JPH05285965A - Manufacture of foam-molded body with skin material - Google Patents
Manufacture of foam-molded body with skin materialInfo
- Publication number
- JPH05285965A JPH05285965A JP4114069A JP11406992A JPH05285965A JP H05285965 A JPH05285965 A JP H05285965A JP 4114069 A JP4114069 A JP 4114069A JP 11406992 A JP11406992 A JP 11406992A JP H05285965 A JPH05285965 A JP H05285965A
- Authority
- JP
- Japan
- Prior art keywords
- skin material
- mold
- cavity
- molding
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Landscapes
- Molding Of Porous Articles (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、表皮材を有する発泡成
形体の製造方法であって、表皮材の加熱と成形とを完全
に分離でき、しかも表皮材の成形と発泡性熱可塑性樹脂
の発泡とを同一金型内で行い表皮材と一体的に成形でき
る方法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foamed molded article having a skin material, wherein heating and molding of the skin material can be completely separated, and molding of the skin material and foamable thermoplastic resin The present invention relates to a method in which foaming can be performed in the same mold and integrally molded with a skin material.
【０００２】[0002]
【従来の技術】従来ポリスチレン等の熱可塑性樹脂発泡
粒子を使用する金型内発泡成形方法は広く実施されてい
る。2. Description of the Related Art Conventionally, an in-mold foam molding method using expanded particles of a thermoplastic resin such as polystyrene has been widely practiced.
【０００３】この内、表皮材を有する発泡成形体を金型
内で製造する方法として、発泡粒子を成形する工程で使
用する蒸気又は熱風を熱源として表皮材を加熱し、更に
この蒸気又は熱風の圧力によって表皮を成形し、その後
発泡粒子を充填して再度蒸気によって加熱して成形品を
一体的に得る成形方法が提案されている（特開昭56-109
732号公報）。Among them, as a method for producing a foamed molded article having a skin material in a mold, the skin material is heated by using steam or hot air used in the step of molding the expanded particles as a heat source, and the steam or hot air A molding method has been proposed in which a skin is molded by pressure, then foamed particles are filled and heated again by steam to integrally obtain a molded product (JP-A-56-109).
(732 publication).
【０００４】[0004]
【発明が解決しようとする課題】一般に、熱可塑性樹脂
又は熱可塑性エラストマー等よりなるシート状物（以下
単にシートという）は温度によって伸び応力が変化す
る。従って、温度を一定とすれば、シートの伸び応力よ
り大きな外力を与えなければシートを成形することがで
きず、逆に外力を一定とすれば、シートの伸び応力が外
力より小さくなる様な温度を与えなければシートを成形
することができない。Generally, a sheet-like material (hereinafter simply referred to as a sheet) made of a thermoplastic resin, a thermoplastic elastomer or the like has a change in elongation stress depending on temperature. Therefore, if the temperature is kept constant, the sheet cannot be formed unless an external force greater than the sheet's elongation stress is applied. Conversely, if the external force is kept constant, the sheet's elongation stress becomes smaller than the external force. The sheet cannot be formed unless
【０００５】一方、シートは成形すると残留応力が生ず
る。従って、温度及び外力を適宜選択して成形しても、
少なくとも一時的せよ成形形状を保持しようとすれば、
シートに外力を作用させ、成形したシートがもはや元の
状態に戻ることがない温度まで冷却するか又は成形した
シートの残留応力が外力より小さくなるようにシートの
温度を維持した状態で外力を保持し続けるか又はシート
の温度が維持できない場合は、外力を高めて保持し続け
なければならない。On the other hand, when the sheet is molded, residual stress is generated. Therefore, even if the temperature and external force are appropriately selected and molded,
If you try to retain the molded shape, at least temporarily,
Applying an external force to the sheet to cool the formed sheet to a temperature at which it will no longer return to its original state, or to retain the external force while maintaining the temperature of the sheet so that the residual stress of the formed sheet becomes smaller than the external force If the temperature of the seat cannot be maintained or the temperature of the seat cannot be maintained, the external force must be increased and maintained.
