する工程
（３） 工程（２）で賦形した熱可塑性樹脂製発泡シートで前記凹部の開口部を塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して熱可塑性樹脂成形品を形成する工程
（４） 工程（３）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程
かかる製造方法により得られる熱可塑性樹脂成形品は、熱可塑性樹脂製発泡シートからの機能性部材の引抜き強度の均一性に優れたものであり、また、機能性部材が熱可塑性樹脂製発泡シートに接着剤によらず融着されているので、人体や環境への影響が少ないものである。 Further, the present invention is a method for producing a thermoplastic resin molded article in which a thermoplastic resin functional member is partially fused to a thermoplastic resin foam sheet shaped into a predetermined shape, A method comprising the following steps is provided.
(1) Step of heating and softening a foamed sheet made of thermoplastic resin (2) Having a molded part for shaping the foamed sheet made of thermoplastic resin, and forming a concave part in the shape of the functional member in the molded part Using the molded mold, the thermoplastic resin foam sheet softened in step (1) is formed into a predetermined shape by vacuum forming, pressure forming or vacuum pressure forming (3) is formed in step (2) In a state where the opening of the recess is closed with the thermoplastic resin foam sheet, the molten thermoplastic resin is supplied to the recess through a resin passage provided in the mold so as to pass through the recess. Step (4) forming a thermoplastic resin molded product by fusing and integrating the thermoplastic resin and the thermoplastic resin foam sheet (4) Step of cooling the thermoplastic resin molded product formed in the step (3) and removing it from the mold Heat obtained by such a manufacturing method The plastic resin molded product has excellent uniformity in the pulling strength of the functional member from the thermoplastic resin foam sheet, and the functional member is fused to the thermoplastic resin foam sheet regardless of the adhesive. Therefore, it has little impact on the human body and the environment.

本発明によれば、熱可塑性樹脂製発泡シートからの熱可塑性樹脂製機能性部材の引抜き強度のばらつきの小さい熱可塑性樹脂製成形品が提供され、これは、自動車内装用部品に好適に使用することができる。かかる熱可塑性樹脂製成形品は、本発明の方法により効率的に製造することができる。   ADVANTAGE OF THE INVENTION According to this invention, the thermoplastic resin molded product with a small dispersion | variation in the drawing strength of the thermoplastic resin functional member from the thermoplastic resin foam sheet is provided, and this is used suitably for automotive interior parts. be able to. Such a molded article made of a thermoplastic resin can be efficiently produced by the method of the present invention.

本発明の製造方法により得られる熱可塑性樹脂成形品（以下、「本成形品」と記することがある）における熱可塑性樹脂製発泡シートを構成する熱可塑性樹脂は、広範な熱可塑
性樹脂の中から、該発泡シートに融着させる機能性部材を構成する熱可塑性樹脂の種類に応じて適宜選択することができる。前記熱可塑性樹脂製発泡シートは、一種類の熱可塑性樹脂からなっていてもよく、また二種類以上の熱可塑性樹脂からなっていてもよい。好ましく使用される熱可塑性樹脂としては、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン樹脂（ＡＢＳ樹脂）などを挙げることができる。 The thermoplastic resin constituting the thermoplastic resin foam sheet in the thermoplastic resin molded product obtained by the production method of the present invention (hereinafter sometimes referred to as “the present molded product”) is one of a wide range of thermoplastic resins. Therefore, it can be appropriately selected according to the type of the thermoplastic resin constituting the functional member to be fused to the foam sheet. The thermoplastic resin foam sheet may be made of one kind of thermoplastic resin, or may be made of two or more kinds of thermoplastic resins. Preferred thermoplastic resins include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, ionomer resins, acrylonitrile / butadiene / styrene resins (ABS resins). ) And the like.

上記の熱可塑性樹脂の中でも、耐熱性などの面からはポリプロピレン系樹脂が好ましい。好ましいポリプロピレン系樹脂としては、プロピレンの単独重合体、プロピレン単位を５０モル％以上含む共重合体などを挙げることができる。前記共重合体におけるプロピレンとの共重合成分の好ましい例としては、エチレンおよびα−オレフィンを挙げることができる。α−オレフィンとしては、例えば、１−ブテン、４−メチルペンテン−１、１−ヘキセン、１−オクテンなど、炭素数４〜１０のα−オレフィンが挙げられる。該共重合体中のプロピレン以外のモノマー単位の含有量としては、エチレンについては１０重量％以下、α−オレフィンについては３０重量％以下が好ましい。   Among the above thermoplastic resins, polypropylene resins are preferable from the viewpoint of heat resistance and the like. Preferable polypropylene resins include propylene homopolymers and copolymers containing 50 mol% or more of propylene units. Preferable examples of the copolymer component with propylene in the copolymer include ethylene and α-olefin. Examples of the α-olefin include α-olefins having 4 to 10 carbon atoms such as 1-butene, 4-methylpentene-1, 1-hexene, and 1-octene. The content of monomer units other than propylene in the copolymer is preferably 10% by weight or less for ethylene and 30% by weight or less for α-olefin.

ポリプロピレン系樹脂としては、特開昭６２−１２１７０４号公報に開示されているような、低レベルの電子線架橋によって長鎖分岐が導入されたポリプロピレン樹脂も好ましい。また、超高分子量成分が導入されたポリプロピレン樹脂も好ましく用いられる。   As the polypropylene resin, a polypropylene resin in which long chain branching is introduced by low-level electron beam crosslinking as disclosed in JP-A-62-1121704 is also preferable. In addition, a polypropylene resin into which an ultrahigh molecular weight component is introduced is also preferably used.

