JP7248647B2 - 発泡成形体、積層体及び積層体の製造方法 - Google Patents
発泡成形体、積層体及び積層体の製造方法 Download PDFInfo
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- JP7248647B2 JP7248647B2 JP2020502925A JP2020502925A JP7248647B2 JP 7248647 B2 JP7248647 B2 JP 7248647B2 JP 2020502925 A JP2020502925 A JP 2020502925A JP 2020502925 A JP2020502925 A JP 2020502925A JP 7248647 B2 JP7248647 B2 JP 7248647B2
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- protrusion
- foam molded
- molded article
- heat
- foam
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Description
図1~図3は、突起部の2つの面の境界線が線で表現されているが、この境界線は線で表現できるものに限定されない。例えば、図4に示すように、突起部の断面の外郭線が高次曲線で近似できる線であるとき、2つの面の境界線はその外郭線の変曲点に該当する。変曲点がない場合、2つの面の境界線は2つの面の間で平面になっている部分の中心点が該当する。また、これらの2つの面の境界線は、上から見て(平面視にて)、明確に表れない場合もあり得る。この場合、突起部の2つの面の境界線には、このような前記変曲点及び前記中心点に該当する境界線も含まれるものとする。前記変曲点及び前記中心点に該当する境界線は、図4に示すように、一点鎖線で示す。
以上に説明した突起部の周囲においては、基面110が外部に露出している場合がある。そして、突起部が基面110に略等間隔に配置された場合、基面110はあたかも碁盤目状の溝の様相を呈し、発泡成形体と他部材20とを積層するに際し、基面110は空気を排出する溝としての機能を有することとなる。これにより、発泡成形体と他部材20との間に空気溜まりが発生することを抑制することができる。その結果、発泡成形体と他部材20とを強固に熱融着させることができ、また、接着ムラが生じることを抑制することができる。
なお、突起部の周囲において基面が外部に露出することなく、当該突起部が基面を覆うように複数配置された場合、各突起部の上部同士は離間していることから、突起部の周囲はあたかも碁盤目状の溝の様相を呈することになる。したがって、発泡成形体と他部材20とを積層するに際し、突起部の周囲は空気を排出する溝(隙間)としての機能を有することとなる。これにより、発泡成形体と他部材20との間に空気溜まりが発生することを抑制することができる。その結果、発泡成形体と他部材20とを強固に熱融着させることができ、また、接着ムラが生じることを抑制することができる。ただし、突起部の周囲においては、空気を排出する機能の観点から、基面が外部に露出しているほうがより好ましい。
次に、発泡成形体の製造方法について説明する。発泡成形体を形成するための成形室を形成する固定型の金型及び移動型の金型を用いて、発泡成形体を製造する。まず、固定型の金型及び移動型の金型を型閉じすることで成形室を形成し、成形室に発泡粒子を充填する。次いで、成形室に水蒸気を通過させることにより発泡粒子を加熱し、発泡粒子同士を互いに融着させる。なお、成形室に水蒸気を通過させるためには、公知のベント孔(コアベント)またはキリ穴を金型に設ければよい。その後、金型に冷却水等によりシャワーリングすることにより成形室を冷却し、固定型の金型及び移動型の金型を型開きすることで発泡成形体を取り出す。以上のような方法で発泡成形体を製造することができる。このような方法を型内発泡成形という。ここで説明した方法は一例である。
発泡成形体に他部材20を熱融着させるとき、基面110に少なくとも1つの前述したような突起部が形成された発泡成形体に、予め加熱することなく軟化した、または予め加熱することにより軟化した他部材20を積層してもよい。発泡成形体に他部材20を積層することにより積層体が形成される。他部材20を予め軟化させておくことにより、発泡成形体と他部材20との接着性を向上させることができる。また、他部材20の融点が発泡成形体の融点より低い場合、発泡成形体より他部材20の方が先に軟化する。したがって、積層する際に過剰な圧力を必要としないため、発泡成形体の形状を変化させることがない。また、発泡成形体の樹脂が劣化することを抑制しつつ、発泡成形体に他部材20を積層させることができる。
積層工程は、前記突起部が形成される、発泡成形体の積層面(他部材20を積層する面)に、他部材20を積層する工程であり、具体的には、基面110に少なくとも1つの前述したような突起部が形成された発泡成形体に、予め加熱することなく軟化した、または予め加熱することにより軟化した他部材20を積層する工程である。積層工程で用いられる発泡成形体は、前述した製造方法によって製造された発泡成形体である。
プレス工程は、積層工程で積層した発泡成形体と前記他部材20とをプレスする工程である。プレス圧力は、発泡成形体の形状を変化させることがない圧力であればよく、特に限定されない。また、プレス時間も特に限定されない。
熱融着工程は、前記発泡成形体と前記他部材20とを熱融着する工程である。熱融着工程は、プレス工程と同時に行ってもよく、プレス工程の後に行ってもよい。熱融着温度及び時間は、発泡成形体及び他部材20の融点に応じて設定すればよく、特に限定されない。
(2)予め他部材20を加熱せず、または予め加熱し、発泡成形体と他部材20とを共に、加熱されていない、または加熱された少なくとも1つのロールに通す圧着ロール成形(プレス工程の後に熱融着工程を行う成形、またはプレス工程と熱融着工程とを同時に行う成形、さらには、加熱されていないロールでプレス(プレス工程)を行った後、加熱されたロールで熱融着(熱融着工程)を行う成形)、