【０００６】この成形した形状を保持する条件は、残留
応力の大きい、例えばPVC系シート、熱可塑性エラスト
マー系シート等を成形するときに特に重要であり、表皮
材としてのシートを有する金型内発泡成形体を製造する
方法において、固定金型、可動金型の割型を使用する場
合には、先にシートを成形して金型の成形面（キャビテ
ィ面）に密着した状態を維持しつつ、熱可塑性樹脂発泡
粒子（以下ビーズという）を金型内に充填すべきであっ
て、もしシートが部分的であっても金型のキャビティ面
に密着していない状態でビーズを充填すると、満足すべ
き形状が得られないか若しくは充填不良となって得られ
る発泡体は実用に耐え得ないものとなる。The condition for maintaining the formed shape is particularly important when forming a sheet having a large residual stress, such as a PVC sheet or a thermoplastic elastomer sheet, and foaming in a mold having a sheet as a skin material. In the method of manufacturing a molded body, when using a fixed mold and a split mold of a movable mold, while molding the sheet first, while maintaining a close contact with the molding surface (cavity surface) of the mold, Expanded thermoplastic resin particles (hereinafter referred to as beads) should be filled in the mold, and if the sheet is partially filled with the beads not in close contact with the cavity surface of the mold, it is satisfactory. The foam that cannot be obtained in the desired shape or has poor filling cannot be used practically.
【０００７】しかるに、前記公報に開示されているもの
は、割型の一方の金型をシートの成形型として使用して
いるが、成形したシートを金型の成形面に密接して保持
する手段がないため、残留応力のあるシートではこれを
金型のキャビティ面に密接した状態で保持することが困
難であり、ビーズの充填が不完全になるという欠点を有
する外、シートの成形を他方の金型側のみより蒸気又は
熱風によって圧空成形するものであるから、加熱と成形
が分離できず、成形時に周辺部に比し中央部の伸びが大
きく厚みが薄くなる、所謂偏肉が大きいという欠点を有
し、更には予めシートを成形金型外で加熱する場合は、
別にシートの加熱手段が必要となり、装置が複雑となる
と同時に、操作が繁雑になるという欠点がある。However, although the one disclosed in the above publication uses one of the split molds as a sheet forming die, means for holding the formed sheet in close contact with the forming surface of the die. Since it is difficult to hold a sheet with residual stress in close contact with the cavity surface of the mold because it has no stress, it has the disadvantage of incomplete bead filling. Since pressure molding is performed by steam or hot air only from the mold side, heating and molding cannot be separated, and the central part expands and the thickness becomes thin compared to the peripheral part at the time of molding, so-called uneven thickness is large. If you want to heat the sheet outside the molding die in advance,
In addition, a sheet heating means is required, which complicates the apparatus and also complicates the operation.
【０００８】本発明は、応力が大きいか、残留応力が大
きいか又はその双方が大きいシートであっても、適正な
温度と圧力を蒸気等で付与して成形するもので、割型の
一方の金型をシート成形型として使用し、成形されたシ
ートを確実に金型面に密着させた状態でビーズを充填す
ることを可能ならしめ、シートが成形面より浮く不具合
を解消すると共に、シートの成形及び金型内発泡成形時
の加熱媒体を統一することによって成形装置を簡素化で
きる成形方法を提供するものである。According to the present invention, even a sheet having a large stress, a large residual stress, or a large amount of both, is formed by applying appropriate temperature and pressure with steam or the like. By using the mold as a sheet molding mold, it is possible to fill the beads with the molded sheet firmly in contact with the mold surface, eliminating the problem that the sheet floats from the molding surface, and Provided is a molding method capable of simplifying a molding device by unifying heating media during molding and foam molding in a mold.
【０００９】[0009]
【課題を解決するための手段】本発明は、成形金型を用
いて表皮材を有する発泡成形体を製造する方法におい
て、固定金型と可動金型との間で表皮材を挟持し、キャ
ビティ内の表皮材両側を同一圧力の加熱媒体で加熱した
後、一方の金型側の圧力を低下させて表皮材を該金型の
キャビティ面に密着させ、その後該金型を冷却するか若
しくは該金型側から真空吸引するか又はその両者によっ
て表皮材をキャビティ面に密着した状態に保持し、次い
でその状態で他方の金型側から発泡性熱可塑性樹脂粒子
をキャビティ内へ充填し、加熱して発泡、膨張させて表
皮材と接合させる成形方法である。The present invention relates to a method for producing a foamed molded article having a skin material by using a molding die, wherein the skin material is sandwiched between a fixed die and a movable die, and a cavity is formed. After heating both sides of the inner skin material with a heating medium having the same pressure, the pressure on one die side is reduced to bring the skin material into close contact with the cavity surface of the die, and then the die is cooled or Hold the skin material in close contact with the cavity surface by vacuum suction from the mold side or both, then, in that state, fill the cavity with the expandable thermoplastic resin particles from the other mold side and heat. It is a molding method of foaming, expanding, and joining with a skin material.