上記熱可塑性樹脂製発泡シートの発泡倍率には特に制限はないが、製品の重量と強度とのバランスを考慮すると、２〜１０倍の発泡倍率が好ましい。また上記熱可塑性樹脂製発泡シートのセル径は２ｍｍ〜０．１μｍの範囲であることが好ましく、発泡シートの強度、加工しやすさなどの観点から５００〜１０μｍの範囲であることが特に好ましい。熱可塑性樹脂製発泡シートの厚みは、０．５〜１００ｍｍであることが好ましく、シートの強度、取り扱いやすさなどの点から、厚みは１〜１０ｍｍであることが特に好ましい。人体、環境などへの影響に鑑みて、上記熱可塑性樹脂製発泡シートは、発泡剤として二酸化炭素を用いて製造したものが好ましい。   Although there is no restriction | limiting in particular in the foaming ratio of the said thermoplastic resin foamed sheet, 2-10 times foaming ratio is preferable when the balance of the weight and intensity | strength of a product is considered. The cell diameter of the thermoplastic resin foam sheet is preferably in the range of 2 mm to 0.1 μm, and particularly preferably in the range of 500 to 10 μm from the viewpoint of the strength of the foam sheet and ease of processing. The thickness of the thermoplastic resin foam sheet is preferably 0.5 to 100 mm, and the thickness is particularly preferably 1 to 10 mm from the viewpoint of the strength of the sheet and ease of handling. In view of the influence on the human body and the environment, the thermoplastic resin foam sheet is preferably manufactured using carbon dioxide as a foaming agent.

本成形品における熱可塑性樹脂製の機能性部材は、前記熱可塑性樹脂製発泡シートから突き出すように形成されたものであり、具体的には、前記熱可塑性樹脂製発泡シートを補強する機能を有するリブ、あるいは前記熱可塑性樹脂製発泡シートを他部材に取り付ける機能を有するボス、クリップ、フックなどの部材である。   The thermoplastic resin functional member in the molded product is formed so as to protrude from the thermoplastic resin foam sheet, and specifically has a function of reinforcing the thermoplastic resin foam sheet. It is a member such as a boss, a clip or a hook having a function of attaching a rib or the thermoplastic resin foam sheet to another member.

上記機能性部材を構成する熱可塑性樹脂は、広範な熱可塑性樹脂の中から、該機能性部材を融着させる熱可塑性樹脂発泡シートを構成する熱可塑性樹脂の種類に応じて適宜選択することができる。通常好ましく使用できるものとして、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、ポリアミド系樹脂、アクリロニトリル／ブタジエン／スチレン樹脂（ＡＢＳ樹脂）、ポリカーボネート樹脂、これらの変性物、二以上の樹脂からなるポリマーアロイなどを挙げることができる。上記機能性部材は、一種類の熱可塑性樹脂で構成されてもよく、また、二種類以上の熱可塑性樹脂で構成されてもよい。前記機能性部材を構成する熱可塑性樹脂は、熱可塑性樹脂製発泡シートとの融着強度の面から、該発泡シートの熱可塑性樹脂と相溶性のある熱可塑性樹脂であることが好ましい。   The thermoplastic resin constituting the functional member can be appropriately selected from a wide range of thermoplastic resins depending on the type of thermoplastic resin constituting the thermoplastic resin foam sheet to which the functional member is fused. it can. Usually usable resins include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, ionomer resins, polyamide resins, acrylonitrile / butadiene / styrene resins (ABS). Resin), polycarbonate resin, modified products thereof, and polymer alloys composed of two or more resins. The functional member may be composed of one kind of thermoplastic resin, or may be composed of two or more kinds of thermoplastic resins. The thermoplastic resin constituting the functional member is preferably a thermoplastic resin that is compatible with the thermoplastic resin of the foamed sheet from the viewpoint of fusion strength with the foamed sheet made of thermoplastic resin.

前記機能性部材を構成する熱可塑性樹脂には各種の充填材（例えば、ガラス繊維、カーボン繊維等の無機繊維、タルク、クレー、シリカ、炭酸カルシウム等の無機粒子など）が配合されていてもよい。また、酸化防止剤、紫外線吸収剤、着色剤、難燃剤、低収縮剤など各種の添加剤が適宜配合されていてもよい。   Various fillers (for example, inorganic fibers such as glass fiber and carbon fiber, inorganic particles such as talc, clay, silica, and calcium carbonate) may be blended in the thermoplastic resin constituting the functional member. . Various additives such as an antioxidant, an ultraviolet absorber, a colorant, a flame retardant, and a low shrinkage agent may be appropriately blended.

本成形品において、機能性部材は、熱可塑性樹脂製発泡シートの片面にのみ取り付けられていてもよく、また、該発泡シートの両面に取り付けられていてもよい。また、取り付け位置および取り付け個数なども特に限定されない。   In the molded product, the functional member may be attached only to one surface of the thermoplastic resin foam sheet, or may be attached to both surfaces of the foam sheet. Further, the attachment position and the number of attachments are not particularly limited.

本成形品において、前記熱可塑性樹脂製発泡シートは、その表面に表皮材を備えていてもよい。かかる表皮材は、前記熱可塑性樹脂発泡シートの表面に配されて、装飾、補強、保護などの作用をするものであるが、該表皮材としては、織布、不織布、編布、シート、フィルム、発泡体、網状物などが挙げられる。これら表皮材を構成する材料は特に限定されるものではないが、例としてはポリオレフィン系樹脂、ポリ塩化ビニル系樹脂、ポリスチレン系樹脂などの熱可塑性樹脂、ポリウレタン系樹脂などの熱硬化性樹脂、あるいはシス−１，４−ポリブタジエン、エチレン／プロピレン共重合体などのゴムや熱可塑性エラストマー、綿、麻、竹などセルロース系繊維などの天然繊維などが挙げられる。また、表皮材には、紙や金属箔などを使用することもできる。かかる表皮材には、シボなどの凹凸模様、印刷や染色などが施されていてもよい。表皮材は、単層構成であっても、二以上の層からなる多層構成であってもよい。   In the present molded product, the thermoplastic resin foam sheet may have a skin material on the surface thereof. Such a skin material is arranged on the surface of the thermoplastic resin foam sheet, and functions as decoration, reinforcement, protection, etc. The skin material is woven fabric, nonwoven fabric, knitted fabric, sheet, film. , Foams, nets and the like. The materials constituting these skin materials are not particularly limited, but examples include polyolefin resins, polyvinyl chloride resins, thermoplastic resins such as polystyrene resins, thermosetting resins such as polyurethane resins, or Examples thereof include rubbers such as cis-1,4-polybutadiene and ethylene / propylene copolymers, thermoplastic elastomers, natural fibers such as cellulose fibers such as cotton, hemp and bamboo. Moreover, paper, metal foil, etc. can also be used for a skin material. Such a skin material may be provided with an uneven pattern such as embossing, printing or dyeing. The skin material may have a single-layer structure or a multilayer structure composed of two or more layers.