(3)発泡成形体と軟化状態または溶融状態の他部材20とを分割形式の金型間に配置し、型締めすることにより面接着させる一体ブロー成形(プレス工程と熱融着工程とを同時に行う成形)、
等が挙げられる。
必要に応じて行われる減圧工程は、積層工程、プレス工程及び熱融着工程のうちの少なくとも1つと同時に行ってもよく、積層工程を行う前及び前記各工程間のうちのいずれかに行ってもよく、積層工程を行う前及び前記各工程間を含む全工程を通じて行ってもよい。減圧工程は、プレス工程と同時に行うことが好ましい。減圧度は、発泡成形体の形状を変化させることがない減圧度であればよく、具体的には、発泡成形体と他部材20との間に溜まった空気の量、製造される積層体の表面性等を考慮して、適宜調節すればよい。
なお、プレス工程及び熱融着工程に加えて、前述した減圧工程をさらに行う方法としては、例えば、真空成形及び圧空成形を挙げることができる。そして、減圧工程を行う場合には、気圧差を利用してプレス工程を行うこともできる。このような真空成形及び圧空成形の具体例としては、例えば、布施真空株式会社製のTOM成形機(三次元表面加飾成形機)を用いた成形を挙げることができる。
図5の(a)及び(b)は、発泡成形体の基面が平面ではない場合の発泡成形体の断面を示す断面図である。図5の(a)に示すように、発泡成形体11の基面111は、水平面111aと、垂直面111bと、傾斜平面111cと、から形成されている。
本発明の一態様に係る発泡成形体は、他部材と熱融着する発泡成形体であって、前記発泡成形体の、前記他部材と熱融着する少なくとも1つの面には、少なくとも1つの突起部が形成され、前記突起部には、上から見て(平面視にて)、少なくとも2つの面が存在し、前記2つの面の境界線として、前記突起部の外側から先端中央に向かう方向と交差する、少なくとも1つの境界線が存在する。
さらに、突起部の周囲では基面が外部に露出しているので、発泡成形体と他部材との間に空気溜まりが発生することを抑制することができる。その結果、発泡成形体と他部材とを強固に熱融着させることができ、また、接着ムラが生じることを抑制することができる。
10、10a、10b、10c、10d、10d_1、10e、10f、
10g、10h、10i、10j、11、12、105、106、107 発泡成形体
20 他部材
110、111、112 基面
111a 水平面
111b 垂直面
111c 傾斜平面
120、120a、120a_1、120b、120c、120c_1、
120d、120d_1、120e、120f、120f_1、120g、
120h、120i、120j 突起部
121、121a、121a_1、121b 陥没部
122、131、132、133、135、137 傾斜面
123 陥没底面
124、124a 第1突起部
125、125a、126、126a 第2突起部
134、136、138 上面
139 底面
140~145 曲面
b1~b17 境界線
c1、c2 中心点
d1~d17 方向
v1 変曲点
Claims (11)
- 他部材と熱融着する発泡成形体であって、
前記発泡成形体の、前記他部材と熱融着する少なくとも1つの面には、少なくとも1つの突起部が形成され、
前記突起部には、上から見て(平面視にて)、少なくとも2つの面が存在し、
前記2つの面の境界線として、前記突起部の外側から先端中央に向かう方向と交差する、少なくとも1つの境界線が存在し、
前記他部材と熱融着する少なくとも1つの面は、基面と、前記基面上に形成された前記突起部と、から形成され、
前記基面と前記突起部との間の境界面の面積は、0.25mm 2 以上、100.00mm 2 以下であり、
前記突起部の高さは、0.3mm以上、10.0mm以下であり、
前記突起部は、前記他部材と熱融着する少なくとも1つの面上に1個/cm 2 以上、40個/cm 2 以下の密度で形成され、前記他部材と熱融着する少なくとも1つの面のうち少なくとも20%以上の領域に亘って形成されることを特徴とする発泡成形体。 - 前記突起部は、前記発泡成形体と前記他部材とを熱融着させるときに溶けて広がることを特徴とする請求項1に記載の発泡成形体。
- 前記突起部の形状は、
(1)多段形状、
(2)上から見て、外側から前記突起部の先端に向かう方向に先細りし、前記突起部の先端に稜線を有する形状、及び
(3)前記突起部の先端に複数の突起部を有する形状
からなる群より選択される少なくとも1つであることを特徴とする請求項1または2に記載の発泡成形体。 - 前記突起部は、第1突起部と第2突起部とを含み、
前記第1突起部には、前記第2突起部が形成されることを特徴とする請求項1から3のいずれか1項に記載の発泡成形体。 - 前記突起部は、前記突起部の先端に陥没部が形成されることを特徴とする請求項1から3のいずれか1項に記載の発泡成形体。
- 前記突起部の底面は、円形または楕円形であることを特徴とする請求項1から5のいずれか1項に記載の発泡成形体。
- 発泡粒子から構成されることを特徴とする請求項1から6のいずれか1項に記載の発泡成形体。
- 前記突起部の周囲では前記基面が外部に露出していることを特徴とする請求項1から7のいずれか1項に記載の発泡成形体。
- 請求項1から8のいずれか1項に記載の発泡成形体と前記他部材とが積層されることにより形成されることを特徴とする積層体。
- 請求項1から8のいずれか1項に記載の発泡成形体と前記他部材とを積層して熱融着する積層体の製造方法であって、
前記突起部が形成される積層面に、他部材を積層する積層工程、及び、
積層した発泡成形体と前記他部材とをプレスするプレス工程、
を含むことを特徴とする積層体の製造方法。 - さらに、減圧工程を含むことを特徴とする請求項10に記載の積層体の製造方法。
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