【００１０】[0010]
【実施例】図１〜４は、本発明の一実施例を示したもの
であるが、次ぎに図示例を参照して本発明を具体的に説
明する。以下、理解を容易ならしめるため、成形工程順
に説明する。尚、発泡成形型は一般にバックプレート、
マスタープレート、インナー型等よりなるが、本発明で
は、これらにより組立てられた構造体であっても又は必
要とする機能が具備されていれば異なる構造体であって
も良く、これらを総称して単に金型と呼ぶ。1 to 4 show an embodiment of the present invention, the present invention will be described in detail with reference to the drawings. Hereinafter, in order to facilitate understanding, the steps will be described in the order of molding steps. The foaming mold is generally a back plate,
Although it is composed of a master plate, an inner type, or the like, in the present invention, a structure assembled by these or a different structure may be used as long as it has a required function. It is simply called a mold.
【００１１】工程1) 本発明で使用する金型１は、可動
金型２と固定金型３とからなりその合わせ面にキャビテ
ィ４が形成されており、図２のように、金型２と金型３
との合わせ面に表皮材Ａを挟んだ後、型締めし、次い
で、金型２の蒸気供給孔５ａと、金型３の蒸気供給孔７
ａから金型２、３内に蒸気を導入し、その時、ドレン排
出孔５ｂと７ｂのみを開いて金型２と金型３内部が同圧
になるように調整しながら蒸気を導入すると、蒸気はキ
ャビティ４の面に形成された細孔部９からキャビティ４
内に導入され、所望の圧力に達せしめて表皮材Ａを所望
の温度に加熱して軟化させる。Step 1) The mold 1 used in the present invention comprises a movable mold 2 and a fixed mold 3, and a cavity 4 is formed on the mating surface thereof. As shown in FIG. Mold 3
After sandwiching the skin material A on the mating surface with, the mold is clamped, and then the steam supply hole 5a of the mold 2 and the steam supply hole 7 of the mold 3 are clamped.
When steam is introduced from a into molds 2 and 3, and at the same time steam is introduced while adjusting only the drain discharge holes 5b and 7b so that the pressure inside molds 2 and 3 is the same, From the fine hole portion 9 formed on the surface of the cavity 4 to the cavity 4
Introduced into the inside, the desired pressure is reached and the skin material A is heated to a desired temperature to be softened.
【００１２】工程2) 次ぎに、蒸気供給孔５ａ及びドレ
ン排出孔５ｂを閉じ、直ちに蒸気又は冷却水排出孔６ｂ
を適宜開いてキャビティ４内の表皮材Ａで仕切られた金
型２側の蒸気の一部乃至全部を排出して表皮材Ａの金型
２側の圧力を低下させ、キャビティ４内の表皮材Ａの両
側に差圧を生じさせ、表皮材Ａを図３のように、キャビ
ティ４内の金型２の面の形状に沿って密着させて成形さ
せる。Step 2) Next, the steam supply hole 5a and the drain discharge hole 5b are closed, and immediately the steam or cooling water discharge hole 6b is closed.
Is partially opened to discharge part or all of the vapor on the side of the mold 2 partitioned by the skin material A in the cavity 4 to reduce the pressure of the skin material A on the mold 2 side, and the skin material in the cavity 4 A differential pressure is generated on both sides of A, and the skin material A is closely adhered and molded along the shape of the surface of the mold 2 in the cavity 4 as shown in FIG.
【００１３】前記の工程によって表皮材Ａの加熱と成形
を完全に分離した工程とすることが可能となり、表皮材
Ａを成形に最も適した温度とした後に成形することを可
能にするため偏肉を少なくすることができる外、金型２
のキャビティ４の面に凹凸模様を刻設しておけば、該凹
凸模様の転写が極めて良好となるという利点を有する。
尚、この際表皮材Ａの加熱温度及び成形時の差圧につい
ては、表皮材Ａの成形条件下での応力及び伸びの温度依
存性を考慮して適宜定めるべきものであることは当然で
ある。By the above steps, it is possible to completely separate heating and forming of the skin material A from each other, and it is possible to form the skin material A after the temperature is most suitable for the molding, so that the uneven thickness is obtained. The mold 2 which can reduce the
If an uneven pattern is formed on the surface of the cavity 4, the transfer of the uneven pattern will be very good.