本成形品は、熱可塑性樹脂製発泡シートの片面、あるいは両面に配された多孔質層を介して機能性部材が該熱可塑性樹脂製発泡シートに融着された構成であってもよい。多孔質層は、それを介して機能製部材が熱可塑性樹脂製発泡シートに融着され得るものであれば、その形態は特に限定されず、織布、不織布、網状物、連通孔を有する発泡体などが可能であるが、不織布が好ましく用いられる。多孔質層を構成する材料の例としては、ポリオレフィン系樹脂、ポリエステル系樹脂、ポリ塩化ビニル系樹脂、ポリスチレン系樹脂などの熱可塑性樹脂、無機化合物微粒子を含有する熱可塑性樹脂、綿、麻、竹などのセルロース系繊維などの天然繊維、金属、鉱物などが挙げられる。   The molded product may have a configuration in which a functional member is fused to the thermoplastic resin foam sheet through a porous layer disposed on one surface or both surfaces of the thermoplastic resin foam sheet. The form of the porous layer is not particularly limited as long as the functional member can be fused to the thermoplastic resin foam sheet via the porous layer, and the foam has a woven fabric, a non-woven fabric, a net-like material, and communication holes. Although a body etc. are possible, a nonwoven fabric is used preferably. Examples of the material constituting the porous layer include thermoplastic resins such as polyolefin resins, polyester resins, polyvinyl chloride resins, polystyrene resins, thermoplastic resins containing fine inorganic compound particles, cotton, hemp, bamboo And natural fibers such as cellulosic fibers, metals and minerals.

図１乃至図５に、熱可塑性樹脂製発泡シート２とこれに部分的に融着された熱可塑性樹脂製の機能性部材３とからなる熱可塑性樹脂成形品１の例を示した。図１に示す熱可塑性樹脂成形品１は、熱可塑性樹脂製発泡シート２と機能性部材３とからなる。図２に示す熱可塑性樹脂成形品１は、熱可塑性樹脂製発泡シート２の表面に表皮材４を有する。図３は、機能性部材２が多孔質層５を介して熱可塑性樹脂製発泡シート２に融着された熱可塑性樹脂成形品１を示している。図４は、機能性部材２が、表面に表皮材４を有する熱可塑性樹脂製発泡シート２に多孔質層５を介して融着された熱可塑性樹脂成形品１を示している。図５は、熱可塑性樹脂製発泡シート２の両面に機能性部材３が融着された熱可塑性樹脂成形品１を示している。   FIG. 1 to FIG. 5 show an example of a thermoplastic resin molded article 1 including a thermoplastic resin foam sheet 2 and a thermoplastic resin functional member 3 partially fused thereto. A thermoplastic resin molded article 1 shown in FIG. 1 includes a thermoplastic resin foam sheet 2 and a functional member 3. A thermoplastic resin molded article 1 shown in FIG. 2 has a skin material 4 on the surface of a thermoplastic resin foam sheet 2. FIG. 3 shows a thermoplastic resin molded product 1 in which the functional member 2 is fused to the thermoplastic resin foam sheet 2 via the porous layer 5. FIG. 4 shows a thermoplastic resin molded product 1 in which the functional member 2 is fused via a porous layer 5 to a thermoplastic resin foam sheet 2 having a skin material 4 on the surface. FIG. 5 shows a thermoplastic resin molded product 1 in which the functional member 3 is fused on both surfaces of the thermoplastic resin foam sheet 2.

本成形品は、熱可塑性樹脂製発泡シートに部分的に補強用のリブや他部品への取付具であるボス、クリップ、フックなどの熱可塑性樹脂製機能性部材が融着されているので、例えば、自動車の天井やドアなどの自動車内装用部品として好適に使用することができる。   In this molded product, functional parts made of thermoplastic resin such as ribs for reinforcement and bosses, clips, hooks, etc., which are fixtures to other parts, are fused to the foam sheet made of thermoplastic resin. For example, it can be suitably used as automotive interior parts such as automobile ceilings and doors.

本成形品は、以下に述べる方法により効率的に製造することができる。
第一の方法は、下記の工程の組み合せからなる方法である。
（１） 少なくとも一方に前記機能性部材の形状に対応する形状の凹部が形成された一対の金型間に、予め所定形状に賦形された熱可塑性樹脂製発泡シートを供給する工程、（２） 金型を閉じて、前記凹部の開口部を熱可塑性樹脂製発泡シートで塞ぐ工程、（３） 金型を閉じ、前記凹部を熱可塑性樹脂製発泡シートで塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して前記熱可塑性樹脂成形品を形成する工程、および（４） 工程（３）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程 This molded product can be efficiently produced by the method described below.
The first method is a method comprising a combination of the following steps.
(1) A step of supplying a thermoplastic resin foam sheet shaped in advance into a predetermined shape between a pair of molds having a recess corresponding to the shape of the functional member formed on at least one of them (2) ) Closing the mold and closing the opening of the recess with the thermoplastic resin foam sheet; (3) Closing the mold and closing the recess with the thermoplastic foam sheet, and communicating with the recess. In this way, the thermoplastic resin in a molten state is supplied to the recess through a resin passage provided in the mold, and the thermoplastic resin and the thermoplastic resin foam sheet are fused and integrated to form the thermoplastic resin molded product. And (4) a step of cooling the thermoplastic resin molded product formed in step (3) and removing it from the mold

この方法では、予めプレス成形、真空成形、圧空成形、真空圧空成形などの任意の方法で所定形状に賦形された熱可塑性樹脂製発泡シートを使用することができる。また、表皮材および／または多孔質層を有する熱可塑性樹脂製発泡シートを使用することもできる。   In this method, it is possible to use a thermoplastic resin foam sheet that has been previously shaped into a predetermined shape by any method such as press molding, vacuum molding, pressure molding, or vacuum / pressure molding. A foamed sheet made of a thermoplastic resin having a skin material and / or a porous layer can also be used.

