JP7089276B2 - Manufacturing method of patterned foam molded products - Google Patents

Manufacturing method of patterned foam molded products Download PDF

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JP7089276B2
JP7089276B2 JP2018121693A JP2018121693A JP7089276B2 JP 7089276 B2 JP7089276 B2 JP 7089276B2 JP 2018121693 A JP2018121693 A JP 2018121693A JP 2018121693 A JP2018121693 A JP 2018121693A JP 7089276 B2 JP7089276 B2 JP 7089276B2
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泰平 一宮
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Sanwa Kako Co Ltd
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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 product.

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 product having a pattern on the outer surface, the foam before molding has been pressurized and heated by using a mold having 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 one, the outer surface pattern of the foam molded product is limited to the uneven shape of the mold. Therefore, with the conventional one, it is not possible to obtain a foam molded product having a different pattern on the outer surface unless the mold itself, which is a relatively expensive facility, is changed. In other words, it has become extremely difficult to flexibly manufacture foam molded products having different patterns by the conventional method for manufacturing foam molded products.

特開昭５７－７７５３８号公報Japanese Unexamined Patent Publication No. 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 by paying attention to the above circumstances, and provides a method for manufacturing a foam molded product with a pattern, which can flexibly manufacture a foam molded product having a different pattern without changing the mold. 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って、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模様入り発泡体成形品の製造方法である。
The invention according to claim 1 is to obtain an intermediate molded product by forming a foundation pattern composed of recesses on the outer surface of the foundation foam, and then arrange the intermediate molded product between a pair of molds. It is a method for manufacturing a patterned foam molded product, which is obtained by pressurizing and heating with a pair of dies to obtain a patterned foam molded product in which a final pattern consisting of recesses after processing is exposed on the outer surface . A foam molded product with a pattern in which a breathable cloth material is placed between the molding surface of the mold and the intermediate molded product, and then the intermediate molded product is heated and pressed by the mold. It is a manufacturing method .

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。 The invention according to claim 2 is the patterned foam according to claim 1, wherein the basic foam is in the shape of a flat plate, and the main molding surface constituting the molding surface of the mold is in the shape of a flat surface. It is a manufacturing method of a body molded product.

請求項３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 the invention according to claim 1 or 2, wherein the outer surface of the basic foam is cut using a router processing machine to obtain an intermediate molded product having a basic pattern composed of the recessed portion on the outer surface. It is a manufacturing method of a foam molded product with a pattern.

請求項４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又は３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 4 is the manufacture of the patterned foam molded article according to claim 1, 2 or 3, wherein the depth dimension of the recess formed in the intermediate molded article is set to 3 to 5 mm. The method.

請求項５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又は４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 5 is the method for manufacturing a patterned foam molded product according to claim 1, 2, 3 or 4, wherein the patterned foam molded product is a floor panel or a wall surface 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 manufacturing a foam molded product with a pattern, which can flexibly manufacture a foam molded product having a different pattern without changing the 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。The perspective view which shows the intermediate molded article in one Embodiment of this 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。The schematic end view which shows the manufacturing process using the 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。The perspective view which shows the 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。The explanatory view of the manufacturing process of the foam molded article with a pattern in the same embodiment. 図１におけるＡ－Ａ線断面図。FIG. 1 is a cross-sectional view taken along the line AA in FIG. 図３におけるＢ－Ｂ線断面図。FIG. 3 is a sectional view taken along line BB in FIG. 図５におけるＸ部分拡大図。X partial enlarged view in FIG. 図６におけるＹ部分拡大図。FIG. 6 is an enlarged view of the Y portion 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. 1 to 8.

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。 This embodiment applies the present invention to a method for manufacturing a patterned foam molded product 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 product 3 has a substantially rectangular plate shape. The patterned foam molded product 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 product 3 is processed by pressurization and heating by a pair of molds K1 and K2, that is, upper and lower molds K1 and K2 (so-called “thermal pressure molding”, and in the following, It is made through "thermal pressure molding").

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 patterned foam molded product 3 expresses the brick pattern M2, which is the final pattern that can be visually grasped, by the presence of the post-processed recessed portion h2 provided on the outer surface by undergoing thermal pressure molding.