At this time, the heating temperature of the skin material A and the differential pressure during molding should be appropriately determined in consideration of the temperature dependence of stress and elongation under the molding conditions of the skin material A. ..
【００１４】工程3) 前記成形の後、蒸気供給孔７ａを
閉じ、必要に応じ蒸気又は冷却水排出孔６ｂを開いて金
型２内部の残余の蒸気を排出後これを閉じ、金型２に埋
設された冷却水の通路１０に冷却水を導入して表皮材Ａ
を冷却すると同時に、金型２の排気孔１１で真空吸引し
て表皮材Ａをキャビティ４の面に密着した状態を保持せ
しめつつ、金型３の蒸気又は冷却水排出孔８ｂを開いて
キャビティ４の表皮材Ａで仕切られた金型３側の空間部
と金型３内部の残余の蒸気を排出する。Step 3) After the molding, the steam supply hole 7a is closed, and if necessary, the steam or cooling water discharge hole 6b is opened to discharge the residual steam inside the mold 2 and then closed to form the mold 2. By introducing cooling water into the buried cooling water passage 10, the skin material A
Simultaneously with cooling, the vacuum hole is sucked through the exhaust hole 11 of the mold 2 to keep the skin material A in close contact with the surface of the cavity 4, and the steam or cooling water discharge hole 8b of the mold 3 is opened to open the cavity 4 The residual steam inside the space on the side of the mold 3 and the inside of the mold 3 which is partitioned by the skin material A is discharged.
【００１５】この工程3)は重要であって、表皮材Ａが成
形されることによって発生する残留応力によって収縮
し、金型２のキャビティ４の面に密着している表皮材Ａ
が該面より浮くのを防止するものであり、ひいては後述
するビーズの完全な充填を可能にし、更には得られる発
泡成形体の形状不良を防止することができる。This step 3) is important, and the skin material A shrinks due to the residual stress generated by the molding of the skin material A and adheres closely to the surface of the cavity 4 of the mold 2.
Is prevented from floating above the surface, which in turn makes it possible to completely fill the beads described below, and further to prevent defective shape of the resulting foamed molded product.
【００１６】工程4) 次いで、公知の方法に従い、図４
に示すように金型２と金型３とをビーズが通過し得ない
程度に僅かに開き、ビーズ導入部１２からビーズ１３を
キャビティ４内の表皮材Ａと金型３の面との間に充填し
（クラッキング充填）、冷却水通路１０の冷却水を排出
し、金型３の蒸気又は冷却水排出孔８ｂ及びビーズ導入
部１２を閉じると共に、再度型締めを行って金型２の排
気孔１１を閉じる。Step 4) Then, according to a known method, as shown in FIG.
As shown in FIG. 2, the mold 2 and the mold 3 are slightly opened to the extent that the beads cannot pass, and the beads 13 are introduced from the bead introduction portion 12 between the skin material A in the cavity 4 and the surface of the mold 3. Filling (cracking filling), discharging the cooling water in the cooling water passage 10, closing the steam or cooling water discharge hole 8b of the mold 3 and the bead introduction part 12, and performing mold clamping again to exhaust the mold 2. Close 11
【００１７】工程5) その後、蒸気供給孔５ａ、７ａ及
びドレン排出孔５ｂ、７ｂ を開き、ビーズ１３の性状
に応じて所望の温度となるように蒸気を導入してビーズ
１３を発泡又は膨張せしめると共に、ビーズ１３同士及
び成形された表皮材Ａに融着させて一体的に成形する。Step 5) After that, the steam supply holes 5a, 7a and the drain discharge holes 5b, 7b are opened, and steam is introduced so as to reach a desired temperature according to the properties of the beads 13 to foam or expand the beads 13. At the same time, the beads 13 are fused to each other and the molded skin material A to be integrally molded.
【００１８】工程6) 次ぎに、蒸気供給孔５ａと７ａを
閉じ、蒸気又は冷却水排出孔６ｂと８ｂを開いて残余の
蒸気を排出してから、冷却水導入孔６ａと８ａを開いて
金型２と金型３内に具備されている冷却水をシャワー状
又はスプレー状に噴出する部材（図示省略）によって金
型２及び金型３を介して発泡成形体を冷却する。Step 6) Next, the steam supply holes 5a and 7a are closed, the steam or cooling water discharge holes 6b and 8b are opened to discharge the remaining steam, and then the cooling water introduction holes 6a and 8a are opened. The foamed molded article is cooled through the molds 2 and 3 by a member (not shown) that ejects cooling water provided in the molds 2 and 3 in a shower shape or a spray shape.