この方法には、一対の金型を用いる。少なくとも一方の金型には、形成させる機能性部材の個数および形状に対応した個数および形状の凹部が設けられている。製品のデザインが許す限り、凹部にはその開口部が広く、底部が狭くなるようにテーパーが付けられていることが、製品の脱型の容易さの点から好ましい。金型には前記凹部に前記機能性部材形成用の熱可塑性樹脂を供給するための樹脂通路が設けられている。
なお、ここで述べた金型への凹部および樹脂通路の配備については、後に述べる二つの方法に使用する金型についても同様である。 This method uses a pair of molds. At least one mold is provided with recesses having the number and shape corresponding to the number and shape of the functional members to be formed. As long as the design of the product permits, it is preferable that the recess is tapered so that the opening is wide and the bottom is narrowed from the viewpoint of easy demolding of the product. The mold is provided with a resin passage for supplying the functional member-forming thermoplastic resin to the recess.
In addition, about the arrangement | positioning of the recessed part and resin channel | path to a metal mold | die described here, it is the same also about the metal mold | die used for two methods described later.

工程（２）では、引き続き後述の工程（３）を行うために、金型を閉じて前記凹部の開口部を前記熱可塑性樹脂製発泡シートで塞ぐ。工程（３）では、凹部に供給された熱可塑性樹脂が凹部から漏れ出すことがないように、金型を閉じて熱可塑性樹脂製発泡シートで前記凹部の開口部を塞いだ状態で、該凹部に溶融状態の熱可塑性樹脂を供給し、これを前記熱可塑性樹脂製発泡シートと融着一体化させる。工程（４）においては、工程（３）で形成された熱可塑性樹脂成形品の機能性部材を冷却固化した後に、該成形品を金型から取り外す。   In step (2), in order to perform step (3), which will be described later, the mold is closed and the opening of the recess is closed with the thermoplastic resin foam sheet. In the step (3), in order to prevent the thermoplastic resin supplied to the recess from leaking out from the recess, the mold is closed and the opening of the recess is closed with a foamed sheet made of thermoplastic resin. A thermoplastic resin in a molten state is supplied to and fused and integrated with the thermoplastic resin foam sheet. In the step (4), after cooling and solidifying the functional member of the thermoplastic resin molded product formed in the step (3), the molded product is removed from the mold.

第二の方法は、下記の工程の組み合せからなる方法である。
（１） 熱可塑性樹脂製発泡シートを加熱し軟化させる工程、（２） 熱可塑性樹脂製発泡シートを賦形するための成形部を有し、少なくとも一方の金型の該成形部に前記機能性部材の形状の凹部が形成された雄雌一対の金型間に、工程（１）で軟化させた熱可塑性樹脂製発泡シートを供給する工程、（３） 金型を閉じて、熱可塑性樹脂製発泡シートを所定形状に賦形する工程、（４） 金型を閉じて工程（３）で賦形した熱可塑性樹脂製発泡シートで前記凹部の開口部を塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して前記熱可塑性樹脂成形品を形成する工程、および（５） 工程（４）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程。 The second method is a method comprising a combination of the following steps.
(1) a step of heating and softening a foamed sheet made of thermoplastic resin, (2) a molded part for shaping the foamed sheet made of thermoplastic resin, and the functionality of the molded part of at least one mold A step of supplying the thermoplastic resin foam sheet softened in the step (1) between a pair of male and female molds each having a concave portion in the shape of the member; (3) the mold is closed and the thermoplastic resin A step of shaping the foam sheet into a predetermined shape, (4) closing the mold and closing the opening of the recess with the thermoplastic resin foam sheet shaped in step (3) so as to pass through the recess The thermoplastic resin in a molten state is supplied to the recess through a resin passage provided in the mold, and the thermoplastic resin and the thermoplastic resin foam sheet are fused and integrated to obtain the thermoplastic resin molded product. And (5) heat formed in step (4). Cooling the sexual resin molded product, the step of removing from the mold.

第三の方法は、下記の工程の組み合せからなる方法である。
（１） 熱可塑性樹脂製発泡シートを加熱し軟化させる工程、（２） 熱可塑性樹脂製発泡シートを賦形するための成形部を有し、該成形部に前記機能性部材の形状の凹部が形成された金型を使用し、工程（１）で軟化させた熱可塑性樹脂製発泡シートを真空成形、圧空成形または真空圧空成形により所定形状に賦形する工程、（３） 工程（２）で賦形した熱可塑性樹脂製発泡シートで前記凹部の開口部を塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して熱可塑性樹脂成形品を形成する工程、および（４） 工程（３）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程 The third method is a method comprising a combination of the following steps.
(1) a step of heating and softening the foamed sheet made of thermoplastic resin, (2) a molded part for shaping the foamed sheet made of thermoplastic resin, wherein the molded part has a concave portion in the shape of the functional member. Using the formed mold, the step of shaping the thermoplastic resin foam sheet softened in step (1) into a predetermined shape by vacuum forming, pressure forming or vacuum pressure forming, (3) in step (2) Supplying the molten thermoplastic resin to the concave portion through a resin passage provided in the mold so as to communicate with the concave portion in a state in which the opening portion of the concave portion is closed with a shaped thermoplastic resin foam sheet, A step of fusing and integrating the thermoplastic resin and the thermoplastic resin foam sheet to form a thermoplastic resin molded product, and (4) cooling the thermoplastic resin molded product formed in step (3), Process to remove from mold

第二および第三の方法では、工程（１）において、熱可塑性樹脂製発泡シートを適宜の加熱手段を用いて加熱し、軟化させる。加熱には、例えば赤外線ヒータ、オーブンなどを用いることができる。該発泡シートの加熱温度はその素材などにより異なるが、例えばポリプロピレン製発泡シートの場合には、１３０〜１６０℃程度に加熱するのが好ましい。   In the second and third methods, in the step (1), the thermoplastic resin foam sheet is heated and softened using an appropriate heating means. For example, an infrared heater or an oven can be used for heating. Although the heating temperature of the foam sheet varies depending on the material, for example, in the case of a polypropylene foam sheet, it is preferably heated to about 130 to 160 ° C.