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 product 3 will be described in detail with reference to FIGS. 1 to 8 in particular. Note that FIG. 4 schematically shows the 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, the 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 cross-linking 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), the foundation pattern M1 composed of the recessed portion h1, that is, the foundation pattern M1 which is the basis of the final brick pattern M2 is formed on the outer surface of the foundation foam 1, thereby intermediate. Obtain the molded product 2. It is desirable that the thickness dimension w1 of the intermediate molded product 2 shown in FIG. 5 (same as the thickness dimension of the basic foam 1) is set within 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 foundation pattern M1 formed on the intermediate molded product 2 partially scrapes the outer surface of the foundation foam 1 using a router processing machine (not shown) to form a recessed portion h1 having a predetermined depth dimension d1. It is provided by doing. The recessed portion h1 provided in the intermediate molded product 2 has a bottom surface portion h11 and a side surface portion h12 extending from both ends of the bottom surface portion h11 in a direction substantially orthogonal to the bottom surface portion 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 recessed portion h1 formed on the outer surface of the intermediate molded product 2 is set within the range of 3 to 5 mm. When the depth dimension d1 of the recessed portion h1 is shorter than 3 mm, the brick pattern M2 composed of the recessed portion h2 after processing that appears after being pressurized and heated by the upper and lower molds K1 and K2 becomes significantly unclear. It turned out that it would be. On the other hand, when the depth dimension d1 of the recessed portion h1 formed on the outer surface of the intermediate molded product 2 is longer than 5 mm, the recessed portion is pressed and heated by the upper and lower molds K1 and K2. The portion h1 is not uniformly deformed, and as a result, burrs and distortions that are elements that impair the appearance are formed in the post-processed recessed portion h2 after being pressurized and heated by the upper and lower molds K1 and K2. There was found. In other words, if the depth dimension d1 of the recessed portion h1 in the intermediate molded product 2 is set to 3 to 5 mm, the bottom surface portion h21 and the side surface portion constituting the post-processed recessed portion h2 in the patterned foam molded product 3 The portion 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 placed between the upper and lower molds K1 and K2, which are a pair of molds, and then both molds. The intermediate molded product 2 is pressurized and heated under predetermined conditions by the molds K1 and K2. The upper and lower molds K1 and K2 are provided with molding surfaces K11 and K21 on the side facing the intermediate molded product 2, respectively. Each of the molded surfaces K11 and K21 includes main molded surfaces K111 and K211 facing the main outer surface of the intermediate molded product 2, and edge molded surfaces K112 and K212 arranged on the peripheral edges of the main molded 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 planar. Further, when the upper and lower dies K1 and K2 are in close contact with each other, that is, when hot pressure forming is performed by the upper and lower dies K1 and K2, the separation dimension between the main forming surfaces K111 and K211 is set to 8 mm. ing. As a result, the thickness dimension w2 of the final patterned foam molded product 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。 The upper and lower jerseys J1 and J2, which are breathable cloth materials, are arranged between the molding surfaces K11 and K12 of the upper and lower molds K1 and K2 and the intermediate molded product 2. In other words, the intermediate molded product 2 and the upper and lower jerseys J1 and J2 covering the outer surface of the intermediate molded product 2 are pressurized and heated using both molds K1 and K2 to obtain a final brick pattern. The foam molded product 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 of the intermediate molded product 2 including the basic pattern M2 in the process of thermal pressure forming by the upper and lower molds K1 and K2. .. Therefore, the upper and lower jerseys J1 and J2 impart the same fine outer surface characteristics (fine uneven shape) to substantially the entire outer surface of the intermediate molded product 2 based on the fine mesh peculiar to the material. It is something to gain. Further, the upper and lower jerseys J1 and J2 make it easy to take out the final patterned foam molded product 3 from the upper and lower dies K1 and K2 after being processed by 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 molds K1 and K2 is set within the range of 120 ° C to 160 ° C. In this embodiment, the heating temperature by the molds 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。 The pressing force applied to the intermediate molded product 2 by the upper and lower molds K1 and K2 is set within the range of 50 kg / cm 2 to 150 kg / cm 2 . In this embodiment, the pressing force 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 for hot-press molding the intermediate molded product 2 by the upper and lower dies K1 and K2 (that is, the time for 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 pressurizing and heating the intermediate molded product 2 having the basic pattern M1 with the upper and lower molds 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. When the temperature is cooled to ~ 35 ° C, both molds K1 and K2 are opened. In this embodiment, the intermediate molded product 2 is cooled to 24 ° C. over 20 minutes, and then the final molded product is separated from both molds K1 and K2. Then, the jerseys J1 and J2 are removed by peeling off from the surface of the foam molded product 3 after pressurization and heating, and the final brick pattern M2 as shown in FIG. 4D is exposed. The body molded product 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 for producing the patterned foam molded product 3 according to the present embodiment, the intermediate molded product 2 is obtained by forming the basic pattern M1 composed of the recessed portion h1 on the outer surface of the basic foam 1. Later, the intermediate molded product 2 is placed between the upper and lower dies K1 and K2, which are a pair of dies, and then pressurized and heated by the dies K1 and K2. The foam molded product 3 with a pattern in which the patterned brick pattern M2 is exposed is obtained. Therefore, it is possible to provide a method for manufacturing a patterned foam molded product 3 that can flexibly manufacture a foam molded product 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 foundation pattern M1 composed of the recessed portion h1 on the outer surface of the foundation foam 1, and then the intermediate molded product 2 is heated and pressed by the molds K1 and K2. , The final patterned foam molded product 3 is obtained. Therefore, in the method for manufacturing the patterned foam molded product 3 shown in the present embodiment, various basic patterns M1 are provided on the intermediate molded product 2 without depending on the uneven shape provided on the molds K1 and K2. This makes it possible to flexibly manufacture the foam molded product 3 having a different pattern.