【００１９】工程7) 所望の温度まで冷却後、冷却水導
入部６ａと８ａを閉じ、常法によって金型２と金型３を
開いて発泡体を取り出す。図５は本発明の方法によって
得られた表皮材Ａと発泡層Ｂを有する発泡成形体であっ
て、表皮材Ａの不用部をトリミングして除去したものを
示している。Step 7) After cooling to a desired temperature, the cooling water introducing parts 6a and 8a are closed, the mold 2 and the mold 3 are opened by a conventional method, and the foam is taken out. FIG. 5 shows a foamed molded product having a skin material A and a foam layer B obtained by the method of the present invention, in which the unnecessary portion of the skin material A is trimmed and removed.
【００２０】以上の方法によって、単一金型で表皮材を
有する発泡成形体が得られるが、前記各工程は表皮材Ａ
及びビーズ１３の性状又は所望の成形体の形状によって
種々の変形が可能であり、例えば、工程2)における蒸気
供給孔５ａと同時に蒸気供給孔７ａを閉じても良く、工
程3)で蒸気又は冷却水排出孔６ｂを開く前に冷却水通路
部１０に冷却水を通しても良く、更には工程4)でクラッ
キング充填ではなく、金型を閉じた状態で、ビーズに内
圧を付与することによって与えた二次発泡能を保持する
ため又は粒子が圧縮された状態を保持するため系を加圧
状態に保ちながら充填することもできる。更に、細孔９
は市販の通気部材（コアーベント）、キリ穴、スリッ
ト、ポーラス電鋳、ポーラスセラミック又はこれらの組
合わせ等より適宜選定して形成せしめることができる。By the above method, a foamed molded article having a skin material can be obtained with a single mold.
Various modifications are possible depending on the properties of the beads 13 or the shape of the desired molded body. For example, the steam supply hole 5a may be closed at the same time as the steam supply hole 5a in step 2), and steam or cooling may be performed in step 3). Cooling water may be passed through the cooling water passage portion 10 before opening the water discharge hole 6b, and further, by applying internal pressure to the beads in a closed state of the mold instead of cracking filling in step 4). The system can also be filled while maintaining a pressurized state in order to maintain the secondary foaming ability or to maintain the compressed state of the particles. Furthermore, the pores 9
Can be appropriately selected and formed from commercially available ventilation members (core vents), drill holes, slits, porous electroforming, porous ceramics, or combinations thereof.
【００２１】本発明で使用する表皮材は、熱可塑性樹脂
又は熱可塑性エラストマーで、かつ実質的に通気性のな
いシート、フイルム、板状物、シート状発泡体又はこれ
らの積層体、更にはこれらと編織布、不織布等の積層体
等で成形し得るものであれば良く、この熱可塑性樹脂と
してはポリエチレン、ポリプロピレン、エチレンーαー
オレフイン共重合体、エチレンー酢酸ビニル共重合体、
塩素化ポリエチレン、エチレンー酢酸ビニルー塩化ビニ
ル共重合体、エチレンー塩化ビニル共重合体、ポリ塩化
ビニル、アイオノマー、ポリブテン、ポリスチレン、ア
クリル樹脂、熱可塑性ポリエステル、ポリウレタン等が
例示され、また熱可塑性エラストマーとしてはポリスチ
レン系、ポリオレフイン系、ポリウレタン系、ポリエス
テル系、ポリアミド系、エチレンー酢酸ビニル系、ポリ
塩化ビニル系、塩素化ポリエチレン系等のエラストマー
が例示されるが、これらは必要に応じてブレンドした
り、他の改質材や添加剤等を配合したりしても良いこと
は勿論であって、また前記表皮材が積層体である場合に
は、熱融着、接着剤、ホットメルトフイルム等により積
層し得る。The skin material used in the present invention is a thermoplastic resin or a thermoplastic elastomer, and is a substantially air-impermeable sheet, film, plate, sheet foam or laminate thereof, and further these As long as it can be molded with a laminate such as a knitted fabric and a nonwoven fabric, a thermoplastic resin such as polyethylene, polypropylene, an ethylene-α-olefin copolymer, an ethylene-vinyl acetate copolymer,
Chlorinated polyethylene, ethylene-vinyl acetate-vinyl chloride copolymer, ethylene-vinyl chloride copolymer, polyvinyl chloride, ionomer, polybutene, polystyrene, acrylic resin, thermoplastic polyester, polyurethane, etc. are exemplified, and thermoplastic elastomer is polystyrene. Examples include elastomers such as series, polyolefins, polyurethanes, polyesters, polyamides, ethylene-vinyl acetate series, polyvinyl chloride series, chlorinated polyethylene series, etc. Needless to say, a quality material, an additive and the like may be blended, and when the skin material is a laminate, it can be laminated by heat fusion, an adhesive, a hot melt film or the like.