第二の方法の工程（２）では、熱可塑性樹脂発泡シートを賦形するための成形部を有し、少なくとも一方の金型が機能性部材を形成するための凹部を有する雄雌一対の金型間に、工程（１）で軟化させた熱可塑性樹脂発泡シートを供給する。工程（３）では、前記金型を閉じて、軟化している熱可塑性樹脂製発泡シートを所定形状に賦形する。通常は前記雄雌金型の少なくとも一方の金型は駆動装置に連結されて可動であり、工程（２）において両金型間に前記軟化した発泡シートを供給した後に両金型を相対的に接近させることにより、該発泡シートをプレスし賦形する。   In the step (2) of the second method, a pair of male and female gold having a molded part for shaping the thermoplastic resin foam sheet and at least one mold having a recess for forming a functional member. The thermoplastic resin foam sheet softened in the step (1) is supplied between the molds. In the step (3), the mold is closed, and the softened foamed sheet made of thermoplastic resin is shaped into a predetermined shape. Usually, at least one of the male and female molds is connected to a driving device and is movable, and after the softened foam sheet is supplied between the two molds in the step (2), the two molds are relatively moved. By bringing them closer, the foam sheet is pressed and shaped.

第三の方法の工程（２）では、熱可塑性樹脂製発泡シートを賦形するための成形部を有し、機能性部材を形成するための凹部を該成形部に有する金型を用いて、真空成形、圧空成形または真空圧空成形により、工程（１）で軟化させた熱可塑性樹脂製発泡シートを所定形状に賦形する。真空成形、圧空成形または真空圧空成形は、雄金型、雌金型あるいは雄雌一対の金型を使用して常法に従って行うことができ、必要に応じて、気密状態を作るための補助部材を金型と併用することができる。第三の方法の工程（２）では、成形方法（すなわち、真空成形、圧空成形または真空圧空成形）に応じて、金型を含む成形装置に設けた吹気機構および／または吸気機構を適宜作動させ、熱可塑性樹脂製発泡シートの賦形を行う。   In step (2) of the third method, using a mold having a molded part for shaping the foamed sheet made of thermoplastic resin and having a concave part for forming a functional member in the molded part, The foamed sheet made of the thermoplastic resin softened in the step (1) is shaped into a predetermined shape by vacuum forming, pressure forming or vacuum pressure forming. Vacuum forming, compressed air forming or vacuum compressed air forming can be performed in accordance with a normal method using a male mold, a female mold or a pair of male and female molds, and if necessary, an auxiliary member for creating an airtight state Can be used in combination with a mold. In step (2) of the third method, a blower mechanism and / or an intake mechanism provided in a molding apparatus including a mold is appropriately operated according to a molding method (that is, vacuum forming, pressure forming, or vacuum / pressure forming). To form a thermoplastic resin foam sheet.

第二の方法の工程（４）、および第三の方法の工程（３）では、熱可塑性樹脂製発泡シートの賦形に使用した金型の機能性部材形成用の凹部の開口部を、前工程で賦形した熱可塑性樹脂製発泡シートで塞いだ状態で、該凹部に溶融状態の熱可塑性樹脂を供給し、該凹部の開口部を塞いでいる熱可塑性樹脂製発泡シートと融着一体化させる。第二の方法では、この工程は金型を閉じた状態で行う。   In the step (4) of the second method and the step (3) of the third method, the opening of the concave portion for forming the functional member of the mold used for shaping the thermoplastic resin foam sheet is formed in the front. In a state where the thermoplastic resin foam sheet formed in the process is closed, a molten thermoplastic resin is supplied to the concave portion, and the thermoplastic resin foam sheet closing the opening of the concave portion is fused and integrated. Let In the second method, this step is performed with the mold closed.

第二の方法の工程（５）、および第三の方法の工程（４）では、形成された熱可塑性樹脂成形品の機能性部材を冷却固化した後に、該成形品を金型から取り外す。   In the step (5) of the second method and the step (4) of the third method, after the functional member of the formed thermoplastic resin molded product is cooled and solidified, the molded product is removed from the mold.

上記第二および第三の方法においても、表皮材および／または多孔質層を有する熱可塑性樹脂製発泡シートを使用することにより、熱可塑性樹脂製発泡シートの表面に表皮材を有する成形品や、機能性部材が多孔質層を介して熱可塑性樹脂製発泡シートに融着された成形品を得ることができる。また、第二の方法では、工程（２）において、熱可塑性樹脂製発泡シートと共に表皮材および／または多孔質層を金型間に供給することによっても、上記と同様の成形品を得ることができる。   Also in the second and third methods, by using a thermoplastic resin foam sheet having a skin material and / or a porous layer, a molded product having a skin material on the surface of the thermoplastic resin foam sheet, It is possible to obtain a molded product in which the functional member is fused to the thermoplastic resin foam sheet via the porous layer. In the second method, in the step (2), a molded product similar to the above can be obtained also by supplying a skin material and / or a porous layer together with a thermoplastic resin foam sheet between molds. it can.

第二および第三の方法は、機能性部材を接着剤により熱可塑性樹脂製発泡シートと接着する方法と比較して、熱可塑性樹脂発泡シートの賦形、機能性部材の形成および前記発泡シートと機能性部材との一体化を一連の工程で実施することができるため効率的であり、成形品の製造コストを低くすることができる。しかも、接着剤を使用しないので人体および環境への影響が少ない。   In the second and third methods, compared with the method in which the functional member is bonded to the thermoplastic resin foam sheet with an adhesive, the shaping of the thermoplastic resin foam sheet, the formation of the functional member, and the foam sheet The integration with the functional member can be carried out in a series of steps, which is efficient and can reduce the manufacturing cost of the molded product. Moreover, since no adhesive is used, there is little influence on the human body and the environment.