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 plate shape. The main molding surfaces K111 and K211 constituting the molding surfaces K11 and K21 of the upper and lower molds K1 and K2 are flat. Therefore, as the upper and lower molds K1 and K2, those having an extremely simple form can be adopted, and the plate-shaped foam molded product 3 having a different outer surface pattern without changing the molds K1 and K2. Can be flexibly manufactured.

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。 After arranging the upper and lower jerseys J1 and J2, which are breathable cloth materials, between the molding surfaces K11 and K21 of the upper and lower molds K1 and K2 and the intermediate molded product 2, the intermediate molded product 3 is placed on the upper and lower molds. It is heated and pressurized by the molds K1 and K2. Therefore, as a result of completing the process of thermal pressure forming by the molds K1 and K2, all the exposed surfaces including the basic pattern M2 in the intermediate molded product 3 are provided with a fine uneven shape based on the fine stitches of the jersey material. As a result, uniform visual and tactile properties can be imparted to the region used as the outer surface of the final foam molded product 3. That is, there is a problem due to the difference in the outer surface characteristics between the post-machining concave recess h2 and the flat surface portion adjacent to the post-machining concave recess h2, for example, a difference in the degree of dust accumulation, or non-uniformity in touch feeling. It is possible to suitably solve the problem that the problem occurs.

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。 An outer surface of the foundation foam 1 is cut using a router processing machine (not shown) to obtain an intermediate molded product 2 having a foundation pattern M1 having a recessed portion h1 on the outer surface. Therefore, by forming the foundation pattern M1 composed of various recesses h1 on the outer surface of the foundation foam 1 by the router processing machine, it is possible to manufacture various intermediate molded products 2 having different foundation patterns M1. It 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 dimension d1 of the recessed portion h1 formed in the intermediate molded product 2 is set to 3 to 5 mm. Therefore, even after thermal pressure molding (heating and pressurization) by the upper and lower dies K1 and K2, the visible final pattern M2 can be appropriately expressed, and the post-processing recessed portion h2 constituting the final pattern M2 is formed. The finish will be appropriate without spoiling the appearance.

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 product 3 is a floor panel or a wall surface panel, a foam molded product having various variations of patterns can be suitably obtained by the manufacturing method of the patterned foam molded product 3. It becomes a thing.

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。 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 of the basic foam can be adopted, and the shape is not limited to that 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 that shown in the above-described embodiment.

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 composition of the basic foam is also not limited to that shown in the above-described embodiment. For example, the basic foam may be formed by combining 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 displayed on the intermediate molded product may be formed on a part of the outer surface, and does not have to be formed on the entire outer surface. For example, when the intermediate molded product has a flat plate shape, it may be at least one having a basic pattern formed on the outer surface on one side.

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 of the mold corresponding to the outer surface of the intermediate molded product is not necessarily limited to a flat surface.

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 product is not limited to the one made by using the router processing machine, and it goes without saying that the basic pattern may be formed by a 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 part 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） 1 ... Basic foam 2 ... Intermediate molded product 3 ... Foam molded product with pattern M1 ... Basic pattern M2 ... Final pattern (brick pattern)
K1, K2 ... Mold (upper mold, lower mold)

Claims (5)

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って、
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模様入り発泡体成形品の製造方法。 After obtaining an intermediate molded product by forming a foundation pattern consisting of recesses on the outer surface of the foundation foam, the intermediate molded product is placed between a pair of dies and then pressurized and heated by the pair of dies. Then, it is a manufacturing method of a patterned foam molded product in which a patterned foam molded product in which a final pattern consisting of a concave portion after processing is expressed on the outer surface is obtained.
A patterned foam molded product in which a breathable cloth material is placed between the molding surface of the mold and the intermediate molded product, and then the intermediate molded product is heated and pressed by the mold. Manufacturing method . 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。 The method for producing a molded foam product with a pattern according to claim 1, wherein the basic foam is in the shape of a flat plate, and the main molding surface constituting the molding surface of the mold is in the shape of a flat surface. 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又は２記載の模様入り発泡体成形品の製造方法。 The method for manufacturing a patterned foam molded product according to claim 1 or 2, wherein the outer surface of the basic foam is cut using a router processing machine to obtain an intermediate molded product having a basic pattern consisting of the recessed portion on the outer surface. .. 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又は３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 product according to claim 1, 2 or 3, wherein the depth dimension of the recess formed in the intermediate molded product 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又は４記載の模様入り発泡体成形品の製造方法。 The method for manufacturing a patterned foam molded product according to claim 1, 2, 3 or 4, wherein the patterned foam molded product is a floor panel or a wall surface panel.
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JP2007176053A (en) 2005-12-28 2007-07-12 Inoac Corp Manufacturing method for polyolefin foam product, and mold

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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
JP3611701B2 (en) * 1997-05-14 2005-01-19 三和化工株式会社 Secondary molding method for cross-linked polyethylene foam

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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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