【００２２】また、本発明で使用するビーズは、公知の
物であって、例えば、ポリスチレン、αーメチルポリス
チレン又はこれらとポリフェニレンエーテル若しくはポ
リフェニレンスルフィドの混合物等のポリスチレン系、
エチレン、プロピレン、αーオレフイン、ブタジエン、
ブテン等の単独重合体又は共重合体等のポリオレフイン
系のものが例示でき、更にはこれらは容易に揮発可能な
炭化水素、ハロゲン化炭化水素、フルオルカーボン等の
揮発性発泡剤を含有させて加熱により発泡させるか又は
加熱、加圧下で気化性発泡剤を含浸後、大気圧中に解放
する等の方法によりビーズとし、これが、尚発泡剤を含
有しており、発泡能を有する場合はそのまま、発泡能を
有していない場合は、再度揮発性発泡剤を含有させる
か、必要に応じ加熱、加圧して空気等のガスを圧入して
内圧を付与するか又は加圧圧縮して体積を縮小せしめる
こと等によりビーズに発泡、膨張能を付与してから成形
用金型内に充填し、次ぎにこれを加熱してビーズを更に
発泡、膨張させると共に、相互に融着させることにより
金型内で発泡成形体を製造できる。The beads used in the present invention are known ones, and examples thereof include polystyrene, α-methyl polystyrene, or polystyrene-based such as polyphenylene ether or polyphenylene sulfide.
Ethylene, propylene, α-olefin, butadiene,
Examples thereof include polyolefins such as homopolymers or copolymers such as butene, and further, those containing a volatile foaming agent such as easily volatile hydrocarbons, halogenated hydrocarbons and fluorocarbons. When the beads are formed by a method of foaming by heating or impregnating a vaporizable foaming agent under heating and pressure, and then releasing the beads to the atmospheric pressure, when the beads still contain the foaming agent and have foaming ability, they are left as they are. If it does not have a foaming ability, either add a volatile foaming agent again, or if necessary, heat and pressurize to pressurize a gas such as air to give an internal pressure, or pressurize it to reduce the volume. After the beads have been expanded and expanded by giving them the ability to expand, they are filled in a molding die, and then this is heated to further expand and expand the beads, and the beads are fused together to form a mold. Within the foam molding It can be produced.
【００２３】表皮材と発泡層を接合する方法としては、
それらが熱融着しうる組合わせの場合はそのままでよい
が、そうでない場合は表皮材の接合面を熱融着しうる樹
脂で被覆するか又は接合面に予め熱活性化しうる接着剤
若しくはホットメルトフイルム等の接着層を付与してお
けばよい。As a method for joining the skin material and the foam layer,
If they are a combination that can be heat-sealed, they may be used as they are, but if they are not, they may be coated with a heat-sealable resin on the joint surface of the skin material, or an adhesive or a hot agent that can be preheat-activated on the joint surface. An adhesive layer such as a melt film may be provided.
【００２４】実施例１〜４ 表１に示す材料及び条件によって表皮材の成形及び金型
内発泡成形を行い、表皮材を有する発泡成形体を得た。
これらの形状及び発泡粒子の融着状態を調べたところ、
金型形状をよく再現しており、内部にボイドもなく良好
な製品であった。更に、２つに切断して中央部の表皮材
の偏肉を目視評価したところ、表１に示すような結果が
得られ、従来より大幅に改善されていた。尚、金型とし
ては図１に示す形状のものを使用し、得られた箱形状の
外寸は、500×500×100mmであり、その肉厚は20mmであ
った。Examples 1 to 4 Using the materials and conditions shown in Table 1, molding of the skin material and in-mold foam molding were carried out to obtain a foam molded article having the skin material.