なお、上記三つの方法において、互いに体積の異なる複数の機能性部材を有する成形品を製造する場合、すなわち、互いに容積の異なる複数の凹部を有する金型を用いる場合には、各凹部の樹脂供給口を互いに独立して開閉可能な機構を採用し、各樹脂供給口の開閉のタイミングを適宜調節することにより、全ての凹部に対して熱可塑性樹脂を過不足なく充填することができる。   In addition, in the above three methods, when a molded product having a plurality of functional members having different volumes is manufactured, that is, when a mold having a plurality of recesses having different volumes is used, the resin supply of each recess By adopting a mechanism capable of opening and closing the ports independently of each other and appropriately adjusting the opening and closing timing of each resin supply port, it is possible to fill the thermoplastic resin into all the recesses without excess or deficiency.

前記第二の方法の一例について、図６乃至図９を参照して説明する。図６において、雌金型６は、上下に駆動するプレス機（図示せず）の上プラテン（図示せず）に取り付けられており、雌金型成形面７および雌金型内周面８を有する。雄金型９は、プレス機の固定下プラテン（図示せず）に取り付けられており、雄金型成形面１０と、前記雌金型内周面８と摺動する雄金型外周面１１とを有している。雄金型９には、機能性部材（クリップ）を成形するための凹部１２が設けられている。また、雄金型には、凹部１２に溶融状態の熱可塑性樹脂を供給するための樹脂通路１３が設けられている。溶融状態の熱可塑性樹脂は、樹脂通路１３を経て樹脂供給口１４から凹部１２に供給される。樹脂供給路の一端は、該樹脂供給路に溶融状態の熱可塑性樹脂を供給するための樹脂供給装置（図示せず）に接続されている。雄金型９の外周部には、雌金型６の降下下限位置を決定するためのストッパー１５が設けられている。   An example of the second method will be described with reference to FIGS. In FIG. 6, a female die 6 is attached to an upper platen (not shown) of a press machine (not shown) that is driven up and down, and a female die molding surface 7 and a female die inner peripheral surface 8 are connected to each other. Have. The male mold 9 is attached to a fixed lower platen (not shown) of the press machine, and includes a male mold forming surface 10 and a male mold outer peripheral surface 11 that slides on the female mold inner peripheral surface 8. have. The male mold 9 is provided with a recess 12 for molding a functional member (clip). The male mold is provided with a resin passage 13 for supplying a molten thermoplastic resin to the recess 12. The molten thermoplastic resin is supplied from the resin supply port 14 to the recess 12 through the resin passage 13. One end of the resin supply path is connected to a resin supply apparatus (not shown) for supplying a molten thermoplastic resin to the resin supply path. A stopper 15 for determining a lowering lower limit position of the female die 6 is provided on the outer peripheral portion of the male die 9.

図示していないが、先ず、オーブンを用いて熱可塑性樹脂製発泡シートを加熱し、軟化させる。次に、図６に示すように、軟化させた熱可塑性樹脂製発泡シート２を雄金型成形面１０上に載置する。次いで、図７に示すように、雌金型６の下端がストッパー１５に当接するまで雌金型６を降下させる。この雌金型６の降下により、熱可塑性樹脂製発泡シート２を雌金型成形面７と雄金型成形面１０とで加圧して賦形する。   Although not shown, first, the foamed sheet made of thermoplastic resin is heated and softened using an oven. Next, as shown in FIG. 6, the softened thermoplastic resin foam sheet 2 is placed on the male mold molding surface 10. Next, as shown in FIG. 7, the female mold 6 is lowered until the lower end of the female mold 6 contacts the stopper 15. As the female mold 6 is lowered, the foamed sheet 2 made of thermoplastic resin is pressed by the female mold molding surface 7 and the male mold molding surface 10 to be shaped.

図８に示すように、雌金型６がストッパー１５に当接したと同時あるいはその直後に、樹脂供給口１４より凹部１２に所定量の溶融状態の熱可塑性樹脂１６を供給し、熱可塑性樹脂製発泡シート２に融着一体化された所定形状のクリップを形成する。これにより、熱可塑性樹脂成形品が形成される。その後、図９に示すように、金型を開いて熱可塑性樹脂成形品１を取り出す。   As shown in FIG. 8, at the same time as or immediately after the female mold 6 abuts against the stopper 15, a predetermined amount of molten thermoplastic resin 16 is supplied to the recess 12 from the resin supply port 14, and the thermoplastic resin is supplied. A clip having a predetermined shape fused and integrated with the foamed sheet 2 is formed. Thereby, a thermoplastic resin molded product is formed. Thereafter, as shown in FIG. 9, the mold is opened and the thermoplastic resin molded article 1 is taken out.

以下に本発明を実施例により更に説明するが、本発明はこれらの実施例に限定されるものではない。   EXAMPLES The present invention will be further described below with reference to examples, but the present invention is not limited to these examples.

引抜き強度の測定
株式会社島津製作所製オートグラフＤＳＳ２０００を使用した。先ず、オートグラフの上下可動式のバーに装着したクランプに熱可塑性樹脂成形品を固定し、次いで、該成形品の熱可塑性樹脂製発泡シートに融着されているクリップを、オートグラフのロードセルに固定した棒状治具先端に取り付けた。次に、該クリップが前記熱可塑性樹脂製発泡シートから外れるまで引張り速度２ｍｍ／ｍｉｎで引張り、この引張り過程における引張り強度のピーク値を測定した。同条件で作製した１０個の熱可塑性樹脂成形品について同様の測定を行い、得られたピーク値の最大値と最小値との差に基いて、引抜き強度のばらつきを評価した。 Measurement of pulling strength Autograph DSS2000 manufactured by Shimadzu Corporation was used. First, a thermoplastic resin molded product is fixed to a clamp attached to a vertically movable bar of the autograph, and then the clip fused to the thermoplastic resin foam sheet of the molded product is used as a load cell of the autograph. It was attached to the tip of a fixed rod-shaped jig. Next, it was pulled at a pulling speed of 2 mm / min until the clip was detached from the thermoplastic resin foam sheet, and the peak value of the tensile strength in this pulling process was measured. The same measurement was performed on ten thermoplastic resin molded articles produced under the same conditions, and the variation in the drawing strength was evaluated based on the difference between the maximum value and the minimum value of the obtained peak values.

実施例１
雄金型（下型）にクリップ形成用の凹部を一つ有する雄雌一対の金型（成形面の大きさ：長さ＝３００ｍｍ、幅＝３００ｍｍ）を使用した。ポリプロピレン製発泡シート（住友化学工業製、商品名：スミセラー発泡ＰＰシート、発泡倍率＝３倍、長さ＝３００ｍｍ、幅＝３００ｍｍ、厚み＝２ｍｍ）をオーブンで１３０℃に加熱し、雄金型成形面上に載置した。雌金型（上型）を雄雌金型の成形面間隔が２ｍｍになるまで降下させ、雌金型の降下完了と同時に、雄金型内に設けた樹脂通路より前記凹部に溶融状態の熱可塑性樹脂（２４０℃）を供給した。熱可塑性樹脂としては住友ノーブレンＡＸ５６８（住友化学工業製ポリプロピレン、メルトインデックス＝６５ｇ／１０分）を使用した。雄雌金型の成形面温度は３０℃に、プレス圧力は３．９ＭＰａに設定した。その結果、クリップが発泡シートに融着した成形品を得た。上記方法で作製した１０個の成形品について、クリップ部分の引抜き強度のピーク値を測定し、引抜き強度のばらつきを評価した。結果を表１に示す。 Example 1
A pair of male and female dies (size of molding surface: length = 300 mm, width = 300 mm) having one male mold (lower mold) with one recess for forming a clip was used. A polypropylene foam sheet (manufactured by Sumitomo Chemical Co., Ltd., trade name: Sumiceller foam PP sheet, foaming magnification = 3 times, length = 300 mm, width = 300 mm, thickness = 2 mm) is heated to 130 ° C. in an oven to form a male mold. Placed on the surface. The female mold (upper mold) is lowered until the molding distance between the male and female molds becomes 2 mm. Simultaneously with the completion of the lowering of the female mold, the molten heat is introduced into the recess from the resin passage provided in the male mold. A plastic resin (240 ° C.) was supplied. As the thermoplastic resin, Sumitomo Nobrene AX568 (manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min) was used. The molding surface temperature of the male and female dies was set to 30 ° C., and the press pressure was set to 3.9 MPa. As a result, a molded product in which the clip was fused to the foamed sheet was obtained. About ten molded articles produced by the above method, the peak value of the pulling strength of the clip portion was measured, and the variation of the pulling strength was evaluated. The results are shown in Table 1.

実施例２
実施例１で使用したポリプロピレン発泡シートの代わりにポリプロピレン製不織布（目付量＝１１０ｇ／ｍ2）を片面に貼着したポリプロピレン発泡シート（住友化学工業製、商品名：スミセラー発泡ＰＰシート、発泡倍率＝３倍、長さ＝３００ｍｍ、幅＝３００ｍｍ、厚み＝２ｍｍ）を使用し、これを前記不織布を雄金型側に向けて雄金型成形面上に載置した以外は実施例１と同様にして、クリップが前記不織布を介して発泡シートに融着した成形品を得た。上記方法で作製した１０個の成形品について、クリップ部分の引抜き強度のピーク値を測定し、引抜き強度のばらつきを評価した。結果を表１に示す。 Example 2
Polypropylene foam sheet (manufactured by Sumitomo Chemical Co., Ltd., trade name: Sumiceller foam PP sheet, foaming ratio =) with a nonwoven fabric made of polypropylene (weight per unit area = 110 g / m 2 ) attached to one side instead of the polypropylene foam sheet used in Example 1 3 times, length = 300 mm, width = 300 mm, thickness = 2 mm), and this was the same as in Example 1 except that the nonwoven fabric was placed on the male mold molding surface with the male mold side facing the male mold side. Thus, a molded product in which the clip was fused to the foamed sheet via the nonwoven fabric was obtained. About ten molded articles produced by the above method, the peak value of the pulling strength of the clip portion was measured, and the variation of the pulling strength was evaluated. The results are shown in Table 1.

比較例１
実施例１で用いたポリプロピレン発泡シートの代わりにポリプロピレン（住友ノーブレンＳ６００２Ｄ、住友化学工業製、メルトインデックス＝６ｇ／１０分）からなる非発泡シート（厚み＝４ｍｍ；密度＝０．９ｇ／ｃｍ3）を使用し、雄雌金型の成形面間隔が４ｍｍになるまで雌金型を降下させた以外は実施例１と同様にして、クリップが非発泡シートに融着した成形品を得た。上記方法で作製した１０個の成形品について、クリップ部分の引抜き強度のピーク値を測定し、引抜き強度のばらつきを評価した。結果を表１に示す。 Comparative Example 1
Non-foamed sheet (thickness = 4 mm; density = 0.9 g / cm 3 ) made of polypropylene (Sumitomo Nobrene S6002D, manufactured by Sumitomo Chemical Co., Ltd., melt index = 6 g / 10 min) instead of the polypropylene foamed sheet used in Example 1 Was used to obtain a molded product in which the clip was fused to the non-foamed sheet in the same manner as in Example 1 except that the female die was lowered until the molding surface interval of the male and female dies became 4 mm. About ten molded articles produced by the above method, the peak value of the pulling strength of the clip portion was measured, and the variation of the pulling strength was evaluated. The results are shown in Table 1.