When examining the fusion state of these shapes and expanded particles,
The shape of the mold was reproduced well, and it was a good product with no voids inside. Furthermore, when cut into two pieces and visually evaluated the uneven thickness of the skin material in the central portion, the results shown in Table 1 were obtained, which was a great improvement over the conventional one. A metal mold having the shape shown in FIG. 1 was used, and the obtained box-shaped outer dimensions were 500 × 500 × 100 mm and the wall thickness was 20 mm.
【００２５】比較例１ 表皮材を成形後、これの冷却を行わず、かつ成形後の面
へ密着保持するための真空吸引を行わなかった外は、実
施例１と同様に処理した。得られた成形体は表皮材の成
形後の残留応力による収縮により型形状を再現しておら
ず、不満足なものであった。Comparative Example 1 A skin material was treated in the same manner as in Example 1 except that after the skin material was molded, it was not cooled and vacuum suction was not performed to hold the skin material in close contact with the surface. The obtained molded body was unsatisfactory because it did not reproduce the mold shape due to shrinkage due to residual stress after molding the skin material.
【００２６】比較例２ 固定金型と可動金型との間に表皮材を挟み、固定金型側
のみから蒸気を供給して表皮材を成形した外は、実施例
３と同様に行った。２つに切断して中央部の表皮材の偏
肉を目視評価したところ、明らかに薄くなっているのが
認められた。Comparative Example 2 The procedure of Example 3 was repeated except that the skin material was sandwiched between the fixed mold and the movable mold, and steam was supplied only from the fixed mold side to mold the skin material. When it was cut in two and visually evaluated for uneven thickness of the skin material in the central part, it was confirmed that the thickness was clearly thin.
【００２７】前記実施例と比較例との材料、条件及び結
果を表１に示す。Table 1 shows the materials, conditions and results of the above Examples and Comparative Examples.
【００２８】[0028]
【表１】 [Table 1]
【００２９】[0029]
【発明の効果】以上の如く本発明は、成形する表皮材に
適合した温度及び圧力を別個に選定できるため、広範囲
の熱可塑性樹脂及び熱可塑性エラストマーについて偏肉
もなく成形でき、しかも成形した表皮材を金型面に密着
させた状態でビーズを充填するため、完全なビーズの充
填が可能となり、併せて形状不良が防止できるが、また
表皮材とビーズとの成形における加熱媒体を共通化で
き、従って、別の表皮材の加熱ゾーンを必要とせず、単
一の金型のみで成形できるから、成形装置の簡素化、製
造サイクルの短縮、ひいては低コスト化が図られるほ
か、表皮材を成形する金型面に凹凸模様を刻設した場合
は、これが表皮材表面によく転写され、意匠性に優れた
発泡成形体を得ることができる。INDUSTRIAL APPLICABILITY As described above, according to the present invention, since the temperature and the pressure suitable for the skin material to be molded can be selected separately, a wide range of thermoplastic resins and thermoplastic elastomers can be molded without uneven thickness, and the molded skin Since the beads are filled while the material is in close contact with the mold surface, it is possible to completely fill the beads, and at the same time, it is possible to prevent shape defects, but it is also possible to use a common heating medium for molding the skin material and beads. Therefore, since a separate heating zone for the skin material is not required and only a single mold can be used for molding, the molding equipment can be simplified, the manufacturing cycle can be shortened, and the cost can be reduced. When an uneven pattern is engraved on the surface of the mold, it is well transferred to the surface of the skin material, and a foamed molded article having excellent design can be obtained.
【図１】本発明に使用する金型の一例の断面図である。FIG. 1 is a cross-sectional view of an example of a mold used in the present invention.
【図２】図１の金型で表皮材を挟持した説明図である。FIG. 2 is an explanatory view in which a skin material is sandwiched between the molds of FIG.
【図３】図２の表皮材を成形する説明図である。FIG. 3 is an explanatory diagram for forming the skin material of FIG.
【図４】図３のキャビティにビーズを充填する説明図で
ある。4 is an explanatory view of filling beads in the cavity of FIG. 3. FIG.
【図５】本発明で得られた発泡体の一例の断面図であ
る。FIG. 5 is a cross-sectional view of an example of the foam obtained in the present invention.