Figure 0004165527
Figure 0004165527

図１は、本発明の製造方法で得られる熱可塑性樹脂成形品の一例を示す。FIG. 1 shows an example of a thermoplastic resin molded article obtained by the production method of the present invention. 図２は、本発明の製造方法で得られる熱可塑性樹脂成形品の他の例を示す。FIG. 2 shows another example of a thermoplastic resin molded article obtained by the production method of the present invention. 図３は、本発明の製造方法で得られる熱可塑性樹脂成形品の他の例を示す。FIG. 3 shows another example of a thermoplastic resin molded article obtained by the production method of the present invention. 図４は、本発明の製造方法で得られる熱可塑性樹脂成形品の他の例を示す。FIG. 4 shows another example of a thermoplastic resin molded article obtained by the production method of the present invention. 図５は、本発明の製造方法で得られる熱可塑性樹脂成形品の他の例を示す。FIG. 5 shows another example of a thermoplastic resin molded article obtained by the production method of the present invention. 図６は、本発明の方法の一つの実施形態において、軟化させた熱可塑性樹脂製発泡シートを雄金型成形面上に載置した状態を示す断面図である。FIG. 6 is a cross-sectional view showing a state in which the softened thermoplastic resin foam sheet is placed on the male mold molding surface in one embodiment of the method of the present invention. 図７は、本発明の方法の一つの実施形態において、雌金型の降下を完了し、凹部に溶融状態の熱可塑性樹脂を供給している場面を示す断面図である。FIG. 7 is a cross-sectional view showing a scene in which the lowering of the female mold is completed and molten thermoplastic resin is supplied to the concave portion in one embodiment of the method of the present invention. 図８は、本発明の方法の一つの実施形態において、凹部に供給した溶融状態の熱可塑性樹脂が熱可塑性樹脂製発泡シートと融着一体化した状態を示す断面図である。FIG. 8 is a cross-sectional view showing a state in which the molten thermoplastic resin supplied to the recess is fused and integrated with the thermoplastic resin foam sheet in one embodiment of the method of the present invention. 図９は、本発明の方法の一つの実施形態において、熱可塑性樹脂成形品を金型から取り出している場面を示す断面図である。FIG. 9 is a cross-sectional view showing a scene in which a thermoplastic resin molded article is taken out from a mold in one embodiment of the method of the present invention.

符号の説明Explanation of symbols

１ 熱可塑性樹脂成形品
２ 熱可塑性樹脂製発泡シート
３ 機能性部材
４ 表皮材
５ 多孔質層
６ 雌金型
７ 雌金型成形面
８ 雌金型内周面
９ 雄金型
１０ 雄金型成形面
１１ 雄金型外周面
１２ 凹部
１３ 樹脂通路
１４ 樹脂供給口
１５ ストッパー
１６ 熱可塑性樹脂 DESCRIPTION OF SYMBOLS 1 Thermoplastic resin molded product 2 Thermoplastic resin foam sheet 3 Functional member 4 Skin material 5 Porous layer 6 Female mold 7 Female mold molding surface 8 Female mold inner peripheral surface 9 Male mold 10 Male mold molding Surface 11 Male mold outer peripheral surface 12 Recess 13 Resin passage 14 Resin supply port 15 Stopper 16 Thermoplastic resin

Claims (3)

所定形状に賦形された熱可塑性樹脂製発泡シートに、部分的に熱可塑性樹脂製の機能性部材が融着されてなる熱可塑性樹脂成形品の製造方法であって、下記の工程を含むことを特徴とする方法。
（１） 少なくとも一方に前記機能性部材の形状の凹部が形成された一対の金型間に、予め所定形状に賦形された熱可塑性樹脂製発泡シートを供給する工程
（２） 金型を閉じて、前記凹部の開口部を熱可塑性樹脂製発泡シートで塞ぐ工程
（３） 金型を閉じて前記凹部の開口部を熱可塑性樹脂製発泡シートで塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して前記熱可塑性樹脂成形品を形成する工程
（４） 工程（３）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程 A method for producing a thermoplastic resin molded article in which a thermoplastic resin functional member is partially fused to a thermoplastic resin foam sheet shaped into a predetermined shape, and includes the following steps: A method characterized by.
(1) A step of supplying a thermoplastic resin foam sheet preliminarily shaped into a predetermined shape between a pair of molds in which at least one of the functional member-shaped recesses is formed (2) Closing the mold (3) Closing the opening of the recess with a thermoplastic resin foam sheet (3) Close the mold and close the opening of the recess with the thermoplastic resin foam sheet so that it passes through the recess. A molten thermoplastic resin is supplied to the recess through a resin passage provided in the mold, and the thermoplastic resin and the thermoplastic resin foam sheet are fused and integrated to form the thermoplastic resin molded article. Step (4) Step of cooling the thermoplastic resin molded product formed in Step (3) and removing it from the mold 所定形状に賦形された熱可塑性樹脂製発泡シートに、部分的に熱可塑性樹脂製の機能性部材が融着されてなる熱可塑性樹脂成形品の製造方法であって、下記の工程を含むことを特徴とする方法。
（１） 熱可塑性樹脂製発泡シートを加熱し軟化させる工程
（２） 熱可塑性樹脂製発泡シートを賦形するための成形部を有し、少なくとも一方の金型の該成形部に前記機能性部材の形状の凹部が形成された雄雌一対の金型間に、工程（１）で軟化させた熱可塑性樹脂製発泡シートを供給する工程
（３） 金型を閉じて、熱可塑性樹脂製発泡シートを所定形状に賦形する工程
（４） 金型を閉じて工程（３）で賦形した熱可塑性樹脂製発泡シートで前記凹部の開口部を塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して前記熱可塑性樹脂成形品を形成する工程
（５） 工程（４）で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程 A method for producing a thermoplastic resin molded article in which a thermoplastic resin functional member is partially fused to a thermoplastic resin foam sheet shaped into a predetermined shape, and includes the following steps: A method characterized by.
(1) Step of heating and softening a foamed sheet made of thermoplastic resin (2) A molded part for shaping the foamed sheet made of thermoplastic resin, and the functional member in the molded part of at least one mold A step of supplying the thermoplastic resin foam sheet softened in the step (1) between a pair of male and female molds each having a recess having a shape of (3), the mold being closed, and the thermoplastic resin foam sheet (4) Closing the mold and closing the mold with the thermoplastic resin foam sheet molded in the process (3), the mold is formed so as to pass through the recess. A step of supplying a molten thermoplastic resin to the recess through a resin passage provided therein, and fusing and integrating the thermoplastic resin and the thermoplastic resin foam sheet to form the thermoplastic resin molded article (5) Thermoplastic resin molded product formed in step (4) Cooled, step of removing from the mold 使用する熱可塑性樹脂製発泡シートが表皮材および／または多孔質層を有することを特徴とする請求項１又は２に記載の方法。 The method according to claim 1 or 2 , wherein the foamed sheet made of a thermoplastic resin to be used has a skin material and / or a porous layer.
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