１：金型 ２：可動金型 ３：固定金型 ４：キャビティ ５ａ、７ａ：蒸気供給孔 ５ｂ、７ｂ：ドレン排出孔 ６ａ、８ａ：冷却水導入孔 ６ｂ、８ｂ：蒸気又は冷却水排出孔 ９：細孔部 １０：冷却水通路 １１：排気孔 １２：ビーズ導入部 １３：ビーズ Ａ：表皮材 Ｂ：発泡層 1: Mold 2: Movable mold 3: Fixed mold 4: Cavity 5a, 7a: Steam supply hole 5b, 7b: Drain discharge hole 6a, 8a: Cooling water introduction hole 6b, 8b: Steam or cooling water discharge hole 9 : Pore part 10: Cooling water passage 11: Exhaust hole 12: Bead introduction part 13: Beads A: Skin material B: Foam layer
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.5 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｂ２９Ｌ 9:00 4Ｆ ─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 5 Identification code Internal reference number FI Technical display location B29L 9:00 4F
Claims (1)
形体を製造する方法において、固定金型と可動金型との
間で表皮材を挟持し、キャビティ内の表皮材両側を同一
圧力の加熱媒体で加熱した後、一方の金型側の圧力を低
下させて表皮材を該金型のキャビティ面に密着させ、そ
の後該金型を冷却するか若しくは該金型側から真空吸引
するか又はその両者によって表皮材をキャビティ面に密
着した状態に保持し、次いでその状態で他方の金型側か
ら発泡性熱可塑性樹脂粒子をキャビティ内へ充填し、加
熱して発泡、膨張させて表皮材と接合させることを特徴
とする表皮材を有する発泡成形体の製造方法。1. A method for producing a foamed molded article having a skin material using a molding die, wherein the skin material is sandwiched between a fixed die and a movable die, and the same pressure is applied to both sides of the skin material in the cavity. After heating with one heating medium, the pressure on one mold side is lowered to bring the skin material into close contact with the cavity surface of the mold, and then the mold is cooled or vacuum suction is performed from the mold side. Alternatively, the skin material is held in close contact with the cavity surface by both of them, and then in that state, the expandable thermoplastic resin particles are filled into the cavity from the other mold side and heated to foam and expand the skin material. A method for producing a foamed molded article having a skin material, the method comprising:
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4114069A JPH05285965A (en) | 1992-04-07 | 1992-04-07 | Manufacture of foam-molded body with skin material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4114069A JPH05285965A (en) | 1992-04-07 | 1992-04-07 | Manufacture of foam-molded body with skin material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH05285965A true JPH05285965A (en) | 1993-11-02 |
Family
ID=14628263
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP4114069A Pending JPH05285965A (en) | 1992-04-07 | 1992-04-07 | Manufacture of foam-molded body with skin material |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH05285965A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2003076159A1 (en) * | 2002-03-13 | 2003-09-18 | Nissei Kabushiki Kaisha | Process for producing biodegradable molded item and molding dies therefor |
| CN104945654A (en) * | 2014-03-28 | 2015-09-30 | 株式会社Jsp | Skin-covered foamed molded article and energy absorbing member |
| JP2021504523A (en) * | 2017-11-27 | 2021-02-15 | エボニック オペレーションズ ゲーエムベーハー | PESU particle foam for use in aircraft interiors |
-
1992
- 1992-04-07 JP JP4114069A patent/JPH05285965A/en active Pending
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2003076159A1 (en) * | 2002-03-13 | 2003-09-18 | Nissei Kabushiki Kaisha | Process for producing biodegradable molded item and molding dies therefor |
| KR100749975B1 (en) * | 2002-03-13 | 2007-08-16 | 니세이 가부시끼 가이샤 | Process for producing biodegradable molded item |
| US8043539B2 (en) | 2002-03-13 | 2011-10-25 | Nissei Company, Ltd. | Process for producing biodegradable molded item and molding dies therefor |
| CN104945654A (en) * | 2014-03-28 | 2015-09-30 | 株式会社Jsp | Skin-covered foamed molded article and energy absorbing member |
| JP2015193802A (en) * | 2014-03-28 | 2015-11-05 | 株式会社ジェイエスピー | Skin material-covered foam molded body and energy absorption member |
| JP2021504523A (en) * | 2017-11-27 | 2021-02-15 | エボニック オペレーションズ ゲーエムベーハー | PESU particle foam for use in aircraft interiors |
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